Xerox DocuPrint 180 Service Manual

Transmittal Page Product

Title

Part Number

DocuPrint 180F

Service Manual

720P16290

Status

Date

Revision This is a complete revision of the DocuPrint 180F Service Manual. This Service Documentation supersedes all other releases.

November 2000

THIS PAGE INTENTIONALLY LEFT BLANK

THE DOCUMENT COMPANY XEROX

DocuPrint 180F Service Manual

720P16290 November 2000

Prepared by: Xerox Corporation Global Knowledge and Language Services 555 S. Aviation Blvd., ESM1-058 El Segundo, CA 90245 © 1999, 2000 by Xerox Corporation. All rights reserved. Xerox ® and all identifying numbers used in connection with the Xerox products mentioned in this publication are trademarks of the Xerox Corporation. All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product-trained service personnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or modules, components, or parts of such equipment may affect whether Xerox is responsible to fix machine defects under 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. Adobe® is a registered trademark of Adobe Systems, Inc. AppleTalk® is a registered trademark of Apple Computer, Inc. Compaq® is a register trademark of Compaq. Microsoft®, MS-DOS® are registerd trademarks, and Windows™ is a trademark of Microsoft Corporation. Novell®, NetWare®, PConsole®, and NPrint® are registered trademark of Novell, Inc. PostScript® is a registered trademark of Adobe Systems, Inc. While Xerox has tried to make the documentation accurate, Xerox will have no liability arising out of any inaccuracies or omissions.

WARNING This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to subpart J of part 15 of FCC rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case the user, at his own expense, will be required to correct the interference.

Introduction About this Manual ........................................................................................................... Organization and Use of the Manual............................................................................... Reference Symbology..................................................................................................... Glossary of Terms...........................................................................................................

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Introduction

Introduction

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Revision DocuPrint 180F Service Manual

About this Manual

Organization and Use of the Manual

The Service Manual is part of the multinational documentation system for the printer. When used in conjunction with the Service Data, this manual will help in the isolation and repair of faults that may occur in the printer.

Organization Overview

The service manual contains information that applies to USCO, XL, and XCL printers. USCO references normally apply to XCL as well. If USCO and XCL are different, the specific USO information has a "USO Only" note, and the specific XCL information will be shown as "XCL only." All "XL" references apply to Xerox Limited 50 Hz Printing Systems. Service Manual Revision

The Service Manual is comprised of the following primary Sections: Introduction Section 1: Service Call Procedures Section 2: Status Indicator RAPs Section 3: Print Quality RAPs

The service manual will be updated as the printer changes or as problem areas are identified.

Section 4: Repairs/Adjustment Procedures

Publication Comment Sheet

Section 5: Parts List

A Publication Comment Sheet (PCS) is provided at the end of the Service Manual. The PCS allows field users to communicate information regarding the Service Documentation to MC

Section 6: General Procedures/Information Section 7: Wiring Data

Service Information (yellow pages) Service Information pages are inserted in the back of the Service Manual. Service Information is made of information considered temporary in nature. This information will be incorporated into procedures if appropriate, or removed when the situation no longer applies. Included are Bulletins, Tag and Kit information, current top problems, and other temporary information.

Section 8: Installation Manual or Procedures Section 9 & 10: Accessories or Other important additional information.

Organization Descriptions Introduction The Introduction contains information pertaining to the organization of the Service Manual: Reference Symbology, Voltage Tolerances, Relay Cross References, and a Glossary of Terms that are used in the documentation. Section 1: SERVICE CALL PROCEDURES This section contains procedures that determine what actions are to be taken during a service call on the Printing System and in what sequence they are to be completed. This is the entry level for all service calls. The Call Flow Procedure is intended to provide an orderly approach to the entire call. Inital Action identifies the recommended steps for getting an overview of the machine condition. Corrective Action describes the recommended process for diagnosing and repairing the failure. Scheduled Maintenance identifies the cleaning and replacement of items according to the Service Manual intervals. Final Action describes what precautions are recommended to ensure that the machine is in the best possile condition when the call is completed.

Preliminary Working Document No Product Name Assigned

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Section Name

About this Manual, Organization and Use of the

System Fault Analysis creates an orderly process for diagnosing the cause of the failue when it may not be apparent, or when there are conflicting or ambiguous symptoms. It is important that this procedure be used in order to ensure that the correct symptom is being diagnosed. The Non-Repeatable Diagnostics section is intended to provide process steps toward diagnosing problems that are not occuring frequently enough to diagnose using the more traditional procedures. Section 2: STATUS INDICATOR RAPs This section contains the Repair Analysis Procedures (RAPs) and Circuit Diagrams (CDs) that are used to diagnose fault codes and faults that do not generate other fault codes.

The RAP/CD number is identical to the Fault Code that is generated by the machine, with the exception that the RAP/CD does not carry the leading 0 (0X-XX) that is displayed by the machine.

•

The first digit or pair of digits in a RAP/CD number identify the functional area to which the Fault Code refers.

•

200 series Fault Codes (XX-200) refer to timing faults, and 300 series Fault Codes (XX300) refer to communication and synchronization faults.

•

Warnings and Cautions Hazards are present when replacing some components. When directed to the repair procedure in the Service Documentation, be sure to follow all Warnings and Cautions. Their definitions are as follows

WARNING A Warning is used whenever an operating or maintenance procedure, practice, condition, or statement could result in personal injury if not strictly observed.

The following information pertains to the RAP and CD numbering: •

This section contains Plug/Jack locational drawings and Wirenet diagram of the power distribution networks in the Printing System. Individual wire networks are shown in the Circuit Diagrams contained in Section 2. Wirenets are not generated for signal wires without a wire number. The use of the Circuit Diagram is required when tracing signal wiring. This section also contains Block Schematic Diagrams for the Printing System.

CAUTION A Caution is used whenever an operating or maintenance procedure, practice, condition, or statement could result in machine damage if not strictly observed.

Voltage Specifications Table 1 Logic Voltages Voltage

RAP/CDs numbered 600 and 700 (XX-600 and XX-700) are assigned by Service Education. The Machine software cannot identify these failures, and therefore cannot assign a fault code.

Tolerance

DC Com

0.0 to +0.8 VDC

+5 VDC

H = +5.05 to +5.25 VDC

+12 VDC

H = +11.3 to +12.7 VDC

+15 VDC

H = +14.25 to +15.75 VDC

-15 VDC

H = -14.25 to -15.75 VDC

+24 VDC

H = +21.6 to +25.5 VDC

This section contains the repair/adjustment procedures for the Printing System.

+34 VDC

H = +33.5 to +35.5 VDC

Section 5: PARTS LIST

-34 VDC

(H) -33.5 to -35.5 VDC

L = 0.0 to +0.8 VDC

Section 3: PRINT QUALITY RAPs This section contains the RAPs and CDs and other diagnostic aids for troubleshooting Xerographic print defect problems. RAPs associated with print defect symptoms all contain the prefix "PQ" to differentiate them from the rest of the failure symptoms (PQ9-xxx). If a Xerographic fault code (9-xxx) is present, diagnostics of that failure should be done using the appropriate RAP in the Status Indicator RAPs section. The section also contains print quality specifications and print defect samples

L = 0.0 to +0.8 VDC L = 0.0 to +0.8 VDC L = 0.0 to +0.8 VDC

Section 4: REPAIRS/ADJUSTMENT PROCEDURES

L = +0.0 to +0.8 VDC L = 0.0 to +0.8 VDC L = 0.0 to +0.8 VDC

Section 6: GENERAL PROCEDURES/INFORMATION This section contains text versions of the dC (Diagnostic Programs) found on the IOT Monitor screen. If one of the dC routines does not seem clear when using the IOT Monitor, refer to the text to clarify the procedure.

AC Voltage Specifications

The section also contains special checkout procedures and Generic RAPs which are used to troubleshoot sensors, solenoids, and relays. Section 7: WIRING DATA

Section Name

Organization and Use of the Manual

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Preliminary Working Document No Product Name Assigned

Measurements of AC Voltage can be made to the frame of the machine on 60Hz machines, unless another reference is specified in a diagnostic procedure. On 50Hz machines, all measurements of 220/230/240 VAC should be made with respect to ACN. All references to 115 VAC on circuit diagrams and BSDs are measured with respect to AC Return. Table 2 AC Voltage Specifications - USMG and XCI Service

Line-to-Neutral

Line-to-Line

Single Phase

103-107 VAC

207-253 VAC

Three Phase

103-127 VAC

179-219 VAC

Table 3 AC Voltage Specifications - XL Service

Phase-to-Neutral

Phase-to-Phase

WYE 220 VAC

198-242 VAC

342-418 VAC

WYE 230 VAC

207-253 VAC

358-438 VAC

WYE 240 VAC

216-264 VAC

373-457 VAC

DELTA 220 VAC

198-242 VAC

DELTA 230 VAC

207-253 VAC

DELTA 240 VAC

216-264 VAC

Table 4 Autotransformer AC Voltage Specification - XL Service

AC Power-AC Ret

WYE

103-127 VAC

DELTA

103-127 VAC

Preliminary Working Document No Product Name Assigned

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Section Name

Organization and Use of the Manual

Reference Symbology

Section Name

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Preliminary Working Document No Product Name Assigned

Figure 1 Reference Symbology

Preliminary Working Document No Product Name Assigned

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Section Name

Figure 2 Parts List Symbology

Section Name

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Preliminary Working Document No Product Name Assigned

Figure 3 TAG/MOD

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Section Name

Glossary of Terms

Table 1 Glossary of Terms

Glossary of Terms

Term

Definition

Concurrent

Means the "time overlap" that can be achieved when two or more activities can be performed at the same time. For example, an activity concurrent with the print process would be binding, because the two activities overlap in time giving the operator additional free (productive) time.

CPU

Central Processing Unit: The location in a computer where data are processed.

The Glossary contains terms and phrases that are used throughout the Service Documentation. Table 1 Glossary of Terms Term

Definition

A3

Paper size 297 millimetres (11.69 inches) x 420 millimetres (16.54 inches).

CRT

Cathode Ray Tube (picture tube)

A4

Paper size 210 millimetres (8.27 inches) x 297 millimetres (11.69 inches).

CRT Monitor

The CRT and the high voltage video electronics

D/A

Digital to Analog

ACT

Advanced Customer Training: A course that teaches customers to perform some of the service normally performed by a CSE.

Dash Symbol

(MICR unique) The Dash is sometimes used as seperator within the On-Us Field.

Dead Cycle

A/D

Analog to Digital

One or more of the machine drive motors are running; the machine is not making prints or there is a component energized in Standby.

Default

Preset values in NVM or preset selections on the IOT Monitor Screen

Diagnostics

Hardware or software that monitors or improves the integrity of the control system. The service documentation is also considered diagnostics.

ADA

Analog to Digital and Digital to Analog

ADA PWB

Analog to Digital and Digital to Analog PWD: Fifteen A/D inputs, 12 D/A outputs, and 8 digital outputs. This board converts digital signals to analog information and vise versa.

Amount Symbol

The two amount symbols tell the reader/sorter that the numbers between the symbols are the amount of the check.

AMAT

Active MATrix: Material used to make the photoreceptor.

DIO

Digital Input/Output

Applications Layer

One of a series of seven layers designed into the UI Core and Video Engine PWB that determine what is displayed on the CRT by the Video Engine.

DIO PWB

Digital Input/Output PWB: Sixteen inputs from switches or sensors. 16 DC output drivers, and local bus interface circuitry.

APPS

APPlications Software: The programs used by the processor to perform specific tasks.

AUX

DSS

Density Sample Sensor: The IRD (Infra-Red Densitometer)

E13B

A specific font used for MICR characters. The E13B MICR font consists of numbers and symbols used to print in the Clear Band area of a check.

EPROM

Erasable Programmable Read-Only Memory: A ROM that can be erased and then programmed again with new software.

Auxiliary

AZAP

All Zones, All Paper

B4

Paper size 257 millimetres (10.12 inches) x 364 millimetres (14.33 inches).

BCR

Bar Code Reader

ESV

Electrostatic Voltmeter The Integrated Circuits (chips) on a PWB

Bit

BInary digiT, either 1 or 0, representing an electrical state.

Firmware

Boot

The process of loading the operating system software to RAM from a mass memory storage device.

Floppy Disk

Bus

An electrical connection that allows data flow in two directions at the same time.

A plastic or mylar disk, coated with magnetic oxide, used to store computer information. The floppy disk for the System Controller is a 5 1/4 inch flexible disk.

Hardware

Byte

A combination of eight bits representing the letters, numbers, and symbols in a microprocessor.

The mechanical and electronic parts that make up a computer or machine.

HFSI

High Frequency Service Items

Chip

An Integrated Circuit (IC)

I/O Controller

Clear Band

A 5/8" wide strip running along the bottom of a MICR document from left to right.

The Input/Output Controller: Acts as an interface between the CPU and the devices used for inputs and outputs. The I/O Controller translates the information so that the receiving device (CPU or I/O device) understands it.

IC

An Integrated Circuit is a micro circuit that contains hundreds of electrical components. It is also known as a chip.

Section Name

0/0/00 ?-10

Preliminary Working Document No Product Name Assigned

Table 1 Glossary of Terms

Table 1 Glossary of Terms

Term

Definition

Term

Definition

IFS

Inverter/Feeder Stacker

On-Us Symbol

A symbol that tells the reader/sorter that the next few numbers identify what account number and financial institution the check is drawn on.

OS

The Operating System contains the guidelines on how all components in the processor communicate. It provides the instructions to the CPU, which control the flow of information among the computer components.

Output

Moving the information from the computer to a destination

OZAC

Ozone and AC. A system in which the AC leads from the High Voltage Output Module are routed inside the ozone ducts. This is done in order to minimize the possibility of the AC arcing to the machine frames.

Parallel Transmission

The transmission of information, one byte at a time, over multiple electrically parallel wires

PHM

Paper Handling Module.

PHN

Paper Handling Node

Input

Information from a source to a computer

IOP

Input/Output Processor: A PWB which connects to the local bus and contains a microprocessor.

IRD

Infared Densitometer, also known as a DSS (density Sample Sensor)

KC

Kilo or 1000 prints

LE

Lead Edge

LED

Light Emitting Diode

LEF

Long Edge Feed

Local Bus

A high speed, serial transmission line connecting a Core PWB with I/O PWBs.

LVPS

Low Voltage Power Supply

Mass Memory Storage Device

A device used to store software information in a form directly readable by the processor, but external to it. In the Siena Printer, the mass memory storage device is the rigid disk.

POPO

Power Off/Power On

Print Defect

Those defects that are xerographic and/or cosmetic related (dark horizontal bands, streaks, smears, gloss, etc.)

MEBJ

Mean Events Between Jams

MPBJ

Mean Prints Between Jams is the mathematical average number of prints between jams.

PQ

Print Quality

MIB

The Marking/Imaging Buffer: A buffer on a circuit board in the Marking/Imaging area that is used in analog to digital conversions.

PQE

Print Quality Evaluation

Program

The CPU in one Integrated Circuit (IC) that controls all hardware, such as ROM (Read Only Memory) and RAM (Random Access Memory) devices.

A sequence of instructions that the CPU reads and interprets to carry out tasks, such as mathematic, logic, and control functions.

PROM

Programmable Read Only Memory: ROMs that contain software information and cannot be erased and reprogrammed.

Micro-processor

MICR

Magnetic Ink Character Recognition

MIM

Marketing/Imaging Module

MIN

Marketing/Imaging Node

Node

A control system with a Core PWB (the main intelligence of the node) and other PWBs, and I/O processors that depend on the Core PWB. The I/O processor PWBs control the lowest level of interface to the machine hardware. The Core PWB communicates with the I/O processor PWBs over a shared line called a local bus. A node may also contain a Job Manager Core PWB which has responsibility for high level machine control over a number of base machine core PWBs. The core PWBs communicate over a shared line called a System Bus.

NOHAD

Noise, Ozone, Heat, Air, Dirt

NVM

Non-Volatile Memory: A RAM (Random Access Memory) device that stores information as long as a DC voltage is applied.

Preliminary Working Document No Product Name Assigned

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PWB

Printed Wiring Board

PWBA

Printed Wiring Board Assembly

Queued Fault

Active faults which need to be cleared. Some queued faults will not appear to the customer unless that feature is selected.

Range Fault

NVM logged conditions which provide a warning of an approaching fault or of an existing fault which is not obvious to the customer.

RAM

Random Access Memory device: A digital memory circuit from which information can be accessed or where software information can be stored. RAM is its accepted name, but does not describe its function. A better name would be the Read and the Write Memory, because the controller can read the information and it can write the information.

RCC

Remote Controller Chip: Sixteen digital inputs and 16 digital outputs used to drive remote digital I/O. This chip is used on the DIO.

Rigid Disk

A metal or plastic disk coated with magnetic oxide for information storage. It is a mass memory storage device.

Section Name

Table 1 Glossary of Terms Term

Definition

ROM

Read Only Memory device: A digital memory circuit designed to contain permanent software information. The name means that the controller on the PWB can only read the information from the ROM. The controller or any other device cannot change the values or write any software information to the ROM. Most of the memory for the machine is in ROM.

SAN

System Administrator Node

SCP

Service Call Procedures

SEF

Short Edge Feed

Self-test

An automatic process used to check the Control Logic circuitry. Any fault detected during self-test is displayed by a fault code or by LEDs on the PWBs.

Serial Transmission

The transmission of microprocessor information, one bit at a time, on a single wire

SLC

A Shared Line Controller is a large scale integrated device that contains an SLR and SLT.

SLR

Shared Lint Receiver is one of the functional blocks within the SLC.

SLT

Shared Line Transmitter is one of the functional blocks within the SLC.

Soft Failure

A software error or an intermittent hardware failure

Software

The programs (specified instructions) that inform the processor how to process information.

SPI

Spots Per Inch (a print quality parameter)

System Bus

A shared Line used by a Serial Transmission channel for high level communications between nodes.

TE

Trail Edge

Transit Symbol

There are always two transit symbols in a MICR line. They tell the reader/sorter that the numbers between these symbols identify the institution upon which the check drawn.

TVCF

Top Vacum Corrugated Feeder

VSAD

Vertical Solid Area Deletion

WDT

Watch Dog Timer: Monitors a processor for normal operation. The processor is assumed to be operating normally as long as it refreshes (clears) the WDT periodically.

XIC

Xerox Initiated Call: A service call that is not placed by a customer, but by Xerox or the CSE for the purpose of visiting the machine to observe operation, installing a retrofit, performing scheduled maintenance, etc.

3 Pitch Mode

The number of impressions that can be placed on the photoreceptor when printing onto paper that is wider than 9 inches.

7 Pitch Mode

The number of impressions that can be placed on the photoreceptor when printing onto paper that is 9 inches wide or less.

Section Name

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Preliminary Working Document No Product Name Assigned

1. Service Call Procedures Call Flow 0-1 Initial Action RAP ...................................................................................................... 0-2 Corrective Action RAP .............................................................................................. 0-3 Scheduled Maintenance Action RAP ........................................................................ 0-4 Final Action RAP.......................................................................................................

1-3 1-4 1-4 1-5

PHN DIO PWB #2 Inputs/Outputs................................................................................... PHN DIO PWB #3 Inputs/Outputs................................................................................... PHN DIO PWB #6 Inputs/Outputs................................................................................... PHN Registration Servo PWB Inputs/Outputs................................................................. Printer Group Fault Tables Purpose And Procedure.......................................................

Paper Handling PHM Group Fault Tables

Initial Action Initial Action Procedure ................................................................................................... Maintenance Hints .......................................................................................................... HFSI TABLES .................................................................................................................

1-7 1-9 1-10

Paper Handling PHM Group Fault Tables....................................................................... Paper Handling PHM Group Fault Table (2 of 4) ............................................................ Paper Handling PHM Group Fault Table (3 of 4) ............................................................ Paper Handling PHM Group Fault Table (4 of 4) ............................................................

1-15 1-16 1-18 1-18 1-19 1-19 1-20

Xerographics Group Fault Table (1 of 4)........................................................................ Xerographics Group Fault Table (2 of 4)........................................................................ Xerographics Group Fault Table (3 of 4)......................................................................... Xerographics Group Fault Table (4 of 4)......................................................................... Run Control Group Fault Tables .....................................................................................

System Checks System Fault Analysis Procedures ................................................................................. Printer Entry Procedure................................................................................................... Printer Power Entry Procedure ....................................................................................... Print Damage Entry Procedure ....................................................................................... UIM Boot Entry Procedure .............................................................................................. Print Defect Entry Procedure .......................................................................................... Jam/Fault Code Entry Procedure....................................................................................

Functional Checks Corrective Action for the DP180......................................................................................

1-21

Physical Checks Print Paper Diagnostics...................................................................................................

1-23

Subsystem Maintenance Every Call Activities......................................................................................................... Subsystem Checks .........................................................................................................

1-27 1-28

Non-Repeatable Diagnostics Non-Repeatable Problem Entry Procedure..................................................................... Printer Electrical Noise Procedure .................................................................................. Part 1: 9-XXX Fault Code Procedures ............................................................................ Part 2: Electrical NODE Procedures ............................................................................... Part 3: 06-XXX Fault Code Procedure ............................................................................ Part 4: Defeature Isolation Procedure............................................................................. Features Bypass Tables ................................................................................................

1-31 1-34 1-35 1-38 1-39 1-39 1-40

Inputs and Outputs Tables FSN DIO PWB # 1A Inputs ............................................................................................. FSN DIO PWB # 1 Outputs............................................................................................. FSN DIO PWB # 2 Inputs/Outputs .................................................................................. FSN DIO PWB # 3 Inputs/Outputs .................................................................................. FSN Stepper PWB A Inputs/Outputs .............................................................................. MIN ADA PWB #1 Inputs/Outputs................................................................................... MIN ADA PWB #2 Inputs/Outputs................................................................................... MIN DIO PWB Inputs/Outputs......................................................................................... PHN DIO PWB #1 Inputs/Outputs...................................................................................

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1-46 1-46 1-47 1-47 1-48

1-41 1-41 1-42 1-42 1-43 1-43 1-44 1-44 1-45

1-49 1-50 1-51 1-52

Xerographics Group Fault Tables 1-53 1-54 1-55 1-56 1-57

Power/All Other Faults Group Fault Tables Power/All Other Faults Group Fault Table (1 of 4) .......................................................... Power/All Other Faults Group Fault Table (2 of 4) .......................................................... Power/All Other Faults Group Fault Table (3 of 4) .......................................................... Power/All Other Faults Group Fault Table (4 of 4) .......................................................... Printer Fault Code Tables Purpose And Procedure ........................................................ 1 NRD Fault Code Tables ............................................................................................... 3 NRD Fault Code Tables ............................................................................................... 4 NRD Fault Code Tables ............................................................................................... 6 NRD Fault Code Tables ............................................................................................... 7 NRD Fault Code Tables ............................................................................................... 8 NRD Fault Code Tables ............................................................................................... 9 NRD Fault Code Tables ............................................................................................... 10 NRD Fault Code Tables ............................................................................................. 11 NRD Fault Code Tables ............................................................................................. DC140 Analog Display Diagnostic Procedure................................................................. DC909 P/R Belt Seam And Xerographic Test................................................................. DC951 Auto Xerographic Setup ...................................................................................... NRD General Information And Diagnostic Hints ............................................................. FSM PHM Fault Code Sensor Location Diagram............................................................ Inverter Feeder Stacker DC226 Timing Interval Graphs ................................................. Printer DC726 Timing Interval Graphs ............................................................................ Final Action......................................................................................................................

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1-60 1-61 1-62 1-63 1-64 1-66 1-69 1-74 1-75 1-79 1-83 1-94 1-105 1-111 1-120 1-127 1-133 1-137 1-142 1-144 1-150 1-158

Service Call Procedures

Service Call Procedures

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0-1 Initial Action RAP

7.

The purpose of the Initial Action RAP is to help the Service Representative organize the service call. The Service Rep will use the System Status Information, Printer Performance Report (PPR) and input from the Customer to accomplish this objective.

Print the PPR Log and run print samples. Review the data and prioritize the Actions and Activities. A brief review of this information will help structure the Service Call by providing a summary of the System problems which need to be corrected.

8.

If this is a Scheduled Maintenance visit, go to the 0-3 Scheduled Maintenance Action RAP, otherwise go to the 0-2 Corrective Action RAP.

Initial Actions •

If questions exist regarding the Initial Action RAP, go to the Initial Action Procedure for a detailed description of each step.

NOTE: For Third Party Technicians, refer to GP 1000 Diagnostic Programs And Procedures for work-around if the diagnostic routine mentioned in the documentation is not located on the screen.

Procedure 1.

Question the Customer for details about the system malfunction and service call. If possible, obtain information about the problem, the job configuration, the mode-of-entry operation and any other problems that may be occurring. Verify the primary reason for the call. a.

Primary Activity: The Customer problem description. Within the Printer, this activity also includes: •

b.

Examining Fault History Files

•

Going to the HFSI TABLES and performing all due HFSI

•

Repairing queued faults for the related subsystem

Secondary Activity: All activities not related to the reported reason for the call. Within the Printer, this activity also includes: •

All unrelated Fault History Files

•

Going to the HFSI TABLES and performing all due HFSI

•

Queued Faults

•

Range Faults

2.

Confirm by duplicating the problem with the Customer. If possible, verify the reported problem by running the system in order to duplicate the problem. Ask the Customer to demonstrate the problem. Enter the Service Mode at the Printer. Enter [Fault List] Icons and record all Fault Codes prior to clearing any Faults.

3.

If the Call is a Print Quality problem, inspect the rejected print and determine the cause of the rejection by the Customer.

4.

(IPS) Ensure that the Customer varies the system off-line (Job Integrity). Ensure that the system is off-line and that no pages are left on the disk or in memory to be printed (have the Customer ensure Job Integrity.

5.

Verify that the System has booted properly and is capable of entering and displaying commands.

6.

Enter Service Mode at the Controller. Perform the Administration tasks: •

Obtain the Serial Number and the Initial Meter Reading

•

Review previous Call Information and Status

•

Verify/Record Diagnostic Locking Licensing String

•

Record the Initial Meter "A" count to establish proper service billing credits during Final Actions. The Serial Number must be verified to ensure service is rendered on the correct Machine.

Preliminary Working Document No Product Name Assigned

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Section Name

0-1 Initial Action RAP

0-2 Corrective Action RAP

0-3 Scheduled Maintenance Action RAP

The purpose of the Corrective Action RAP is to correct problems that were identified in the Initial Action RAP.

Procedure

Procedure 1.

1.

Store the PPR Printouts in the Machine Log Book. Reset the PPR upon completion. Select the Service Mode Function.

2.

Enter the Printer Service Mode.

Primary Activity:

•

Perform Scheduled Maintenance activities or go to the HFSI TABLES and performing all due HFSI activities as required.

Repair the Primary Problem as identified by the Customer.

•

Perform Subsystem Checks for all the subsystems that were serviced.

As required, perform all the related Subsystem tasks.

•

Investigate and perform Corrective Actions as required after review of the following:

•

Go to the System Fault Analysis Procedures.

• •

NOTE: The performance of the following Secondary Activities at this time should be negotiated with the Customer. Otherwise record the required action in the Machine Log Book. Perform the Secondary Activity at the next scheduled maintenance. 2.

Secondary Activity:

a.

Queued Faults

b.

Shutdown Information

c.

Range Faults

•

Perform previously recorded Secondary Activities.

•

Perform Every Call Activities.

•

Repair any secondary problems that would prevent the Printer from running.

•

Verify other Customer reported problems.

3.

Reset the HFSI dC107 Counter (as required).

•

Verify problems that may generate a UM prior to the next scheduled maintenance call.

4.

Using dC101, save the "Set Up Parameters" to the Floppy Disk and store with the Machine Log Book.

3.

Perform Every Call Activities. Reset the HFSI dC107 Counters as required.

5.

4.

Confirm that the Problems are corrected by exercising the area of the System which was repaired.

Select [Service Mode Exit] on the Printer Initial Actions screen. Exit the Service Mode at the Controller and return to the Operator mode.

6.

Go to the 0-4 Final Action RAP.

5.

If in the Printer Service Mode, select [Service Mode Exit] on the Printer Initial and Final Call actions screen. Exit the Service Mode at the Controller and return the System to the Operator Level.

6.

Print samples using the Largest size paper available:

7.

•

TRAY I-10 Dimensional (Duplex) (DIM.PS)

•

TRAY 2-10 White Dustings (DUST.PS)

•

TRAY 3-10 Halftone (HALF.PS)

•

TRAY 4-10 Xerographic (XEROX.PS)

Go to 0-4 Final Action RAP after all Corrective Actions are complete.

Section Name

0-2 Corrective Action RAP, 0-3 Scheduled Mainte-

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Preliminary Working Document No Product Name Assigned

0-4 Final Action RAP The purpose of the Final Action RAP is to provide the activities to be taken to complete the call properly.

Procedure NOTE: Ensure that the Service Mode is exited before beginning this procedure. 1.

Run Verify. This is a Verification Test of the system Controller and Printer interface and proper Printer operation.

2.

If the Printer was serviced, "Reset Printer Fault History". •

Record the "Meter A" reading and use this to calculate Billing Meter Credits for the Customer.

•

Close the Call Closure screen, (LPS).

3.

Return to Administer level for NPS, Log Level 2, or the Main windows for IPS.

4.

Run a Customer job (cause of initial action if possible). Verify that the reported problem was corrected by having the Customer run an appropriate job in order to duplicate the initial problem

5.

Make all Final Entries to the Machine Log Book. If this is a MICR Machine, complete the MICR Image Quality Analysis Procedure, PQ 9-639, and store with the Machine Log Book.

6.

Check the Customer supply inventory. Provide order if supplies are needed, inform the Customer and information if necessary.

7.

Close the call with the Work Support Center.

Preliminary Working Document No Product Name Assigned

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Section Name

0-4 Final Action RAP

Section Name

0-4 Final Action RAP

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Preliminary Working Document No Product Name Assigned

Initial Action Procedure

Scheduled Maintenance -With this strategy the Service Representative will perfom all of the primary activities related to the Customer description of the reason for the call. Secondary activities are to be performed at a time convenient for the Customer.

PURPOSE The purpose of the Initial Action section of the Service Call Procedures is to help the Service Representative organize the service call. The Service Representative will use the Initial Call Action, Info screen, (which provides a summary of the condition of the system), and input from the Customer to accomplish this objective.

If the analysis of call and fault histories indicate a high potential for another UM before the next scheduled call, the problem must corrected before leaving the account. Software Revision Level: Identifies the current software level resident in the machine. 6.

PROCEDURE 1.

Obtain from the Customer a description of the reason for the call and, if possible, obtain information on the nature of the job being run and mode of operation of the system at the time of the problem. Also, ask the Customer to describe any other problems that may be occuring. •

•

Inspect any rejected prints, if possible. Look for indications of excessive paper jams, such as wrinkles in the paper, unfused images, skewed images, excessive misregistration. Try to identify the specific defects which caused the Customer to reject the print.

Determine if any of the information is related to the description of the problem. For example, HFSI due could contribute to the problem. The subsystem which is likely to be the cause of the primary problem may be out of threshold range, see Table 1-1. There also may be Range Faults which could be related to the primary problem. Make a note of secondary activities required. Run the machine, if necessary, to verify the problem or ask the Customer to demonstrate the problem.

NOTE: Record the Queued faults on a sheet of paper in case you need to reference to them during Corrective Action.

For MICR defects only, ensure that there is no printing on the second side oth the print in the Clear Band Area, and ensure that the MICR line is properly formatted.

a.

NOTE: If the Customer reports an Odor problem, go to 4-707 RAP. •

•

Primary Activities: Are all activities related to the Customer description of the reason for the call. Primary activities include the repair for the reason for the call, Fault History files for the related module, HFSI due for the related chain, Queued Faults for the related chain, and all print quality defects identified by the Customer.

In the event of the following Queued Faults the information displayed in the Shutdown Information may not be valid. 03-201 thru 03-205 are EDN to other Node Communication Faults

Secondary Activities: Are all activities not related to the Customer description of the reason for the call. This includes all unrelated Fault History Files, HFSI due, Queued Faults and Range Faults.

03-372 thru 03-375 are Node Internal Failure 03-380 thru 03-385 are Download Failure 09-201 fault code

NOTE: For Third Party Technicians, refer to GP 1000, Diagnostic Programs and Procedures, for work-arounds if the diagnostic routine mentioned in the documentation is not located on the UI Screen. 2.

Enter Diagnostics at Printer by selecting [Tools]. If the selection can not be selected, go to the System Fault Analysis Procedures to repair, then return to step 3 of this procedure.

3.

Note the reading on meter A. Select [CALL SERVICE] and verify that the Serial Number matches the number on the screen.

Go to the System Fault Analysis Procedures to repair all of the listed Queued Faults. If any of the listed Queued Faults were repaired using the System Fault Analysis Procedure, it is necessary to select [Update Data] for accurate screen information. Return to this step to continue. All Queued Faults should be cleared or repaired in order to totally restore the system to its full operating condion. If the Customer description for the call is a fault code and all of the listed Queued Faults have been repaired, then the first 2 digits of the fault code define the primary activities. For example, if the fault code is an 10-101, all HFSI, Queued Faults, and Range Faults that start with a 10 are primary activities. The Faults screen History Files containing the fault code is also a primary activity. Determine the Faults screen History Files primary activity by viewing the Top 15 Actual.

Select [SERVICE] and enter the Diagnostic Access Code. Select [Enter][SCP] to gain access to the Service Call Procedure Dialogue. 4.

Initial Call Actions: Study the Initial Call Actions screen. The information on this screen will help to structure the service call by providing a summary of the system problems which need to be corrected. Depending upon the type of the problem, some of the SCP activities may not be needed.

5.

Account Information: This Information provides the Serial Number of the machine, Total Print Count and the Software Revision Level. Serial Number -As mentioned in step 3, the serial number must be verified to ensure that service is rendered on the correct machine. Total Print Count -Are the total prints for billing. Total Print Counter, counts up to 999,999,999, rolls over, and repeats. It is an independent counter.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-7

Queued Faults: These are active faults in the system which need to be cleared. Some Queued Faults will not appear in the Customer status handler unless that feature is selected. Remember that there may be more of these faults than are displayed in the Initial screen. The total number of Queued Faults is shown in the Info area of the screen and the faults not listed will be displayed when the listed faults are cleared.

b.

Shutdown Information: Examine the Shutdown Information for an area shutdown rate that is over threshold, (Table 1). If any area is a potential secondary activity, refer to the Faults file. Review Top 15 Actual to find the specific fault codes that are contributing to the shutdown rate. Table 1 Shutdown Information Thresholds AREA

THRESHOLD

Xero.

4 Fault

NOTE 2

Comm.

2 Fault

2 Section Name

Initial Action Procedure

Almost Jam: Is to be used in conjunction with the RAPS to identify problem associated with wear and slippage.

Table 1 Shutdown Information Thresholds AREA

THRESHOLD

NOTE

Other

6 Fault

2

Total Shutdown

2000 MEBJ

1 Rate

If an over threshold value is in the same area as the primary cause of the call, then isolate the cause of the problem by using information from:

NOTE: 1. As the rates increase, the performance of the machine is improving. As the rates go down, the performance of the machine is degrading. Diagnosis is indicated when the rate for the Area is equal to or less than the established threshold NOTE: 2. As the number of faults increase, the performance of the machine is worsening. As the number of faults decrease, the performance of the machine is improving. Diagnosis is indicated when the rate for the Area is equal to or greater than the established threshold. (Step b, continued) Compare these threshold values to the rates displayed on the Initial Call Actions screen for each area. Initially, for new installs, the thresholds provided should be used to determine when in-depth diagnosis of an area is required. For example, if the threshold for the Inverter Feeder Stacker is 10,000 and SCP for I F/S displays 7,000, enter the top 15 for I F/S and review the jams data. If the module rate of 7,000 was caused by one jam, no action is required. If the rate was caused by more than one jam in the same area, evaluation of the area is justified. if so, the area should be reviewed completely in order to ensure all problems are identified. When the area is operating at optimum for a specific machine, a standard level of performance can be established over a series of service calls. These rates than become the expected performance for that machine and should be entered as the threshold values. Variable factors, such as paper type, transparencies and labels, Customer errors and general machine environment will affect expected machine performance. If the over threshold value is not in the primary area of service, search for the cause as a secondary activity and continue to diagnose the primary cause of the call. Total Shutdown Rate MEBJ (Mean Events Between Jams) The Total Shutdown Rate equals Prints since last call divided by the number of shutdowns since last call. The total shutdown rate is used as an overall indicator of machine performance. The Last 50 lists the most current faults at the top of the first column. The print count, at the time a fault is declared is recorded next to each fault. The Last 50 display records the primary cause of a shutdown in print. Secondary or coast faults are not recorded. With the exception of 03 code no shutdowns are recorded in standby. The Last 50 Shutdowns are used: •

To verify the primary reason for the call

•

To identify possible problems not observed by the Customer

•

To display grouped faults, combination faults, and/or random faults

•

To view codes to identify time related groups.

Top 15 Faults/Jams: These are used to identify what has contributed to the frequency of module faults/jams.

Section Name

Top 15 Faults/Jams display

•

Last 50 Shutdowns display

High Frequency Service Items (HFSIs) Due: These are HFSIs which have exceeded predetermined limits and are therefore in need of service. Remember that there may be more of these items than are displayed in the Initial screen. The total number of HFSI is shown in the Info area of the screen, and the ulist-ordereded items will be displayed when the listed items are cleared. To review the HFSI, select HFSI, select HFSI screen. On the HFSI screen, HFSIs that have reached "threshold" or "almost threshold" will have either a Red or Yellow arrow pointing to the count on the item. The Red arrow iluminates when the item has actually reached, or exceeded, the service interval. When the red arrow is illuminated, the item is shown in "HFSI due" on the Initial screen. The Yellow arrow illuminates when an item is within approximately 100k counts of the established service interval. The Yellow arrow alerts the Service Representative to an impending part or parts replacement, allowing for spares and SM planning. HFSIs due in the same area as the primary cause of call are primary activities. Contained in the FA file is additional HFSI info on the task required when the HFSI screen indicates a clean, replace, or lube action is due. The next table lists the HFSI counters letters explanation. Table 2 HFSI Counters Letters Letter

Explanation

C

Clean

L

Lube

R

Replace/Repair

RO

Rotated

Range Faults Range Faults are NVM logged conditions that indicated degraded machine operation (something going to happen or has already occurred). These conditions, if not corrected, may appear as other faults. The purpose is to provide a warning of an approaching fault, or of an existing fault which is not obvious to the Customer, so that corrective action can be taken to prevent machine shutdown from occurring. These conditions will not show up as a Customer status code.

The Top 15 display arranges the area data in a specific sequence. For the sequence starts with the worst MEBJ and MEBJ at the top. Xerox, Comm, and Other Faults, the sequence starts with the largest number of faults at the top.

Initial Action Procedure

c.

•

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Range Faults alert the Service Representative to an impending part or parts replacement, allowing for spares and call planning. Range Faults in the same area as the primary cause of call are primary activities. Any other Range Faults are secondary activities.

Preliminary Working Document No Product Name Assigned

NOTE: For step 7, if unable to make prints, go to the System Fault Analysis Procedures.

Maintenance Hints

NOTE: Save prints for inspection during Level 1 - System Fault Analysis diagnostics examination.

PROCEDURE

7.

After the print samples have been made, go to the Corrective Action for the DP180 section.

The items in Table 1 are service actions that should not be performed when servicing the various subsystems within the machine. Table 1 Service actions that SHOULD NOT be performed SUBSYSTEM All Xerographics

SERVICE ACTION Unless directed, do not lubricate any components in the Machine. Do not wash the PR Belt. Do not wash the Dicorotrons. Do not vacuum the Density Sample Sensor.

Panels

Do not clean the outside panels with any substance other than Formula A and water.

Fuser

Do not touch the glass of the Heat Rod. Do not use film remover to clean the Fuser and the Pressure Rolls.

Preliminary Working Document No Product Name Assigned

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Section Name

Initial Action Procedure, Maintenance Hints

HFSI TABLES

The following HFSI intervals are recommended initial values. The CSE has the ability to modify these intervals as needed to address unique Customer requirements.

PROCEDURE The following High Frequency Service Items are serviced in 1M increments. The items in each group, Table 1 and Table 2, should reach the indicated intervals (1M/2M) at about the same time since they all depend on total impressions made rather than any special mode of operation.

Items identified with a * signify the items contained in SM Kit 1. SM Kit 1 is Part Number 600K25793. Items identified with a ** signify the items contained in SM Kit 2. SM Kit 2 is Part Number 600K25814.

NOTE: If an item fails before its scheduled service interval, service the item and reset the HFSI counter, but keep the item on the same service schedule with the other items in the same group. The additional HFSI activities in Table 3 and Table 4 will be performed during SM as required based on individual HFSI counter values. In the comments column for each HFSI counter is additional information on the tasks required when an HFSI is due for service. Table 1 1M SM HFSI Activities CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

01-801

Cleaner Filter * / **

1000K

Replace

PL 9.21

Before installing the new Filter Bag and Toner Cooling Filter, vacuum any loose toner from the enclosure base and machine frame.

01-802

LVPS Filters * / **

500K

Replace

PL 1.10

Do not vacuum the filters. Ensure the LVPS fans are not turning when replacing the filters.

03-803

Toner Cooling Filter * / **

1000K

Replace

PL 4.7

Inspect for leaks in and around the Toner Dispenser Housing and repair as required.

08-818

System Cleaning

1000K

Clean

09-803

Transfer Assist Blade

1000K 4000K (W/ 3 Layer Blade)

Replace

09-809

POP Sensor

500K

Clean

Do not vacuum; clean with a cotton towel.

09-815

Dicorotron Shields

500K

Clean

Clean the Dicorotron shields by wiping them with a clean, dry towel (35P3191) only. Inspect for discoloration when cleaning. White or yellow deposits over 25% of the shield surface is reason to replace the shield. Detack and Preclean Shields especially are prone to these deposits. If deposits are found, check them for poor OZAC connectors, and look for evidence of poor connections (e.g., arcing, discoloration).

Section Name

HFSI TABLES

Vacuum any loose toner and paper dust visible to the Customer from the entire IOT (Processor, Inverter Feeder/Stacker, and Feeder/Stacker modules), including all paper path Static Ground Brushes. Clean the Xerographic sensors and paper handling sensors with a cleaning pad (600S1276). Vacuum any contamination from the Controller ESS Card Cage Cooling Air Filter. If the contaminates cannot be vacuumed, replace the Air Filter. Inspect all areas for wear and loose hardware. PL 9.11

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Ensure the adhesive securing the End Tab is fully intact and the Tab is at 90 degrees to the blade. Check the solenoids and linkage for freedom of movement. Check for the presence of a special Customized TAB before replacement. Ensure the blade is seated properly by viewing with a flashlight.

Preliminary Working Document No Product Name Assigned

Table 1 1M SM HFSI Activities CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

09-822

Preclean Dicorotron

1000K

Replace

PL 9.10

Do not touch or attempt to clean the glass coated wire! Touching or attempting to clean can cause the glass to crack. These cracks may not be visible and the dicorotron must be replaced. Touch and clean only the sides of the dicorotron. During scheduled dicorotron replacement, inspect the OZAC connectors, looking for evidence of poor connections (e.g., arcing, discoloration). Perform the dC951 Xerographic Setup routine (ADJ 9-3). NOTE: After installing known good Dicorotrons, do not remove Dicorotrons to clean the Dicorotron wire. Use "chopped" Dicorotron (125K1450) in the Preclean position.

09-824

Detack Dicorotron

1000K

Replace

PL 9.10

See Notes for 09-822.

09-825

Developer

1000K (w/o MICR) 600K (W/MICR)

Replace

10-801

Metering Blade

1000K

Rotate/ Replace

PL 10.7

Clean the paper residue from bottom of the Sump, and remember to replace wick and Fuser Agent Filter when rotating or replacing the Blade. Inspect for Fuser Agent leaks. Ensure the proper Blade positioning. Check the new Blade edge for nicks. Place a notch in the used Blade edge. Ensure there is full length contact arc between the fuser and donor rolls. Ensure the donor roll loading arms are not bent.

10-802

Wick and Agent Filter */**

1000K

Replace

PL 10.7 PL 10.8

Clean the paper residue from bottom of the Sump. Ensure the proper clamp positioning. Purge Fuser Agent Line of air bubbles via dC330 (i.e., energize Fuser Solenoid Pump). Inspect for Fuser Agent Leaks. Install automotive-type clamp (Part #: 419W1250) to replace the crimped brass tube at the end of the hose to the Sump, if necessary. Ensure there is full length contact arc between the fuser and donor rolls. Ensure the donor roll loading arms are not bent.

10-814

Metering Assembly

1000K

Clean

Do not perform a Dump and Thump procedure during a routine scheuled Developer replacement. Perform the procedure only when the Developer is contaminated (e.g., cleaner droppings are in the developer). Vacuum the developer seals, Developer Catch Tray and clean any loose toner from the Developer roll gears. Inspect the Developer Rolls 1 and 2 for wear or smooth surfaces. Perform the dC951 Xerographic Setup routine (ADJ 9-3).

Clean the Sump. Ensure there is full length contact arc between the fuser and donor rolls. Ensure the donor roll loading arms are not bent. Inspect for Fuser Agent Leaks. Check the Bearing Seats for wear.

Table 2 2M SM HFSI Activities CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

08-816

Registration Cross Rolls **

2000K

Replace

PL 8.7

Verify that the Upper Transport Baffle is seated properly, not damaged or deformed. (W/TAG P-267) Two (2) Cross Roll Kits are required to replace the four (4) Cross Rolls.

09-801

Cleaner Brush & Blades **

2000K

Replace

PL 9.24

Before replacing the Brush and Blades, vacuum any loose toner from the housing, and clean the Flicker Bar. If the discarded Cleaner Blades have fused toner adhering to the lead edge, inspect the Upper and Lower Detoning Rolls for loss of anodized coating. Ensure correct reinstallation of the white plastic Auger channels. Vacuum the new Cleaner Brush before replacement.

Preliminary Working Document No Product Name Assigned

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Section Name

HFSI TABLES

Table 2 2M SM HFSI Activities CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

09-805

Post-Cleaner Blade (Spots Blades)

2000K

Replace

PL 9.26

Lubricate the blade with the toner impregnated cloth, provided with the Kit. Perform the Post-Cleaner Blade (Spots Blade) Contact Adjustment (ADJ 9-16 ) if the discarded Blade shows an uneven wear pattern and/or the P/R Belt shows evidence of scratches. Verify the Spots Blade is installed correctly; backwards will trap excessive debris.

09-820

Charge 1 Dicorotron

2000K

Replace

PL 9.10

Do not touch or attempt to clean the glass coated wire! Touching or attempting to clean the wire can cause the glass to crack. These cracks may not be visible and the Dicorotron must be replaced. Touch & clean only the sides of the dicorotrons. During scheduled dicorotron replacement, inspect the OZAC connectors, looking for evidence of poor connections (e.g., arcing, discoloration). Perform the dC951 Xerographic Set Up routine (ADJ 9-3). NOTE: After installing known good Dicorotrons, do not remove Dicorotrons to clean the Dicorotron wire. Use "chopped" Dicorotron (125K1450) in the Preclean position.

09-823

Transfer Dicorotron

2000K

Replace

PL 9.10

09-826

Cleaner housing, manifold and hose

2000K

Clean

Remove the Brush, Blades, Flicker Bar and Filter Bag. Thoroughly vacuum the Cleaner Housing and gear train. Pull (vacuum) any loose toner through hose at Filter Bag.

10-815

Prefuser Transport vacuum holes

2000K

Clean

Clean the transport base. Check the manifold plate for warp and air leaks.(i.e., gasket, manifold cracks, etc.) Ensure that the vacuum holes are clear of debris. NOTE: Prefuser Transport Belts are replaced every 6000K prints.

CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

03-802

Cooling Fan / Particulate Filter (DP 180MX Only)

2000K (with P-314) 1500K (W/O P-314)

Replace

PL 9.8 PL 4.8

Vacuum any contamination from Cooling Fan Housing + grill.

10-805

Prefuser and Fuser Jam Sensors

750K

Clean

10-806

Pressure Roll / Stripper Finger

1500K, 750K (w/MICR)

Replace/ Clean

See Notes for 09-820.

Table 3 HFSI Activities Less Than 2M

Clean the Q1009 sensor and mirror with a cleaning pad and Lens & Mirror Cleaner, 43P81. Clean the Q1010 sensor with cotton swabs and Lens & Mirror Cleaner, 43P81. Inspect for Fuser Agent Leaks. PL 10.4 and PL 10.5

Inspect for Fuser Agent leaks; inspect Fuser Gears for tooth wear and "fretting". Ensure that the Metering and Donor Rolls are seated properly by ensuring that the arms are not bent and are in the locked position. Ensure a full length contact arc is evident between the fuser and donor rolls.

Table 4 HFSI Activities Greater Than 2M CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

08-802

Tray 1 Feed Belt

1000K (Tray 1 Feeds)

Replace

PL 7.10

Visually check the Takeaway Rolls for any wear, any damage or contamination. Clean the Takeaway Rolls with Film Remover, and clean the Stack Relief sensors with a cleaning pad (600S1276). Check/adjust Feed Belt tension if required, Check the Tray 1 Drive Coupling for binding; lubricate with Lubriplate (70P31) as required.

Section Name

HFSI TABLES

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Preliminary Working Document No Product Name Assigned

Table 4 HFSI Activities Greater Than 2M CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

08-804

Tray 2 Feed Belt

1000K (Tray 2 Feeds)

Replace

PL 7.10

Visually check the Takeaway Rolls for any wear, any damage or contamination. Clean the Takeaway Rolls with Film Remover, and clean the Stack Relief sensors with a cleaning pad (600S1276). Check/adjust Feed Belt tension if required, Check the Tray 2 Drive Coupling for binding; lubricate with Lubriplate (70P31) as required.

08-810-X

Tray X Blower O Ring Drive Belt

15000K (Tray X Feeds)

Replace

PL 8.14

No additional actions are required.

03-801

Printer Monitor Filters

3000K (Imps.)

Replace

PL 2.3

No additional actions are required.

09-821

Charge 2 Dicorotron

3000K (Imps.)

Replace

PL 9.10

Do not touch or attempt to clean the glass coated wire! Touching or attempting to clean can cause the glass to crack. These cracks may not be visible and the dicorotron must be replaced. Touch and clean only the sides of the dicorotron. During scheduled dicorotron replacement, inspect the OZAC connectors, looking for evidence of poor connections (e.g., arcing, discoloration). Perform the dC951 Xerographic Set Up routine (ADJ 9-3). NOTE: After installing known good Dicorotrons, do not remove Dicorotrons to clean the Dicorotron wire. Use "chopped" Dicorotron (125K1450) in the Preclean position.

08-808

Vertical Transport Belts

3000K (Tray 1 +Tray 2 +Duplex Feeds)

Replace

PL 8.1

Check the drive coupling wear element, magnetic skis, and the switch actuator for damage.

08-817

Registration Servo Shaft Rolls

3000K (Imps.)

Clean

10-812

Metering Roll

3000K (Sheets Thru Fuser)

Replace

09-806

P/R Drive Coupling

4000K (Imps.)

Clean/Lube

Clean with film remover. Run dC703 to optimize Dynamic Width measurement counter. PL 10.7

Inspect for Fuser Agent leaks; inspect Fuser Gears for tooth wear and "fretting". Ensure that the Metering and Donor Rolls are seated properly. Check the Metering Donor Roll and Metering Blade for nicks. Check the Bearing Seats for wear. Check metering roll bearing seats for wear. Lubricate with Moly Grease, 70E120. See Rollovers (PC 3676, RO 177643) in the Service Information Section for additional information on the lubricant and a tool for its application. Inspect the Drive Dogs for wear.

09-808

Cleaner Flicker Bar

4000K

Replace

09-827

Developer Drive Coupling and Gears/Tray 1 & 2 Drive Couplings

4000K (Imps.)

Clean/Lube

Lubricate with Moly Grease, 70E120 (PL 25.1). See Rollovers (PC 3676, RO 177643) in the Service Information Section for additional information on the lubricant and a tool for its application. Inspect the Drive Dogs and the Developer Drive Coupling Gears for wear.

10-816

Fuser/Pre-Fuser Drive Couplings

4000K (Imps.)

Clean/Lube

Lubricate with Moly Grease, 70E120 (PL 25.1). See Rollovers (PC 3676, RO 177643) in the Service Information Section for additional information on the lubricant and a tool for its application. Inspect the Drive Dogs for wear.

09-XXX

Dicorotron shield assy

5000K

Replace

PL 9.10

Replace the Dicorotron shield assembly for all Dicorotrons

10-811

Prefuser Transport Belts

6000K

Replace

PL 8.9

Clean the Transport base. Ensure that the vacuum holes are clear of debris. Replace the Transport Belts. Clean and lubricate the Drive Coupling with Lubriplate (70P31).

09-802

Agitator Spring

7850K (PR Belt Rev's)

Replace

PL 9.23

Inspect for impacted toner and clean channels as required.

Preliminary Working Document No Product Name Assigned

PL 9.24

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Vacuum the Top Manifold Assembly.

Section Name

HFSI TABLES

Table 4 HFSI Activities Greater Than 2M CODE

ITEM

INTERVAL

ACTION

PARTS LIST

COMMENTS

09-830

Developer Bead Carry Out Seal

4200K (Imps)

Replace

PL 9.17

Vacuum loose debris and toner deposits on Developer seals, Catch Tray and Developer gears. Ensure the Seal substrate material is not rubbing on Roll 1 or Roll 2. Trim substrate material as required.

10-803

Donor Roll

8000K

Replace

PL 10.8

Inspect for Fuser Agent leaks; inspect Fuser Gears for tooth wear and "fretting". Ensure that the Metering and Donor Rolls are seated properly by ensuring that the arms are not bent and are in the locked position. Ensure a full length contact arc is evident between the fuser and donor rolls.

08-806-X

Tray X Feed Belt

15000K (Tray X Feeds)

Replace

PL 8.13

Check the Feeder Drive Coupling Wear Element for signs of wear or damage.

11-802-X

Disk Stepper Motor Coupling

15000K (Sheets Entering Stacker X)

Replace

PL 11.30

Ensure correct Drive Shaft coupling alignment.

09-807

Cleaner Blower ORing Drive Belts

10,000K

Replace

PL 9.20

Inspect the blower pulley for toner buildup in grooves, and clean as required.

10-813

Decurler Belts

15000K (Sheets Thru Fuser)

Replace

PL 10.12

Inspect bearing on shafts, repair as required. Ensure the Decurler Sensor is adjusted fully ccw. Inspect the Decurler Sensor for missing or weak spring.

Section Name

HFSI TABLES

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Preliminary Working Document No Product Name Assigned

A Go to the Jam/Fault Code Entry Procedure.

System Fault Analysis Procedures Initial Actions 1.

Enter this procedure only from the Call Flow Procedure.

2.

Review the Maintenance Hints in the Initial Action Section to become aware of the service action that should not be performed.

3.

Make Sure all the power cords are connected and power is available. Ensure that all the ELCI circuit breakers are in the On position.

Procedure Question the operator to determine the failure symptoms. If this is an Online system, (IPS) request that the operator vary the system offline. The problem reported has a fault code or status message associated with the printer. Y N The problem reported Boot error message associated with the System Controller. Y N There is an obvious Print Quality defect with the delivered prints. Y N There is a problem observed or that is reported by the Customer and is related to the printer. Y N The System Controller and all peripherals are operational and Service Mode can be entered. Y N Go to the System Fault Analysis Procedure in the DP NPS Service Manual or DP IPS Service Manual. Observe the PPR and return to 0-2 Corrective Action RAP in the Call Flow Procedures. The problem reported is an Odor problem. Y N Go to the Printer Entry Procedure. Go to 4-707 RAP. The defect is related to the image location (Skew, Registration, or magnification). Y N Run DIM.PS, 10 Prints. Observe the prints and identify the defect. Enter Printer Service Mode, and go to the PQ 9-601, Printer Image Quality Entry RAP. Enter Printer Service Mode, and go to the PQ 9-601, Printer Image Quality Entry RAP. Go to the System Fault Analysis Procedure in the DP NPS Service Manual or DP IPS Service Manual. The problem is associated with a fault code. Y N Go to the Printer Entry Procedure in Printer Fault Analysis Procedures. A Preliminary Working Document No Product Name Assigned

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Section Name

System Fault Analysis Procedures

A

B

C

D

Printer Entry Procedure

E

F

G

H

I

J

K Y

Procedure Enter UI Lockout, and Printer Service Mode. A Fault Code is declared. Y N The reported problem can be repeated on the System. Y N Go to the Non-Repeatable Problem Entry Procedure, Section 1. Ensure the Printer Main Power Switch is on and the Local Remote Switch is in the Remote position. Ensure that all circuit breakers are on. The Printer UI Monitor is completely black (not illuminating). Y N The problem occurred while doing a Printer software upgrade. Y N There is a Floppy Disk problem. Y N The Printer UI Monitor screen has Icons. Y N Go to the UIM Boot Entry Procedure.

N There is a problem with the prints stacking in the stacker. Y N Go to the NRD 1, NonRepeatable Problem Entry Procedure to isolate the problem. Go to 11-600, Poor Stacking Quality RAP.

Go to 10-607, Unable to Type on Prints RAP. Go to the Print Defect Entry Procedure. Go to the Print Damage Entry Procedure. Go to the 4-702, Processor Drive Noise RAP or 11712, Inverter/Stacker Noise RAP.

The "Not Ready Please Wait: Fuser warming up" or "READY" message appears on the screen. Y N Go to 3-700, the Printer Boot RAP.

The unfused prints exhibit lead edge-to-trail edge streaks. Y N Go to the 10-608, Dry Ink Not Fixed RAP.

All "On-Screen" selections can be made. Y N Go to 2-700, the Printer UI Entry Procedure.

Go to the 10-605, Lead Edge-To-Trail Edge Streaks RAP. Go to the OF-3, Machine Failure With No Fault Code RAP.

The printer UI Monitor has one or more of the following problems: 1) Color, distortion, 2) Missing information, 3) 7-segment display, 4) Hard buttons, 5) Audio tone. Y N The problem is with a status message. Y N There is a Dead Cycle problem (One or more of the machine drive motors are running or a component that does not work and no fault code or message is displayed. Y N There is an unfused print problem. Y N There is an audible noise or odor problem. Y N The print is being damaged. Y N There is a print defect Quality problem. Y N There is a "cannot type on prints" problem.

A

B

C

D

E

F

G

H

Section Name

Printer Entry Procedure

I

J

K

Go to the OF-2, Diagnostics RAP. Go to the 2-700, Printer UI Entry Procedure. Go to the 3-701, Floppy Disk Drive Failure RAP. Go to the 3-703, Software Upgrade Problem RAP. The top LED on the EDN is off. Y N The problem occurred while doing a Printer software upgrade. Y N There is a Floppy Disk problem. Y N The Printer UI Monitor screen has Icons. Y N Go to the UIM Boot Entry Procedure. The "Not Ready Please Wait: Fuser warming up" or "READY" message appears on the screen. A

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M

N Preliminary Working Document No Product Name Assigned

A

L

M

N

A Y

N Go to 3-700, the Printer Boot RAP.

L

M

N

O

P

Q Y

All "On-Screen" selections can be made. Y N Go to 2-700, the Printer UI Entry Procedure.

N Go to the 10-608, Dry Ink Not Fixed RAP.

Go to the 10-605, Lead Edge-To-Trail Edge Streaks RAP. Go to the OF-3, Machine Failure With No Fault Code RAP.

The printer UI Monitor has one or more of the following problems: 1) Color, distortion, 2) Missing information, 3) 7-segment display, 4) Hard buttons, 5) Audio tone. Y N The problem is with a status message. Y N There is a Dead Cycle problem (One or more of the machine drive motors are running or a component that does not work and no fault code or message is displayed). Y N There is an unfused print problem. Y N There is an audible noise or odor problem. Y N This print is being damaged. Y N There is a print defect or a MICR Quality problem. Y N There is a "cannot type on prints" problem. Y N There is a problem with the prints stacking in the stacker. Y N Go to the NRD 1, NonRepeatable Problem Entry Procedure to isolate the problem.

Go to the OF-2, Diagnostics RAP or System Checks in the DP IPS or DP NPS. Go to the 2-700, Printer UI Entry Procedure. Go to the 3-701, Floppy Disk Drive Failure RAP. Go to the 3-703, Software Upgrade Problem RAP. Go to the Printer Power Entry Procedure. Go to the Jam/Fault Code Entry Procedure.

Go to 11-600, Poor Stacking Quality RAP. Go to 10-607, Unable to Type on Prints RAP. Go to the Print Defect Entry Procedure. Go to the Print Damage Entry Procedure. Go to the 4-702, Processor Drive Noise RAP or 11712, Inverter/Stacker Noise RAP. The unfused prints exhibit lead edge-to-trail edge streaks. A

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O

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Q

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Section Name

Printer Entry Procedure

Printer Power Entry Procedure

Print Damage Entry Procedure

Initial Actions

Procedure

Ensure the Printer is connected to the power source and that power is available.

The printed sheet is wrinkled. Y N Refer to Panic Stop Procedure in the General Procedures. Stop the machine. Examine the prints throughout the machine. The damage is occurring at the fuser. Y N The damage is occurring somewhere in the PHM other than the fuser. Y N The print damage is in the stacker. Go to the 11-600, Poor Stacking Quality RAP.

Procedure The ELCI/RCD device is tripped. Y N On the line Interface Module, Circuit Breaker: CB 101 (60Hz), CB 104 (50Hz), or CB 105 (50Hz), is switched off. Y N Go to the 1-713, +5 VDC RAP.

Go to the 8-705, PHM Print Damage RAP.

Reset the circuit breaker. The circuit breaker switches off again. Y N Return to the Call Flow, 0-1 Initial Action RAP (Initial Actions).

Go to the 10-701, Bent Corners RAP. Go to the 10-603, Wrinkle RAP.

Go to the 1-721, (60Hz), or 1-724 (50Hz), Circuit Breakers Switching Off RAP. Reset the ELCI/RCD. The ELCI/RCD trips again. Y N Return to the Call Flow, 0-1 Initial Action RAP (Initial Actions). Go to the 1-731 RAP.

Section Name

Printer Power Entry Procedure, Print Damage Entry

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Preliminary Working Document No Product Name Assigned

UIM Boot Entry Procedure

Print Defect Entry Procedure

Procedure

Procedure

Switch off the Printer, wait 30 seconds, (some systems may require a full 2 minute wait), and switch on the Printer. The screen is displaying vertical or horizontal lines.. Y N 30 seconds after powering on the Printer, the UI screen is illuminated (lit) with picture (1 or 2 on screen). Y N Go to the 2-700, Printer UI Entry Procedure.

The defect is dark horizontal bands/streaks seen only on blank inserts or covers. Y N Refer to Panic Stop Procedure in the General Procedures. Stop the machine. Examine the prints. The defect is Fuser related (lead edge smear, print gloss, lead edge-totrail edge smear). Y N Go to the PQ 9-601, Printer Image Quality Entry RAP.

60 seconds after Power on, only "X__-XX-__X" is displayed on the 7-segment display. Y N The 7-segment display is alternating "8888888888" and "0000000000". Y N The 7-segment display illuminated at some point during the boot process. Y N Go to the 2-700, Printer UI Entry Procedure.

Go to the appropriate RAP: • 10-601, Fuser Lead Edge Smear RAP. •

10-602, Fuser Print Gloss RAP.

•

10-605, Lead Edge to Trail Edge Streaks (Unfuser Prints) RAP.

•

10-607, Unable to Type on Prints RAP.

Go to the PQ 9-611, Dark Streaks/Scratches/Bands RAP.

Go to the 3-224, RAP. Go to the 3-380, RAP. Go to the 3-224, RAP. Go to the 2-700, Printer UI Entry Procedure.

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Section Name

UIM Boot Entry Procedure, Print Defect Entry Pro-

A

Jam/Fault Code Entry Procedure Procedure Enter Printer Service Mode. Circuit Breaker CB 102 or CB 103 is switched off. (60Hz machine only). Y N A fault code was in the queue during the Initial Action. Y N Go to the Non-Repeatable Problem Entry Procedure. A single fault code is in the queue. Y N The multiple fault codes include a 9-201. Y N The fault codes include 6-250 or 6-251. Y N The multiple fault codes include one or more 9-203, 9-213, 9-215, or 9-32X codes. Y N The multiple fault codes include one or more 3-XXX (any chain 3) codes. Y N The primary problem is always present, or can be made to occur frequently enough to diagnose. Y N Go to the NRD1, Non-Repeatable Problem Entry Procedure in Section 1, to troubleshoot the problem.

B The fault code is a 3-XXX code. Y N Does the fault code support the primary activity. Y N Treat this fault code as a secondary activity. Go to the NRD1, Non-Repeatable Problem Entry Procedure in Section 1, to identify and troubleshoot the primary problem. The problem is always present, or can be made to occur frequently enough to diagnose. Y N Go to the NRD1, Non-Repeatable Problem Entry Procedure in Section 1, to troubleshoot the problem. Go to the appropriate RAP or FA screen. Press R. Allow 60 seconds for the system to reset. Select [dC], then [SCP]. The code(s) are cleared from the queue. Y N Go to the RAP or FA screen for the first 3-XXX fault code in the queue.

fault

Go to the 3-730, Intermittent Entry RAP. Go to 1-721, Circuit Breakers Switching Off RAP.

Go to the appropriate RAP. Press R. Allow 60 seconds for the system to reset. Select [dC], then [SCP]. The fault code(s) are cleared from the queue. Y N Go to the RAP or FA screen for the first 3-XXX fault code in the queue. Go to the 3-730, Intermittent Entry RAP. The fault codes alternate between any combination of any of the following codes: 9-325, 9-326, 9-327, and 9-329. Y N The codes repeat after resetting. Y N Go to the Printer Electrical Noise Procedure in NRD, Section 1. Go to the appropriate RAP. Go to the 9-328. Go to the 6-250/251. Go to the 9-201 RAP. A

B

Section Name

Jam/Fault Code Entry Procedure

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Preliminary Working Document No Product Name Assigned

Corrective Action for the DP180 PURPOSE The purpose of the Corrective Action section is to repair any problems that were identified in the Initial Action section.

PROCEDURE 1.

Go to System Fault Analysis Procedures to troubleshoot/repair the primary problem. Perform all primary activities. NOTE: If the problem solution is not identified within 1 hour after starting diagnostics, escalate the call.

2.

a.

Range Faults - Investigate the primary Range Faults. Repair as required.

b.

Subsystem Checks/HFSIs due - Perform the Subsystem Checks and go to the HFSI TABLES and perform all due HFSI in the primary subsystem. •

Subsystem Checks shall be done only when the problem is in that subsystem. For example, if the problem was for Fuser misstrips, perform the Fuser Subsystem Checks.

•

Contained in the FA file is additional HFSI Info on the task required when the HFSI screen indicates a clean, replace, or lube action is due.

•

Every Call Activity - If greater than 100K prints or five Customer working days since the last call, perform the Every Call Activities.

•

If the account is under situational or scheduled maintenance, go to step 3.

SECONDARY ACTIVITY NOTE: If determined that any identified secondary activity could potentially cause a problem, discuss with the Customer the secondary service actions you would perform and how long they would take. If the Customer approves, perform the secondary activities. If the Customer requires the use of the machine, schedule a time to return and perform the secondary activities. If scheduled maintenance option is in effect, perform the secondary activities at the next scheduled maintenance. a.

Shutdown Information - To achieve longer intervals between calls, perform a brief investigation of the recent Shutdown Information to identify any problem that could drive an earlier than expected call back.

b.

Range Faults - If other Range Faults have been detected, perform corrective actions as required.

c.

HFSI - go to the HFSI TABLES and perform all the secondary HFSI due.

d.

Print Quality - Inspect the prints for Print Quality/MICR Quality perform corrective actions as required. NOTE: If you determine that any identified secondary activity could potentially cause a UM call, repair before leaving the account.

3.

Verify that problems are corrected by exercising the area of the system which was repaired.

4.

After all corrective actions are complete, go to the Final Action section.

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Section Name

Corrective Action for the DP180

Section Name

Corrective Action for the DP180

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Preliminary Working Document No Product Name Assigned

Print Paper Diagnostics

If unsuccessful, then try another ream of the same stock.

PROCEDURE

If unsuccessful, then try different stock. Check Customer's paper supply. Curl is usually due to a high moisture content. Customer should avoid using paper that has acclimated to a moist environment, particularly if reams are opened. Also, some paper as received from the supplier may contain excessive moisture. Also, with short grained stock, it may be difficult-toimpossible to decurl adequately.

Use the following suggestions for diagnosing paper-related problems that are causing jams or IQ problems. Run a few single and double sided prints to the Sample Tray. Check the prints for curl, fluff, etc. If one of the symptoms is present, refer to the following table and use the procedures indicated for that problem (number in the parenthesis next to the paper condition symptom).

If unsuccessful, then the job may have to be split into smaller segments to reduce the number of prints placed in the Sample Tray or Stacker Bins. b.

Prints can be examined during a job by using the Proof button to deliver single sample prints to the Sample Tray. To check prints in the Stacker Modules the Stop button can be used.

Adjust the decurler to induce a small amount of curl in the process direction to oppose and overcome the cross curl.

The Operator Guide also contains additional helpful information about paper-related problems. Table 1 PRINT PAPER DIAGNOSTICS PROBLEM

PAPER CONDITION

Jams entering Duplex Inverter

Edge Reinforced paper (9)

If unsuccessful, repeat the checks used to diagnose "Curled Prints in the Process Direction." 2.

Fluffy Print (2)

If unsuccessful, then try another ream of the same stock.

Operator selection mismatch of size or type

If unsuccessful, then try different stock.

Operator changed paper size or type with job incomplete

Check Customer's paper supply. Curl is usually due to a high moisture content. Customer should avoid using paper that has acclimated to a moist environment, particularly if reams are opened. Also, some paper as received from the supplier may contain excessive moisture.

Shingled multifeed (3) Dog eared print paper (4) Skewed sheets (12) Jams entering Stacker Bins when bins are nearing full

If unsuccessful, then the job may have to be split into smaller segments to reduce the number of prints placed in the Sample Tray or Stacker Bins.

Curled Print (1) 3. Fluffy Print (2)

Shingled multifeed: Two sheets overlap so that the sheet width is detected as too long or as a trail edge late jam. Check stock for defective cutting, edge welding, or interlocking drilled holes.

Multifeeds

Poorly cut/drilled stock (7)

Fuser misstrips

Curled Stock (5)

Photoreceptor misstrips

Curled Stock (5)

Try fanning the edges of the stock to be sure that edges and/or drilled holes are not interlocking sheet to sheet.

Transfer deletions

Moist Stock (6)

If successful, instruct the operator on when and how to do this.

Debris Centered deletions

Paper debris or poorly cut/drilled stock (7)

Spots on prints

Paper debris (7)

Smear with preprinted forms

Preprinted forms (8)

Paper jams at decurler, top transport interface, or in the top transport using light weight paper

Light weight paper curl (10)

If unsuccessful, then check the feeder. 4.

Dog Ears: (Folded corners) Look for obstructions in the paper path. If none found, then check the feeder. If no improvement after checking the feeder and path to the point of dog ears, then try another type of stock.

5. 1.

Fluffy Prints: This is a condition where the thickness of a paper stack will be significantly thicker than normal. The paper may exhibit a cockeled or wavy appearance. This type of paper defect will stress bin and sample tray capacity. Try turning stock over. This will normally not fix the problem but may reduce the stack height somewhat.

Curled Print (1) 8-901, 902, 904-1, 904-2 jams

Prints Curl across the Process Direction

Curled stock (curl in the ream before printing)

Curled Prints: Refer to the Curl Limit Figure 1 for recommended Curl Limits.

Try another ream of the same stock

a.

Curled Prints in the Process Direction

If unsuccessful, then try a different stock.

Press "STOP", wait until the printer cycles down then Adjust the Decurler. Check the effect of different decurler setting on the curl.

Check Customer's paper supply. Curl is usually due to a high moisture content. Customer should avoid using paper that has acclimated to a moist environment, particularly if reams are opened. Also, some paper as received from the supplier may contain excessive moisture.

If unsuccessful, then try turning stock over. Try decurler adjustment if improvement was seen.

Preliminary Working Document No Product Name Assigned

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Section Name

Print Paper Diagnostics

6.

Moist stock: (Paper with excessive moisture content) Try another ream of the same stock If unsuccessful, then try a different stock Check Customer's paper supply. Curl is usually due to a high moisture content. Customer should avoid using paper that has acclimated to a moist environment, particularly if reams are opened. Also, some paper as received from the supplier may contain excessive moisture.

7.

Debris: Most commonly from poorly cut and/or drilled stock or stock produced in a dusty environment. Check for cutting and or drilling debris If present, try another stock. If unsuccessful, then the debris is not coming from the paper. If problem was the stock, then point out to the Customer that the stock is defective and results with that stock cannot be improved.

8.

Preprinted prints Be sure stock printing does not line up with Tray 1 or 2 Feed Head. Be sure stock has thoroughly dried ink. Fresh offset prints may present a smear problem if not cured for a day or longer.

9.

Edge reinforced stock This stock can cause jams if entering the Duplex tray with the edge reinforcement facing up. Load stock in Feed Trays 1 and/or 2 so reinforcement faces down.

10. Away from Image (AI) curl with light weight paper Light weight paper is especially prone to jam at the top transport or top transport decurler interface if curled significantly in the AI direction. Adjust to achieve less AI curl. Refer to "Curled Prints." 11. Up Curl with light weight paper Adjust to achieve curl between flat and down. Refer to "Curled Prints." 12. Skewed sheets Check from the feeder through the registration transport for any obstructions which may be causing skew. Check that the edge guides in the supply tray are set correctly.

Section Name

Print Paper Diagnostics

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Preliminary Working Document No Product Name Assigned

Figure 1 60 HZ Curl Measurements

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Section Name

Print Paper Diagnostics

Section Name

Print Paper Diagnostics

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Every Call Activities

PROCEDURE The Every Call Activities (see Table 1 Every Call Activities) should be performed on every service call. However, it is not necessary to perform the Every Call Activities, if less than 50K prints since the last call. Table 1 Every Call Activities

SUBSYSTEM

ACTIVITY

NOTES

Tray 3/4/5/6

Verify Stack Height Sensor, Q735 actuator not damaged (bent or broken).

Development

Check for excess Developer Beads in the Catch Tray. It is normal to find a small quantity of beads (a tablespoon or less in Go to PQ 9-616, Development RAP a normal 150K interval between UIM calls), mainly at the Tray ends. Empty the Developer Beads Catch Tray. and/or PQ 9-631, Bead Carryout RAP.

Photoreceptor Module Area

1. Clean the Air Dam Seal of the Stripper Finger Assembly. 2. Clean the POP Sensor. 3. Check for dry ink buildup. 4. Inspect the Lamps for burnt out segments.

Fuser

1. Check for Fuser Agent leaks and spillage. 2. Fill the Fuser Agent reservoir. 3. Visually check the condition of the Fuser, Donor and Pressure Rolls.

Subsystem Checks

(PL 7.16)

1. Use dry cloth 35P3191. 2. Use dry cloth 35P3191. 3. Clean and repair cause for buildup. 4. Repair as required.

3. Replace as required: a. Fuser Roll (PL 10.7) b. Donor Roll (PL 10.9) c. Pressure Roll (PL 10.4)

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

NOTES

Fuser

SUBSYSTEM

1. Check the Reservoir (PL 10.1), Pan (PL 10.1) and Fuser Entrance Baffle (PL 10.4) under the Pressure Roll for Fuser Agent leaks. 2. Check the Pressure and Fuser Rolls for excessive Agent and for proper Agent level in the Reservoir. 3. Clean the Fuser Entrance Baffle channel on each end that directs the Agent back to the Reservoir. 4. Inspect the Fuser Roll Idler and the input gears for tooth wear; replace as required. Listen for excessive gear noise with the Rolls cammed in. Replace the gears if they are noisy. 5. Ensure that the Metering/Donor Rolls are seated properly. 6. Clean the Fuser Jam Sensor, Q1010, (PL 10.6) and the Prefuser Sensor, Q1009, (). 7. Clean the surface of the Airknife Manifold and ensure that the air holes are open. 8. Enter Printer dC330. Select [10], [Compressor].Verify that the Fuser air pressure is 20 +/- 1 PSI. 9. Visually inspect the Fuser, Donor and Pressure Rolls for evidence of early failure.

1. Replace as required. Fill the Reservoir. 2. Go to 10-702, Fuser Air System Checkout RAP.

Cleaning

1. Check the Cleaner for toner buildup after cleaning. 2. If the Cleaner fails by binding, suspect the Cleaner Drive Bracket (rear of the Machine) failed. Replace the bracket if bent or twisted. 3. Check the Photoreceptor for fine scratches in the process direction. If present, check for causes. 4. Clean the toner from the machine drives (rear of the Machine).

1. Go toPQ 9-617, Cleaner RAP. 2. Replace the developer after performing (REP 9-4), Dump and Thump. 3. Replace the P/R (PL 9.1) if the scratches print. Go toPQ 9-604 to determine cause of scratches.

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Section Name

Every Call Activities

Table 1 MIM System Checks SUBSYSTEM

ACTIVITY

NOTES

Development

1. Check the ends of the Developer Rolls for caked dry ink and developer. 2. Check the Drive coupling freedom. 3. Check the dirt seals and air baffles traces of any escaping dry ink, toner and/or developer. 4. Empty the Developer Bead Catch Tray. 5. Clean the dirt seals, the entrance and the exit lips and the Manifold surface.

Charge/Transfer/Erase

Clean the Dicorotron Shields.

Belt Module

1. Check the operation of the Cleaner Zone Roll mechanism and the Belt Module latch. 2. Clean the Pretransfer and Precharge Erase Lamps. Replace the lamps if any of the individual LEDs do not light. 3. Clean the DSS and the Belt Hole Sensor (Q901). 4. Clean the POP Sensor (Q904) and the Waste Bottle Full Sensor (Q901). 5. Check the condition of the Photoreceptor ground strip and ground brushes. 6. Check for dry ink and toner buildup patterns. 7. Clean loose dry ink from the Photoreceptor edge guides. If dry ink is fused to the edge guide, replace the edge guide.

Section Name

Subsystem Checks

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1. Symptom of excess heat. 2. Lube/repair as required (PL 9.14). 3. Repair as required (PL 9.15).

2. Pretransfer Erase Lamps (PL 9.3) Precharge Erase Lamps (PL 9.4)

7. Edge Guide (PL 9.5)

Preliminary Working Document No Product Name Assigned

Table 2 PHM System Checks SUBSYSTEM

ACTIVITY

NOTES

Tray 1 and Tray 2 Feed- 1. Check the entrance guide for wear or contamination. ers 2. Check the takeaway rolls for wear, any damage or contamination. 3. Clean the Feed Belts, Retard Rolls, #1 Takeaway Roll Sensor (Q811), #1 Stack Relief Sensor (Q812), #2 Takeaway Roll Sensor (Q821) and #2 Stack Relief Sensor (Q822). NOTE: If a print lead edge shears or for excessive multifeeds, replace the Retard Roll and Brake. Tray 3/4

Check the Tray Latch operation. Press the Tray release button and ensure that the Tray can be opened when the READY TO OPEN light switch is lit. Close the Tray and ensure that the Latch engages. 2. Check the O-ring drive for any wear, stretch or cracks.

Registration Transport

Verify that the Lower Transport Baffle is seated properly.

Vertical Transport

1. Check the Drive Coupling wear element, magnetic skis and the switch actuator for wear. 2. Check and clean the Transport Belts.

Top Transport

1. Check the Drive and Idler Rolls for any wear or contamination. 2. Check the Static Brushes for wear, adjustment or any damage. 3. Check the Jam Sensor Actuators (Q1011 and Q1012) for damage.

General

Check and clean the Friction Drive Elements and Sensors area for excessive paper dust.

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1. (PL 7.13) 2. (PL 7.10) 3. (PL 7.13) Retard Roll Brake (PL 7.13)

Section Name

Subsystem Checks

Section Name

Subsystem Checks

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Non-Repeatable Problem Entry Procedure

NOTE: Do not use the Single Standout displayed on the Printer and Controller Fault History Summary frames. Refer to the NRD General Information And Diagnostic Hints section for details on determining a single standout.

PROCEDURE Use the following procedure to determine the corrective action to isolate/repair non-repeatable problems. If the problem is repeatable, go to the hard failure RAPs in the Service Dialog or the Service Manual (Section 2 or 3).

Print Subsystems 1.

Initial Action: For PQ related non-repeatable problems, go to the PQ 9-601 System PQ Entry Level RAP in Section 3. NOTE: Intermittent problems can be operator or account related due to different job types, varying operator skill levels, or changing environmental factors. For detailed list of possible environmental factors and interrogation procedures, go to NRD General Information And Diagnostic Hints. Continue through this procedure until confident that the Non-repeatable problem has been corrected.

2.

3.

Question the Operator Obtain as much information as possible on the job being run when the non-repeatable problem(s) occurred.

Environmental factors

4.

5.

Take into account any possible environmental factors that might be contributing to the problem.

Overdue HFSIs Select [SCP] HFSIs in the Service Dialog and perform if due.

Paper Handling Jams over threshold a.

For single standout fault codes, go to the appropriate Chain Fault Code Table.

b.

For no single standout fault codes, go to the Paper Handling PHM Group Fault Tables.

Feeder Stacker Jams over threshold a.

For single standout fault codes, go to the 11 NRD Fault Code Tables.

b.

For no single standout fault codes, go to the FSM Group Fault Tables.

Xerographic Faults over threshold a.

6 and 9 fault codes are listed, go to the Printer Electrical Noise Procedure.

b.

For single standout fault codes, go to the appropriate 6 NRD Fault Code Tables or 9 NRD Fault Code Tables.

c.

For no single standout fault codes, go to the Xerographics Group Fault Table (1 of 4.

Run Control Faults over threshold a.

For single standout fault codes, go to the appropriate 3 NRD Fault Code Tables.

b.

For no single standout fault codes, go to the Run Control Group Fault Tables.

All Other Faults over threshold a.

For single standout fault codes, go to the appropriate Chain Fault Code Table.

b.

For no single standout fault codes, go to the Power/All Other Faults Group Fault Table (1 of 4).

For additional SCP fault history analysis hints, go to the NRD General Information And Diagnostic Hints section for the following specific information:

The Operator is complaining of excessive Process Optimization occurrences (i.e.., frequent “Adjusting Print Quality Messages”) Go to 9-203, 9-213.

–

Definition of a Single Standout fault code

–

Using the Fault History data, i.e., Last 50 Shutdowns, Almost Jams, and Range Faults

–

Using the Timing and Bypass Routines

1.

View the SCP scorecard Fault History threshold displayers to determine if any subsystem threshold is > 100%.

–

dC226 and dC726 Timing graphs

2.

If a subsystem threshold is >100%, check for a Single Standout Fault Code in each subsystem Top 15 Jams (or Faults) list.

–

Miscounting Almost Jam Counters

–

Using the Controller NRDs

–

PHM and FSM Fault Code/Sensor Location Diagrams

NOTE: Specific information on Group Fault Table/Fault Code Table usage (which may include the running of stress tests/functional tests) can be found in the following sections; check the NRD Section Contents for the appropriate page number: –

Printer Group Fault Table Usage

–

Printer Fault Code Table Usage

–

Controller Fault Code Table Usage

Go to the appropriate Fault Code Table or Group Fault Table as defined in the following paragraphs.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-31

Section Name

Non-Repeatable Problem Entry Procedure

Figure 1 Non-Repeatable Diagnostics Flow Diagram.

Section Name

Non-Repeatable Problem Entry Procedure

0/0/00 ?-32

Preliminary Working Document No Product Name Assigned

Figure 2 Non-Repeatable Diagnostics Flow Diagram.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-33

Section Name

Non-Repeatable Problem Entry Procedure

Printer Electrical Noise Procedure

c.

PURPOSE

2.

The purpose of this NRD Procedure is to assist in the isolation of the cause of electrical noise in the Printer to a specific subsystem area or component. NOTE: While performing this procedure, remember that the cause of the fault or faults is probably electrical noise. Question the operator to determine if the fault or faults can be isolated to a specific operational phase (start-up, print, cycle-down, etc.) and/or operation (PHN, MIN, or FSN) of the machine.

Check the routing of the harnesses in and around the Compressor and the rear of the Electrical Module.

If 6-xxx faults are NOT being declared or if the previous step has been completed, perform steps a, b, c, and d to determine which part of this procedure to go to:

NOTE: Before beginning the 9-xxx procedure, enter dC314 and ensure that all the Dicorotron Power Supply calibrations are correct.

If crashes and/or shutdowns have been occurring, check the SCP Printer Shutdown History (Last 50 Faults), and the Xerographics Top 15 Faults to determine if 9-201, 9-203, 9-213, 9215, 9-3xx, or 6-xxx faults have been occurring. If 3-xxx and 6-xxx fault codes are occurring about the same time as the 9-xxx fault, there is a strong possibility that it is the result of an arcing or an electrical noise problem. If the 3-xxx faults can be reset, the problem probably is not a PWB failure.

General Troubleshooting Hints:

a.

If one of the 9-201, 9-203, 9-213, 9-215, or 9-3XX fault codes are occurring, go to the appropriate 9-XXX Fault Code Procedure in Part 1: 9-XXX Fault Code Procedures of this NRD.

b.

If the faults are related to a PHN, MIN, or FSN node, go to the appropriate Electrical Node Procedure in Part 2: Electrical NODE Procedures . If no problem is found, continue to step c.

c.

If 6-xxx fault codes are occurring, go to the 6-xxx Fault Code Procedure in Part 3: 06-XXX Fault Code Procedure. If no problem is found, continue to Part 4: Defeature Isolation Procedure.

d.

For all other faults, go to the Defective Isolation Procedure in Part 4: Defeature Isolation Procedure.

If it is suspected that more than one Dicorotron or Ozac connector is arcing, remove all dicorotrons, and reinstall them one at a time to see if the fault can be recreated. Multiple arcing is not uncommon. When replacing a Dicorotron or Ozac connector, check the mating connector for signs of arcing, wear, contamination, and looseness. Loose, intermittent or arcing connections on AC Motors or components can cause electrical noise to be introduced into the system and result in false shutdowns (e.g. cooling fans, main drive motors, vent fans). The purpose of this procedure is to identify known causes of false 6-xxx fault codes being declared by electrical noise. The purpose of this procedure is to allow running the Printer with selected functions turned off. It is expected that when the output generating the noise is turned off, the noise also will be turned off. Use this procedure to disable outputs by using dC131 and other dC routines.

PROCEDURE NOTE: The ROS components are prone to electrical noise generated by other components in the Printer. Some of the following checks ensure that the latest electrical noise resistant components have been added to the system. Others ensure that the most likely electrical noise generators in the Printer are not causing the false fault codes. 1.

If 6-xxx faults are being declared, perform the following steps to ensure that the latest electrical noise resistant components have been added to the system: a.

Inspect for 9-201 faults. Components associated with 9-201 faults can cause false 6 ROS faults. Ensure that all repairs have been made to eliminate the 9-201 faults.

b.

Check that the routing of the OZAC high voltage wiring is correct (PL 9.4).

Section Name

Printer Electrical Noise Procedure

0/0/00 ?-34

Preliminary Working Document No Product Name Assigned

Part 1: 9-XXX Fault Code Procedures Table 1 Part 1: 9-XXX Fault Code Procedures Code

Procedures

9-201

The most common causes of 9-201 faults are as follows: - Cracked dicorotron wire glass coating - Dicorotron contamination - Contamination by conductive brush fibers 1. Perform the following steps: - Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing. - Inspect the Ozac connectors and the dicorotron connectors for the following symptoms: - A yellow, gray or light brown film (most common) - Cracks on the connectors - Pitting on the AC Dicorotron connectors - Inspect the Ozac ducts where they pass near the machine frame. It is possible for the wires inside the duct to arc to the frame (discoloration of the tube will be noticeable). - Inspect the Dicorotrons for cracked glass, very excessive contamination, or for brush fibers on the wire or at the end blocks. - Inspect for proper P/J mating at the Ozac and HVAC PWB connectors. - Inspect the HVAC Output Module. Remove the module, and look for signs of arcing at the output lead or between the resistor and frame. 2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are the Cleaner and Developer subsystems. 3. If the above efforts have not corrected the problem, replace the HVAC PWB or the HV Output Module one at a time. (An intermittent component is suspected. 4. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.

BSD 9.1 (Sheet 1)

5. 9-201 faults have been caused by broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll.

9-203

A true 9-203 fault indicates that the Photoreceptor is at end of life. As a general guideline, PR belts with less than 500K copies on them should not be at end of life. There are other causes that can trigger the fault code. The most common causes of 9-203 faults are as follows: Charging system problems - Incorrect dicorotron height. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 and ADJ 9-6 ) - Process Control feedback problems - Incorrect ESV spacing. Check/adjust the ESV Height adjustment (ADJ 9-12 ). - Stray light - Ensure that all inner and outer covers are installed correctly. The most common electrical causes of 9-203 faults are as follows: - Poor or faulty Ozac connectors - Poor Dicorotron connectors - System electrical noise 1. Check the PR Belt for physical damage, delamination of the belt seam, and ground strip damage. If any is noted find and repair the cause of the damage before replacing the PR Belt. 2. Perform the following: - Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing. - Inspect the Ozac connectors and the dicorotron connectors for the following symptoms:

Preliminary Working Document No Product Name Assigned

0/0/00 ?-35

Section Name

Part 1: 9-XXX Fault Code Procedures

Table 1 Part 1: 9-XXX Fault Code Procedures Code

Procedures - A yellow, gray or light brown film (most common) - Cracks in the connectors - Pitting on the AC Dicorotron connectors - Inspect for proper P/J mating at the Ozac and HVPS connectors. Ensure that the connections to the HVDC PWB are correct and tight. If the above efforts have not corrected the problem, replace the HVDC PWB. (An intermittent PWB is suspected.) 3. Enter dC140 [Dicorotron Values]. In Standby, if any Dicorotron value is greater than 0.3 VDC replace the HVDC PWB (PL 1.7 ). 4. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The high suspect causes are the Cleaner and Developer subsystems.

BSD 9.4 (Sheet 1)

5. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.

9-213

The most common cause of 9-213 faults is incorrect ESV spacing. - Check/adjust the ESV Height Adjustment (ADJ 9-12 ). The most common electrical causes of 9-213 faults are as follows: - Poor or faulty Ozac connectors - Poor PR grounding - Poor Dicorotron connectors - High voltage PWB connector problems - Loss of ESV signal or faulty ESV 1. Perform the following steps: - Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and a hotspot. - Inspect the Ozac connectors and dicorotron connectors for the following: - A yellow, gray or light brown film (most common) - Cracks in the connectors - Pitting on the AC Dicorotron connectors - Loose, missing, or broken fibers on the PR Ground Brush - Vacuum the belt module, the PR Ground Brush (replace if necessary), and the surrounding area - Inspect Ozac contacts for arcing and reseat all Dicorotrons. - Inspect for proper P/J mating at Ozac and HVPS connectors. 2. Enter dC140 [Dicorotron Values]. In Standby, if any Dicorotron value is greater than 0.3 VDC replace the HVDC PWB (PL 1.7 ). 3. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are the Cleaner and Developer subsystems. If developer beads are noted outside the Developer Housing check the developer drive gears for wear. 4. 9-201 faults have been caused by broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll. 5. Go to PQ 9-619, ESV RAP in Section 3, IQ. 6. Look for a loss of the +24 VDC, ESV components failure, or an ADA PWB problem. 7. If the problem has not been resolved, replace the ESV assembly.

BSD 9.4 (Sheet 1)

8. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.

9-212 9-215

Intermittent electrical noise induced on the DSS signal line can cause a false 9-212. The most common electrical causes of 9-212 and / or 9-215 faults are as follows: - Poor or faulty Ozac connectors - Loose dicorotron connectors - Poor or missing PR ground brush

Section Name

Part 1: 9-XXX Fault Code Procedures

0/0/00 ?-36

Preliminary Working Document No Product Name Assigned

Table 1 Part 1: 9-XXX Fault Code Procedures Code

Procedures 1. Perform the following: - Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and hotspots. - Inspect the Ozac connectors and the dicorotron connectors for the following symptoms: - A yellow, gray or light brown film - Cracks in the connectors - Loose, missing, or broken fibers on the PR Ground Brush - Vacuum the belt module, the PR Ground Brush (replace if necessary), and the surrounding area. - Inspect the Dicorotrons for frosted glass, excessive contamination of the glass coated wire or the end block. 2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The high suspect causes are the Cleaner and Developer subsystems. 3. If the above efforts have not corrected the problem, replace the DSS (an intermittent DSS is suspected).

BSD 9.5

4. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.

9-32X 9-330

The most common electrical causes for 9-32X and 9-330 (current out of range) faults are as follows: - Poor or dirty connections of the Dicorotron shields causing current or voltage out of range conditions - Loose, intermittent, or faulty high voltage connections between the supply PWB and the dicorotron shield connector - Either arcing Dicorotrons shield contact connectors or Dicorotron contact arcing, causing excessive contamination of the dicorotron shield, and a frosted appearance of the Dicorotron wire glass coating - Poor seating of plug/jacks to the HVAC and HVDC PWB connectors 1. Perform the following steps: - Ensure that the HVDC PWB is installed correctly, the harness is connected properly, and that the quarter-turn screws are secured. - Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and hotspots. - Inspect the Ozac connectors and the dicorotron connectors for the following symptoms: - A yellow, gray or light brown film - Cracks in the connectors - Pitting on the AC Dicorotron connector - Inspect the Dicorotrons for frosted glass and for excessive contamination of the glass coated wire or the end block. - Inspect all HVPS connectors for proper P/J mating. 2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are the Cleaner and Developer subsystems.

BSD 9.1 and BSD 9.2

3. If the problem has not been resolved, replace the HVDC PWB (An intermittent HVDC PWB is suspected.)

Part 2: Electrical NODE Procedures Table 1 Part 2: Electrical NODE Procedures Node

Procedures

MIN

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

Preliminary Working Document No Product Name Assigned

0/0/00 ?-37

Section Name

Part 1: 9-XXX Fault Code Procedures

Table 1 Part 2: Electrical NODE Procedures Node

Procedures -- Inspect for arcing between the Charge 1 and 2 Dicorotron connectors and the backside of the HVPS Card Cage. Remove the back covers and swing out the card cage. The arcing occurs on the inside half of the metal card cage panel. Look for discolored metal and replace the Dicorotron connectors as required. -- Inspect for cuts in or belts rubbing on the Ozac tubes, wires, and connectors -- Inspect the Ozac tubes for leaks, discoloration, and other signs of arcing - An intermittent Core PWB, which can cause 3-203 faults. Before replacing any Core PWB for an intermittent fault, attempt to reseat the Local Bus, Shared Lines, and the Power and Identification connectors. Also inspect for any spreading (marginally touching) contacts. - Excessive developer or toner contamination in the Xerographic area. Find and repair the cause of the contamination. The high suspect causes are the Cleaner and Developer subsystems. - Developer beads or conductive fibers in the dicorotrons. Arcing can occur when a new cleaner brush is installed. The new brush may have loose conductive fibers and should be vacuumed prior to installation. - HVDC wires (red) out of the HVPS Card Cage that are pinched and/or shorted to machine frame. - Loose, missing, or broken fibers on the PR Ground Brush. 9-201 and 9-32x faults can occur when the brush fibers get into the Dicorotrons. - Poor PR belt Ground Brush contact. The brush must make good contact to the PR. - Poor harness routing may cause ESV faults. Avoid wrapping or routing the ESV Probe or harness near AC harnesses. - Broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll. - Check the HVAC Output Module output cables for arcing to a metal bracket near the cable.

PHN

The most common causes of non-repeatable electrical noise in the PHN are: - An intermittent Core PWB, which can cause 3-204 faults. Before replacing any Core PWB for an intermittent fault, attempt to reseat the Local Bus, Shared Lines, and the Power and Identification connectors. - Broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll. Also inspect for any spreading (marginally touching) contacts.

FSN

The most common causes of non-repeatable electrical noise in the FSN are: - Static problems - Poor or missing machine grounds, including the strapping between the modules - Poorly routed Shared Communication Lines. The cables may be shorted intermittently or bent to the point that the line shield becomes intermittent. - An intermittent +24 VDC Stacker interlock circuit can cause crashes. Check the Printer Fault History (Last 50 faults) for +24 VDC failures at or near the same time as the FSN faults. Troubleshoot as required. - An intermittent Core PWB, which can cause 3-205 faults. Before replacing any Core PWB for an intermittent, try reseating the local bus, shared line, and the power and identification connectors. Also inspect for any spreading (marginally touching) connector contacts.

Part 3: 06-XXX Fault Code Procedure PROCEDURE 1.

The purpose of this procedure is to identify known causes of false 6-XXX fault codes being declared by electrical noise. Listed below are known causes of false 6-XXX fault codes. It does not contain all causes, only those that have been identified to date. Any AC Motor or component with loose, intermittent or arcing contacts can cause electrical noise to be introduced into the system and result in false 06-XXX fault codes.

2.

Check the following components: a.

Section Name

Part 3: 06-XXX Fault Code Procedure, Part 4: Defea-

0/0/00 ?-38

Faulty UI Power Supply generating electrical noise Preliminary Working Document No Product Name Assigned

3.

b.

Cavity Cooling Fan P/J loose or arcing contacts

Part 4: Defeature Isolation Procedure

c.

Loose ground wires in the Fuser Metering Roll assembly & Transfer Assist Device areas.

PROCEDURE

d.

The HVAC Output Module output cables for arcing to a metal bracket near the cable.

e.

Motor and capacitors in Feeder/Stacker loose connectors improper fastening or arcing contacts.

1.

The purpose of this procedure is to allow running the Printer with selected functions turned off. It is expected that when the output generating the noise is turned off, the noise also will be turned off. Use this procedure to disable outputs by using dC131 and other dC routines.

If no problem is found, continue to Part 4: Defeature Isolation Procedure.

NOTE: Use extreme care when making the changes in NVM. Ensure that the correct Node is selected and that a record is made of all NVM values that are being changed prior to the change. This will enable the locations to be reset to their original values after the troubleshooting is complete. Ensure that all values changed during troubleshooting are reset back to their original values prior to completion of the service call. Refer to the appropriate level Software dC131 Table (Section 6, General Procedures, in the Service Manual) for current Data default values. 2.

Refer to the Features Bypass chart. Functions can be bypassed by changing the values for the appropriate address. To enable or disable a function, add or subtract the value in the table, from the value found in that address in dC131. Run the machine with the disabled feature in an attempt to determine if the fault also has been disabled. It may be helpful to disable more than one function at a time. If the cause of the electrical noise can be isolated to a specific Node, go to Part 2: Electrical NODE Procedures, and perform the activities listed. Disconnect inputs or outputs as required in an attempt to isolate the cause of the fault or noise. Use care when disconnecting the wires. An intermittent connection may occur, which can cause more problems than were originally present. Also, be sure to use the Molex Pin Extractor, when appropriate, to avoid damaging the wires or connectors.

3.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-39

If the non-repeatable fault or noise can be isolated to a specific PWB, use the PWB Input/ Output tables to isolate the cause of the fault to a specific component or its associated wiring. Refer to the appropriate PWB Input/Output chart.

Section Name

Part 3: 06-XXX Fault Code Procedure, Part 4: Defea-

Features Bypass Tables Table 1 MIN Features Bypass Address

128

64

32

16

8

4

2

1

Defaults

124

Enable Closed Loop

Enable Toner Control

Enable Charge Control (ESV)

Enable Rest Recovery

Enable PGEN Setup

Enable TC Setup

Enable ROS Setup

Enable Electrostatic Setup

255

125

Enable RDR Analysis Position (Precision Patch)

Enable VLD ROS

Enable RDR Fault

Enable Variable Length

Enable Pixel Counting

Enable Video Generator

Enable Pattern

252

176

Enable PIDC Collection

Enable Walk PGEN Enable Declare Fault

178

Disable SOB Sensor

179

Disable ARC Simulation at Power Up

466

Enable Dual Lamp Fuser

Enable Hi-C Fuser Roll

Address

128

64

176

Enable Patch Print

Enable MIN Occurrence Logging

00

Disable 50 Hz Phase Detection Disable HVPS Fault Detection

00 Disable HV

Enable MIN 24V detection

Enable Digital PGen

Disable HVAC Enable MICR materials

Disable PDIC controller

Enable PR unifor- Enable Speed Up mity Features

01 219 223 (MICR)

Table 2 PHN Features Bypass 32

16

8

4

Enable copy Disable Dynamic counter to count by Paper Width Faults 1

2

Enable hole jump Disable 14 TransDisable 9" Paper fer Assist Blade

178 179

1

Defaults

Disable Multi Bar Code SBA retry

00

Enable Mis Reg Detection

00

Enable TAB setup value usage after 08-226 250

Disable Initialization of Transfer Assist Blade

251

Disable 14” Transfer Blade Solenoid

Disable 13” Transfer Blade Solenoid

Disable 12” Transfer Blade Solenoid

Address

128

64

32

Disable 11” Transfer Blade Solenoid

00

00

00

Table 3 EDN Features Bypass 16

8

Enable 7x10 Paper Handling

Enable Large Paper

4

2

222 262 488

Enable FSN Fixture

Enable Variable Enable JB5 Paper Internal Image RDR Handling ROS Type Image Enhancement

Section Name

Features Bypass Tables

ROS Type Image Enhancement

Enable MICR

1

Defaults

Enable Duplex

01 64 66 (MICR) 00

0/0/00 ?-40

Preliminary Working Document No Product Name Assigned

FSN DIO PWB # 1A Inputs

FSN DIO PWB # 1 Outputs

Table 1 FSN DIO PWB # 1A Inputs Description Stacker A Stack Height Sensor

Signal Conn J7-18

Signal TP Rtn Conn TS 12

J7-17

Table 1 FSN DIO PWB # 1 Outputs

LED Conn

LED TP

BSD

TS 11

J7-16

11.7

J7-15

TS 10

J7-14

TS 09

J7-13

Back Tamper Position Sensor

J7-12

TS 08

J7-11

TS 07

J7-10

11.8

Front Tamper Position Sensor

J7-09

TS 06

J7-08

TS 05

J7-07

11.8

Container Size Switch-A

J7-03

TS 02

J7-02

TS 01

J7-01

11.8

Container Size Switch-B

J7-06

TS 04

J7-05

TS 03

J7-04

11.8

Container Size Switch-C

J7-24

TS 16

J7-23

TS 15

J7-22

11.8

Disk Lead Edge Sensor

J7-21

TS 14

J7-20

TS 13

J7-19

11.5

Drawer In Switch

J6-04

TS 17

J6-05

TS 27

J6-06

11.7

Elevator Down Sensor

J6-21

TS 28

J6-20

TS 18

J6-19

11.7

Bin Unload Button

J6-24

TS 21

J6-23

TS 20

J6-22

11.7

Stacker Empty Sensor

J6-27

TS 24

J6-26

TS 30

J6-25

11.7

Stacker Elevator Motor Encoder Sensor

J6-30

TS 32

J6-29

TS 31

J6-28

11.7

Main Pallet Latch Sensor

J6-07

TS 19

J6-08

TS 29

J6-09

11.7

Disk Sheet Sensor

J6-10

TS 22

J6-11

TS 23

J6-12

11.5

A3 Trail Edge Sensor

J6-13

TS 25

J6-14

TS 26

J6-15

11.5

Preliminary Working Document No Product Name Assigned

Description

Signal TP

Output Conn

Volt

BSD

Back Tamper Clutch

J2-11

TS 43

J2-12

+24VDC

11.6

Front Tamper Clutch

J2-09

TS 52

J2-10

+24VDC

11.6

Stacker Main Drive Start Relay

J2-07

TS 44

J2-08

+24VDC

11.3

J2-05

TS 53

J2-06

+5VDC

11.3

J2-01

TS

J2-02

J2-03

TS 45

J2-04

J3-01

TS 42

J3-02

J3-03

TS 50

J3-04

J3-19

TS 46

J3-20

+5VDC

11.7

Stacker In Use Indicator

J3-17

TS 47

J3-18

+5VDC

11.7

Stacker Please Wait Indicator

J3-15

TS 39

J3-16

+5VDC

11.7

J3-13

TS 48

J3-14

Stacker Main Drive Run Relay

Stacker Ready to UNLOAD Indicator

0/0/00 ?-41

Signal Conn

Stacker Elevator Motor Up

J3-11

TS 40

J3-12

+5VDC

11.7

Stacker Elevator Motor Down

J3-09

TS 49

J3-10

+5VDC

11.7

Back Tamper Motor

J3-07

TS 51

J3-08

+5VDC

11.6

Front Tamper Motor

J3-05

TS 41

J3-06

+5VDC

11.6

Section Name

FSN DIO PWB # 1A Inputs, FSN DIO PWB # 1 Out-

FSN DIO PWB # 2 Inputs/Outputs

FSN DIO PWB # 3 Inputs/Outputs

Table 1 FSN DIO PWB # 2 Inputs Description

Signal Conn

Signal TP

LED Conn

HCT Stack Height Sensor

J7-18

TS 12

J7-15

TS 10

J7-12

TS 08

Table 1 FSN DIO PWB # 3 Inputs LED TP

Rtn

Description

Signal Conn

Signal TP

LED Conn

J7-17

TS 11

J7-16

Horiz X-Port Sensor

J7-18

TS 12

J7-14

TS 09

J7-13

Turn Baffle Sensor

J7-15

TS 10

J7-11

TS 07

J7-10

Purge Tray Jam Sensor

J7-12

LED TP

Rtn

J7-17

TS 11

J7-16

J7-14

TS 09

J7-13

TS 08

J7-11

TS 07

J7-10 J7-07

BSD

HCT Position Sensor

J7-09

TS 06

J7-08

TS 05

J7-07

Vertical X-port Sensor

J7-09

TS 06

J7-08

TS 05

[LED drive used for S13B]

J7-03

TS 02

J7-02

TS 01

J7-01

Bypass X-port Sensor

J7-03

TS 02

J7-02

TS 01

J7-01

HCT Length Sensor A

J7-06

TS 04

J7-05

TS 03

J7-04

Back Offset Encoder Sensor

J7-06

TS 04

J7-05

TS 03

J7-04

HCT Length Sensor B

J7-24

TS 16

J7-23

TS 15

J7-22

J7-21

TS 14

J7-20

TS 13

J7-19

HCT Close Switch

J7-21

TS 14

J7-20

TS 13

J7-19

Stacker Top Cover Intlk Switch

J6-04

TS 17

J6-05

TS 27

J6-06

1.4

J6-04

TS 17

J6-05

TS 27

J6-06

Stacker Left Door Intlk Switch

J6-21

TS 28

J6-20

TS 18

J6-19

1.4

HCT Unlock Switch

J6-21

TS 28

J6-20

TS 18

J6-19

Vertical X-port Door Intlk Switch

J6-24

TS 21

J6-23

TS 20

J6-22

1.4

HCT Width Sensor

J6-24

TS 21

J6-23

TS 20

J6-22

J6-27

TS 24

J6-26

TS 30

J6-25

1.4

J6-27

TS 24

J6-26

TS 30

J6-25

Horiz X-port Door Interlock Switch

Feed Sensor Q857

J6-30

TS 32

J6-29

TS 31

J6-28

LVPS 24 V SENSE

J6-30

TS 32

J6-29

TS 31

J6-28

TBD

J6-09

Stacker Right Door Intlk Switch

J6-07

TS 19

J6-08

TS 29

J6-09

1.4

J6-10

TS 22

J6-11

TS 23

J6-12

J6-13

TS 25

J6-14

TS 26

J6-15

J6-07 HCT Tray Down / Low Paper Sensors

TS 19

J6-08

TS 29

J6-10

TS 22

J6-11

TS 23

J6-12

J6-13

TS 25

J6-14

TS 26

J6-15

Feeder Stacker Interlock Bypass Switch

11.4

1.4

Table 2 FSN DIO PWB #2 Outputs Description

Signal Conn

Signal TP Rtn Conn

J2-11

TS 43

J2-12

J2-09

TS 52

J2-10

J2-07 J2-05

Release Solenoid

Table 2 FSN DIO PWB #3 Outputs

TS 44 TS 53

Volt Description Feeder Main Drive Start Relay

Signal Conn

Signal TP

Output Conn

J2-11

TS 43

J2-12

J2-08

J2-09

TS 52

J2-10

J2-06

J2-07

TS 44

J2-08

J2-05

TS 53

J2-06 J2-02

J2-01

TS

J2-02

HCF Horz. Jam Clearance Light

J2-03

TS 45

J2-04

Over Size Nip Release Solenoid

J2-01

TS

J3-02

+24VDC

Bypass X-port Gate Solenoid

J2-03

TS 45

J2-04

Feeder Main Drive Run Relay

J3-01

TS 42

J3-02

J3-01

TS 42

Feed Clutch

J3-03

TS 50

J3-04

+24VDC

Tray Capacity Control Line 0

J3-19

TS 46

J3-20

+5VDC

J3-03

TS 50

J3-04

+5VDC

J3-19

TS 46

J3-20

+5VDC

J3-17

TS 47

J3-18

+5VDC

J3-15

TS 39

J3-16

+5VDC

J3-13

TS 48

J3-14

+5VDC

J3-11

TS 40

J3-12

TS 49

J3-10

Tray Capacity Control Line 1 Tray Capacity Control Line 2 Tray Capacity Control Line 3 Elevator Motor Up Elevator Motor Down Blower Motor

J3-17 J3-15 J3-13 J3-11 J3-09

TS 47 TS 39 TS 48 TS 40 TS 49

J3-18 J3-16 J3-14 J3-12 J3-10

J3-07

TS 51

J3-08

+5VDC

J3-09

J3-05

TS 41

J3-06

+5VDC

J3-07

TS 51

J3-08

J3-05

TS 41

J3-06

Section Name

FSN DIO PWB # 2 Inputs/Outputs, FSN DIO PWB # 3

0/0/00 ?-42

Volt

BSD

+24VDC

11.4

Preliminary Working Document No Product Name Assigned

FSN Stepper PWB A Inputs/Outputs

MIN ADA PWB #1 Inputs/Outputs

Table 1 FSN Stepper PWB A Inputs Signal Conn

Description

Signal TP

LED Conn

Table 1 MIN ADA PWB #1 Inputs

LED TP

Rtn

BSD

Description

Signal Conn

Signal TP

Rtn Conn

Rtn TP

Shield

BSD

Disk Home Sensor

J3-04

TS 14

J3-05

TS 16

J3-06

11.5

ESV Monitor

J6-3

TS21

J6-4

TS22

---

9.4

Right Guide Home Sensor

J3-07

TS 04

J3-08

TS 06

J3-09

11.6

Coronode AC Voltage Monitor

J6-7

TS27

J6-8

TS28

---

9.1 (2)

Back Guide Home Sensor

J3-10

TS 05

J3-11

TS 02

J3-12

11.6

TS30

J6-10

TS31

---

9.1

TS 03

J3-14

TS 13

J3-15

Upper Detoning Roll Voltage Monitor

J6-9

J3-13 J3-21

TS 17

J3-20

TS 11

J3-19

J6-11

TS33

J6-12

TS34

---

9.1 (1)

J3-24

TS 10

J3-23

TS 07

J3-22

Lower Detoning Roll Voltage Monitor

J3-27

TS 12

J3-26

TS 01

J3-25

Cleaner Brush Voltage Monitor

J6-13

TS47

J6-14

TS48

J6-15

9.1 (1)

J3-28

Fuser Voltage Line Monitor

J6-17

TS35

J6-16

TS36

---

10.1 (1)

Metering Roll Temperature Control

J6-19

TS37

J6-18

TS38

---

10.1 (1)

J3-30

TS 15

J3-29

TS 08

Table 2 FSN Stepper PWB A Outputs Description

Signal Conn

Signal TP

Rtn

Volt

Disk Motor Coil A

J2-01

TS 27

J2-03

+24VDC

BSD

Disk Motor Coil B

J2-02

TS 26

J2-03

+24VDC

11.5

J2-05

TS 23

J2-04

+24VDC

11.5

Disk Motor Coil D

J2-06

TS 22

J2-04

+24VDC

11.5

Right Guide Position Motor Coil A

J2-07

TS 25

J2-09

+24VDC

11.6

Right Guide Position Motor Coil B

J2-08

TS 19

J2-09

+24VDC

11.6

Right Guide Position Motor Coil C

J3-11

TS 21

J3-10

+24VDC

11.6

Right Guide Position Motor Coil D

J3-12

TS 20

J3-10

+24VDC

11.6

Back Guide Position Motor Coil A

J3-13

TS 32

J3-15

+24VDC

11.6

Back Guide Position Motor Coil B

J3-14

TS 31

J3-15

+24VDC

11.6

Back Guide Position Motor Coil C

J3-17

TS 29

J3-16

+24VDC

11.6

Back Guide Position Motor Coil D

J3-18

TS 28

J3-16

+24VDC

11.6

Preliminary Working Document No Product Name Assigned

J6-21

TS39

J6-20

TS40

---

10.1 (1)

J6-23

TS41

J6-22

TS42

---

9.1 (2)

J7-1

TS51

J7-2

TS52

J7-3

9.5

DSS Monitor

11.5

Disk Motor Coil C

Fuser Temperature Control Coronode AC Current Monitor

Table 2 MIN ADA PWB #1 Outputs Description

Signal Conn

Signal TP

Rtn Conn

Rtn TP

BSD

Coronode AC Voltage Control

J5-2

TS2

J5-1

TS56

9.1 (2)

Lower Detoning Roll Voltage Control

J5-4

TS3

J5-3

TS56

9.1 (1)

Cleaner Brush Voltage Control

J5-6

TS1

J5-5

TS56

9.1 (1)

Upper Detoning Roll Voltage Control

J5-8

TS4

J5-7

TS56

9.1 (1)

Table 3 MIN ADA PWB #1 Outputs

0/0/00 ?-43

Description

Signal Conn

Signal TP

Input Conn

Output Volt

Input TP

Toner Thumper Solenoid

J4-1

TS32

J4-2

+24

TS58

9.6

Start Relay On

J4-3

TS29

J4-4

+24

TS58

4.1 (1) 4.1 (1)

BSD

Run Relay On

J4-5

TS26

J4-4

+24

TS58

HVAC Arc Test

J4-9

TS20

J4-10

---

---

9.1 (1)

HVAC Enable

J4-13

TS16

J4-14

---

---

9.1 (1)

DSS Enable

J4-17

TS10

---

---

---

9.5

DSS Calibrate

J4-19

TS8

---

---

---

9.5

Section Name

FSN Stepper PWB A Inputs/Outputs, MIN ADA PWB

MIN ADA PWB #2 Inputs/Outputs

MIN DIO PWB Inputs/Outputs

Table 1 MIN ADA PWB #2 Inputs

Table 1 MIN DIO PWB Inputs

Description

Signal Conn

Signal TP

Rtn Conn

Rtn TP

Shield

BSD

Description

Signal Conn

Dev Rolls 1 & 2 Voltage Monitor

J6-1

TS18

J6-2

TS19

---

9.2 (3)

Paper at POP Sensor

J6-4

TS17

Preclean Voltage Monitor

J6-3

TS21

J6-4

TS22

---

9.2 (1)

HVAC Arc Detected

J6-7

TS19

Preclean Current Monitor

J6-5

TS24

J6-6

TS25

---

9.2 (1)

Low Toner Sensor

J6-10

Charge 2 Current Monitor

J6-7

TS27

J6-8

TS28

---

9.2 (1)

Ozone Vacuum Switch

Charge 2 Voltage Monitor

J6-9

TS30

J6-10

TS31

---

9.2 (1)

Transfer Voltage Monitor

J6-11

TS33

J6-12

TS34

---

9.2 (1)

Charge 1 Voltage Monitor

J6-17

TS35

J6-16

TS36

---

9.2 (1)

Charge 1 Current Monitor

J6-19

TS37

J6-18

TS38

---

9.2 (1)

Dev Roll 3 Voltage Monitor

J6-21

TS39

J6-20

TS40

---

9.2 (3)

Detack Current Monitor

J6-23

TS41

J6-22

TS42

---

9.2 (1)

Transfer Current Monitor

J6-25

TS43

J6-24

TS44

---

9.2 (1)

Table 2 MIN ADA PWB #2 Outputs Signal Conn

Description

Signal TP

Input Conn

Input Volt

Input TP

BSD

Patch Enable

J4-9

TS20

J4-10

+5

TS60

9.4

Discharge Lamps On

J4-11

TS17

1TB4

+24

---

9.7 (2)

Fuser Relay On

J4-13

TS16

J4-14

+5

TS60

P10.1 (1)

Metering Roll Heater On

J4-15

TS13

J4-16

+5

TS60

P10.1 (1)

PGEN Reference

Signal Conn J5-2

Signal TP

Rtn Conn

TS2

J5-1

Rtn TP

BSD

TS56

9.5 9.2 (1)

Detack Current Control

J5-12

TS9

J5-11

TS56

Dev Rolls 1 & 2 Voltage Control

J5-14

TS11

TS13

TS56

9.2(3)

Charge 2 Current Control

J5-16

TS14

J5-15

TS56

9.2 (1)

Dev Roll 3 Voltage Control

J5-18

TS5

J5-17

TS56

9.2 (3)

Transfer Current Control

J5-20

TS7

J5-19

TS56

9.2 (1)

Charge 2 Voltage Control

J5-22

TS12

J5-21

TS56

9.2 (1) )

Preclean Current Control

J5-24

TS15

J5-23

TS56

9.2 (1)

Section Name

MIN ADA PWB #2 Inputs/Outputs, MIN DIO PWB In-

LED TP

BSD

J6-6

J6-5

TS27

9.7 (1)

J6-9

---

---

9.1 (1)

TS22

J6-12

1TB4

---

9.6

J6-13

TS25

J6-15

---

---

9.8

Waster Bottle Full Sensor

J6-24

TS21

J6-22

J6-23

TS20

9.7 (1)

DSS Diagnostic Monitor

J6-27

TS24

J6-25

---

---

---

Patch Generator Diagnostic Monitor

J6-30

TS32

J6-28

---

---

---

Release Agent Low Switch

J7-3

TS2

J7-1

J7-2

TS1

P10.4

50 Hz Phases Correct

J7-9

TS6

J7-7

J7-8

TS5

1.7

Belt Hole Sensor

J6-9

TS15

J6-7

J6-8

TS14

9.3

Machine Clock Pulse

J6-3

TS11

TS22

---

---

4.3

Table 2 MIN DIO PWB Outputs

Table 3 MIN ADA PWB #2 Outputs Description

LED Conn

Signal TP Rtn Conn

0/0/00 ?-44

Description

Signal Conn

Signal TP

Input Conn

Page Sync

J2-1

TS54

J2-2

---

---

6.6 (3)

Registration Sync Pulse

J2-3

TS45

J2-4

---

---

4.4

Patch Generator High

J2-5

TS53

J2-6

---

---

9.5

ESV Reset

J2-11

TS43

J2-12

---

---

9.4

Input Volt Input TP

BSD

Prefuser Vacuum Motor

J3-15

TS39

J3-16

+5

TS35

10.2 (1)

Toner Motor

J3-17

TS47

J3-18

+5

TS35

9.6

Preliminary Working Document No Product Name Assigned

PHN DIO PWB #1 Inputs/Outputs

Table 2 PHN DIO PWB #1 Outputs

Table 1 PHN DIO PWB #1 Inputs

Description

Signal Conn

Signal TP

Rtn Conn

Unlock Switch

J7-3

TS2

J7-1

---

---

7.1B (3)

Stack Height Sensor

J7-6

TS4

J7-4

J7-5

TS3

7.1B (3)

Description

LED Conn

LED TP

BSD

Signal Conn

Signal TP

Input Conn

Input Volt

Input TP

BSD

Capacity Bit 1

J3-9

TS49

J3-10

+5

TS35

7.1C (4)

Capacity Bit 0

J3-11

TS40

J3-10

+5

TS35

7.1C (4)

Tray 1

Down/Low Paper Sensor

J7-9

TS6

J7-7

J7-8

TS5

7.1B (3)

Interlock Switch

J7-12

TS8

J7-10

---

---

7.1B (1)

Paper Length B Sensor

J7-15

TS10

J7-7

J7-14

TS9

7.1B (2)

Stack Relief Sensor

J7-18

TS12

J7-4

J7-17

TS11

TBD

Takeaway Roll Sensor

J7-21

TS14

J7-4

J7-20

TS13

TBD

Paper Length A Sensor

J7-24

TS16

J7-7

J7-23

TS15

7.1B (2)

Paper Length A Sensor

J6-4

TS17

J6-25

J6-5

TS27

7.1C (2)

Stack Height Sensor

J6-7

TS19

J6-9

J6-8

TS29

7.1C (3) TBD

Tray 2

Stack Relief Sensor

J6-10

TS22

J6-9

J6-11

TS23

Takeaway Roll Sensor

J6-13

TS25

J6-9

J6-14

TS26

TBD

Paper Length B Sensor

J6-21

TS28

J6-25

J6-20

TS18

7.1C (2) 7.1C (1)

Interlock Switch

J6-24

TS21

J6-22

---

---

Down/Low Paper Sensor

J6-27

TS24

J6-25

J6-26

TS30

7.1C (3)

Unlock Switch

J6-30

TS32

J6-28

---

---

7.1C (3)

Table 2 PHN DIO PWB #1 Outputs Signal Conn

Signal TP

Input Conn

Input Volt

Input TP

Stack Relief Solenoid

J2-1

Elevator Motor Down

J2-9

TS54

J2-2

+24

TS34

TBD

TS52

J2-10

+5

TS33

7.1B (1)

Elevator Motor Up Feed Clutch

J2-11

TS43

J2-10

+5

TS33

7.1B (1)

J3-1

TS42

J2-2

+24

TS34

TBD

Capacity Bit 3

J3-13

TS48

J3-18

+5

TS35

7.1B (4)

Capacity Bit 2

J3-15

TS39

J3-18

+5

TS35

7.1B (4)

Capacity Bit 1

J3-17

TS47

J3-18

+5

TS35

7.1B (4)

Capacity Bit 0

J3-19

TS46

J3-18

+5

TS35

7.1B (4)

Stack Relief Solenoid

J2-3

TS45

J2-4

+24

TS34

TBD

Elevator Motor Down

J2-5

TS53

J2-6

+5

TS33

7.1C (1)

Description

BSD

Tray 1

Tray 2

Elevator Motor Up

J2-7

TS44

J2-6

+5

TS33

7.1C (1)

Feed Clutch

J3-3

TS50

J2-4

+24

TS34

8.1C (1)

Capacity Bit 3

J3-5

TS41

J3-10

+5

TS35

7.1C (4)

Capacity Bit 2

J3-7

TS51

J3-10

+5

TS35

7.1C (4)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-45

Section Name

PHN DIO PWB #1 Inputs/Outputs

PHN DIO PWB #2 Inputs/Outputs

PHN DIO PWB #3 Inputs/Outputs

Table 1 PHN DIO PWB #2 Inputs Signal Conn

Description

Signal TP

Rtn Conn

Table 1 PHN DIO PWB #3 Inputs

LED Conn

LED TP

BSD

Description

Signal Conn

Signal TP

Rtn Conn

LED Conn

LED TP

BSD

Tray 3 Down /Low Paper Sensor

J6-13

TS25

J6-15

J6-14

TS26

7.1A (1) & 4

Decurler Jam Sensor

J6-4

TS17

J6-6

J6-5

TS27

10.7 (2)

Vertical Transport Sensor

J6-7

TS19

J6-9

J6-8

TS29

TBD

Left Door Intlk Switch

J6-10

TS22

J6-12

J6-11

TS23

1.4

Tray 3 Unlock Switch

J6-21

TS28

J6-19

---

---

7.1A (4)

1.4

Tray 3 Width Sensor

J6-24

TS21

J6-22

J6-23

TS20

7.1A (2)

Tray 3 Open Sensor

J6-27

TS24

J6-25

J6-26

TS30

7.1A (3)

Processor Intlk Bypass Switch

J6-13

TS25

J6-15

---

---

Right Door Intlk Switch

J6-21

TS28

J6-19

J6-20

TS18

1.4

Tray 3 Feed Sensor

J6-30

TS32

J6-28

J6-29

TS31

TBD

Fuser Jam Sensor

J6-24

TS21

J6-22

J6-23

TS20

10.7 (1)

Tray 3 Transport Sensor

J7-3

TS2

J7-1

J7-2

TS1

TBD 7.1A (2)

Prefuser Jam Sensor

J6-27

TS24

J6-25

J6-26

TS30

10.2 (2)

Tray 3 Length Sensor A

J7-6

TS4

J7-4

J7-5

TS3

Top Cover Intlk Switch

J6-30

TS32

J6-28

J6-29

TS31

1.4

Tray 3 Position C Sensor

J7-9

TS6

J6-15

J7-8

TS5

7.1A (1)

Top Transport Jam Sensor

J7-3

TS2

J7-1

J7-2

TS1

10.7 (2)

Tray 3 Position B Sensor

J7-12

TS8

J7-13

J7-11

TS7

7.1A (1)

Printer Intlk Sensor

J7-6

TS4

J7-4

---

---

1.3

Tray 3 Position A Sensor

J7-15

TS10

J7-13

J7-14

TS9

7.1A (1)

Transfer Blade Sensor

J7-9

TS6

J7-7

J7-8

TS5

9.2A

Tray 3 Stack Height Sensor

J7-18

TS12

J7-16

J7-17

TS11

7.1A (4)

Fuser Interlock Switch

J7-12

TS8

J7-10

J7-11

TS7

1.4

Tray 3 Closed Switch

J7-21

TS14

J7-19

---

---

7.1A (3)

Fuser Cam Out Sensor

J7-15

TS10

J7-13

J7-14

TS9

P10.3

Tray 3 Length Sensor B

J7-24

TS16

J7-22

J7-23

TS15

7.1A (2)

Fuser Cam In Sensor

J7-18

TS12

J7-16

J7-17

TS11

P10.3

Sheet at Cross Roll Sensor

J7-21

TS14

J7-19

J7-20

TS13

TBD

Registration Transport Sensor

J7-24

TS16

J7-22

---

---

TBD

Table 2 PHN DIO PWB #3 Outputs

Table 2 PHN DIO PWB #2 Outputs Description

Signal Conn

Signal TP

Input Conn

Input Volt

Input TP

BSD

Description

Signal Conn

Signal TP

Input Conn

Input Volt

Input TP

BSD

Tray 3 Release Solenoid

J3-1

TS42

J3-2

+24

TS36

7.1A (3) TBD

Tray 3 Feed Clutch

J3-3

TS50

J3-4

+24

TS36

Tray 3 Drive and Blower Motors

J3-7

TS51

J3-6

+5

TS35

TBD

Tray 3 Elevator Motor Down

J3-9

TS49

J3-10

+5

TS35

7.1A (4)

24 VDC Enable

J2-5

TS53

J2-6

+10

TS33

1.3A (1)

Tray 3 Elevator Motor Up

J3-11

TS40

J3-12

+5

TS35

7.1A (4)5

Cross Roll Motor On

J2-9

TS52

J2-10

+5

TS33

TBD

Capacity Bit 3

J3-13

TS48

J3-20

+5

TS35

7.1A (4)

Camming Motor On

J2-11

TS43

2TB4-12

+5

TS33

10.3

Capacity Bit 2

J3-15

TS39

J3-20

+5

TS35

7.1A (4)

Right Cross Roll Solenoid

J3-1

TS42

J3-2

+24 Intlk

TS36

TBD

Capacity Bit 1

J3-17

TS47

J3-20

+5

TS35

7.1A (4)

Capacity Bit 0

J3-19

TS46

J3-20

+5

TS35

7.1A (4)

Left Cross Roll Solenoid

J3-3

TS50

J3-4

+24 Intlk

TS36

Not In Use Agent Pump Solenoid

TBD

J3-5

TS41

J3-6

+24

TS35

---

J3-7

TS51

J3-8

+24

TS35

10.4 10.7 (1)

Duplex Gate Solenoid

J3-9

TS49

J3-10

+24

TS48

Vertical Transport Clutch

J3-11

TS40

J3-12

+24

TS35

TBD8.3

Air Knife Solenoid

J3-13

TS48

J3-14

+24

TS35

10.6 (2)

Section Name

PHN DIO PWB #2 Inputs/Outputs, PHN DIO PWB #3

0/0/00 ?-46

Preliminary Working Document No Product Name Assigned

PHN DIO PWB #6 Inputs/Outputs

PHN Registration Servo PWB Inputs/Outputs

Table 1 PHN DIO PWB #6 Inputs Signal Conn

Description

Signal TP

Rtn Conn

Table 1 PHN Registration Servo PWB Inputs LED Comm

LED TP

BSD

Description

Signal Conn

Signal TP

Rtn Conn

LED Conn

Shield Conn

BSD TBD

Duplex Inverter Position Sensor

J7-9

TS6

J7-7

J7-8

TS5

TBD

Registration Sync

J4-8

TS4

---

---

J4-9

Duplex Inverter Exit Sensor

J7-21

TS14

J7-19

J7-20

TS38

TBD

Machine Clock Sensor

J4-13

TS7

J4-14

---

J4-15

TBD

Registration Transport Sensor

J4-20

TS3

J4-21

J4-19

J4-22

TBD

Registration Transport Servo Encoder

J4-28

TS8

J4-29

J4-27

---

TBD

BSD

Table 2 PHN DIO PWB #6 Outputs Signal Conn

Signal TP

Input Conn

Input Volt

Input TP

BSD

Duplex Over Size Nip Release Solenoid

J2-1

TS54

J2-2

+24

TS36

TBD

Not In Use

J2-3

TS45

J2-4

---

---

---

Description

Signal Conn

Signal TP

Shield Conn

Grd Conn

Transfer 4 Solenoid

J2-5

TS53

2TB2-15

+24

---

9.2A

Registration Servo Motor Low

J2-1

TS18

---

J4-29

TBD

Transfer 3 Solenoid

J2-7

TS44

2TB2-15

+24

---

9.2A

Registration Servo Motor High

J2-3

TS16

---

J4-29

TBD

Transfer 2 Solenoid

J2-9

TS52

2TB2-15

+24

---

9.2A

Machine Clock to PHN

J4-10

TS14

J4-11

---

4.3

Transfer 1 Solenoid

J2-11

TS43

2TB2-15

+24

---

9.2A

Registration Sensor to DIO

J4-16

TS9

---

J4-17

TBD

Description

Table 2 PHN Registration Servo PWB Outputs

Duplex Inverter Forward Clutch

J3-1

TS42

J3-2

+24

TS36

TBD

Registration Sync

J4-23

TS6

---

J4-24

4.4

Duplex Inverter Reverse Clutch

J3-3

TS50

J3-4

+24

TS36

TBD

Machine Clock to MIN

J4-25

TS14

J4-26

---

4.3

Preliminary Working Document No Product Name Assigned

0/0/00 ?-47

Section Name

PHN DIO PWB #6 Inputs/Outputs, PHN Registration

Printer Group Fault Tables Purpose And Procedure

NOTE: Use the Functional Groups to help identify the group pattern or functional area of the machine that is malfunctioning.

PURPOSE The Group Fault Tables are used to determine fault code patterns when a subsystem is over threshold; and, there is a non-repeatable fault code listed in the SCP Top 15 and/or Shutdown History Last 50 Faults but, there is no Single Standout fault code.

PROCEDURE 1.

2.

This section contains the following Printer Group Fault Tables (GFT): a.

Paper Handling (PHM) - 08-1XX, 10-1XX, 09-1XX fault codes.

b.

Feeder Stacker (FSM) 8-XXX, 11-XXX fault codes.

c.

Xerographic - 6-XXX, 9-2XX, 9-3XX, 10-2XX fault codes.

d.

Run Control - 3 fault codes.

e.

Power/All Other Faults - 1, 4, 7-2XX, 8-3XX, 12-2XX fault codes. The order of the subsystem GFTs in this section is the same as the order of the SCP Fault History frames.

Listed in the Group Fault Tables are fault codes with problems (Components/Adjustments) that can cause that fault (Refer to Group Fault Table Example). The top of the Group Fault Table lists the functional group associated with specific fault codes.

3.

View the first row of Xs.

4.

Determine whether this group of codes closely matches the patterns seen in the Top 15. a.

If it matches, go to the Components/Adjustments column.

b.

If a specific component or adjustment is listed, troubleshoot that component or perform that adjustment first.

c.

If the problem is not resolved, go to the NRD listed in the component/ adjustment column.

d.

If a specific component or adjustment is not listed, go to the referenced NRD.

e.

If there is not a match, continue to the next row and again determine whether this group of codes closely matches the patterns seen in the SCP screens. Continue evaluating the rows until a pattern can be determined. If a match still cannot be made, for 1XX jam codes, go to the Fault Code/Sensor Location Diagrams and check for a common suspected faulty sensor. Table 1 Group Fault Table Example Functional Groups

Paper Handling (PHM) Components Adjustments

Fusing 10-101

10-102

10-104

Failed fuser relay (10-202 NRD)

X

X

Pressure roll needs replacing (10-102 NRD)

X

Compressor problems (10-102 NRD) Prefuser Transport Problems (10-101 NRD) Dirty/failed/fuser thermistor (10-201 NRD)

X

10-201

10-202 X

X

X

X

X

X

X

X

X

X

Section Name

Printer Group Fault Tables Purpose And Procedure

X

0/0/00 ?-48

Preliminary Working Document No Product Name Assigned

Paper Handling PHM Group Fault Tables

VT- Vertical Transport

Abbreviations:

VT (D)- Vertical Transport (Duplex)

SR- Stacker Relief Table 1 Paper Handling (PHM) Group Fault Table (1 of 4) SR TAR

Functional Groups Paper Handling (PHM) Components Adjustments

VT

8-111 8121

8-112 8122

Q711 (721) Stack Height/Adj (8-111 NRD)

X

X

Q714 (724) Down/Low Paper/Adj (8-111 NRD)

X

X

Q812 (821) Stack Relief (8-111 NRD)

X

X

X

X

X

Q811 (822) TAR (8-112 NRD)

8-113 8123

Paper Feed

8-115

8-XXX

X

X

8-XXX

Paper Transport 8-XXX

8-XXX

X

X

Duplex Inverter 8-144

8-145

8-146

8-147

X

X

Q841 Duplex Sheet Sensor (8-145 NRD)

X

Q842 Duplex TAR Sensor (8-145 NRD)

X

X

X

X

CL841, 842 Inverter Gear Box Assembly (8-145 NRD)

X

X

X

X

Duplex Gate (8-145 NRD)

X

SOL851 Nip Release Solenoid (8-145 NRD)

X

Duplex Inverter Turn Roll (8-145 NRD)

X

X

X

X

Duplex Inverter Exit Roll (8-144 NRD)

X

X

X

X

Q851 Vertical Transport Sensor (8-115 NRD)

X

X

X

Q861 Registration Transport Sensor (8152 NRD) Q871 Cross Roll Sensor (8-152 NRD) SOL811 (821) Stack Relief Solenoid (8111 NRD)

X

X

X

X

SOL861 (862) Cross Roll Solenoids (8151 NRD) Feed Clutch (Respective Tray) (8-xxx NRD for respective tray)

X

X

X

X

X

PR stalling/slipping (8-151 NRD)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-49

Section Name

Paper Handling PHM Group Fault Tables

Paper Handling PHM Group Fault Table (2 of 4)

VT- Vertical Transport

SR- Stacker Relief

VT (D)- Vertical Transport (Duplex) Table 1 (PHM) Group Fault Tables (2 of 4)

Functional Groups Paper Handling (PHM) Components Adjustments

VT (D)

VT*

8-149

8-151

Reg Transport 8-152

8-XXX

Duplex Position 8-155

Sheet Width

8-170

8-171

8-172

8-173

X

X

X

X

X

X

X

X

X

X

8-191 8194

8-192 8195

8-193 8196

X

X

X

Q711 (721) Stack Height/Adj (8-111 NRD) Q714 (724) Down/Low Paper/Adj (8-111 NRD) Q811 (821) Stack Relief (8-111 NRD) Q812 (822) TAR (8-112 NRD) 841 Duplex Inverter Position Sensor (8145 NRD) Q842 Duplex Inverter Exit Sensor (8-145 NRD) CL841, 842 Inverter Gear Box Assembly (8-145 NRD) Duplex Gate (8-145 NRD) SOL851 Nip Release Solenoid (8-145 NRD)

X X

X

Duplex Inverter Turn Roll (8-145 NRD)

X

X

X

X

Duplex Inverter Exit Roll (8-144 NRD)

X

X

X

X

Q851 Vertical Transport Sensor (8-115 NRD)

X

X

X

Q861 Registration Transport Sensor (8152 NRD)

X

X

X

Q871 Cross Roll Sensor (8-152 NRD)

X

X

X

X

X

X

X

X

X

X

X

X

X

SOL811 (821) Stack Relief Solenoid (8111 NRD) SOL861 (862) Cross Roll Solenoids (8151 NRD)

X

Feed Clutch (Respective Tray) (8-xxx NRD for respective tray) PR stalling/slipping (also 8-903, 10-102, and prints may be smeared.)

Section Name

Paper Handling PHM Group Fault Table (2 of 4)

0/0/00 ?-50

Preliminary Working Document No Product Name Assigned

Paper Handling PHM Group Fault Table (3 of 4)

VT- Vertical Transport

SR- Stacker Relief

VT (D)- Vertical Transport (Duplex) Table 1 (PHM) Group Fault Tables (3 of 4)

Functional Groups Paper Handling (PHM) Components Adjustments

SR 8-111 8121

TAR 8-112 8122

VT

8-113 8123

Retard Roll (Tray1/Tray2) (8-111 NRD)

X

X

X

Passive Latch Failure (8-111 NRD)

X

X

X

X

X

Feed Clutch Belt (Tray 1/Tray2) (8-111 NRD)

X

X

X

Feed Head Setup Series (Tray1/Tray2) (8-111 NRD)

X

X

X

Feeder Drive Adj (Tray 1/Tray2) (8-111 NRD)

X

X

Lock/Latch Assembly (Tray 1/2/3) (8-111 NRD)

X

X

Takeaway Shaft Endplay (Tray 1/Tray 2) (8-111 NRD)

X

X

8-115

Skew/Damage Auto Latch Adj (Tray 1/Tray 2) (8-111 NRD)

Paper Feed 8-XXX

8-XXX

X

X

Paper Transport 8-XXX

8-XXX

X

X

Duplex Inverter 8-144

8-145

8-146

8-147

X

Elevator Position (BSDs 7.1 A, B, C (Sheet 2))

PHM Drive Belt Tension (7-238 NRD)

X

X

X

X

X

Pretransfer Baffle (8-155 NRD) Reg Transport Upper Baffles (8-152 NRD)

X

dC703 Paper Width Timing (8-302 NRD)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-51

Section Name

Paper Handling PHM Group Fault Table (3 of 4)

Paper Handling PHM Group Fault Table (4 of 4)

VT- Vertical Transport

SR- Stacker Relief

VT (D)- Vertical Transport (Duplex) Table 1 (PHM) Group Fault Tables (4 of 4)

Functional Groups Paper Handling (PHM) Components Adjustments

VT (D)

VT*

Reg Transport

8-149

8-151

8-152

X

X

8-XXX

Duplex Position 8-155

8-170

8-171

8-172

Sheet Width 8-173

8-191 8194

8-192 8195

8-193 8196

X

X

X

X

X

X

Retard Roll (Tray1/Tray2) (8-111 NRD) Passive Latch Failure (8-111 NRD) Skew/Damage (8-131 NRD)

X

Air System Checkout (Tray 3) (8-131 NRD) Auto Latch Adj (Tray 1/Tray 2) (8-111 NRD) Elevator Position (BSDs 7.1 A, B, C (Sheet 2)) Feed Clutch Belt (Tray 1/Tray2) (8-111 NRD) Feed Head Setup Series (Tray 1/Tray 2) (8-111 NRD) Feeder Drive Adj (Tray 1/Tray2) (8-111 NRD) X

Lock/Latch Assembly (Tray 1/2/3) (8-111 NRD) Takeaway Shaft Endplay (Tray 1/Tray 2) (8-111 NRD) PHM Drive Belt Tension (7-238 NRD) Pretransfer Baffle (8-155 NRD)

X

Reg Transport Upper Baffles (8-152 NRD) dC703 Paper Width Timing (8-302 NRD)

X

X

X

X

X

Section Name

Paper Handling PHM Group Fault Table (4 of 4)

X

0/0/00 ?-52

Preliminary Working Document No Product Name Assigned

Xerographics Group Fault Table (1 of 4) Table 1 Xerographics Group Fault Table (1 of 4) Functional Groups

Stripping

Xerographic Components Adjustments

9-101 9102

Dicors/Process Control/PR Timing/Environment 9-201

9-202

ESV (9-203 NRD)

9-203 9213 X

ACV AT 210/245 (9-202 NRD)

X

9-215

Charge Dicors (9-202 NRD)

X

X

X

X

X

X

X

PreTransfer Lamp (9-203 NRD)

X

9-320

9-321

9-322

9-323

9-324

Patch generator (9-203 NRD)

X

X

Discharge Lamp/PS (9-203 NRD)

X

Light leaks (9-203 NRD)

X

Stray light (9-203 NRD)

X

Electrical noise (Electrical Noise Procedure)

X

X

X

X

X

Ground Brush (9-201 NRD)

X

X X

X

X

X

X

A

X

Photoreceptor ground (9-203 NRD)

X

High dark decay (9-203 NRD)

X

X

X X

X

Scratched Photoreceptor (9203 NRD)

X

X

Xero setup prep not performed (9-203 NRD)

X

ROS (9-203 NRD)

X

No Product Name Assigned

9-221

X

X

Preliminary Working Document

9-220 9222

X

Toner passed the cleaner (9202 NRD)

Overtoned (9-202 NRD)

9-212

Cleaner

X

DSS (9-203 NRD)

Dicors/connectors (OZAC) (9201 NRD)

9-211

Developer

X

X

0/0/00 ?-53

X

Section Name

Xerographics Group Fault Table (1 of 4

Xerographics Group Fault Table (2 of 4) Table 1 Xerographics Group Fault Table (2 of 4) Functional Groups Xerographic Components Adjustments

Dicorotrons 9-325

9-326

9-327

9-328

Process Control 9-329

9-330

9-331

9-332

ESV (9-203 NRD)

9-352

9-354

X

X

DSS (9-203 NRD)

X

ACV AT 210/245 (9-202 NRD)

X

X

Charge Dicors (9-202 NRD)

X

X

Toner passed the cleaner (9-202 NRD) Dicors/connectors (OZAC) (9-201 NRD)

9-355

X X

X

X

X

X

X

X

X

X

X

X

X

X

PreTransfer Lamp (9-203 NRD)

X

X

X

Patch generator (9-203 NRD)

X

X

X

Discharge Lamp/PS (9-203 NRD)

X

X

X

X

Light leaks (9-203 NRD)

X

X

X

X X

Stray light (9-203 NRD) Electrical noise (Electrical Noise Procedure)

X X

X

X

X

X

X

X

X

X

X

Ground Brush (9-201 NRD)

X

X

X

Photoreceptor ground (9-203 NRD)

X

X

X

High dark decay (9-203 NRD)

X

Overtoned (9-202 NRD)

X

X

X

X

X

X

Xero setup prep not performed (9203 NRD)

X

X

ROS (9-203 NRD)

X

Scratched Photoreceptor (9-203 NRD)

Section Name

Xerographics Group Fault Table (2 of 4)

X

0/0/00 ?-54

Preliminary Working Document No Product Name Assigned

Xerographics Group Fault Table (3 of 4) Table 1 Xerographics Group Fault Table (3 of 4) Functional Groups

Stripping

Xerographic Components Adjustments

9-101 9102

Dicors/Process Control/PR Timing/Environment 9-201

9-202

9-203 9213

X

X

X

9-211

9-212

+5 Volts (9-215 NRD)

9-220 9222

9-221

9-320

9-321

X

X

X

+24 Volts (9-215 NRD) MIB PWB (9-203 NRD)

X X

X

MIN ADA PWB #1 (9-201 NRD)

X

X

MIN ADA PWB #2 (9-202 NRD)

X

MIN Stepper PWB (9-203 NRD)

X

X X

X

X

X

X

X

X

X

X X

HVAC Output Module (9-201 NRD)

X

X

X

X

X

X

X X

X

X X

X

X

115 VAC (9-215 NRD)

X

X

X

X

X

X

X

X

X X

X

X

X

Photoreceptor drives (9-220 NRD)

No Product Name Assigned

X

X

X

Preliminary Working Document

X

X

X

Cleaner system (9-203 NRD)

9-324

X

HVAC PWB (9-201 NRD)

Developer/toner system (9203 NRD)

9-323

X X

MIN AC Remote PWB #1 (9215 NRD)

Drawer Roll up cable (9-101 NRD)

9-322

X

MIN DIO PWB (9-201 NRD)

HV Arc (9-101 NRD)

Cleaner

X

+15 Volts (9-201 NRD)

HVDC PWB (9-101 NRD)

9-215

Developer

X X

X

0/0/00 ?-55

X

Section Name

Xerographics Group Fault Table (3 of 4)

Xerographics Group Fault Table (4 of 4) Table 1 Xerographics Group Fault Table (4 of 4) Functional Groups Xerographic Components Adjustments

Dicorotrons

Process Control

9-325

9-326

9-327

9-328

9-329

9-330

9-331

X

X

X

X

X

X

X

+5 Volts (9-215 NRD) +15 Volts (9-201 NRD)

9-332

9-352

X

+24 Volts (9-215 NRD)

X

X

X

X

9-354

9-355

X

X

X

X

X

MIB PWB (9-203 NRD)

9-358

X X

MIN DIO PWB (9-201 NRD)

X

MIN ADA PWB #1 (9-201 NRD) MIN ADA PWB #2 (9-202 NRD)

9-356

X X

X

X

X

X

X

X

X

X

X

X

X

X

X X

MIN Stepper PWB (9-203 NRD) MIN AC Remote PWB #1 (9215 NRD) HVDC PWB (9-101 NRD)

X

X

X

X

HVAC Output module (9-201 NRD)

X

X

X

X

X

HV Arc (9-101 NRD)

X

X

X

X

X

X

X

X

X

X

X

X

X

HVAC PWB (9-201 NRD)

115 VAC (9-215 NRD)

X

X

X

X

X

X

X

X

X

X

Drawer Roll up cable (9-101 NRD) Developer/toner system (9-203 NRD)

X

Photoreceptor drives (9-220 NRD)

X

Cleaner system (9-203 NRD)

Section Name

Xerographics Group Fault Table (4 of 4)

X

X

0/0/00 ?-56

X

X

Preliminary Working Document No Product Name Assigned

Run Control Group Fault Tables Table 1 Chain 1 Fault Codes Code

Description/Reference

Procedures NOTE: View the Top 15 and Shutdown History in [SCP] [Printer Fault History] to determine which 3-xxx fault category to access in the following Group Fault Table.

3-2xx

Communications Faults

1. If the fault code is 3-201, 3-23, 3-204, or 3-205, enter dC303 [EDN]. Decrease the System Bus Delay Interval to one-half of its present value. Go to the Printer Electrical Noise Procedure, and perform the checks. 2. Check for a poor intermittent electrical connection: An intermittent fault can also be caused by poor electrical connections. It can be isolated by using the CD that contains the function which controls the area of the Printer that is producing the problem. -Pull on the wires and shake the connectors in order to induce the fault. -Check the wiring and the plug and jack connectors for loose, bent, or corroded pins. Removing the pins without using the extracting tool is a common cause of loose or failed pins. -Check for areas where the wiring may be rubbing on other parts and shorting. -Check for connectors that do not mate properly. -Check the voltage and ground sources for the proper levels. -Check the wiring, connectors, and components close to the problem area for any signs of arcing. 3. Check for electrical intermittent noise: An intermittent fault that is caused by electrical noise usually is one of two types, random or event related. Try to determine the type. Try to determine the exact mode of operation the system is in when the fault occurs and run the system in that mode. Completely Random: -If the fault cannot be isolated to a specific function within the Printer, refer to the Shutdown History information and look for multiple occurrences of fault codes that may locate the fault within a certain function and use the NRD Fault Code Table to troubleshoot the fault. Specific Events Related: -If the fault has a consistent pattern, try to relate the pattern to events in the Printer, then eliminate as many functions as possible to isolate a specific event. -When the cause of the intermittent is isolated to a specific function, go to that functional area and check the grounding straps within that function. CAUTION Do not exchange an EDN Core PWB from one Printer with an EDN Core PWB from another Printer, unless you perform an EDN initialization (dC323).

System Procedure: Electrical Noise

If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the PWB to the new location, replace the PWB. If the problem does not follow the PWB, replace the communication bus cables.

BSD 3.1, BSD 3.2, BSD 3.3, BSD 3.3A, 4. If the above procedures were followed and the problem continues, and if the suspected PWB has not yet been replaced. replace BSD 3.3B, BSD 3.3C, BSD 3.4, BSD the suspected PWB now. 3.4A, BSD 3.4B 3-370 to 3-376 3- Internal Error Faults 377 3-378

1. Check for electrical intermittent noise: An intermittent fault that is caused by electrical noise usually is one of two types, random or event related. Try to determine the type. Try to determine the exact mode of operation the system is in when the fault occurs and run the system in that mode. Completely Random: -If the fault cannot be isolated to a specific function within the Printer, refer to the Shutdown History information and look for multiple occurrences of fault codes that may locate the fault within a certain function.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-57

Section Name

Run Control Group Fault Tables

Table 1 Chain 1 Fault Codes Code

Description/Reference

Procedures -Use the NRD Fault Code Table to troubleshoot the fault. Specific Events Related: -If the fault has a consistent pattern, try to relate the pattern to events in the Printer, then eliminate as many functions as possible to isolate a specific event. -When the cause of the intermittent is isolated to a specific function, go to that function area and check the grounding straps within that function. 2. Go to the Printer Electrical Noise Procedure, and perform the checks. 3. If the above procedures were followed and the problem continues, and if the suspected PWB has not yet been replaced, then replace the suspected PWB now. 4. Ensure that the latest release of software is loaded. If the problem continues, look for related fault codes. NOTE: A related fault code is a fault which is associated with other faults by time stamp. -Enter [Print/display SIL Log]. View the Printer Shutdown History (last 50 shutdowns) to determine if there are any other fault codes listed which have occurred within 10 seconds of 3-370 to 3-375, 3-377 and 3-378. -If there are other fault codes listed within 10 seconds of the 3-370 to 3-375, 3-377 and 3-378 go to the NRD for that fault. -If there are not any other faults listed within 10 seconds of the 3-370 to 3-375, 3-377 and 3-378 faults, check the Software Release Document to see if the problem has been identified and if there is a recommended work-around process. If the problem persists, call the Customer Support Center for additional software support information.

System Procedure: Electrical Noise 3-380 to 3-385 3- Download Faults 387

NOTE: If a software problem is found, a Software Problem Action Report (SPAR) is required. 1. CAUTION: Do not exchange an EDN Core PWB from one Printer with an EDN Core PWB from another Printer. Exchange as follows the suspected generic Core PWB with another generic Core PWB: -PHN Core PWB and MIN Core PWB (Termination Jumpers, J2, on Norm pin 1) -PHN Core PWB (Termination Jumper, J2, on Norm pin 1) and FSN Core PWB (Termination Jumper, J2, on Test pin 3) If the problem follows the Core PWB to the new location, replace the Core PWB. 2. Go to the Printer Electrical Noise Procedure and perform the checks. 3. Check for electrical intermittent noise: An intermittent fault that is caused by electrical noise usually is one of two types, random or event related. Try to determine the type. Try to determine the exact mode of operation the system is in when the fault occurs and run the system in that mode. Completely Random: -If the fault cannot be isolated to a specific function within the Printer, refer to the Shutdown History information and look for multiple occurrences of fault codes that may locate the fault within a certain function. -Use the NRD Fault Code Table to troubleshoot the fault. Specific Events Related: -If the fault has a consistent pattern, try to relate the pattern to events in the Printer, then eliminate as many functions as possible to isolate a specific event.

3-340 3-341

System Procedure: Electrical Noise

-When the cause of the intermittent is isolated to a specific function, go to that function area and check the grounding straps within that function.

Turnaround Faults

Turnaround Tests (3-340 and 3-341) are only executed at Printer power-up. Turnaround Tests may only fail some of the time. 1. Enter dC303 [MIN Turnaround Test]. If there are Signal Names highlighted, go to the respective CD and check the wiring and connectors. -If there are no Signal Names highlighted, or a problem is not found in the previous step: Check all the wires and connectors that are listed for the PWB that is failing. 2. Replace the following components in the order given:

Section Name

Run Control Group Fault Tables

0/0/00 ?-58

Preliminary Working Document No Product Name Assigned

Table 1 Chain 1 Fault Codes Code

Description/Reference

Procedures -PWB failing the Turnaround Test (MIN ADA PWB #1 for fault 3-340, MIN ADA PWB #2 for fault 3-341) (PL 1.8) -Associated wire in the +24 VDC harness (Wiring Data) -Printer LVPS (PL 1.9)

3-362 3-370 to 3- Control Software faults 377

These faults are caused by software errors that may be related to Printer hardware problems. -If there are other fault codes listed within 10 seconds of the 3-xxx fault, go to the NRD for that fault. -If there are not any other faults listed within 10 seconds of the 3-xxx fault, check the Software Release Document to see if the problem has been identified and if there is a recommended work-around process. If the problem persists, call the Customer Support Center for additional software support information. NOTE: If a software problem is found, a Software Problem Action Report (SPAR) is required.

-378

System Controller

TBD

3-390 to 3-393

UIM Rigid Disk Faults

TBD

Preliminary Working Document No Product Name Assigned

0/0/00 ?-59

Section Name

Run Control Group Fault Tables

Section Name

Run Control Group Fault Tables

0/0/00 ?-60

Preliminary Working Document No Product Name Assigned

Power/All Other Faults Group Fault Table (1 of 4) Table 1 Power/All Other Faults (1 of 4) Functional Groups PRINTER FAILURES

Interlock Power 1-220

24 volt intermittent (open) (1-220 NRD)

X

24 volt intermittent (short) (1-220 NRD)

X

24 volt missing (open) (1-220 NRD)

X

1-121

COM* 3-415 3-254

4-201 4-203

X

X

X

24 volt enable harness (1-220 NRD)

X

LVPS K103 (34V) (1-220 NRD)

X

LVPS K104 (24V) (1-220 NRD)

X

LVPS Control PWB (1-mod LVPS) (1-220 NRD)

X

PHN DIO #2 (1-220 NRD)

X

PHN DIO #2 ID conn (J5) (1-220 NRD)

X

X 241, 242

Static Discharge at Fuser grounds (1-220 NRD)

X

X 242

X

4-211 4-213

4-212

8-310

X X

24 v Supply lines to Inductive loads

X

No Product Name Assigned

4-210

Reg Xpt

X

Ass. local Node SCL/Conn(3-415 NRD)

Preliminary Working Document

4-202

Reg Sync

X

24 volt crowbar (short) (1-220 NRD)

Power Line surges (3-250 NRD)

Machine Clock

0/0/00 ?-61

X

X X

Section Name

Power/All Other Faults Group Fault Table (1 of 4)

Power/All Other Faults Group Fault Table (2 of 4) Table 1 Power/All Other Faults (2 of 4) Functional Groups 11-250 PRINTER FAILURES

Dicorotrons Process Control 9-201

9-212

9-213

9-220

Fuser Temp 9-32X

10-203 X

24 volt intermittent (open) (1-220 NRD)

X

X

24 volt intermittent (short) (1-220 NRD)

X

X

24 volt missing (open) (1-220 NRD)

X

X

10-204 10206

Fuser Camming 10-205

24 volt crowbar (short) (1-220 NRD) 24 volt enable harness (1-220 NRD)

X

X

LVPS K103 (34V) (1-220 NRD)

X

X

10-216

12-217

FSN 24V 11-250

X

X

X

X

X

X

X

X

X

X

LVPS K104 (24V) (1-220 NRD)

X

X

X

X

LVPS Control PWB (1-mod LVPS) (1-220 NRD)

X

X

X

X

X

X

X

PHN DIO #2 (1-220 NRD) PHN DIO #2 ID conn (J5) (1-220 NRD)

X

Static Discharge at Fuser grounds (1-220 NRD) X

Ass. local Node SCL/Conn(3-415 NRD)

X

24 v Supply lines to Inductive loads

Section Name

X X

Power Line surges (3-250 NRD)

Power/All Other Faults Group Fault Table (2 of 4)

X

X

0/0/00 ?-62

X

X

Preliminary Working Document No Product Name Assigned

Power/All Other Faults Group Fault Table (3 of 4) Table 1 Power/All Other Faults (3 of 4) Functional Groups PRINTER FAILURES

Interlock Power 1-220

1-121

COM* 3-415 3-254

HVAC/HVDC PWBs/harness (3-250 NRD)

X MIN PHN

HV ARC (3-250 NRD)

X MIN PHN

+ 5 VDC/return (3-415 NRD)

X

PR drawer connector (BSD 4.3

X

Machine encoder/clock/harness (4-201 NRD)

Machine Clock 4-201 4-203

4-202

4-210

Reg Sync 4-211 4213

4-212

Reg Xpt 8-310

X X X

Binding drives/driven component (BSD 12.10)

X

Main Drive motor (4-201 NRD)

X

PR drive coupling misalign/wear (4-201 NRD)

X

PR drive belt (4-201 NRD)

X

+15 VDC/return (open/short) (4-201 NRD)

X

-15 VDC/return (open/short) (4-201 NRD)

X

Intermittent 115 VAC open(4-201 NRD)

X

X

34 VDC/return (open/short) (9-201 NRD) PR Drawer Roll Up cable

Preliminary Working Document No Product Name Assigned

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Section Name

Power/All Other Faults Group Fault Table (3 of 4)

Power/All Other Faults Group Fault Table (4 of 4) Table 1 Power/All Other Faults (4 of 4) Functional Groups 11-250 PRINTER FAILURES

Dicorotrons/Process Control 9-201

9-212

9-213

9-220

Fuser Temp 9-32X

HVAC/HVDC PWBs/harness (3-250 NRD)

X

X

HV ARC (3-250 NRD)

X

X

+5 VDC/return (3-415 NRD)

10-203

10-204 10206

Fuser Camming 10-205

10-216

12-217

FSN 24V 11-250

X

PR drawer connector (BSD 4.3)

X

Machine encoder/clock/harness (4-201 NRD)

X

Binding drives/driven component (BSD 12.10)

X

Main Drive motor (4-201 NRD) PR drive coupling misalign / wear (4-201 NRD)

X

PR drive belt (4-201 NRD)

X

+15 VDC / return (open/short) (4-201 NRD)

X

-15 VDC / return (open/short) (4-201 NRD)

X

X

Intermittent 115 VAC open (4-201 NRD) 34 VDC / return (open/short) (9-201 NRD) PR Drawer Roll Up cable

X

X

X

X

X

X

X

X

X X

X X

X

Section Name

Power/All Other Faults Group Fault Table (4 of 4)

X

X

0/0/00 ?-64

Preliminary Working Document No Product Name Assigned

Printer Fault Code Tables Purpose And Procedure PURPOSE These tables consist of fault code-specific procedures, which are intended to be used when there is a non-repeatable fault code related problem in the Printer Module and the fault code is a Single Standout code listed at the top of the SCP Printer Fault History Top 15 Jams/Faults frame.

PROCEDURE 1.

Access the appropriate NRD procedure based on the specific fault code.

2.

Perform the steps in the procedure using the BSD as a reference and run the appropriate stress test identified below.

Stress tests and Functional tests 1.

The purpose of a stress test is to induce a failure to occur (if a subsystem is operating marginally) or verify that a problem has been fixed properly.

2.

The purpose of a functional test is to utilize the common/unique hardware to determine, for example, whether a problem is common to all 3 - 6 paper trays or is unique to only one (or two) of the trays.

Paper Handling 1.

Use normal 20 lb. paper when running the timing interval routines to compare the graphs with those in the NRD General Information and Diagnostic Hints section.

2.

Use light weight or heavy weight paper to induce a failure.

3.

Run paper from each of the paper trays to determine whether the problem is unique to a tray. If it is not, then the problem is probably in one of the paper transport areas.

4.

Use Printer dC606 (select Dark Dusting) to run dark lead edge prints to stress the Fuser area.

Xerographics 1.

Run dC910 in High Stress mode.

Preliminary Working Document No Product Name Assigned

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Section Name

Printer Fault Code Tables

Figure 1 Fault Code Table Example

Section Name

Printer Fault Code Tables

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Preliminary Working Document No Product Name Assigned

1 NRD Fault Code Tables Table 1 Chain 1 Fault Codes Code

Description/Reference

Procedures

1-210

Processor Left Door Interlock Switch S106 was opened in the Print mode.

1. Measure the voltages of the sensor portion of the Processor Left Door Interlock Switch, Processor Right Door Interlock Switch, or Processor Top Cover Interlock Switch. If a voltage is out of specification, replace the appropriate switch (PL 4.3, and PL 4.5).

1-211

Processor Right Door Interlock Switch S105 was opened in 2. Check the following components: - The Switch Connectors for loose installation, - The Switch Actuator the Print mode. adjustments (PL 4.3), - Door/Cover for proper latching, - Wiring from the Switches to the PHN DIO PWB #2.

1-212

Processor Top Cover Interlock Switch S104 was opened in the Print mode.

1-221

The +24 VDC Sense Circuit of the Processor Interlock System indicates that the Processor Left Door, Right Door, and Top Cover are closed, but the +5 VDC Status Switches indicate that one of them is open.

3. Check/replace the following components, in the order given: - The appropriate Switch (PL 4.3, and PL 4.5), The appropriate Switch Connectors (PL 4.3, and PL 4.5), - PHN DIO PWB #2

Other dCs:330[1-4] BSD 1.4 -211

Go to the 1-210 NRD

-212

Go to the 1-210 NRD

1-214

Fuser Interlock Switch S101 was opened in the Print mode. 1. Measure the voltages of the sensor portion of the Fuser Interlock Switch. If a voltage is out of specification, replace the switch (PL 10.1). 2. Check the Switch Connector for loose installation, the Switch Actuator alignment, Fuser Drawer for proper latching, Wiring from the Switch to the PHN DIO PWB #2. 3. Check/replace the following components, in the order given: The Fuser Interlock Switch (PL 10.1) The Switch Connector (PL 10.1) Other dCs: 330[1-4] BSD 1.4

1-220

PHN DIO PWB #2

Occurs when a failure in the Processor interlock system is detected. The +5 VDC status switches indicate that the Processor Left Door, Right door, and Top Cover are closed and the +24 VDC sense circuit indicates that one of them is open. This fault can also occur if one of the following conditions exists: +24 VDC from the LVPS has been interrupted due to a P03 fault (Power Interrupt Mode). A short circuit in the +24 volt distribution has caused the LVPS to switch off the +24 VDC Output PWBs. The 24 VDC Enable signal which enables the +24 VDC sections of the LVPS is lost due to a hardware failure. The +24 VDC section of the LVPS has failed.

10-216

Indicates that the Camming Motor MOT1004 failed to operate when commanded to do so. This fault code will cause the Printer to enter the Power Interrupt mode and will disable the +24 VDC section of the LVPS. A loss of +24 VDC from the LVPS will declare a false 10-216 upon Power-Up.

Preliminary Working Document No Product Name Assigned

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Section Name

1 NRD Fault Code Tables

Table 1 Chain 1 Fault Codes Code

Description/Reference

Procedures

11-250-1 11-250-2 Occurs when there is a failure detected in the Finisher interlock system. The +5 VDC status switches indicate that all of the Finisher covers and doors are closed and the +24 VDC sense circuit indicates that a Finisher cover or door is open. 1. This procedure is divided into two categories: - Type I, which only requires a [Reset] to clear the fault - Type 11, which requires a Printer Power Off/Power On to clear the fault. 2. The following problems could cause a Type I ([Reset]) fault: - A software/ hardware interaction problem. If this is a software/hardware interaction problem, the 1-220 fault will only be in the [All Other Faults] Top 15 Faults. - Talk to the operator about how they are clearing the fault. If they are not aware of the fault and have never pressed [Reset] to recover, then this is a timing problem with an interlock switch and the LVPS. The Printer Shutdown History [Last 50 Shutdowns] could be filled with 1-220 faults. There is nothing you can do to correct this condition. The system is detecting and logging these faults, but they are transparent to the operator. - If the operator is clearing the fault, continue the procedure. - Misaligned Interlock Switches; Check the interlock switches for correct adjustment (ADJ 4-1, ADJ 4-3). 3. Use dC 330 to determine if this is the problem. Electrical noise causing PHN DIO #2 to go off line (3-242) momentarily: This could happen with any of the following noise induced faults: - 9-32X, 9-21, 203, etc. Go to Printer Electrical Noise Procedure. - An intermittent open on the Processor Interlock Sense line from the LVPS to PHN DIO#2; Go to BSDs 1.3D (Figure 4) and BSD 1.4 and check the circuit for intermittent connections. 4. A Type II (PO/PO) fault is caused by an intermittent short in the +24 VDC distribution or an intermittent LVPS. - Check the LEDs on the LVPS before clearing the fault to determine which LED is on. Use the +24 VDC Distribution Wirenet for the appropriate LED position to troubleshoot the short. - Check the Printer Fault History for faults which occurred at the same time as 1-220. - Troubleshoot the wiring of the components associated with those faults first, if they are in the appropriate wirenet. The following is a list of areas where harnesses have shorted to frame in the past: - Transfer Assist area - Thumper Solenoid - Main DC harness along the Inverter Feeder/Stacker frame where the rear covers may hit or rub. - Pinch point near the MIN Compressor. NOTE: Jumpers can be added to the machine that will allow overriding the 24 VDC Enable signal and the 24 VDC Under Voltage Disable signal. If the LVPS senses an over current condition, the DC Output PWB with the over current condition will shut down its 24 VDC output, regardless of the jumpers. The jumpers will keep the other 24 VDC sections of the LVPS on while you try to determine the root cause of the problem. CAUTION: These jumpers are diagnostic tools only. Do not leave them in the machine when you leave the account. 5. Connect a jumper between TS53 and TS37 on the PHN DIO PWB #2 to override the 24 VDC Enable signal. 6. Connect a jumper between TH15 and TH14 on the LVPS to override the 24 VDC Under Voltage Disable signal. 7. Run the system with the jumpers installed. When the machine shuts down

Section Name

1 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 1 Fault Codes Code

Description/Reference

Procedures 8. First check the LVPS to see which LED is lit. Then check the Queued Faults to see if there are other new faults occurring at the same time.

Other dCs: 330[1-4] BSD 1.4 06-367

Insufficient air flow through the Printer Card Cage.

9. Use this information along with the Wirenets and BSDs to troubleshoot the problem. Use dC 330 to energize components in the area of the Printer where you suspect the problem is occurring. 1. Check the Card Cage for obstructions, dirt, or debris that may inhibit air flow through the Card Cage. 2. Check the wiring to the Printer Card Cage Fans for intermittent connections. 3. Replace the following components, in the given order: - SLB/RDR PWB (PL 1.11)

06-353

BSD 1.6

- Card Cage Backplane (PL 1.11)

ROS LVPS output voltages are out of range.

1. Go to the ROS +36 VDC and -5.2 VDC wirenets (Figure 58) and check the circuits for intermittent short circuits. 2. Replace the following components, in the given order: - ROS LVPS (PL 1.11) - Pixel PWB (PL 1.11)

06-358

BSD 1.6

- Card Cage Backplane (PL 1.11)

+/-15 VDC outputs from the Printer LVPS to the Pixel PWB are out of range.

1. Go to the +15 VDC Figure 45 and -15 VDC Figure 46 wirenets and check the circuits for intermittent connections. 2. Replace the following components, in the given order: - Pixel PWB (PL 1.11) - SLB/RDR PWB (PL 1.11)

BSD 1.6

Preliminary Working Document No Product Name Assigned

- Card Cage Backplane (PL 1.11)

0/0/00 ?-69

Section Name

1 NRD Fault Code Tables

3 NRD Fault Code Tables Table 1 Chain 3 Fault Codes Code

Description/Reference

Procedures

3-201

EDN Core PWB cannot communicate with all other nodes.

1. If the P3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.

3-202

S/R Service Manual description

3-203

MIN Core PWB failed to acknowledge a message from another Core PWB.

2. Enter dC303. Decrease the System Bus Delay Interval to one half its current value for System Bus Communication faults.

3-204

PHN Core PWB failed to acknowledge a message from another Core PWB.

- Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced, replace the communications cable related to the failure.

3-205

FSN Core PWB failed to acknowledge a message from another Core PWB.

- Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair/replace the wire or connector related to the failure. Hints: A particular failure can be identified to be either a Communications or a Power/PWB related type problem. While monitoring the dC303 routine: - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that do not also go off line, the problem is related to the specific PWB or the power/connections/wiring to the PWB. - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that also go off line, the problem is related to a communication/cable/connector to the PWB. 3. Reseat the Communications, Power, and Identification connectors for the suspected PWB. 4. If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the PWB to the new location, replace the PWB. If the problem does not follow the PWB, replace the communication bus cables.

System Procedure: Electrical Noise BSD 3.1, BSD 3.2, BSD 3.3, BSD 3.3A, BSD 3.3B, BSD 3.3C, BSD 3.4, BSD 3.4A, BSD 3.4B

5. If all of the above procedures were followed and the problem continues, and if the suspected PWB was not yet replaced, replace the suspected PWB now.

3-413

MIN Core PWB cannot communicate with any board on its Local Bus.

1. If the 3-413 or 3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.

3-231

MIN Core PWB cannot communicate with the MIN DIO PWB.

2. Enter dC303. Increase the Background Checksum Rate for Local Bus Communication faults.

3-232

MIN Core PWB cannot communicate with the MIN ADA PWB #1.

- Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced, replace the communications cable related to the failure.

3-233

MIN Core PWB cannot communicate with the MIN ADA PWB #2.

- Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair / replace the wire or connector related to the failure.

3-234

MIN Core PWB cannot communicate with the SLB/RDR PWB.

Hints: A particular failure can be identified to be either a Communications or a Power/ PWB related type problem. 3. While monitoring the dC303 routine: - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that do not also go off line, the problem is related to the specific PWB or the power/connections/wiring to the PWB. - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that also go off line, the problem is related to a communication/cable/connector to the PWB. 4. Reseat the Communications, Power, and Identification connectors for the suspected PWB.

Section Name

3 NRD Fault Code Tables

0/0/00 ?-70

Preliminary Working Document No Product Name Assigned

Table 1 Chain 3 Fault Codes Code

Description/Reference

Procedures 5. If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the PWB to the new location, replace the PWB. If the problem does not follow the PWB, replace the communication bus cables.

System Procedure: Electrical Noise BSD 3.1, BSD 3.2, BSD 3.3, BSD 3.3A, BSD 3.3B, BSD 3.3C, BSD 3.4, BSD 3.4A, BSD 3.4B

6. If all of the above procedures were followed and the problem continues, and if the suspected PWB was not yet replaced, replace the suspected PWB now.

3-241

PHN Core PWB cannot communicate with the PHN DIO PWB #1.

1. For Fault Code 3-241, check the Fuser ground wiring.

3-242

PHN Core PWB cannot communicate with the PHN DIO PWB #2.

2. If the 3-415 or 3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.

3-245

PHN Core PWB cannot communicate with the PHN DIO PWB #5.

3. Enter dC303. Increase the Background Checksum Rate for Local Bus Communication faults.

3-246

PHN Core PWB cannot communicate with the PHN DIO PWB #6.

- Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced, replace the communications cable related to the failure.

3-247

PHN Core PWB cannot communicate with the PHN Registration Servo PWB.

- Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair/replace the wire or connector related to the failure.

3-414

PHN Core PWB cannot communicate with any board on its Local Bus.

Hints: A particular failure can be identified to be either a Communications or a Power/ PWB related type problem. While monitoring the dC303 routine: -If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that do not also go off line, the problem is related to the specific PWB or the power/connections/wiring to the PWB. - If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that also go off line, the problem is related to a communication/cable/connector to the PWB. 4. Reseat the Communications, Power, and Identification connectors for the suspected PWB. 5. If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the PWB to the new location, replace the PWB. If the problem does not follow the PWB, replace the communication bus cables. 6. If all of the above procedures were followed and the problem continues, and if the suspected PWB was not yet replaced, replace the suspected PWB now.

System Procedure: Electrical Noise BSD 3.1, BSD 3.2, BSD 3.3, BSD 3.3A, BSD 3.3B, BSD 3.3C, BSD 3.4, BSD 3.4A, BSD 3.4B 3-415

FSN Core PWB cannot communicate with any board on its Local Bus.

1. For Fault Code 3-252, check the grounding for the Finisher Bins Door.

3-251

FSN Core PWB cannot communicate with the FSN DIO PWB #1.

2. If the 3-415 or 3-2xx fault only occurs during Print, and the fault code can be reset, go to the Printer Electrical Noise Procedure. If the problem is not resolved by the Electrical Noise Procedure, proceed to step 2.

3-252

FSN Core PWB cannot communicate with the FSN DIO PWB #2.

3. Enter dC303.

3-253

FSN Core PWB cannot communicate with the FSN DIO PWB #3.

- Increase the Background Checksum Rate for Local Bus Communication faults.

3-254

FSN Core PWB cannot communicate with the Stepper PWB.

- Flex the System Communications Cables while observing the diagnostic routine. If a fault can be induced, replace the communications cable related to the failure.

3-255

FSN DIO #4 is off line

- Pull on the wires and shake the connectors to try to induce the fault. If a fault can be induced repair / replace the wire or connector related to the failure.

Preliminary Working Document No Product Name Assigned

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Section Name

3 NRD Fault Code Tables

Table 1 Chain 3 Fault Codes Code

Description/Reference

Procedures

3-256

FSN DIO #5 is off line

Hints: A particular failure can be identified to be either a Communications or a Power / PWB related type problem. While monitoring the dC303 routine:

3-257

FSN DIO #6 is off line

- If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that do not also go off line, the problem is related to the specific PWB or the power/connections/wiring to the PWB.

3-258

FSN Stepper PWB #2 is off line

- If a particular PWB is observed going off line and there are successive PWBs on the same communication Bus Line that also go off line, the problem is related to a communication/cable/connector to the PWB. 4. Reseat the Communications, Power, and Identification connectors for the suspected PWB. 5. If it is possible, exchange the suspected PWB with another PWB of the same type. If the problem follows the PWB to the new location, replace the PWB. If the problem does not follow the PWB, replace the communication bus cables.

System Procedure: Electrical Noise BSD 3.1, BSD 3.2, BSD 3.3, BSD 3.3A, BSD 3.3B, BSD 3.3C, BSD 3.4, BSD 3.4A, BSD 3.4B 3-412

6. If all of the above procedures were followed and the problem continues, and if the suspected PWB was not yet replaced, replace the suspected PWB now.

UIM can not talk to any Node on Local Bus

3-225

UIM Communication problem with Video Engine PWB

3-224

Video Engine PWB Communication problem with the UIM

3-223

CP-IOP is unable to communicate with the Touch Screen

3-221

UIM communication problem with CP-IOP PWB

3-208

EDN HDLC Transmitter/Receiver failed selftest or the Con- 1. This fault is only logged since it detects communication problems with the Controller from the Printer side of troller failed to acknowledge a message sent by the Printer. the communications link. RAP: 3-208

2. Enter OSDS and check SIL Log

3-340

MIN ADA PWB #1 Turnaround test has failed.

1. Enter dC303 [MIN Turnaround Test]. Look for a connector which is highlighted and go to the associated CD and check the wiring for a short circuit to ground.

3-341

MIN ADA PWB #2 Turnaround test has failed.

2. Replace the respective ADA PWB (PL 1.8).

3-342

SLB/RDR PWB to Pixel PWB Turnaround test has failed.

1. Check the PWB and Backplane Connectors for loose, bent, or corroded pins. Reseat the SLB/RDR and the Pixel PWBs.

3-343

SLB/RDR PWB to ROS Turnaround test has failed.

2. Check the Power and ROS Connectors on the Backplane for loose, bent, or corroded pins.

3-344

SLB/RDR PWB to EPMD PWB Turnaround test has failed.

3. Replace the SLB/RDR PWB and the respective PWB associated with the particular fault code (PL 1.11).

3-345

FSN Stepper #1 turnaround failure

3-346

FSN Stepper #2 turnaround failure

3-361

EDN Core PWB Battery has failed

1. Replace the EDN Core PWB (PL 1.11). NOTE: Perform the EDN Core PWB Replacement Procedure (REP 1-13) to ensure that the NVM Setup Parameters are saved. 2. Replace the LVPS (PL 1.9).

3-362

EDN NVM not initialized

3-370

SLB / RDR PWB internal failure.

1. Check the PWB and Backplane Connectors for loose, bent, or corroded pins. Reseat the SLB/RDR PWB.

3-371

EDN Core PWB internal failure.

1. Perform the Electrical Noise Procedure.

3-372

UIM problem requiring software reset caused by hardware

2. Replace the SLB/RDR PWB (PL 1.11). 2. Check the PWB and Backplane Connectors for loose, bent, or corroded pins. 3. Replace the EDN Core PWB (PL 1.11). Note: Perform the EDN Core PWB Replacement Procedure (REP 113) to ensure the NVM Setup Parameters are saved.

Section Name

3 NRD Fault Code Tables

0/0/00 ?-72

Preliminary Working Document No Product Name Assigned

Table 1 Chain 3 Fault Codes Code

Description/Reference

Procedures 4. Enter SCP [Printer Fault History]. Examine the Printer Shutdown History. If there are any other fault codes listed within 10 seconds of the 3-37x fault, go to the respective NRD Procedure for the other faults listed.

System Procedure: Electrical Noise BSD 3.1 3-373

MIN Core PWB internal failure.

3-374

PHN Core PWB internal failure.

1. Perform the Printer Electrical Noise Procedure. 2. Check the PWB Connectors for loose, bent, or corroded pins.

3-375

FSN Core PWB internal failure.

3. Replace the respective Core PWB MIN Core PWB (PL 1.8) , PHN Core PWB (PL 1.4) , F5N Core PWB (PL 1.16). NOTE: A suspect Core PWB may be swapped with another Core PWB and if the problem follows the PWB, the PWB is defective. 4. Enter SCP [Printer Fault History]. Examine the Printer Shutdown History. If there are any other fault codes listed within 10 seconds of the 3-37x fault, go to the respective NRD Procedure for the other faults listed.

3-377

Video Engine PWB problem requiring software reset

3-378

PHN received incorrect software control message.

1. Enter CTM. Select [CTM Diagnostics] [Boot Test] [Continuous] [Continue]. Allow 3 cycles to complete. If a fault code is displayed, go to the respective NRD. Ensure that there is not a disk utilization problem. 2. Ensure that the latest release of software is loaded on the machine. 3. Enter SCP [Printer Fault History]. Examine the Printer Shutdown History. If there are any other fault codes listed within 10 seconds of the 3-300 to 334, 3-360, 3-363, 3-365, 3-378 faults, go to the respective NRD Procedure for the other faults listed. 4. These faults are related to job specific type software problems. Try to recreate the failure by running the same job that the customer was running when the failure occurred. If a specific failure mode can be identified, check the Software Release Document to see if the problem has been identified and if there is a recommended work-around process. If the problem is not identified in the Software Release Document, call the Customer Support Center for additional software support information.

System Procedure: Electrical Noise BSD 3.2, BSD 3.3, BSD 3.4 3-380

UIN Core PWB Boot ROM download failure.

1. Enter SCP [Controller Fault History]. Look for related faults, C16-201 or C16-375. If any of these faults are also occurring, go to the respective NRD.

3-381

EDN Core PWB download failure.

2. Replace the EDN Core PWB (PL 1.11) NOTE: Perform the EDN Core PWB Replacement Procedure (REP 113) to ensure that the NVM Setup Parameters are saved.

3-382

UIM Core PWB download failure

1. Enter SCP [Controller Fault History]. Look for Disk related faults, C17-323, 324, 325, 327, or 328. If any of these faults are also occurring, go to the respective NRD.

3-383

MIN Core PWB download failure.

2. Replace the respective Core PWB (PL 1.8) , PHN Core PWB (PL 1.4) , FSN Core PWB (PL 1.16).

3-384

PHN Core PWB download failure.

3-385

FSN Core PWB download failure.

3-387

Video Engine PWB download failure.

3-390

UIM Core PWB Rigid Disk access fault.

3-391

UIM Core PWB Rigid Disk access fault

3-393

Video Engine Rigid Disk access fault

3-392

Video Engine detected a Rigid Disk failure.

3-401

EDN System Bus Communication failure

3-402

EDN Communication problem with the UIM

3-403

System Communication problem with the MIN

3-404

System Communication problem with the PHN Transient

Preliminary Working Document No Product Name Assigned

NOTE: A suspect Core PWB may be swapped with another Core PWB and if the problem follows the PWB, the PWB is defective.

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Table 1 Chain 3 Fault Codes Code

Description/Reference

Procedures

3-405

System Communication problem with the FSN

3-461

EDN problem requiring software reset caused by noise.

1. Perform the Specific Related Checks above for the associated fault, then continue with this procedure.

3-462

UMI problem requiring software reset caused by noise.

2. Ensure that the latest release of software is loaded on the machine.

3-463

MIN problem requiring software reset caused by noise

3. Enter SCP [Printer Fault History]. Examine the Printer Shutdown History. If there are any other fault codes listed within 10 seconds of the 334, 3-360, 3-363, 3-365, 3-378 faults, go to the respective NRD Procedure for the other faults listed.

3-464

PHN problem requiring software reset caused by noise

4. These faults are related to job specific type software problems. Try to recreate the failure by running the same job that the customer was running when the failure occurred.

3-465

FSN problem requiring software reset caused by noise

If a specific failure mode can be identified, check the Software Release Document to see if the problem has been identified and if there is a recommended work-around process. If the problem is not identified in the Software Release Document, call the Customer Support Center for additional software information.

3-471

EDN problem requiring software reset (Software)

3-472

UIM problem requiring software reset (Software)

3-473

MIN problem requiring software reset (Software)

3-474

PHN problem requiring software reset (Software)

3-475

FSN problem requiring software reset (Software)

3-480

Too many segments in the queue

3-482

EDN received an unexpected stacker delivery signal

3-483

Stacker delivery routine made 2 requests for a segment

3-485

ESS print response late or not received by IOT

3-492

MIN Main Drive enable response timeout

3-494

PHN received a bad segment from the job manager

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4 NRD Fault Code Tables Table 1 Chain 4 Fault Codes Code

Description/Reference

Procedures

4-201

Indicates a Main Drive acceleration fault at Start Print.

1. Check the wiring from the Machine Clock Sensor Q401 to the PHN Registration Servo PWB for intermittent connections.

4-202

Indicates a Main Drive acceleration fault (too many clock counts).

2. Check the wiring from the PHN Registration Servo PWB to the MIN Core PWB for intermittent connections.

4-203

Indicates a Main Drive acceleration fault (too few clock counts).

3. Check the wiring from the PHN Registration Servo PWB to the PHN Core PWB for intermittent connections.

4-210

Indicates that the Machine Clock Signal is missing at the PHN Core PWB.

4. Check the following components: - Photoreceptor drive components for binding (PL 4.17 - Main drive components for binding (PL 4.18) 5. Replace the following components, in the order given: - Machine Clock Sensor Q401 (PL 9.3) - PHN Registration Servo PWB (PL 1.5) - PHN Core PWB (PL 1.5) - MIN Core PWB (PL 1.5)

BSD 4.3 4-202

Go to the 4-201 NRD.

4-203

Go to the 4-201 NRD.

-210

Go to the 4-201 NRD.

4-211

Indicates that the Registration Sync Signal is missing at the 1. Check the wiring from the MIN DIO PWB #1 to the PHN Registration Servo PWB for intermittent connections. PHN Core PWB.

4-212

Indicates that the Registration Sync Signal is missing at the 2. Check the wiring from the PHN Registration Servo PWB to the PHN Core PWB for intermittent connections. PHN Core PWB.

4-213

Indicates that the Registration Sync Signal arrived unexpectedly at the PHN Core PWB.

3. Go to Printer Electrical Noise Procedure and check for electrical noise. 4. Replace the following components, in the order given: - MIN DIO PWB #1 (PL 1.8) - PHN Registration Servo PWB (PL 1.5) - PHN Core PWB (PL 1.8)

Other dCs:330[1-4] BSD 4.4 -212

Go to the 4-211 NRD.

-213

Go to the 4-211 NRD.

4-220

Indicates that the three phases of AC power entering the machine are not connected in the correct configuration (50 Hz only).

1. Check the wiring from the 3 Phase Detection PWB to the MIN DIO PWB for intermittent connections.

2. Replace the following components in the order given: - 3 Phase Detection PWB (PL 1.1) - MIN DIO PWB (PL 1.8) BSD 1.7

Preliminary Working Document No Product Name Assigned

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4 NRD Fault Code Tables

6 NRD Fault Code Tables Table 1 Chain 6 Fault Codes Code 6-250/251

Description/Reference

Procedures

6-250 indicates that a Continue of Scan signal was missing 1. Enter SCP [Printer Fault History]. If Fault Codes 6-350, 6-354, 6-355, 6-356, 6-359 or 6-365 are occurring at 6-251 indicates that a End of Scan signal was missing the same timestamp as the 6-250 and/or the 6-251 faults, go to the appropriate NRD associated with the other fault codes first. 2. Depending on the frequency of the problem, dC330 [6] may indicate when the problem has been repaired. Enter dC330 [6]. Select [Laser Write]. Press the Continue button. The SOS Missing and EOS Missing Input signals should toggle from L to H. Leave [Laser Write] energized for a few minutes, and check the input counters for an increase greater than 1. An increase above 1 indicates a loss of the SOS and/or EOS Missing signals. 2. Check the following components: - Video cables for damage or poor connections - Wires and connectors to the ROS LVPS for damage or poor connections 3. Enter dC910 [High Stress]. Select [Continue]. If any of the Dicorotrons are arcing, replace it (PL 9.10 and PL 9.11). 4. Check for electrical noise due to arcing. 5. Replace the following components in the order given: For 6-250 faults only: - SOS PWB (PL 6.1) For 6-251 faults only: - SOS PWB (PL 6.1) For 6-250 and/or P6-251 faults: - Pixel Clock PWB (PL 1.11) - SLB/RDR PWB (PL 1.11) - ROS Assembly (PL 6.1) System Procedure: Electrical Noise BSD 6.7 (Sheet 2)

6-252/253

Indicates that the an extra SOS or EOS signal was generated within the nominal timing for SOS or EOS

1. Enter SCP [Fault History]. If fault codes 6-350, 6-354, 6-355, 6-356, 6-359 or 6-365 are occurring at the same timestamp as the 6-252 and/or 6-253 faults, go to the appropriate NRD associated with the other fault codes first. 2. Check the following components: - Video cables for damage or poor connections - Wires and connectors to the ROS LVPS for damage or poor connections 3. Enter dC910 [High Stress]. Select [Continue]. If any of the Dicorotrons are arcing, replace it (PL 9.10 and PL 9.11). 4. Replace the following components in the order given: For 6-252 fault only: - SOS PWB (PL 6.1) For 6-253 fault only: - EOS PWB (PL 6.1) For 6-252 and/or 6-253 faults: - Pixel Clock PWB (PL 1.11) - SLB/RDR PWB (PL 1.11) - ROS Assembly (PL 6.1)

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Table 1 Chain 6 Fault Codes Code

Description/Reference

Procedures

System Procedure: Electrical Noise BSD 6.7 (Sheet 2) 6-351

Indicates that the Voltage Controlled Oscillator was out of range

1. Enter SCP [Printer Fault History]. If Fault Codes 6-250 and/or 6-251 are occurring at the same timestamp as the 6-352 faults, go to the 6-250/251 NRD first. 2. Depending on the frequency of the problem, dC330 [6] may indicate when the problem has been repaired. Enter dC330 [6]. Select [Laser Write]. Press the Continue button. The Voltage Controlled Oscillator Input signal should toggle from L to H. Leave [Laser Write] energized for a few minutes and check the input counter for an increase greater than 1. An increase above 1 indicates a loss of the Voltage Controlled Oscillator Input signal. 3. Replace the following components in the order given: - Pixel Clock PWB (PL 1.11) - Polygon Motor (PL 6.1) - SLB/RDR PWB (PL 1.11) - ROS Assembly (PL 6.1)

System Procedure: Electrical Noise BSD 6.7 (Sheet 3) 6-352

Indicates that the SLB/RDR Byte Clock signal was missing

1. Enter SCP [Printer Fault History]. If Fault Codes 6-250 and/or 6-251 are occurring at the same timestamp as the 6-351 faults, go to the 6-250/251 NRD first. 2. Depending on the frequency of the problem, dC330 [6] may indicate when the problem has been repaired. Enter dC330 [6]. Select [Laser Write]. Press the Continue button. The SLB/RDR Byte Clock signal should toggle from L to H. Leave [Laser Write] energized for a few minutes, & check the input counter for an increase greater than 1. An increase above 1 indicates a loss of the SLB/RDR Byte Clock signal. 3. Replace the following components in the order given: - Pixel Clock PWB (PL 1.11)

System Procedure: Electrical Noise BSD 6.7 (Sheet 3) 6-353

Indicates that one or more of the voltages supplied by the ROS LVPS is missing. The absence of the voltages is detected by monitoring LVPS MON is on (L), a 6-353 Fault is declared.

- SLB/RDR PWB (PL 1.11) Remove the following in the order given. Monitor for the restoration of the missing voltage. Replace the component which dragged down the missing voltage. • Pixel PWB (PL 1.11) •

SLB/RDR PWB (PL 1.11)

•

ROS LVPS PWB (PL 1.11)

•

The cable between J114 on the Card Cage to the ROS

•

Various ROS PWBs (PL 6.1)

•

The Backplane (PL 1.11)

System Procedure: Electrical Noise BSD 6.7 (Sheet 2) 6-354

Indicates that one or more of the Polygon Motor Phase(s) were missing

1. Depending on the frequency of the problem, dC330 [6] may indicate when the problem has been repaired. Enter dC330 [6]. Check the Motor Driver Output signal counter for a few minutes. An increase above 0 indicates a loss of the Motor Driver Output signal. 2. Replace the following components in the order given: - Polygon Motor (PL 6.1) - CRCM PWB (PL 6.1) - SLB/RDR PWB (PL 1.11)

System Procedure: Electrical Noise BSD 6.4 (Sheet 1) 6-355

Indicates that the +5 VDC was missing on the SOS PWB.

Preliminary Working Document No Product Name Assigned

1. Enter SCP [Printer Fault History]. If the two fault codes are occurring, check the circuit from P/J205-15 & 7 on the Distribution PWB back towards the +5 VDC source voltage. If only one fault code is occurring, continue with step 2.

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6 NRD Fault Code Tables

Table 1 Chain 6 Fault Codes Code

Description/Reference

Procedures 2. For 6-355 faults, check the circuit from TH10 on the Distribution PWB thru the SOS PWB to the SLB/RDR PWB. If no problem is found, replace the following components in the order given: - SOS PWB (PL 6.1) - CRCM PWB (PL 6.1) - SLB/RDR PWB (PL 1.11) 3. Check the Ground wire on the Metering Roll for proper connection.

6-356

Indicates that the +5 VDC was missing on the EOS PWB.

4. For 6-356 faults, check the circuit from TH10 on the Distribution PWB thru the EOS PWB to the SLB/RDR PWB. If no problem is found, replace the following components in the order given: - EOS PWB (PL 6.1) - CRCM PWB (PL 6.1) - SLB/RDR PWB (PL 1.11)

System Procedure: Electrical Noise BSD 6.2 (Sheet 2) 6-358 6-364

TBD Indicates that the Scan Beam Intensity was out of range

1. Enter SCP [Printer Fault History]. If Fault Codes 6-250 and/or 6-251 are occurring at the same timestamp as the 6-364 faults, go to the 6-250/251 NRD first. 2. Check for electrical noise due to arcing. 3. Perform the following steps to check for a possible Beam 1 to Beam 2 mismatch at an Exposure Intensity set to 0: - Enter dC606 ROS Intensity Test and set the Exposure Value to 0. - Read and record the values for SOS and EOS with the Exposure Value at 0. - If the difference between Beam 1 and Beam 2 values is greater than 1 VDC, perform the actions in Step 6. 4. Perform the following steps to check the for a possible Beam 1 to Beam 2 mismatch at Exposure Intensity set to 128: - Enter dC606 ROS Intensity Test and set the Exposure Intensity to 128. - Read and record the values for SOS and EOS with the Exposure Value at 128. - Evaluate the difference between the SOS and EOS values. - If the difference between Beam 1 and Beam 2 values is greater than 1 VDC, perform the actions in Step 6. 5. Perform the following steps to check the for a possible Beam 1 to Beam 2 mismatch at Exposure Intensity set to 255: - Enter dC606 ROS Intensity Test and set the Exposure Intensity to 255. - Read and record the values for SOS and EOS with the Exposure Value at 255. - Evaluate the difference between the SOS and EOS values. - If the difference between Beam 1 and Beam 2 values is greater than 1 VDC, perform the actions in Step 6. 5. Replace the following components in the order given: - EOS PWB (PL 6.1) - SOS PWB (PL 6.1) - ROS Assembly (PL 6.1) - SLB/RDR PWB (PL 1.11)

System Procedure: Electrical Noise BSD 6.2 (Sheet 2) 6-366

Polygon Motor fault (other than AC output) (IOT)

TBD

6-367

Card Cage Overtemp

TBD

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6 NRD Fault Code Tables

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Table 1 Chain 6 Fault Codes Code 6-701

Description/Reference

Procedures

Fault Code 6-701 is used to troubleshoot ROS related prob- 1. Replace the following in the order given: lems that can cause non-repeatable Xerographic faults - SLB/RDR PWB (PL 1.11) - ROS Assembly (PL 6.1) - MIN ADA PWB #2 (PL 1.8) - MIB PWB (PL 1.8)

Preliminary Working Document No Product Name Assigned

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6 NRD Fault Code Tables

7 NRD Fault Code Tables Table 1 Chain 7 Fault Codes Code

Description/Reference

Procedures

7-211

Indicates that the Tray 1 Elevator was late to actuate the Stack Height Sensor Q711 or indexed on more than 2 consecutive feeds

1. Measure the voltages of the Stack Height Sensor (PL 7.1) and Down/Low Paper Sensor (PL 7.4). If a voltage is out of specification, replace the appropriate sensor.

7-212

Indicates that the Tray 1 Elevator was late to the Tray 1 Down/Low Paper Switch Q714

2. Check the resistance of the Interlock Switch (PL 7.9), Elevator Up Limit Switch (PL 7.6), and Elevator Down Limit Switch (PL 7.4). Replace as required. 3. Ensure that tag 171 is installed. 4. The Elevator Motor may be overheating. After the motor cools, the overheat sensor automatically will reset, and the motor will work properly until it overheats again. Enter dC330 [7B]. Drive the Elevator Motor up and down to check if it overheats. Also check for binding, wear or damage to the motor and the drives. 5. Check the following components/adjustments: - Passive Latches for damage and for holding the tray in the locked position during operation. - Lock Arm for binding on the frame pin, wear or damage - Feed Head for binding and for seized bearings or harness interference - Interlock Switch Actuator for damage, binding or wear - Interlock Switch Actuator Spring for bends or breaks - Interlock Switch Bracket for bends or looseness - Drive belts or pulleys for damage - Drive belt tensions - Elevator for binding, wear or damage - Lock Assembly adjustment (ADJ 7-10) - Paper Feed Setup Series adjustment (ADJ 7-9) - Elevator Drive Belt Tension adjustment (ADJ 7-11)

BSD 7.1B (Sheet 1, 3) 7-214

Indicates that the Tray 1 Interlock Switch S710 opened in print

1. Check the resistance of the Interlock Switch (PL 7.9). Replace as required. 2. Ensure that tag 171 is installed. 3. Check the following components/adjustments: - Passive Latches for damage and for holding the tray in the locked position during operation - Lock Arm for binding on the frame pin, wear or damage - Interlock Switch Actuator for damage, binding or wear - Interlock Switch Actuator Spring for bends or breaks - Interlock Switch Bracket for bends or looseness - Lock Assembly adjustment (ADJ 7-10) - Paper Feed Setup Series adjustment (ADJ 7-9) - Elevator Drive Belt Tension adjustment (ADJ 7-11)

Other dCs: 330 [7B] BSD 7.1B (Sheet 1) 7-221

Indicates that the Tray 2 Elevator was late to actuate the Stack Height Sensor Q721 or indexed on more than 2 consecutive feeds.

Section Name

7 NRD Fault Code Tables

1. Measure the voltages of the Stack Height Sensor (PL 7.1) and Down/Low Paper Sensor (PL 7.4). If a voltage is out of specification, replace the appropriate sensor.

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Table 1 Chain 7 Fault Codes Code 7-222

Description/Reference Indicates that the Tray 2 Elevator was late to the Tray 2 Down/Low Paper Switch Q724

Procedures 2. Check the resistance of the Interlock Switch (PL 7.9), Elevator Up Limit Switch (PL 7.6), and Elevator Down Limit Switch (PL 7.4). Replace as required. 3. Ensure that tag 171 is installed. 4 . The Elevator Motor may be overheating. After the motor cools, the overheat sensor automatically will reset, and the motor will work properly until it overheats again. Enter dC330 [7B]. Drive the Elevator Motor up and down to check if it overheats. Also check for binding, wear, or damage to the motor and the drives. 5. Check the following components/adjustments: - Passive Latches for damage and for holding the tray in the locked position during operation - Lock Arm for binding on the frame pin, wear or damage - Feed Head for binding and for seized bearings or harness interference - Interlock Switch Actuator for damage, binding or wear - Interlock Switch Actuator Spring for bends or breaks - Interlock Switch Bracket for bends or looseness - Drive belts or pulleys for damage - Drive belt tensions - Elevator for binding, wear or damage - Lock Assembly adjustment (ADJ 7-10) - Paper Feed Setup Series adjustment (ADJ 7-9) - Elevator Drive Belt Tension adjustment (ADJ 7-11)

BSD 7.1C (Sheet 1, 3) 7-224

Indicates that the Tray 2 Interlock Switch S720 opened in print

1. Check the resistance of the Interlock Switch (PL 7.9). Replace as required. 2. Ensure that tag 171 is installed. 3. Check the following components/adjustments: - Passive Latches for damage and for holding the tray in the locked position during operation - Lock Arm for binding on the frame pin, wear or damage - Interlock Switch Actuator for damage, binding or wear - Interlock Switch Actuator Spring for bends or breaks - Interlock Switch Bracket for bends or looseness - Lock Assembly adjustment (ADJ 7-10) - Paper Feed Setup Series adjustment (ADJ 7-9) - Elevator Drive Belt Tension adjustment (ADJ 7-11)

Other dCs: 330 [7B] BSD 7.1C (SHEET1) 7-241-1 7-241-2

Indicates that the Tray 3/4 Elevator failed to move up to the 1. Measure the voltages of the Stack Height Sensor (PL 7.16), Down/Low Paper Sensor (PL 7.17), If a voltage is feed position out of specification, replace the appropriate sensor.

7-244-1 724-2

Indicates that the Tray 3/4 Elevator failed to move down to the Position A Sensor Q732 or the Tray 3 Down Sensor Q737 was not made

2. Check the resistance of the Closed Switch (PL 7.14) and Overtravel Switch (PL 7.17). Replace as required. 3. The Elevator Motor may be overheating. After the motor cools, the overheat sensor automatically will reset, and the motor will work properly until it overheats again. Enter dC330 [7A]. Drive the Elevator Motor up and down to check if it overheats. Also check for binding, wear, or damage to the motor and the drives. 4. Check the following components/adjustments: - Stack Height Sensor for proper mounting, bent or broken actuator - Switch actuators for damage, binding or wear Preliminary Working Document No Product Name Assigned

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7 NRD Fault Code Tables

Table 1 Chain 7 Fault Codes Code

Description/Reference

Procedures - Drive belts or pulleys for damage - Drive belt tensions - Elevator for binding, wear or damage - Lead Screw Bearings for seizure - Stack Height adjustment (ADJ 7-31) - Paper Plate adjustment (ADJ 7-31) - Elevator Drive Belt Tension adjustment (ADJ 7-30) - Low Paper Sensor adjustment (ADJ 7-33)

BSD 7.1A (Sheet 1, 4) 7-248-1 7-248-2

Indicates that the Tray 3/4 Closed Switch S730 detected the 1. Check the resistance of the Closed Switch (PL 7.14). Replace as required. tray unlatched in print 2. Check the following components/adjustments: - Latch Arm for binding, wear or damage - Release solenoid for burrs, wear or binding - Tray 3 Latch Assembly adjustment (ADJ 7-32) 3. If the problem continues, go to the 7-241 NRD. If no problem is found, return here and continue. 4. Replace the Tray 3 Release Solenoid (PL 7.17) Other dCs: 330 [7A] BSD 7.1A (Sheet 3)

7-250-1 7-250-2

Indicates that the Tray 3/4 Vertical Transport Door Interlock TBD Opened in print

7-701

Used to troubleshoot non-repeatable Tray 1 Capacity Board 1. Check the resistance of the Tray Unlock Switch (PL 7.3). Replace as required. problems 2. Check the following components: - Tray Unlock Switch for binding in the bezel - Tray Unlock button for damage or wear - Wire harness and connectors for pinched wires, or damage 3. Replace the Tray 1 Capacity PWB (PL 7.3). Other dCs: 330 [7B] BSD 7.1B (Sheet 4)

7-702

Used to troubleshoot non-repeatable Tray 2 Capacity Board 1. Check the resistance of the Tray Unlock Switch (PL 7.3). Replace as required. problems 2. Check the following components: - Tray Unlock Switch for binding in the bezel - Tray Unlock button for damage or wear - Wire harness and connectors for pinched wires, or damage 3. Replace the Tray 2 Capacity PWB (PL 7.3). Other dCs: 330 [7B] BSD 7.1C (Sheet 4)

7-703

Used to troubleshoot non-repeatable Tray 3 Capacity Board 1. Measure the voltages of the HCT Position Sensor. If a voltage is out of specification, replace the sensor (PL problems 7.17). 2. Check the resistance of the Tray Unlock Switch (PL 7.15). Replace as required. 3. Check the following components: - Tray Unlock Switch for binding in the bezel

Section Name

7 NRD Fault Code Tables

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Table 1 Chain 7 Fault Codes Code

Description/Reference

Procedures - Tray Unlock button for damage or wear - Wire harness and connectors for pinched wires or damage 4. Replace the Tray 3 Capacity PWB (PL 7.15).

Other dCs: 330 [7A] BSD 7.1A (Sheet 5) 7-704

Used to troubleshoot non-repeatable Tray 3 Unlatch problems

1. Enter dC330 [7A]. Select [Tray 3 Release]. While observing the Release Solenoid, alternately press the Continue and Stop buttons. Check for binding or interference. 2. Check the following components/adjustments: Release Solenoid, plunger, and linkage for damage, binding, wear or interference Latch foot falls down and rests on the top of the pin HCT Latch assembly adjustment (ADJ 7-32)

BSD 7.1A (Sheet 3)

Preliminary Working Document No Product Name Assigned

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Section Name

7 NRD Fault Code Tables

8 NRD Fault Code Tables Table 1 Chain 8 Fault Codes Code 8-100 8-101

Description/Reference

Procedures

Indicates that the Lead edge jam at Tray 3/4 lower Pre-Reg- 1. Inspect the Q850 and Q854 sensors for damage, dirt or obstructions. istration Transport Sensor 2. Check to paper damage or dog ears. If present, go to the high capacity feeders, NRD 8-193. 3. Check all drive rolls, belts, and belt tensions. 4. Check the Preregistration idler roll clearance adj. (ADJ 8-11). 5. Check the FS/M to Printer alignment. 6. Ensure that the 8-100, 8-101 RAP has been followed.

8-102 8-103

Indicates that the Trail edge jam at Tray 3/4 Lower Pre-Reg- 1. Inspect the Q850 sensor for damage, dirt or obstructions. istration Sensor. 2. Check for paper damage or dog-ears. If present faults are mostly induced by the high capacity feeders. Go to 8-705, Paper Damage RAP. 3. Check all drive rolls, pulleys, belts, and belt tensions. 4. Check the Preregistration Idler Rail clearance adjustment (ADJ 8-11). 5. Check the FSM to Printer Alignment. 6. Ensure that 8-102, 8-103 has been followed

8-104 8-105

Indicates that the Tray 3 or 4 Lead Edge was late to the Registration Transport Sensor Q8 61 from the Tray 3 or 4 Transport Sensor Q832 (A3/A4)

1. Measure the voltages of the Cross Roll (PL 8.6) and Registration Transport (PL 8.4) Sensor. If a voltage is out of specification, replace the appropriate Sensor 2. Ensure that tag 97 is installed. Check the Upper Left and Right Baffle adjustment (ADJ 8-11). 3. Enter dC330 [8] [Cycle Outputs], select [Cross Roll Left], and press the Continue. If the solenoid becomes sluggish or intermittent as it warms up. replace it (PL 8.3). Perform the same checks on the [Cross Roll Right] solenoid (PL 8.3). 4. Enter SCP [Printer Fault History]. If 8-180, 8-182 or 8-904 faults are occurring, go to the 8-182 NRD and perform the checks indicated. These faults indicate a possible Tray 3 multifeed problem. go to 8-196 NRD. If 8193 fault occurs check the 8-193 NRD, no problem is found, return here and continue. 5. Enter dC726 [16. 8-153], [Timing Graphs], and press Continue. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Paper stock skewing on the registration transport - Paper stock catching on the registration edge - Cross roll idler lift fingers for binding and correct position - Tray 3 or 4 transport idler nips for proper seating 6. If the lead edge of the sheets of paper are catching or skewing on the lower turn baffles, install Finisher tag 61. 7. Check the level of the IF/S to PHM 8. If the sheets are snagging on the registration edge entrance chute or are skewing in the paper path, go to the 8-706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue. 9. If jam occurs only in 3-pitch mode check the Tray 3 oversize nip release solenoid (Sol852) adjustment (ADJ 813) 10. Check the following components/adjustments: - Registration Transport/components and turn Baffle are installed correctly and not damaged worn, or binding (PL 8.3)

Section Name

8 NRD Fault Code Tables

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Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Lower Registration Baffle for proper seating - Upper Tight Baffle for bows or damage - Obstructions in the paper path (i.e., hardware, wires, paper, etc.) - Turn Baffle for bows or damage - Left and Right Cross Roll assemblies for wear, damage, or binding (PL 8.7) - Cross Roll assembly drive rolls for damage, debonding, or flat spots (PL 8.7) - Cross Roll assemblies and Drives for worn belts, binding, or damage (PL 8.7) - Registration Edge for damage, grooves, and proper seating (PL 8.4) - Servo Drive Rolls and idlers for wear, damage, or binding (PL 8.4) - Preregistration Jam clearance baffle for damage and proper seating adjustment (ADJ 8-10) - IF/S Preregistration baffle adjustment (ADJ 7-10) - IF/S Preregistration idler roller clearance adjustment (ADJ 8-11) - IF/S Preregistration drive roll for wear or contamination - IF/S Preregistration idler spring for damage, stretching or missing - Tray 3 or 4 Transport and components for wear, damage, or binding - Tray 3 or 4 Blower O-ring for wear, damage or stretch - Tray 3 or 4 Lock assembly adjustment (ADJ 7-10) 11. There is a possibility that the fault is related to components in the Registration Controller Servo area. Go to the 8-302 NRD procedure, If no problem is found, return here and continue. 12. Replace the following components in the order given:

Other dCs:727 BSD 8.4 8-111

Indicates the Tray 1 LE was late to the Stack Relief Sensor Q812

- Left and right Cross Roll assemblies (PL 8.4) - Registration Edge (PL 8.4) 1. Measure the voltages of the Stack Height Sensor (PL 7.1 Down/Low Paper Sensor (PL 7.4), and Stack Relief Sensor (PL 7.3). If a voltage is out of specification, replace the appropriate sensor. 2. Enter dC726 [1. 8-112] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Feed Clutch for wear, binding, or slippage - Feed Belt Pulley or Feed Belt Idler one way clutch for binding - Drive belts and idlers that are loose, worn, or damaged - Tube Shaft & Feeder Drive Coupling for binding or wear of the D shaft & drive - Takeaway Shaft Endplay adjustment (ADJ 7-1) - Tray 1 Feeder Drive adjustment (ADJ 4-20) - Feed Clutch Belt adjustment (ADJ 7-0) 3. If available, run 110 lb stock thru the system as a stress test. 4. Check/perform the following adjustments: - Paper Feed Setup Series (ADJ 7-9) - Length Guide Tension (ADJ 7-5) - Tray Down/Low Paper Sensor (ADJ 7-2) - Lock Assembly adjustment (ADJ 7-10) 5. Perform the 8-701 NRD Friction Retard Checkout. If no problem is found, return here and continue. 6. Replace the Feed Clutch (PL 7.12)

Preliminary Working Document No Product Name Assigned

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Section Name

8 NRD Fault Code Tables

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures

Other dCs: 727 BSD: TBD 8-112

Indicates that the Tray 1 LE was late to the Takeaway Roll Sensor Q811

1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage is out of specification, replace the appropriate sensor. 2. Enter dC726 [1. 8-112] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Feed Clutch for wear, binding, or slippage (PL 7.12) - Drive belts and idlers that are loose, worn, or damaged - Feed Belt Pulley or Idler One-Way Clutch for binding - Tube Shaft & Feeder Drive Coupling for binding or wear of the D shaft & drive - Takeaway Roll Idler one way clutch for binding or slippage - Takeaway Shaft Endplay adjustment (ADJ 7-1) - Tray 1 Feeder Drive adjustment (ADJ 4-20) - Feed Clutch Belt adjustment (ADJ 7-0) 3. If available, run 110 lb. stock thru the system as a stress test. 4. Check/perform the following adjustments: - Paper Feed Setup Series (ADJ 7-9) - Length Guide Tension (ADJ 7-5) - Tray Down/Low Paper Sensor (ADJ 7-2) - Lock Assembly (ADJ 7-10) - Feed Clutch Belt (ADJ 7-0) 5. Perform the 8-701 NRD Friction Retard Checkout. If no problem is found, return here and continue. 6. Replace the Feed Clutch (PL 7.12)

Other dCs: 727 BSD: TBD 8-113

Indicates that the Tray 1 TE was late off the Takeaway Roll Sensor Q811

1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage is out of specification, replace the appropriate sensor. 2. Enter dC726 [2.8-113] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Takeaway Roll Drive and Idler for binding, wear or contamination - Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1) - Nip missing in the Takeaway Roll area - Feed Belt for wear or contamination - Idler Springs for wear or out of position - Vertical Transport for slippage, binding or wear - Magnetic Strips for proper position or contamination 3. If available, run 110 lb. stock thru the system as a stress test. 4. Check the following components/adjustments: - Urethane sleeve for bonding to Takeaway Roll (PL 7.13) - Takeaway Drive Roll area for wear, contamination, or obstructions (PL 7.13) - Paper Feed Setup Series adjustment (ADJ 7-9) - Tray 1 Feeder Drive adjustment (ADJ 4-20) - Feed Clutch for wear, binding, or slippage (PL 7.13)

Section Name

8 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Feed Clutch Belt adjustment (ADJ 7-0) - PHM Drive Belt Tension adjustment (ADJ 4-17) - Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1) - Vertical Transport Drive Pulley and Belt for wear, damage or slippage (PL 8.1) - Vertical Transport for binding & wear (PL 8.1) - Vertical Transport Belts (PL 8.1) 5. Replace the following components in the order given: - Feeder Assembly (PL 7.10) 6. Perform the 8-701 NRD Friction Retard Checkout.

Other dCs: 330 [8], 727 BSD: TBD 8-115

Indicates that the Tray 1 LE was late to the Vertical Transport Sensor Q851

1. Measure the voltages Vertical Transport Sensor. If a voltage is out of specification, replace the sensor (PL 8.1). 2. Enter dC726 [4. 8-115] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1) - Vertical Transport for slippage, binding or wear - Magnetic Strips for proper position or contamination - Takeaway Roll Drive and Idler for binding, wear or contamination 4. Check the following components/adjustments: - Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1) - Vertical Transport for binding & wear (PL 8.1) - Vertical Transport Belts (PL 8.1) - PHM Drive Belt Tension adjustment (ADJ 4-17) - Tray 1 Feeder Drive adjustment (ADJ 4-20) - Takeaway Drive Roll area for wear, contamination, or obstructions (PL) 5. Perform the 8-701 NRD Friction Retard Checkout. If no problem is found, return here and continue. 6. Replace the following components in the order given: - Vertical Transport Belts (PL 8.1) - Vertical Transport Clutch (PL 4.18)

8-121

Other dCs: 330 [8], 727 BSD: TBD

Takeaway Roll (PL 7.13)

Indicates that the Tray 2 LE was late to the Stack Relief Sensor Q822

1. Measure the voltages of the Stack Height Sensor (PL 7.1), Down/Low Paper Sensor (PL 7.4), and Stack Relief Sensor (PL 7.13). If a voltage is out of specification, replace the appropriate sensor. 2. If the tray is opening during print, install Tag 171. 3. Enter dC726 [5. 8-122] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Feed Clutch for wear, binding, or slippage - Feed Belt Pulley or Feed Belt Idler one way clutch for binding - Drive belts and idlers that are loose, worn, or damaged - Tube Shaft & Feeder Drive Coupling for binding or wear of the D shaft & drive - Takeaway Shaft Endplay adjustment (ADJ 7-1) - Tray 1 Feeder Drive adjustment (ADJ 4-20)

Preliminary Working Document No Product Name Assigned

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Section Name

8 NRD Fault Code Tables

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Feed Clutch Belt adjustment (ADJ 7-0) 4. If available, run 110 lb stock thru the system as a stress test. 5. Check/perform the following adjustments: - Paper Feed Setup Series (ADJ 7-9) - Length Guide Tension (ADJ 7-5) - Tray Down/Low Paper Sensor (ADJ 7-2) - Lock Assembly adjustment (ADJ 7-10) 6. Perform the 8-701 NRD Friction Retard Checkout. If no problem is found, return here and continue. 7. Replace the Feed Clutch (PL 7.12)

Other dCs: 727 BSD: TBD 8-122

Indicates that the Tray 2 TE was late to the Takeaway Roll Sensor Q821

1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage is out of specification, replace the appropriate sensor. 2. Enter dC726 [1. 8-122] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Feed Clutch for wear, binding, or slippage (PL 7.12) - Drive belts and idlers that are loose, worn, or damaged - Feed Belt Pulley or Idler One-Way Clutch for binding - Tube Shaft & Feeder Drive Coupling for binding or wear of the D shaft & drive - Takeaway Roll Idler one way clutch for binding or slippage - Takeaway Shaft Endplay adjustment (ADJ 7-1) - Tray 1 Feeder Drive adjustment (ADJ 4-20) - Feed Clutch Belt adjustment (ADJ 7-0) 3. If available, run 110 lb. stock thru the system as a stress test. 4. Check/perform the following adjustments: - Paper Feed Setup Series (ADJ 7-9) - Length Guide Tension (ADJ 7-5) - Tray Down/Low Paper Sensor (ADJ 7-2) - Lock Assembly adjustment (ADJ 7-10) - Feed Clutch Belt adjustment (ADJ 7-0) 5. Perform the 8-701 NRD Friction Retard Checkout. If no problem is found, return here and continue. 6. Replace the Feed Clutch (PL 7.12)

Other dCs: 727 BSD: TBD 8-123

Indicates that the Tray 2 TE was late off the Takeaway Roll Sensor Q821

1. Measure the voltages of the Takeaway Roll Sensor (PL 7.13) and Stack Relief Sensor (PL 7.13). If a voltage is out of specification, replace the appropriate sensor. 2. Enter dC726 [8-123] [Timing Graphs]. Select [Continue]. If there are feed variations or operation out of a specified range, check the following components/adjustments: - Takeaway Roll Drive and Idler for binding, wear or contamination - Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1) - Nip missing in the Takeaway Roll area - Feed Belt for wear or contamination - Idler Springs for wear or out of position

Section Name

8 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Vertical Transport for slippage, binding or wear - Magnetic Strips for proper position or contamination 3. If available, run 110 lb. stock thru the system as a stress test. 4. Check the following components/adjustments: - Urethane sleeve for bonding to Takeaway Roll (PL 7.10) - Takeaway Drive Roll area for wear, contamination, or obstructions (PL 7.10 ) - Paper Feed Setup Series adjustment (ADJ 7-9) - Tray 1 Feeder Drive adjustment (ADJ 4-20) - Feed Clutch for wear, binding, or slippage (PL 7.12) - Feed Clutch Belt adjustment (ADJ 7-0) - PHM Drive Belt Tension adjustment (ADJ 4-17) - Vertical Transport Drive Coupling and Drive Coupling Insert for wear or damage (PL 8.1) - Vertical Transport Drive Pulley and Belt for wear, damage or slippage (PL 8.1) - Vertical Transport for binding & wear (PL 8.1) - Vertical Transport Belts (PL 8.1) 5. Replace the Feeder Assembly (PL 7.10) 6. Perform the 8-701 NRD Friction Retard Checkout.

Other dCs: 330 [8], 727 BSD: TBD 8-144

Indicates that the Duplex LE was late to Vertical Transport Sensor Q851

1. Measure the voltages of the Duplex TAR Sensor (PL 10.19) and Vertical Transport Sensor (PL 8.1). If a voltage is out of specification, replace the appropriate sensor. 2. Enter SCP [Printer Fault History]. If 8-146 faults are indicated, the problem is most likely in the Duplex area. If 8-146 faults are not indicated or Tray 1 and 2 faults are indicated, the problem is most likely in the Vertical Transport area. If 8-145 and 8-146 faults are indicated, check the input drives to the Duplex Inverter Assembly. 3. If available, run 110 lb. stock thru the system as a stress test. 4. Check the following components/adjustments: - Flexible Coupling and D Shaft for damage (PL 8.1) - Drive Coupling, Coupling Insert, and Drive Pulley for damage (PL 8.1) - Upper and Lower Shafts for binding - Input drives to the Duplex Inverter Assembly - Belts, Shafts and Bearings for damage, slippage or wear - Vertical Transport Clutch drive belt and idler for damage or wear - Vertical Transport Clutch for slippage, wear or damage (PL 4.18) - Vertical Transport Lower Shaft & Belts for damage or wear - Magnetic Strips for the correct operating position and damage 5. If the output prints are damaged, go to the 8-705 NRD PHM Print Damage Checkout. If no problem is found, return here and continue. 6. Perform the 8-156 and 8-145 NRDs for other possible causes of this problem. If no problem is found, return here and continue. 7. Replace the Vertical Transport Clutch (PL 4.18)

Other dCs: 330 [8], 726, 727 BSD: TBD

Preliminary Working Document No Product Name Assigned

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Section Name

8 NRD Fault Code Tables

Table 1 Chain 8 Fault Codes Code 8-145

Description/Reference Indicates that the Duplex LE was late to the Duplex TAR Sensor Q842 (A4)

Procedures 1. Enter SCP [Printer Fault History]. If 8-171 faults are indicated, go to the 8-171 NRD. If no problem is found, return here and continue. If 8-144 and 8-146 faults are indicated, check the input drives to the Duplex Inverter Assembly. 2. Measure the voltages of the Duplex Inverter Exit Sensor (PL 10.19). If a voltage is out of specification, replace the sensor. 3. Enter dC726 [29. 8-145 & 147] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19) - Forward Reverse Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - Exit Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) 4. Check the following components: - Inverter Exit Sensor actuator for damage or breakage - Foil tape under the Inverter Position Sensor on the lower baffle for dirt, damage or missing - Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19) - Inverter Drag Brake for wear, binding, or free spinning (PL 10.22) - Forward Reverse Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - One Way Clutch for slippage or binding (PL 10.22) - Jam Clearance Baffles for proper latching - Exit Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - Input drives to the Duplex Inverter Assembly and Inverter Gear Box Assembly - Inverter Drive Coupling for wear or damage (PL) - Duplex Gate Fingers (PL 10.21) for interference, bends or damage - Torsion Springs (PL 10.21) for damage or stretch - 5. Check/adjust the Duplex Timing (10-14). Perform this check several times, & if the check is varying by greater than 10mm, replace the Inverter Gear Box Assembly (PL 10.22). 6. Replace the following components in the order given: - One Way Clutch and Dual Drive Roll Shaft (PL 10.22, PL 10.19) - Inverter Drag Brake/Idler Bracket (PL 10.22)

8-146

Other dCs: 330 [8], 727 BSD: TBD

Inverter Gear Box Assembly (PL 10.22)

Indicates that the Duplex TE was late off the Duplex TAR Sensor Q842 (A4)

1. Measure the voltages of the Duplex Inverter Exit Sensor (PL 10.14). If a voltage is out of specification, replace the sensor. 2. Enter SCP [Printer Fault History]. If 8-144 and 8-145 faults are indicated, check the input drives to the Duplex Inverter Assembly. 3. Enter dC726 [30. 8-146] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19) - Exit Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - Wear Element Coupling (PL 10.19) 4. Check the following components: - Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19) - One Way Clutch for slippage or binding (PL 10.22) - Jam Clearance Baffles for proper latching

Section Name

8 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Exit Drive Rolls, Shafts and latching blocks for wear, contamination, or binding (PL 10.19) - Compression Springs on the Lower Baffle Latches for damage (PL 10.22) - Wear Element Coupling (PL 10.19) 4. Replace the following components in the order given: - One Way Clutch and Dual Drive Roll Shaft (PL 10.19, PL 10.22)

Other dCs: 330 [8], 727 BSD: TBD 8-147

Indicates that the Duplex LE was late to the Duplex TARS sensor Q842 (A3)

1. Enter SCP [Printer Fault History]. If 8-171 faults are indicated, go to the 8-171 NRD. If no problem is found, return here and continue. If 8-146 and 8-149 faults are indicated, check the input drives to the Duplex Inverter Assembly. 2. Measure the voltages of the Duplex Inverter Exit Sensor (PL). If a voltage is out of specification, replace the sensor. 3. Enter dC726 [29. 8-145 & 147] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19) - Forward Reverse Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - Exit Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) 4. Check the following components: - Inverter Exit Sensor actuator for damage or breakage - Foil tape under the Inverter Position Sensor on the lower baffle for dirt, damage or missing - Dual Drive Rolls and Shafts for wear, contamination, or binding (PL 10.19) - Inverter Drag Brake for wear, binding, or free spinning (PL 10.22) - Forward Reverse Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - One Way Clutch for slippage or binding (PL 10.22) - Jam Clearance Baffles for proper latching - Exit Drive Rolls and Shafts for wear, contamination, or binding (PL 10.20) - Input drives to the Duplex Inverter Assembly and Inverter Gear Box Assembly - Inverter Drive Coupling for wear or damage (PL) - Duplex Gate Fingers (PL 10.21) for interference, bends or damage - Torsion Springs (PL 10.21) for damage or stretch 5. Check/adjust the Duplex Timing (ADJ 10-14). Perform this check several times, & if the check is varying by greater than 10mm, replace the Inverter Gear Box Assembly (PL 10.22). 6. Replace the following components in the order given: - One Way Clutch and Dual Drive Roll Shaft (PL 10.22, PL 10.19) - Inverter Drag Brake/Idler Bracket (PL 10.22) - Inverter Gear Box Assembly (PL 10.22)

Other dCs: 330 [8], 727 BSD: TBD 8-149

Indicates that the Duplex LE was late to the Vertical Transport Sensor Q851 (A3)

1. Measure the voltages of the Duplex TAR Sensor (PL) and Vertical Transport Sensor (PL 8.1). If a voltage is out of specification, replace the appropriate sensor. 2. Enter SCP [Printer Fault History]. If 8-146 faults are indicated, the problem- is most likely in the Duplex Inverter area. If 8-147 and 8-146 faults are indicated, check the input drives to the Duplex Inverter Assembly. 3. If available, run 110 lb. stock thru the system as a stress test. 4. Check the following components/adjustments:

Preliminary Working Document No Product Name Assigned

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Section Name

8 NRD Fault Code Tables

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Flexible Coupling and D Shaft for damage (PL 8.1) - Drive Coupling, Coupling Insert, and Drive Pulley for damage (PL 8.1) - Upper and Lower Shafts for binding - Input drives to the Duplex Inverter Assembly - Belts, Shafts and Bearings for damage, slippage or wear - Vertical Transport Clutch drive belt and idler for damage or wear - Vertical Transport Clutch for slippage, wear or damage (PL 4.18) - Vertical Transport Lower Shaft & Belts for damage or wear - Magnetic Strips for the correct operating position and damage 5. If the output prints are damaged, go to the 8-705 NRD PHM Print Damage Checkout. If no problem is found, return here and continue. 6. Perform the 8-156 and 8-147 NRDs for other possible causes of this problem. If no problem is found, return here and continue. 7. Replace the Vertical Transport Clutch (PL 4.18)

Other dCs: 330 [8], 727 BSD: TBD 8-151

Indicates that the TE was late off the Vertical Transport Sen- 1. Measure the voltages of the Vertical Transport Sensor (PL 8.1). If a voltage is out of specification, replace the sor Q851 sensor. 2. Enter dC726 [4. 8-115] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Vertical Transport Belts for position and wear (PL 8.1) - Vertical Transport Upper and Lower Shaft assembly for binding - Vertical Transport Assembly for wear, damage, or slippage (PL 8.1) - Vertical Transport Drive Coupling or Drive Coupling Insert for wear or damage (PL 8.1) 3. Enter dC726 [18. 8-151] [Timing Graphs]. If known, program dC726 to run using the paper tray that the customer is having problems with. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Multifed sheets - Paper stock catching on the Registration Edge - Check the Registration Edge for damage or grooves - Cross Roll Drives for wear or contamination - Nip Release Solenoid Assembly for binding, overheating or damage 4. If the sheets are snagging on the Registration Edge entrance chute, or skewing in the paper path, go to the 8706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue. 5. Enter SCP [Printer Fault History]. If 8-152, 8-153, or 8-154 faults are indicated, go to the appropriate NRD and perform the checks indicated. If no problem is found, return here and continue. 6. Check the following components/adjustments: - Vertical Transport Assembly for wear, damage, or slippage (PL 8.1) - Vertical Transport Belts and Drives for wear, damage, or slippage (PL 8.1) - Vertical Transport Drive Belts for wear, damage or slippage - Vertical Transport Magnetic Strips for the correct position or damage - Vertical Transport Clutch for binding, wear, or damage (PL 4.18) - Vertical Transport Magnetic Strips for the correct position or damage (PL 8.2)

Section Name

8 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Registration Transport for correct installation and damage (PL 8.3) - Turn Baffle for seating on inboard pin, spring on baffle and damage (PL 8.4) - Nip Release Solenoid Assembly for binding, overheat or damage (PL 8.5) - Nip Release Solenoid Assembly adjustment (ADJ 8-6) 7. Replace the following components in the order given: - Vertical Transport Belts (PL 8.1) - Vertical Transport Clutch (PL 4.18)

Other dCs: 330 [8], 727 BSD 8.3 8-152

Indicates that the LE was late to the Registration Transport 1. Measure the voltages of the Vertical Transport (PL 8.1), Cross Roll (PL 8.5) and Registration Transport (PL Sensor Q861 from the Vertical Transport Sensor Q851 (A4) 8.5) Sensors. If a voltage is out of specification, replace the sensor. 2. Enter dC330 [8] [Cycle Outputs]. Select [Cross Roll Left]. Press the Continue button. If the solenoid becomes sluggish or intermittent as it warms up, replace it (PL 8.5). Perform the same checks on the [Cross Roll Right] and [Nip Release] solenoids (PL 8.10). 3. If available, run 110 lb. and 16 lb. stock thru the system as a stress test. 4. Enter dC726 [19. 8-152] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Paper Stock skewing on the Registration Transport - Paper stock catching on the Registration Edge - Cross Roll Idler Lift Fingers for binding and correct position 5. If the sheets are snagging on the Registration Edge entrance chute, or skewing in the paper path, go to the 8706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue. 6. If the problem only occurs when the operator is using transparencies, enter SCP [Printer Fault History]. If 8204 faults are occurring, go to the 8-204 NRD and perform the checks indicated. If no problem is found, return here and continue. Verify that the Registration Transport Sensor can be actuated by the transparencies, and clean the Registration Transport and Cross Roll Sensors. 7. Enter SCP [Printer Fault History]. If 8-151 faults are indicated, the problem is most likely with the Vertical Transport components. 8. Check the following components/adjustments: - Left and Right Cross Roll Assemblies for wear, damage, or binding (PL 8.5) - Vertical Transport Assembly for wear, damage, or slippage (PL 8.1) - Vertical Transport Belts and Drives for wear, damage, or slippage (PL 8.1) - Vertical Transport Clutch for binding, wear, or damage (PL 4.18) - Vertical Transport Magnetic Strips for the correct position or damage (PL 8.2) - Cross Roll Assembly drive rolls for damage, debonding, or flat spots (PL 8.7) - Cross Roll Assemblies and Drives for worn belts, binding, or damage (PL 8.7) - Registration Transport, Registration Transport components, and Turn Baffle for correct installation, damage, wear or binding (PL 8.3) - Registration Edge for damage, grooves, and proper seating (PL 8.4) - Servo Drive Rolls for wear, damage, or binding (PL 8.4) - Nip Release Solenoid Assembly for binding, overheat or damage (PL 8.5) - Nip Release Solenoid Assembly adjustment (ADJ 8-6) 9. Replace the following components in the order given:

Preliminary Working Document No Product Name Assigned

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Section Name

8 NRD Fault Code Tables

Table 1 Chain 8 Fault Codes Code

Description/Reference

Procedures - Left and Right Cross Roll Assemblies (PL 8.5) - Registration Edge (PL 8.4)

Other dCs:727

10. There is a possibility that the fault is related to components in the Registration Controller Servo area. Go to the 8-302 NRD procedure. If no problem is found, return here and continue.

BSD : TBD 8-155

Indicates that the TE was late off the Registration Transport 1. Measure the voltages of the Registration Transport (PL 8.4) and Cross Roll (PL 8.5) Sensors. If a voltage is Sensor Q861 out of specification, replace the appropriate sensor. 2. Enter SCP [Printer Fault History]. If 8-196 faults are occurring, go to the 8-196 NRD and perform the checks indicated. If no problem is found, return here and continue. 3. Enter dC726 [20. 8-155] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Paper stock skewing on the Registration Transport - Paper stock catching on the Registration Edge - Cross Roll Idler Lift Fingers for binding and correct position - Vertical Transport Idler Nips for proper seating 4. If the sheets are skewing in the paper path or misregistered, go to the 8-706 NRD PHM Misregistration and Skew Checkout. If no problem is found, return here and continue. 5. Check the following components: - Registration Transport Upper Baffle for damage or bowing. - Registration Edge for damage, grooves, and proper seating (PL 8.4) - Registration Transport and associated components for the correct installation and damage (PL 8.3) - Servo Drive Rolls and Idlers for damage, contamination, slippage or binding - Cross Rolls and Assemblies for binding, damage, or contamination (PL 8.5) - Pretransfer Lift Block for the correct position or damage (PL 8.8) - Pretransfer Baffle for the correct position or damage (PL 8.8) - Mylar Transport Strip between the Registration Transport and the Pretransfer Baffle for proper seating or damage (PL 8.4) 6. Check the Registration Transport Upper Baffle adjustment (ADJ 8-0). 7. Replace the following components in the order given: - Cross Roll Idler Lift Assembly (PL 8.5) System Procedure: Electrical Noise

Registration Edge (PL 8.4 )

Other dCs: 330 [8],727

8. There is a possibility that the fault is related to components in the Registration Controller Servo area. Go to the 8-302 NRD procedure. If no problem is found, return here and continue.

BSD: TBD

Section Name

8 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

9 NRD Fault Code Tables Table 1 Chain 9 Fault Codes Code

Description/Reference

9-101

Indicates a POP jam in A4 mode

9-102

Indicates a POP jam in A3 mode

Procedures 1. Enter SCP [Printer Fault History]. If 9-201, 9-327, 9-328 or 9-329 faults are occurring at the same timestamp as the 9-101 or 9-102 faults, go to the NRD associated with the other fault codes first. 2. Measure the voltages of the POP Sensor Q904. If any voltage is out of specification, replace the sensor (PL). 3. Enter dC314 and ensure that the proper HVDC Calibration values have been entered for the DTAC$$SI and TRANS$$SI values. 4. Enter dC140 [Dicorotron Values]. Select [Continue]. Check the Detack Current Monitor display. If the value is greater than the Detack Current Control display, clean the Dicorotron connectors and clean/replace the Detack Dicorotron & Shield (PL 9.10). 5. Check the following components: - Transition Baffle for damage or burrs - Pretransfer Baffle for damage and the correct operating position - Prefuser Transport for damage and the correct operating position - PR Stripper Fingers for damage and the correct operating position 6. Replace the following components in the order given: - Stripper Fingers (PL 9.3) - Detack Dicorotron and Shield (PL 9.11) - HVDC PWB (PL 1.7)

BSD 9.7 (Sheet 1) 9-201

NOTE: 9-101/102 faults can be caused by the condition of the paper stock (e.g., high humidity, old paper, etc.).

Indicates that a high voltage power supply arc was detected 1. Enter dC910 [High Stress]. Select [Continue]. Run the machine several times, and observe the Dicorotrons for arcing. Replace as required (PL 9.10, PL 9.11). 2. Check the PR Ground Brush for loose, missing, or broken fibers. If a problem is found, replace the PR Ground Brush (PL 9.7) and all Dicorotrons (PL 9.10, PL 9.11). Vacuum the Xerographic area to remove any dislodged fibers. 3. Check the following components for signs of arcing, cracks, pitting, contamination, open circuits, etc.: - Ozac tube and connectors - HVDC Cables and connections - HVAC Output Module & connections - Dicorotrons and Dicorotron pins, sockets, and connectors 4. Replace the following components in the order given: - All Dicorotrons and Shields (PL 9.10, PL 9.11) - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.8) - MIN DIO PWB (PL 1.8) 5. The following list contains the infrequent causes of 9-201 faults: - Intermittent loss of +/- 15 VDC or + 34 VDC to the HVAC PWB - Pinched wires or open grounds in the Transfer Assist Device - Intermittent contact in the Drawer Roll Up Ribbon Cable (PL 9.1) - Broken ground wires in the Fuser Metering Assembly

Preliminary Working Document No Product Name Assigned

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Section Name

9 NRD Fault Code Tables

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures

System Procedure: Electrical Noise Other dCs: 140, 951 BSD 9.1 (Sheet 1) 9-202

Indicates that the AC Coronode Voltage Set point is out-ofrange

1. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7, (ADJ 9-6). 2. Ensure that the Cleaner Zone Roll and bearings are in their operating positions and are not damaged. 3. Check the following components for signs of arcing, cracks, pitting, contamination, open circuits, etc.: - Ozac system and connectors - HVDC Cables and connections - HVAC Output Module & connections - Dicorotrons and Dicorotron pins, sockets, connectors, and shields 4. Enter dC140 [Dicorotron Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any value is out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 5. Enter dC951 [Xerographic] Option] [Setup Initialization with Fault Masking]. Select [Continue]. If any value in the Setup & Initialization part of dC951 is out-of-range, go to the dC951 Xerographic Setup Routine Procedure in this section. If no problem is found, return here and continue. 6. Replace the following components in the order given: - All the Charge Dicorotrons and Shields (PL 9.10) - HVDC PWB (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.7) - MIN ADA PWB #2 (PL 1.7)

BSD 9.1 (Sheet 2) 9-203

Indicates that the Photoreceptor has reached its end of life

1. Check the PR Ground Brush for loose, missing or broken fibers. If a problem is found, replace the PR Ground Brush (PL 9.7) and all the Dicorotrons (PL 9.10, PL 9.11). Vacuum the Xerographic area to remove the dislodged fibers.

9-213

Indicates that the ESV has failed

2. Check/adjust the ESV Height (ADJ 9-12), Charge Dicorotron Height and Balance (ADJ 7-9) and ROS Correction Factor (ADJ 6-3) adjustments. 3. Check the dC131 [MIN] locations 260 (ESV Adjust) and 285 (Patch Location). 4. Ensure that the ROS Assembly is positioned correctly in the rails and is not skewed. 5. Ensure that the Charge Zone Rolls and bearings are in their operating positions and are not damaged. 6. Check the following components for signs of arcing, cracks, pitting, contamination, open circuits, etc.: - Ozac system and connectors - HVDC Cables and connections - HVAC Output Module & connections - Dicorotrons and Dicorotron pins, sockets, connectors and shields. 7. Enter dC314 and ensure that the proper HVDC and HVAC Calibration values have been entered. 8. Enter dC140. While dC140 is running open the processor front doors. If any Dicorotron value is greater than 0.3 VDC after 30 seconds, replace the HVDC PWB (PL 1.7) 9. Enter dC140 [Dicorotron Values]. Select [Continue]. If any Dicorotron Shield Voltage is greater than 9.5, replace the appropriate Dicorotron and Shield (PL 9.10, PL 9.11).

Section Name

9 NRD Fault Code Tables

0/0/00 ?-96

Preliminary Working Document No Product Name Assigned

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures 10. Rerun dC140. Use the dC140 Diagnostic Table in this section as a reference. If any value is out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 11. Enter dC951 [Xerographic Options] [Setup Initialization with Fault Masking]. Select [Continue]. If any value in the Setup & Initialization part of dC951 is out-of-range, go to the DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue. 12. Perform the following IQ RAPs: PQ 9-618 (PR Ground), PQ 9-619 (ESV), PQ 9-621 (Patch Generator), PQ 9-624 Precharge/Pretransfer Lamps), PQ 9-621 (Patch Gen/Patch Integrity), and PQ 9-633 (dC912 PR Uniformity). If no problem is found, return here and continue. 13. Replace the following components in the order given: - PR Belt (PL 9.1), HVAC PWB (PL 1.7) - All the Charge Dicorotrons and Shields (PL 9.10), HVAC Output Module (PL 1.7) - ESV Assembly (PL 1.7), MIB PWB (PL 1.8) - HVDC PWB (PL 1.7), MIN DIO PWB (PL 1.8)

System Procedure: Electrical Noise Other dCs: 99 BSD 9.4 14. If the problem continues, go to the 6-701 NRD. The ROS generates the patch used in process control and could be related to this problem. 9-211

Indicates that the Patch Generator has failed

1. Replace the following components in the order given: Patch Generator (PL 9.10) MIN DIO PWB (PL 1.8)

9-212

BSD 9.5

MIB PWB (PL 1.8)

Indicates that the DSS has failed

1. Check the PR Ground Brush for loose, missing or broken fibers. If a problem is found, replace the PR Ground Brush (PL 9.7) and all the Dicorotrons (PL 9.10). Vacuum the Xerographic area to remove dislodged fibers. 2. Check/adjust the ROS Correction Factor adjustment (ADJ 6-3). 3. Check the Xerographic area of the Printer for an excessive buildup of dirt. If any is found, locate and repair the cause of the dirt. The Cleaner and Developer subsystems may be causing the dirt. 4. Check the following components for signs of arcing, cracks, pitting, contamination, open circuits, etc.: - Ozac system and connectors - HVDC Cables and connections - HVAC Output Module & connections - Dicorotrons and Dicorotron pins, sockets, connectors and shields 5. Check for broken or loose ground wires in Fuser Metering Roll assembly & Transfer Assist Device. 6. Perform the PQ 9-619 ESV & PQ 9-618 PR Ground RAPs. If no problem is found, return here and continue. 7. Replace the following components in the order given: - DSS (PL 9.7) - MIN ADA PWB #1 (PL 9.7) MIN DIO PWB (PL 1.8)

System Procedure: Electrical Noise Other dCs: 99 BSD 9.5 8. If the problem continues, go to the 6-701 NRD. The ROS generates the patch used in process control and could be related to this problem. 9-213

Go to the 9-203 NRD.

9-215

Indicates that the Toner Dispenser has failed

Preliminary Working Document No Product Name Assigned

1. Check the PR Ground Brush for loose, missing or broken fibers. If a problem is found, replace the PR Ground Brush (PL 9.7) and all the Dicorotrons (PL 9.10, PL 9.11). Vacuum the Xerographic area to remove dislodged fibers.

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Section Name

9 NRD Fault Code Tables

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures 2. Clean the DSS, ESV, and Patch Generator with a clean, soft, lint free cloth (anti-static solution, 8R90275, may be used on the DSS). Check the Xerographic area of the Printer for an excessive buildup of dirt. If any is found, locate and repair the cause of the dirt. The Cleaner and Developer subsystems may be causing the dirt. 3. Check the dC 131 locations 260 (ESV Adjust) and 285 (Patch Location) are at the values shown in the appropriate level Software Table (Section 6, General Procedures, in the Service Manual). 4. Enter dC330 [9]. Select [PreClean/PrexTransfer Lamps]. Press the [Continue ] button. If all segments of the Precharge Erase and Pretransfer Lamps do not light, replace the lamp (PL 9.3, PL 9.4). 5. Select [Toner Thumper]. Press the Continue button. If the Toner Thumper Solenoid does not energize, go to the BSD, and check the circuit. If no problem is found, replace the Toner Thumper Solenoid (PL 9.19). 6. Check the following components for signs of arcing, cracks, pitting, contamination, open circuits, etc.: - Ozac system and connectors - HVDC Cables and connections - HVAC Output Module & connections - Dicorotrons and Dicorotron pins, sockets, connectors, and shields 7. Check the following components: - Developer Housing and associated components for proper mechanical condition (rollers, gears, auger, bearings, couplings, etc.) - Developer Gears for wear or noise (PL 9.14) - Input drives to the Developer Housing for wear, slippage, etc. - Developer Housing for clogged dry ink - Cross Mixer Baffle operation - ROS Correction Factor adjustment (ADJ 6-3) - Toner Thumper Solenoid adjustment (ADJ 9-0) 8. Perform the following IQ RAPs: PQ 9-616 (Development) and PQ 9-620 DSS. If no problem is found, return here and continue. 9. Replace the following components in the order given: - MIN AC Remote PWB (PL 1.7), Toner Thumper Solenoid (PL 9.19) - Toner Dispenser Motor (PL 9.19), MIN ADA PWB #1 (PL 1.7) - MIN DIO PWB (PL 1.8), Low Toner Sensor (PL 9.19) - MIB PWB (PL 1.8), Precharge and Pretransfer Erase Lamps (PL 9.3, PL 9.4) - Patch Generator (PL 9.10), Discharge Lamps Power Supply (PL 9.4)

System Procedure: Electrical Noise Other dCs: 951 BSD 9.5 10. If the problem continues, go to the 6-701 NRD. The ROS generates the patch used in process control and could be related to this problem. 9-220

Indicates that the time between belt holes is too long

1. Measure the voltages of the Belt Hole Sensor and LED. If any voltage is out of specification, replace the sensor and/or LED (PL 9.7).

9-222

Indicates that the time between belt holes is too short

2. Enter dC912 [Timing Test]. Select [Continue]. Check the display for random numbers that are far from the others. If any are observed, replace the Machine Clock Sensor (PL 9.3). 3. Check the following components: - PR Module and Drawer for proper seating - PR Belt for damage. If damage is found, check the Developer Housing and Cleaner Housing for foreign particles. Also check the condition of the Ground Brush. - PR Module condition (rolls, bearings, shafts, etc.)

Section Name

9 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures - Machine Clock Sensor for looseness - PR Module Input Drives - Cleaner Module, Developer Housing, or Machine Drives for binding - P/J300 for rubbing on drives 4. Replace the following components in the order given: - Belt Hole Sensor and LED (PL 9.7) - Photoreceptor (PL 9.1) - MIN Core PWB (PL 9.7)

9-221

Other dCs: 330 [9] BSD 9.3

Photoreceptor Module (PL 9.1)

Indicates an ozone blower air flow failure.

1. Check the Ozone Vacuum Switch for intermittent operation. 2. Check the following components: - Air flow blockage in the duct - Ozone Vacuum Switch for binding - Ozone Blower Motor for binding 3. Replace the following components in the order given: - Ozone Vacuum Switch (PL 9.9) - Ozone Blower Capacitor (PL 9.8) - Ozone Blower Motor (PL 9.9)

Other dCs: 330 [9] 9-222

Go to the 9-220 NRD

9-320

Indicates that the Developer Rolls 1 & 2 bias voltage was out-of-range

MIN DIO PWB (PL 1.8) 1. Check the following components: - Developer Zone Roll Adjustment (ADJ 9-1) - Developer Housing for intermittent short circuits - Developer Housing for broken, damaged, or missing contact points (PL 9.15) - Developer Drive Assembly for separation, wobble, or scrapes (PL 9.14) 2. Enter dC140 [DC Bias Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Dev Rolls 1 & 2 Voltage values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 3. Replace the following components in the order given: - Developer Drive Assembly (PL 9.14) - HVDC PWB (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #2 (PL 1.7)

9-321

System Procedure: Electrical Noise BSD 9.2 (Sheet 3)

MIN ADA PWB #1 (PL 1.7)

Indicates that the Developer Roll 3 bias voltage is out-ofrange

1. Check the following components: - Developer Zone Roll Adjustment (ADJ 9-1) - Developer Housing for intermittent short circuits - Developer Housing for broken, damaged, or missing contact points (PL 9.15) - Developer Drive Assembly for separation, wobble, or scrapes (PL 9.14)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-99

Section Name

9 NRD Fault Code Tables

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures 2. Enter dC140 [DC Bias Values]. Select [Continue]. Using the dC140 Diagnostic Table in this section as a reference. If any of the displayed Dev Roll 3 Voltage values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 3. Replace the following components in the order given: - Developer Drive Assembly (PL 9.14) - HVDC PWB (PL 1.7)

9-322

System Procedure: Electrical Noise BSD 9.2 (Sheet 3)

MIN ADA PWB #2 (PL 1.7)

Indicates that the cleaner voltage is out-of-range

1. Check the following components: - Cleaner Assembly for intermittent short circuits - Photoreceptor Tension Rolls/Springs for proper actuation - Photoreceptor Tension adjustment (ADJ 9-11) 2. Enter dC140 [DC Bias Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Cleaner Brush Voltage values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 3. Replace the following components in the order given: - HVAC PWB (PL 1.7) - HVDC PWB (PL 1.7)

9-323

System Procedure: Electrical Noise BSD 9.1 (Sheet 1)

MIN ADA PWB #1 (PL 1.7)

Indicates that the UDTR voltage is out-of-range

1. Check the Cleaner Assembly for intermittent short circuits 2. Enter dC140 [DC Bias Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Upper Detoning Roll Voltage values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 3. Replace the following components in the order given: - HVAC PWB (PL 1.7)

9-324

System Procedure: Electrical Noise BSD 9.1 (Sheet 1)

MIN ADA PWB #1 (PL 1.7)

Indicates that the LDTR voltage is out-of-range

1. Check the Cleaner Assembly for intermittent short circuits 2. Enter dC140 [DC Bias Values]. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Lower Detoning Roll Voltage values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 3. Replace the following components in the order given: - HVAC PWB (PL 1.7)

9-325

System Procedure: Electrical Noise BSD 9.1 (Sheet 1)

MIN ADA PWB #1 (PL 1.7)

Indicates that the Charge 2 voltage is out-of-range

1. Enter SCP [Printer Fault History]. If Fault Codes 9-326, 9-327, 9-328 and/or 9-329 are occurring at the same timestamp as the 9-325 faults, there is a problem with the HVAC circuit, which is shared by all these dicorotrons. If no problem is found with the circuit, replace the following components in the order given: - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.7) 2. Check the Charge Dicorotron Height and Balance adjustment (ADJ 9-7, ADJ 9-6) 3. Check the following components for loose connections, contamination, arcing, discoloration, etc.: - Dicorotrons and connectors - Ozac System and connectors

Section Name

9 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures - HVDC and HVAC Cables 4 . Enter dC140. Select [Continue]. Using the dC140 Diagnostic Table in this section as a reference, if either of the displayed Charge 1, or 2 Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 5. Replace the following components in the order given: - All the Charge Dicorotrons and Shields (PL 9.10) - HVDC PWB (PL 1.7)

9-326

System Procedure: Electrical Noise BSD 9.2 (Sheet 1)

MIN ADA PWB #2 (PL 1.7)

Indicates that the Transfer current is out-of-range

1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-327, 9-328 and/or 9-329 are occurring at the same timestamp as the 9-326 faults, there is a problem with the HVAC circuit, which is shared by all these dicorotrons. If no problem is found with the circuit, replace the following components in the order given: - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.7) 2. Check the following components for loose connections, contamination, arcing, discoloration, etc.: - Dicorotrons and connectors - Ozac System and connectors - HVDC and HVAC Cables 3. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Transfer Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 4. Replace the following components in the order given: - Transfer Dicorotron and Shield (PL 9.11) - HVDC PWB (PL 1.7)

9-327

System Procedure: Electrical Noise BSD 9.2 (Sheet 1)

MIN ADA PWB #2 (PL 1.7)

Indicates that the Detack current is out-of-range

1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-326, P9-328 and/or 9-329 are occurring at the same timestamp as the 9-327 faults, there is a problem with the HVAC circuit, which is shared by all these dicorotrons. If no problem is found with the circuit, replace the following components in the order given: - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.7) 2. Check the following components for loose connections, contamination, arcing, discoloration, etc.: - Dicorotrons and connectors - Ozac System and connectors - HVDC and HVAC Cables 3. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Detack Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 4. Replace the following components in the order given: - Detack Dicorotron and Shield (PL 9.11) - HVDC PWB (PL 1.7)

System Procedure: Electrical Noise BSD 9.2 (Sheet 1)

Preliminary Working Document No Product Name Assigned

MIN ADA PWB #2 (PL 1.7)

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Section Name

9 NRD Fault Code Tables

Table 1 Chain 9 Fault Codes Code 9-328

Description/Reference Indicates that the Preclean current is out-of-range

Procedures 1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-326, 9-327 and/or 9-329 are occurring at the same timestamp as the 9-328 faults, there is a problem with the HVAC circuit, which is shared by all these dicorotrons. If no problem is found with the circuit, replace the following components in the order given: - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.7) 2. Check the following components for loose connections, contamination, arcing, discoloration, etc.: - Dicorotrons and connectors - Ozac System and connectors - HVDC and HVAC Cables 3. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Preclean Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 4. Replace the following components in the order given: - Preclean Dicorotron and Shield (PL 9.11) - HVDC PWB (PL 1.7)

9-329

System Procedure: Electrical Noise BSD 9.2 (Sheet 1)

MIN ADA PWB #2 (PL 1.7)

Indicates that the AC Voltage is out-of-range

1. Enter SCP [Printer Fault History]. If Fault Codes 9-325, 9-326, 9-327 and/or 9-328 are occurring at the same timestamp as the 9-329 faults, there is a problem with the HVAC circuit, which is shared by all these dicorotrons. If no problem is found with the circuit, replace the following components in the order given: - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7) - MIN ADA PWB #1 (PL 1.7) 2. Check the following components for loose connections, contamination, arcing, discoloration, etc.: - Dicorotrons and connectors - Ozac System and connectors - HVDC and HVAC Cables 3. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If any of the displayed Coronode AC Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 4. Replace the following components in the order given: - HVAC Output Module (PL 1.7) - HVAC PWB (PL 1.7)

System Procedure: Electrical Noise BSD 9.1 (Sheet 2) 9-330

MIN ADA PWB #1 (PL 1.7)

Indicates that the Charge 2 AC shield current is out-of-range 1. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 & ADJ 9-6). 2. Check the following components for loose connections, contamination, arcing, discoloration, etc.: - Dicorotrons and connectors - Ozac System and connectors - HVDC and HVAC Cables 3. Enter dC99. Select [Continue]. If either of the Charge 1, or 2 Control values are out-of-range, go to the dC99 Routine Procedure in this section. If no problem is found, return here and continue.

Section Name

9 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures 4. Enter dC140. Select [Continue]. Use the dC140 Diagnostic Table in this section as a reference. If either of the displayed Charge 1, or 2 Voltage or Current values are out-of-range, go to the DC140 Analog Display Diagnostic Procedure in this section. If no problem is found, return here and continue. 5. Replace the following components in the order given: - All the Charge Dicorotrons and Shields (PL 9.10) - 2HVDC PWB (PL 1.7)

9-332

System Procedure: Electrical Noise BSD 9.2 (Sheet 1)

MIN ADA PWB #2 (PL 1.7)

Indicates that the Printer failed to complete a cycle in convergence after a power up

1. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 & ADJ 9-6). 2. Check the following components: - Cleaner Zone Roll for proper engagement and operation - PR Ground Strip and Ground Brush for damage, contamination, and wear 3. Perform the Xerographic Setup adjustment (ADJ 9-3). If any value is out-of-range during dC951, go to the DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue. 4. If excessive dirt was found in the Xerographic area during the Xerographic Setup adjustment, locate and repair the cause of the dirt. 5. Replace all the Charge Dicorotrons and Shields (PL 9.10). 6. Perform the PQ 9-601 Print Image Quality Entry Level RAP.

9-353

Indicates that the Printer failed to converge contrast in dC951

1. Enter SCP [Printer Fault History]. If Fault Code 9-203 or 9-213 are occurring at the same timestamp as the 9353 faults, go to the 9-203 NRD. 2. Perform the ROS Low Correction Factor (ADJ 6-3) and Xerographic Set-up adjustments (ADJ 9-3). If any value is out-of-range during dC951, go to the DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue. 3. If excessive dirt was found in the Xerographic area during the Xerographic Setup adjustment, locate and repair the cause of the dirt. The Developer and Cleaner subsystems are high suspects for causes of dirt. 4. The problem may be related to a non-uniform PR Belt. Enter dC912 [Uniformity Test]. Select [Continue]. If any of the displayed values are out-of-range, replace the PR Belt (PL 9.10). 5. Perform the PQ 9-633 dC912 PR Uniformity RAP. If no problem is found, return here and continue. 6. If the problem continues, go to the 6-701 NRD. The ROS generates the patch used in process control and could be related to this problem.

9-354

Indicates that the Printer failed to set toner concentration in 1. Perform the Xerographic Set-up adjustment (ADJ 9-1). If any value is out-of-range, during dC951, go to the dC951 DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue. 2. If excessive dirt was found in the Xerographic area during the Xerographic Setup adjustment, locate and repair the cause of the dirt. The Developer and Cleaner subsystems are high suspects for causes of dirt. 3. Perform the following PQ RAPs: PQ 9-617 Cleaner and PQ 9-621, Patch Gen/Patch Integrity RAP. If no problem is found, return here and continue. BSD 9.5

9-355

4. If the problem continues, replace the DSS (PL 9.7).

Indicates that the printer failed to set the patch generator in 1. Perform the Xerographic Setup adjustment (ADJ 9-1). If any value is out-of-range, during dC951, go to the dC951 DC951 Auto Xerographic Setup in this section. If no problem is found, return here and continue. 2. If excessive dirt was found in the Xerographic area during the Xerographic Setup adjustment, locate and repair the cause of the dirt. The Developer and Cleaner subsystems are high suspects for causes of dirt. 3. Enter dC330 [9] [Patch GEN High]. Press the Continue button. Use a mirror to observe the Patch Generator LEDs. If all four LEDs are not lit, replace the Patch Generator (PL 9.10).

Preliminary Working Document No Product Name Assigned

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Section Name

9 NRD Fault Code Tables

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures 4. Perform the PQ 9-624 Precharge/Pretransfer Lamps RAP. If no problem is found, return here and continue. 5. Replace the following components in the order given: - Patch Generator (PL 9.10) - MIN DIO PWB (PL 1.8) - MIB PWB (PL 1.8)

9-704

BSD 9.5

MIN ADA PWB #2 (PL 1.7)

Used to troubleshoot the non-repeatable problems with the Toner Filter Blower Motor

1. Check the following components: - Toner Filter Blower O-rings for wear and damage (PL 9.20) - Toner Filter Blower Motor for binding or resistance 2. Replace the following components; Toner Filter Blower Motor MOT905 (PL 9.20)

9-705

Other dCs: 330 [9]

Toner Filter Blower Motor Capacitor C902 (PL 9.20)

Used to troubleshoot the non-repeatable problems with the MIM Cooling Fan

1. Check the MIM Cooling Fan for binding or resistance. 2. Replace the MIM Cooling Fan MOT107 (PL 4.9)

BSD 1.6 8-902

Indicates a Tray 2 dynamic width error (first sheet is too long 1. Check the dC131 [PHN] locations 220 (A4 Almost Jam Value) and 222 (A4 Jam Value). or short) 2. Measure the voltages of the Length A and Length B Sensors (PL 7.2). If a voltage is out of specification, replace the sensor. 3. Enter dC330 [8] [Cycle Outputs]. Select [Cross Roll Left]. Press the Continue button. If the solenoid becomes sluggish or intermittent as it warms up, replace it (PL 8.5) 4. Enter dC703 [Paper Width Timing Setup] [Printer Options] [Tray 2] [Printer Options]. Select [Continue]. Check/adjust the Average Error. If the problem still occurs after the adjustment or if the adjustment cannot be achieved, continue with this procedure. 5. Ensure SCP [Printer Fault History]. If 8-123 or 8-155 faults are indicated, go to the 8-123 NRD. If no problem is found, return here and continue. 6. Enter dC726 [21. 8-901, 2, 3] [Timing Graphs]. Select [Continue]. If there are feed variations or operation is out of specified range, check the following components/adjustments: - Paper stock skewing on the Registration Transport - Paper stock catching on the Registration Edge - Cross Roll Idler Lift Fingers for binding and correct position - Vertical Transport Double Nip for proper seating 7. Check the following components/adjustments: - Length Guide and Cam for damage or wear (PL 7.2) - Left Cross Roll Solenoid for binding or damage (PL 8.5) - Length Guide Position and Tension adjustment (ADJ 7-4, ADJ 7-5) - Vertical Transport Magnetic Strips for proper position and damage - Servo Drive Rolls and Idlers for wear, damage, or contamination - Jam Clearance Baffles for proper seating and damage - Registration Transport Sensor lens for damage

Section Name

9 NRD Fault Code Tables

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Preliminary Working Document No Product Name Assigned

Table 1 Chain 9 Fault Codes Code

Description/Reference

Procedures 8. If the following problems are present, go to the appropriate NRD. If no problem is found, return here and continue. - Damaged prints (Go to the 8-705 NRD) - Mutifed sheets (Go to the 8-123 NRD) - Misregistered or skewed sheets (Go to the 8-706 NRD) 9. Perform the 8-302 NRD for other possible causes of this problem. If no problem is found, return here and continue. 10. Replace the following components in the order given: - Registration Transport Sensor (PL 8.4)

BSD: TBD

Preliminary Working Document No Product Name Assigned

- Left Cross Roll Solenoid (PL 8.5)

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Section Name

9 NRD Fault Code Tables

10 NRD Fault Code Tables Table 1 Chain 10 Fault Codes Code

Description/Reference

Procedures

10-101

Print LE was late to the Prefuser Sensor Q1010 after it arrived at the Registration Sensor Q1009.

1. Enter dC726. Select [22. 10-101], [Timing Graphs], [Continue]. When the test is complete, inspect the timing data for Normal, Late, or Random distribution. Perform the checks below which relate to the type of distribution identified in the timing graph. Late Distribution: - Prefuser Transport for vacuum leaks (PL 8.9) - Damaged or contaminated Prefuser Transport Drive Belts (PL 8.9) - Binding Prefuser Transport Bearings (PL 8.9) - Worn Prefuser Transport Drive Coupling (PL 4.16) - Obstructed Prefuser Transport Manifold holes - Prefuser Drive System for worn or misadjusted components (PL 4.16) Normal or Random Distribution: - Measure the voltage of the Registration Sensor Q861 (PL 8.4) and Prefuser Sensor Q1009. If a voltage is out of specification replace the appropriate sensor, (PL 8.9). 2. For Misregistration or Skew, go to the 8-706 NRD. 3. For Print Jams Before the Prefuser Transport perform the following checks: - Obstructions in the sheet path - Condition of paper - Operation and condition of the Transfer and Detack Dicorotrons (PL 9.11) - Condition of the Pretransfer Baffle (PL 8.8) - Condition of the Stripper Finger Assembly (PL 9.3) - Condition and operation of the Transfer Assist Blade (PL 9.11)

Other dCs: 330[10], 727 BSD 10.2

- Condition of the Detack Paper Guide (PL 9.11)

10-102

Print LE was late to the Fuser Sensor Q1010 after it arrived 1. Ensure paper is loaded properly and does not have excessive curl. For duplex mode operation, check the at the Prefuser Sensor Q1009. Decurler Exit Baffle adjustment (ADJ 10-8).

10-104

Print LE was late to the Decurler Sensor Q1011 after it arrived at the Fuser Sensor Q1010.

2. Perform the following stress test to increase the frequency of the failure. For 10-102 faults, enter dC726 Select [23. 10-102], [Timing Graphs], [Continue]. Run the same paper that the customer was having problems with to aid in identification of the faulty component. If a fault cannot be induced, view the Histogram timing data. If random distribution is detected, check the following components: - Check the Fuser Drive Coupling for damage and ensure that it is lubricated (PL 4.17) - Replace the Prefuser Sensor Q1009 and Fuser Sensor Q1010 (PL 8.9 and PL 10.6). - For 10-104 faults, enter dC726 Select [24. 10-104], [Timing Graphs], [Continue]. Run the same paper that the customer was having problems with to aid in identification of the faulty component. If a fault cannot be induced, view the Histogram timing data. If random distribution is detected, check the following components: - Check the Fuser Drive Coupling for damage and ensure that it is lubricated (PL 4.17) - Replace the Fuser Sensor Q1010 and Decurler Sensor Q1011 (PL 10.6 and PL 10.17). Identify the symptom below that relates to the failure. - Skew/misregistration/wrinkles (severe)/dog ears (other than Fuser area) - Go to the 8-706 NRD. Multifeeds.

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Table 1 Chain 10 Fault Codes Code

Description/Reference

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

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Table 1 Chain 10 Fault Codes Code

Description/Reference

Procedures - Go to the third bullet on the previous page and perform the checks. Overtoning Jams - Go to the PQ 9-610 High Image Darkness RAP, Service Manual Section 3IQ. Morning jams - Ensure that Printer Tag 195 is installed. Jams entering the Decurler (for 10-104 Faults only) - Perform the Air Knife Pressure ADJ 10-5 and Vacuum Manifold adjustments (ADJ 10-4). - Check for damaged or contaminated Decurler Belts (PL 10.13). - Check for binding or worn Decurler Drive Belts or Pulleys (PL 10.13). - Replace the Decurler Clutch (PL 10.13) No telltales or indications. - Measure the voltages of the Prefuser Sensor Q1009 (PHN DIO #2, TS24 (+), TS37(-)) and Fuser Sensor Q1010 (PHN DIO #2, TS21(+), TS37(-)). If there is NOT +0.5 VDC or less, clean or replace the appropriate sensor (PL 8.9 and PL 10.6). - Check the Fuser Drive Coupling for damage and ensure that it is not binding on the shaft (PL 4.17). Lubricate the shaft to allow free movement in and out along the shaft. - Check the Photoreceptor Drive Coupling for damage and ensure that it is not binding on the shaft (PL 4.17). Lubricate the shaft to allow free movement in and out along the shaft. Ensure that the Photoreceptor is not slipping or stalling on the Photoreceptor Drive Rolls. - Check the Prefuser Transport for belt slippage and clogged holes. - Check the Prefuser Vacuum Motor for proper operation. - Perform the following adjustments: - Fuser Latch Assembly, Fuser Left and Right Drawer Slide (ADJ 10-12) - Air Knife Manifold (ADJ 10-4) - Air Knife Pressure (ADJ 10-5) - Donor Roll ADJ 10-13 and Pressure Roll (Contact Arc), (ADJ 10-2). - MIM Compressor Air Pressure (ADJ 10-5) - Stripper Finger Baffle (ADJ 10-15) - Pressure Roll (Contact Arc), (ADJ 10-2) - Vacuum Manifold ( ADJ 10-4)

Other dCs: 330[10], 727 BSD 10.2, BSD 10.5, BSD 10.6, BSD 10.7 10-105 10-106 Print TE was late to leave the Decurler Sensor.

1. Enter dC726. Select [25. 10-105&106], [Timing Graphs]. Run 100 sheets of the heaviest print paper the customer has available to the Top Tray. When the test is complete, inspect the timing data for Normal, Late, or Random distribution. Perform the checks below which relate to the type of distribution identified in the timing graph. Late Distribution: - Top Transport Slip Clutch (PL 10.15) - Decurler and Top Transport Belts for proper tension or wear - Decurler and Top Transport drives and pulleys - Decurler Sensor adjustment (ADJ 10-10) Normal or Random Distribution: - Decurler Sensor adjustment (ADJ 10-10)

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Table 1 Chain 10 Fault Codes Code

Description/Reference

Procedures - Decurler Exit Baffle adjustment (ADJ 10-8) - Measure the voltage of the Decurler Sensor Q1009. If the voltage is out of specification replace the sensor (PL 8.9). - Obstructions in the paper path - Top Transport Slip Clutch (PL 10.15) - Damaged paper path components - Loose or worn belts or pulleys in the Decurler Transport Drives (PL 10.13) - Loose or worn belts or pulleys in the Top Transport Drives (PL 10.15) - Ensure that all Top Transport Rolls and Idlers are clean and properly seated and that all springs are properly installed. 2. Print Damage

Other dCs: 330[10], 727 BSD 10.7 10-107

Go to the 8-705 NRD.

Print LE was late to the Top Transport Sensor after it arrived 1. Enter dC726. Select [26. 10-107], [Timing Graphs]. Run 100 sheets of the heaviest print paper the customer has at the Decurler Sensor. available to the Top Tray. When the test is complete, inspect the timing data for Normal, Late, or Random distribution. Perform the checks below which relate to the type of distribution identified in the timing graph. Late Distribution: - Top Transport Slip Clutch (PL 10.15) - Decurler and Top Transport Sensor Actuators for binding Normal or Random Distribution: - Measure the voltage of the Top Transport Sensor Q1012. If the voltage is out of specification replace the sensor (PL 10.17). - Obstructions in the paper path - Top Transport Slip Clutch (PL 10.15) - Loose or worn belts or pulleys in the Top Transport Drives (PL 10.15) - Ensure that all Top Transport Rolls and Idlers are clean and properly seated and that all springs are properly installed. 2. Print Damage Other dCs: 330[10], 727 BSD 10.7

10-108 10-109 Print TE was late to leave the Top Transport Sensor. 10-110

Go to the 8-705 NRD. 1. Enter dC726. Select [27. 10-18, 9 &10], [Timing Graphs]. Run 100 sheets of the heaviest print paper the customer has available to the Top Tray. When the timing diagnostic test is complete, inspect the timing data for Normal, Late, or Random distribution. Perform the checks below which relate to the type of distribution identified in the timing graph. Late Distribution: - Top Transport Slip Clutch (PL 10.15) - Top Transport Idlers and Rolls for binding or wear - Top Transport drives, belts, and pulleys for wear or slipping Normal or Random Distribution: - Measure the voltage of the Top Transport Sensor Q1012. If the voltage is out of specification replace the sensor (PL 10.17). - Duplex Gate adjustment (ADJ 10-9) - Obstructions in the paper path - Top Transport Slip Clutch (PL 10.15)

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Table 1 Chain 10 Fault Codes Code

Description/Reference

Procedures - Decurler Setting - Worn or dirty Top Transport Rolls (PL 10.15) - Worn or damaged Top Transport Drive System components (PL 10.14 and PL 10.18) - Worn or damaged Top Transport pulleys or belts - Ensure that all Top Transport Rolls and Idlers are clean and properly seated and that all springs are properly installed. 2. Print Damage; Go to the 8-705 NRD.

Other dCs: 727 BSD 10.7

3. Manually actuate and deactuate the Duplex Gate. If the Duplex gate does not move freely, repair or replace it (PL 10.15). Enter dC330 [10] [Cycle Outputs]. Select [Duplex Gate Solenoid]. Press the Continue button. If the solenoid Continues to become sluggish or intermittent as it warms up, replace it (PL 10.16).

10-111

Go to 10-105 NRD

10-112

Go to 10-101 NRD

10-201

Fuser did not reach operating temperature within 7 minutes; 1. Inspect the Fuser Roll Thermistor and Metering Roll Thermistor for debris or damage and ensure that they are No change (decrease) in Fuser Thermistor resistance for 3 making proper contact. minutes; No change (decrease) in Thermistor resistance within 10 second after clearing fault code 10-204 2. Measure the resistance of the Fuser Roll Thermistor and Metering Roll Thermistor. If 2 Megohms at room temperature, or 8.5 to 11K ohms is not measured, replace the defective thermistor (PL 10.4 and PL 10.7). 3. Perform the Fuser Roll Thermostat and Metering Roll Thermostat adjustments (ADJ 10-0 and ADJ 10-1). 4. Enter dC701 [Temperature Setups] and check the Fuser Roll Temperature (ADJ 10-6). 5. Replace the Fuser Relay K1002 (PL 1.2). 6. Check the following components: - Fuser Heat Rod (PL 10.7) - MIN ADA PWB#1 (PL 1.8) - MIN ADA PWB#2 (PL 1.8) - MIB PWB (PL 1.8) - Wiring and connectors BSD 10.1

10-202

Fuser has reached a temperature of 435 degrees F (overtemp).

1. Inspect the Fuser Roll Thermistor and Metering Roll Thermistor for debris or damage and ensure that they are making proper contact. 2. Measure the resistance of the Fuser Roll Thermistor and Metering Roll Thermistor. If 2 Megohms at room temperature, or 8.5 to 11K ohms is not measured, replace the defective thermistor (PL 10.4 and PL 10.8). 3. Perform the Fuser Roll Thermostat and Metering Roll Thermostat adjustments (ADJ 10-0 and ADJ 10-1). 4. Enter dC701 [Temperature Setups] and check the Fuser Roll Temperature (ADJ 10-6). 5. Replace the Fuser Relay K1002 (PL 1.2). 6. Check the following components: - Fuser Heat Rod (PL 10.7) - MIN ADA PWB#1 (PL 1.8) - MIN ADA PWB#2 (PL 1.8) - MIB PWB (PL 1.8) - Wiring and connectors

System Fault Group: Other dCs: BSD 10.1

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Table 1 Chain 10 Fault Codes Code

Description/Reference

Procedures

0-203

Voltage to the Fuser is less than 170 VAC

1. Enter dC140 [Fuser Values]. Select [Continue] and check the Fuser Line Voltage. If the Fuser Line Voltage is low, check the Input Line Voltage for a low condition. If OK, replace the MIN ADA PWB #1 (PL 1.8).

10-204

Go to 10-201 NRD

10-205

Go to 10-201 NRD

10-206

Go to 10-201 NRD

10-210

Metering Roll has not reached a temperature of 250 degrees 1. Inspect the Metering Roll Thermistor for debris or damage and ensure that it is making proper contact. F within 7 minutes of Continue up; Metering Roll temperature is below 250 degrees F in Print (under-temperature) 2. Measure the resistance of the Metering Roll Thermistor. If 2 Megohms at room temperature, or 8.5 to 11K ohms is not measured, replace the defective thermistor (PL 10.4 and PL 10.8). 3. Perform the Metering Roll Thermostat adjustment (ADJ 10-1). 4. Enter dC701 [Temperature Setups] and check the Metering Roll Temperature (ADJ 10-7). BSD 10.1

10-211

Go to 10-210 NRD

10-212

Cam-in Sensor (left) was unblocked during print.

10-217

Cam-in Sensor (left) was unblocked during Printer initializa- 2. Measure the voltage of the Cam-in Sensor Q1002. If the voltage is out of specification replace the sensor, (PL tion. 10.5).

1. Check the Camming Flag for debris or damage.

Other dCs: 330[10] BSD 10.5 10-213

Cam-out Sensor (right) was unblocked during print.

10-218

Cam-out Sensor (right) was unblocked during Printer initial- 2. Measure the voltage of the Cam-out Sensor Q1003. If the voltage is out of specification replace the sensor, (PL ization. 10.5).

1. Check the Camming Flag for debris or damage.

Other dCs: 330[10] BSD 10.5 10-214

Camming Motor failed to stop during cam-in while in print.

10-215

Camming Motor failed to stop during cam-out while in print. 2. Check the Camming Motor Brake Release Lever to ensure that it is not actuated by wiring, Ozac Tubes, etc., while in the normal operating position.

1. Check the Camming Flag for debris or damage.

10-219

Camming Motor failed to stop during cam-out at Printer initialization.

3. Measure the voltage of the Cam-in Sensor Q1002 and the Cam-out Sensor Q1003. If the voltages are out of specification replace the appropriate sensor, (PL 10.5).

Other dCs: 330[10] BSD 10.5 10-216

Camming Motor failed to operate when commanded to do so.

1. Check the Camming Flag for debris or damage. 2. Measure the voltage of the Cam-in Sensor Q1002. If the voltage is out of specification replace the sensor, (PL 10.5). 3. Check the following components: - Camming Motor Brake (PL 10.3) - Camming Motor Coupling for loose set screws, damage or wear.

Other dCs: 330[10] BSD 10.3, BSD 10.5 10-217

Go to the 10-212 NRD

10-218

Go to the 10-213 NRD

10-219

Go to the 10-214 NRD

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11 NRD Fault Code Tables Table 1 Chain 11 Fault Codes Code 11-100

Description/Reference

Procedures

The sheet arrived unexpectedly at the Inverter Entrance Sensor Q1101. This fault will be declared when a sheet is detected at Q1101 in print, and PHN has not informed the FSN that a sheet is on the way. 1. Check the following components: - Sheet Path for obstruction - Process Duplex Gate for physical damage (PL 10.15) Other dCs: 330 [10], 226 BSD 11.2

11-102 11-103 Indicates that the lead edge of the print delivered from the Printer Top Transport Sensor, Q1012, did not arrive at the Inverter Entrance Sensor, Q1155, within 560 ms.

- Inverter Entrance Sensor for loose wires (PL 11.24) 2. Enter SCP [Fault]. If Fault Code 10-106 or 10-108 is displayed, go to the appropriate NRD. 1. Measure the voltages of the Inverter Entrance Sensor. If a voltage is out of specification, replace the sensor (PL 11.24) 2. Enter dC226. Select [1. 11-102] and press the Continue button. If any feed variations or operation is out of specified range, check the following components: - Drive Rolls for wear or obstruction (PL 10.14) - Idler Rolls for the correct rotation (PL 10.14) - Idler Spring for the proper mounting (PL 10.14) 3. If the sheets that enter the Inverter are misregistered, skewed, damaged, torn, nicked, or dog eared. go to the 8705, Fault Code Tables.

Other dCs: 330 [10], 227

4. Enter SCP [Fault]. If fault code 10-108 is displayed, go to the appropriate NRD.

BSD 11.2

5. Enter dC726. Select [54. 10-108] and press the Continue Button. If a Random distribution is displayed when the timing diagnostic test is complete, check the Top Transport Drives for loose or worn drive belts.

11-104

Indicates that the trail edge of a print arrived 520 ms (3 pitch) or 300 ms (7 pitch) late at the Inverter Entrance Sensor, Q1155. When this fault is declared, the sensor is unblocked.

1. Measure the voltages of the Inverter Entrance Sensor. If any of the voltages are out of specification, replace the sensor (PL 11.24)

11-105

Indicates that the trail edge of a print arrived 520 ms (3 pitch) or 300 ms (7 pitch) late at the Inverter Entrance Sensor, Q1155. When this fault is declared, the sensor is blocked.

2. Enter dC226. Select [2. 11-104],and press the Continue Button. If any feed variations or operation is out of specified range, check the following components:

- Active and Passive Gates for binding or obstructions (PL 11.23) (Duplex only) - Gate Pivot for binding (PL 11.23) - Solenoid Link and Spring for the proper mounting (PL 11.24) - Drive Rolls for wear or obstruction (PL 10.14) - Idler Rolls for the correct rotation (PL 10.14) - Idler Spring for the proper mounting (PL 10.14) 3. Enter dC330 [10]. Select [Inverter Gate], [Cycle Mode]. Press the Continue button, and wait five minutes to ensure that the Inverter Gate Solenoid is hot. Press the Stop button. 4. Enter dC106. Select [Stacker A] ], and run a duplex job. If the sheet stops at the Inverter Gate, replace the Inverter Gate Solenoid (PL 11.24). 5. Check the following for the Top/Middle/Bottom Shaft Drive components:

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Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures - Inverter Drive Belt and Top/Middle/Bottom Drive Rolls for wear or damage (PL 11.23) - Idler Rolls for the correct rotation (PL 11.23) - Idler Spring for the proper mounting (PL 11.23) 6. Enter dC726. Select [2.11-104], and press the Continue Button. If a random distribution is displayed when the timing diagnostic test is complete, check the Top Transport Drives for loose or worn drive belts.

BSD 11.2 11-106

Indicates that the lead edge of an inverted print arrived earlier than 350ms at the Post Inverter Sensor, Q1156, from the Inverter Entrance Sensor, Q1155. The duplex print missed the Inverter Gate.

11-107

Indicates that the lead edge of an inverted print from the Inverter Entrance Sensor, Q1155, arrived early at the Sample Tray Sensor, Q1157. The print missed the Inverter Gate.

7. Check the Inverter Drive motor to ensure proper operation and the compatibility of the motors and transport 50 or 60 Hz.

1. Check the following paper path components: - Inverter Gate area for obstructions - Inverter Gate Spring for damage (PL 11.24) - Inverter Gate Solenoid plunger for binding (PL 11.24) 2. Check the Inverter Gate to ensure that it pivots freely thru the full range of travel (PL 11.24). 3. Inspect the gate and paper path for obstructions or damage. (PL 11.24) 4. Enter dC330, [10], [Inverter Gate], [Cycle Mode], and press the Continue Button actuate the gate solenoid. After 5 minutes cycle the solenoid and check for sluggish operation or lack of travel. If so replace the gate solenoid (PL 11.24) 5. Check the Sample Tray sensor for damage or loose connections (PL 11.26). 6. Check the Inverter Gate Solenoid adjustment (ADJ 11-1). 11-108 11-109 Indicates that the lead edge of a print delivered from the Inverter Entrance Sensor, Q1155, did not arrive at the Post Inverter Sensor, Q1156, within the specified time.

1. Check the Inverter Gate for binding if okay, enter dC330 [10]. Select [Inverter Gate], [Cycle], & [Mode]. Press the Continue Button and wait five minutes to ensure that the Inverter Gate Solenoid is hot. Press [Stop] button. Enter dC106 and run a duplex job. If the sheet stops at the Inverter Gate, replace the Inverter Gate Solenoid (PL 11.24). 2. Enter dC226. Select [3. 11-108], and press the Continue Button. If any feed variations or operation is out of specified range, check the following components: - Inverter Gate for binding or obstructions (PL 11.24) - Inverter Gate Bearing for damage or binding (PL 11.24) - Top and bottom Hinge adjustment (ADJ 11-4) - Link for damage or any missing parts (PL 11.24) - Return Spring for damage (PL 11.24) 3. Measure the voltages of the Post Inverter Sensor. If a voltage is out of specification, replace the sensor (PL 11.2) 4. Check the following components: - Inverter Gate adjustment (ADJ 11-1) - Inverter Output Baffle (ADJ 11-3) - Passive Gate for straightness and that it is seated properly when pivot assembly is closed (PL 11.25)

Other dCs: 227

- Pivot assembly alignment (ADJ 11-7) - Ensure that all parts are 50 or 60 Hz compatible

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Table 1 Chain 11 Fault Codes Code

Description/Reference BSD 11.2

11-110

Procedures 5. Enter dC226. Select [3. 11-108], and Press the Continue Button. If a random distribution is displayed when the timing diagnostic test is complete, check the Inverter Drives for loose or worn drive belts.

1. Check to ensure that the baffles are closed securely. Indicates that the trail edge of a print did not arrive at the Post Inverter Sensor, Q1156, within 520ms (3 pitch) or 300ms (7 pitch) after the lead edge of the print arrived at the sensor. 2. Check the Post Inverter sensor Q1156 for actuator damage or sluggish operation.(PL 11.2) 3. Inspect the registration rolls for damage or wear (PL 11.22) and check Gap setting (ADJ 11-1) 4. Inspect or drive roll idlers and ensure that they are contacting the drive rolls (PL 11.22). 5. Check the Preregistration drive belt for damage and Retension the belt.(PL 11.22)

11-112

1. Check paper path for obstruction, nicks or burrs. Indicates that the lead edge of the print delivered from the Post Inverter Sensor, Q1156, did not arrive at the Prestacker Sensor, Q1158, within 440ms. When this fault is declared the Prestacker Sensor is unblocked. 2. Check and adjust as necessary the registration corrugator roll adjustment. 3. Ensure that the Post-Inverter nip release solenoid is operating properly if in the 3-pitch mode. Exercise solenoid in the dC330. Feed paper and ensure that they cycle once per pitch and release properly. 4. Perform nip relief rolls adjustment.

11-114

TBS Indicates that the trail edge of a print did not arrive at the Prestacker Sensor, Q1158, within 520 ms (3 pitch) or 300 ms (7 pitch) after the lead edge of the print arrived at the sensor. The valid destination for the sheet is beyond Stacker A.

11-116

Indicates that the lead edge of a print delivered from the 1. Check the sample tray gate for proper operation. Inverter Entrance Sensor, Q1155, did not arrive at the Sample Tray Sensor, Q1157, within 280ms for non-inverted sheets and 720ms (7 pitch) or 950ms (3 pitch) for inverted sheets. When this fault is declared, the sensor is unblocked. 2. Exercise gate in dC330. Ensure that the solenoid is cycling and releasing properly. 3. Perform the sample tray adjustment (ADJ 11-8).

11-117

Indicates that the lead edge of a print delivered from the TBS Inverter Entrance Sensor, Q1155, did not arrive at the Sample Tray Sensor, Q1157, within 280ms for non-inverted sheets and 720ms (7 pitch) or 950ms (3 pitch) for inverted sheets. When this fault is declared, the sensor is blocked.

11-118

Indicates that the trail edge of a print did not arrive at the Sample Tray Sensor, Q1157, within 520ms (3 pitch) or 300ms (7 pitch) after the lead edge of the sheet arrived at the sensor. When the fault is declared, the sensor is unblocked.

TBS

11-119

Indicates that the trail edge of a print did not arrive at the Sample Tray Sensor, Q1157, within 520ms (3 pitch) or 300ms (7 pitch) after the lead edge of the sheet arrived at the sensor. When the fault is declared, the sensor is blocked.

TBS

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Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures

11-120

Indicates that an unexpected sheet arrived at the Sample Tray.

TBS

11-130-1&2

Indicates that the lead edge of a print was detected at the Disk Sheet Sensor, Q1106A, when it was not expected.

1. Check operation of Stacker Bypass gate. Energize gate solenoid to ensure that the solenoid is releasing properly and gate closes fully. 2. Perform gate setup and adjustment 3. If problem persist, disconnect solenoid and determine if problem goes away. If it does perform circuit diagnostic XXX. 4. Energize solenoid and allow it to heat up for 5 minutes, if solenoid does not release or seems sluggish, replace it.

11-131-1

indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106A, within 260ms after the Prestacker Sensor, Q1158 sensed the lead edge. When this fault is declared, the Prestacker Sensor is unblocked and the Disk Sheet Sensor is unblocked.

11-132-1

indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106A, within 260ms after the Prestacker Sensor, Q1158 sensed the lead edge. When this fault is declared, the Prestacker Sensor is blocked and the Disk Sheet Sensor is unblocked. 1. Check the bypass gate adjustment (ADJ 11-11) out of adjustment. Gate can cause LE damage as sheet catches on gate. 2. Turn on solenoid in dC330 for 3 minutes operate in cycle mode and check for sluggish operation. 3. Check for excessive curl in stackers. Check for sheets catching on entrance baffles. Adjust decurler to reduce curl and try flipping paper in the feeders. 4. Check disk entrance nip drive belt and pulleys for wear or damage. Re-tension belt.(PL 11.11) 5. Block the Disk Chute Sensor with sheet of paper and measure voltage at TP. If voltage is less than (TBS), replace sensor. 6. Check baffle and drive rolls for damage, burrs, or obstructions (PL 11.11).

11-131-2

Indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106B, within 330ms after the Bypass Transport Sensor, Q1107A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is unblocked.

11-132-2

Indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106B, within 330ms after the Bypass Transport Sensor, Q1107A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is unblocked. 1. Check the bypass gate adjustment (ADJ 11-11) out of adjustment. Gate can cause LE damage as sheet catches on gate. 2. Turn on solenoid in dC330 for 3 minutes operate in cycle mode and check for sluggish operation. 3. Check for excessive curl in stackers. Check for sheets catching on entrance baffles. Adjust decurler to reduce curl and try flipping paper in the feeders. 4. Check disk entrance nip drive belt and pulleys for wear or damage. Re-tension belt. 5. Block the Disk Chute Sensor with sheet of paper and measure voltage at TP. If voltage is less than (TBS), replace sensor.

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Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures 6. Check baffle and drive rolls for damage, burrs, or obstructions.

11-133-1&2

indicates that the lead edge of print did not arrive at the Disk TBS Sheet Sensor, Q1106A/B, within 260 ms after the Prestacker Sensor, Q1158 sensed the lead edge. When this fault is declared, the Prestacker Sensor is unblocked and the Disk Sheet Sensor is blocked.

11-133-1&2

indicates that the lead edge of print did not arrive at the Disk TBS Sheet Sensor, Q1106A/B, within 330ms after the Bypass Transport Sensor, Q1107A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is unblocked.

11-138-1&2

indicates that the lead edge of the print delivered from the Prestacker Sensor, Q1158, did not arrive at the Bypass Transport Sensor, Q1107A, within 1000ms.

11-140-1&2

indicates that the trail edge of the print did not arrive at the TBS Bypass Transport Sensor, Q1107A/B, within 325ms (7 pitch) or 600 ms (3 pitch) after the lead edge of the print arrived at the Bypass Transport Sensor. When the fault is declared the Bypass Transport Sensor is blocked. The valid destination for this print is beyond Stacker A.

11-141-1&2

indicates that the trail edge of the print did not arrive at the TBS Bypass Transport Sensor, Q1107A/B, within 325ms (7 pitch) or 600 ms (3 pitch) after the lead edge of the print arrived at the Bypass Transport Sensor. When the fault is declared the Bypass Transport Sensor is unblocked. The valid destination for this sheet is beyond Stacker A.

11-142-1&2

indicates that the lead edge of the print delivered from the Stacker A Bypass Transport Sensor, Q1107A/B, did not arrive at the Stacker B Purge Transport Sensor, Q1164, within 450ms. When the fault is declared, the Stacker B Purge Transport Sensor is unblocked and the Stacker A Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray.

TBS

11-143-1&2

indicates that the lead edge of the print delivered from the Stacker A Bypass Transport Sensor, Q1107A/B, did not arrive at the Stacker B Purge Transport Sensor, Q1164, within 450ms. When the fault is declared, the Stacker B Purge Transport Sensor is unblocked and the Stacker A Bypass Transport Sensor is blocked. The valid destination for the print is the Purge Tray.

TBS

11-144-1&2

indicates that the lead edge of the print delivered from the Stacker A Bypass Transport Sensor, Q1107A/B, did not arrive at the Stacker B Purge Transport Sensor, Q1164, within 450ms. When the fault is declared, the Stacker B Purge Transport Sensor is blocked and the Stacker A Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray.

TBS

Section Name

11 NRD Fault Code Tables

TBS

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Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures

11-145-1&2

indicates that the trail edge of the print did not arrive at the TBS Purge Transport Sensor, Q1164, within 350ms (7 pitch) or 670ms (3 pitch) after the lead edge of the print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge Tray.

11-146-1&2 11-147-1&2

Indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166A/B, within 300ms after the lead edge of the print actuated the Disk Sheet Sensor, Q1106A/B. This fault only occurs in the 7 pitch mode.

1. Check the Disk Home Sensor adjustment (ADJ 11-25)

2. Check the Disk Entrance Gate adjustment (ADJ 11-26). These two checks are important if sheets are missing the disk. - Check Disk entrance nip for slipping, nipforce or binding. 3. If lead edge damage is apparent on the sheets, check the bypass gate adjustment (ADJ 11-11). 4. Check Q1166 sensor voltage at the test point while holding a sheet of paper at approx. 10mm from the sensor. If the voltage is less than (TBS), replace the sensor. 5. Check bypass transport alignment (ADJ 10-10). Adjust if necessary. 11-148-1&2

1. Check sensor Q1166 part number to ensure that it is not reversed with Q1167. Indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166A/B, within 123ms of the lead edge of the print actuating the sensor. When the fault is declared, the sensor is blocked. This fault is only declared in the 7 pitch mode.

11-149-1&2

TBS Indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166A/B, within 130ms of the lead edge of the print actuating the sensor. When the fault is declared, the sensor is unblocked. This fault is only declared in the 7 pitch mode.

11-150-1&2

indicates that the trail edge of a print did not arrive at the A3 1. Check the stack height sensor adjustment (ADJ 11-27). Trail Edge Sensor, Q1167A/B, within 800ms after the trail edge was detected at the Disk Lead Edge Sensor, Q1166A/ B. - Check the Trail Edge Right Guide adjustment (ADJ 11-27) 2. Inspect the sheets for any damage or wrinkles that could prevent the sheets from stacking properly. 3. Check the trail edge assist belts for proper operation. Ensure that the belts are not slipping on drive rolls. Clean as required. 4. Check Q1167 sensor voltage at the TP while holding a sheet of paper at approx. 10mm from sensor. If voltage is less than (TBS), replace sensor. 5. Check paper stocks. High humidity and/or lightweight stocks can cause problems. Switch to heavier paper if possible.

11-200

Indicates that the Inverter Front Door Interlock Switch, S1153, opened with the High Capacity Feeder 3 or Stacker A Main Drive Motor on.

Preliminary Working Document No Product Name Assigned

TBS

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Section Name

11 NRD Fault Code Tables

Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures

11-220-1&2

Indicates that the Elevator failed to leave the home position TBS (max down). The Stacker Elevator Down Sensor, Q1135A/B, failed to deactuate within 500ms after the UP winding of the Elevator Motor, MOT1106A/B, was energized to raise the Elevator.

11-221-1&2

Indicates that the Stacker Elevator Down Sensor, Q1135A/ B, failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker Elevator Motor, MOT1106A/B, was energized to lower the Elevator.

1. Check the Stacker elevator motor for loose connection.

2. Check the encoder sensor voltage at the test point. If voltage is less than (TBS), replace sensor. Ensure that the sensor is not blocked by encoder flag. 3. Check the capacitor cxx connections. 4. Check the lead screw belt tension. Check the belt for damage. 5. Check the stacker elevator tray level. Level as required. 11-222-1&2

Indicates that there were no encoder pulses received from 1. Check the Stacker elevator motor for loose connection. the Stacker Elevator Encoder Sensor, Q1124A/B, with the Stacker Elevator Motor, MOT1106A/B, activated. The fault code can result when the motor is activated in either the up or down mode. 2. Check the encoder sensor voltage at the test point. If voltage is less than (TBS), replace sensor. Ensure that the sensor is not blocked by encoder flag. 3. Check the capacitor cxx connections. 4. Check the lead screw belt tension. Check the belt for damage. 5. Check the stacker elevator tray level. Level as required.

11-223-1&2

The Stacker Elevator failed to interrupt the Stack Height Sensor, Q1122, within 28 sec. after the Stacker Elevator Motor, MOT1106, was energized to drive the elevator up/ down.

TBS

11-224-1&2

Indicates that the Stacker Module Top Cover was sensed open while Stacker A was in use.

TBS

11-228-1&2

Indicates that the Stacker Left Door Interlock Switch, S1163A/B, deactuated with print in process to the Stacker bin.

TBS

11-229-1&2

Indicates that the Stacker Right Door Interlock Switch, TBS S1138A/B, deactuated with a print in process to the Stacker bin.

11-230-1&2

Indicates that the Disk Home Sensor, Q1121A/B, was TBS unblocked during a run without a disk cycle. The Disk Stepper failed to maintain the home position.

11-231-1&2

Indicates that there were no transitions in (26 steps w/o FS Tag 5) or (117 steps w/ FS Tag 5) seen on the Disk Home Sensor, Q1121A/B. There were too many steps required to find the disk home position.

1. Check the disk home position adjustment (ADJ 11-25).

2. Check the disk Entrance gate adjustment (ADJ 11-26).

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11 NRD Fault Code Tables

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Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures 3. Check if the bottom of the disk is touching the stack after the shutdown. Check the stack height adjustment (ADJ 11-27). 4. Check the disk home sensor at the test point. Ensure that the flag is not blocking the sensor. If the voltage is less than (TBS) replace the sensor. 5. Check the motor coupling. Tighten as required.

11-232-1&2

Indicates that the Right Guide Home Sensor, Q1132A/B, remained blocked after 100 steps of the Right Guide Motor, MOT1105A/B.

- Check the home sensor, slides, coil cord.

11-233-1&2

Indicates that the Right Guide Home Sensor, Q1132A/B, 1. Run the right guide in dC203. Check for smooth motion. Observe the coil cord and check if it is hanging up or in remained unblocked after 2600 steps (7 pitch) or 100 steps any way preventing the guide from reaching home. If so, replace the cord. (3 pitch) of the Right Guide Motor, MOT1105A.

- Check for loose connections

- Slides may be jammed 2. As the guide moves, check the home sensor and flag for any interference. Ensure that the flag crosses the sensor. 3. Inspect the stepper motor and sensor connections. 4. Inspect the guide for any obstructions or anything that could prevent the guide form reaching home. 11-237-1&2

Indicates that the Back Guide Home Sensor, Q1133A/B, remained blocked after 100 steps of the Back Guide Motor, MOT1105A/B.

-. Check for correct Belt Tension.

- Check the guide squareness adjustment (ADJ 11-33) - Check the Home sensor - Check the Back Guide Motor for binding or intermittent operation 11-238-1&2

Indicates that the Back Guide Home Sensor, Q1133A/B, 1. Check the stepper motor belt tension. Ensure that it is not too tight. Adjust as necessary. remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, MOT1105A/B. 2. Check the back guide squareness adjustment (ADJ 11-33). 3. Run the guide back and forth in dC203, observe if the guide is binding and check for any obstructions (PL 11.7). 4. Inspect the guide harnessing. Ensure that the harness is properly routed and do not interfere with guide movement. 5. Check the home sensor voltage at the test point. If voltage is below (TBS), replace. 6. Inspect the guide for damaged lead screws (PL 11.7).

11-242-1&2

Indicates that there was a Front Tamper positioning failure 1. Inspect front offset assembly for binding linkages, broken or missing parts (PL 11.8). after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper Clutch actuated without the Front Tamper Position Sensor, Q1135A/B, transitioning within 200ms. 2. Inspect offset housing for broken plastic shaft snap-in features 3. Check clutch sensor flag and ensure that it does not hit the retract sensor. 4. Check the retract sensor voltage at the test point make sure the sensor is unblocked if voltage is less than (TBS), replace sensor. 5. Ensure that the front tamper motor coupling is not loose or skipping. 6. Check the rear guide position via dC203 ensure that the guides are not set too tight.

Preliminary Working Document No Product Name Assigned

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Section Name

11 NRD Fault Code Tables

Table 1 Chain 11 Fault Codes Code

Description/Reference

Procedures 7. Cycle the Fingers via dC203. Ensure that the clutch does not move more than 1/2 revolution. Replace clutch if it does.

11-244-1&2

Indicates that there was a Back Tamper positioning failure after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper Clutch actuated without the Back Tamper Position Sensor, Q1134A/B, transitioning within 100ms.

1. Inspect front offset assembly for binding linkages, broken or missing parts (PL 11.8).

2. Inspect offset housing for broken plastic shaft snap-in features 3. Check clutch sensor flag and ensure that it does not hit the retract sensor. 4. Check the retract sensor voltage at the test point make sure the sensor is unblocked if voltage is less than (TBS), replace sensor. 5. Ensure that the front tamper drive belt is properly tensioned and not skipping or damaged. 6. Check the rear guide position via dC203 ensure that the guides are not set too tight. 7. Cycle the Fingers via dC203. Ensure that the clutch does not move more than 1/2 revolution. Replace clutch if it does. 11-250-2

Indicates that a loss of +24 VDC has been detected in the Feeder/Stacker module. The Printer will enter the Power Interrupt mode when this fault occurs.

11-270-2

TBS Indicates that a stray print arrived at the Purge Transport Sensor, Q1164B, unexpectedly. This fault is logged in NVM only.

Section Name

11 NRD Fault Code Tables

TBS

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DC140 Analog Display Diagnostic Procedure

PROCEDURE

PURPOSE

NOTE: The ranges given in the table are only valid during a normal (Print Darkness 5) print run and with a Photoreceptor that has less than 500K prints on it. If the Printer is in a Power Up Convergence cycle, some dC140 values may not be within the ranges specified. If possible, wait for the Power Up Convergence cycle to complete.

NOTE: Prior to performing any of these procedures, ensure that all the appropriate service call procedures have been completed (e.g., Initial Action, RAPs, NRDs, HFSIs due). Use this procedure when isolating the causes of an out-of-range value in dC140. General Troubleshooting Information

1.

Make a print of the frames provided at the end of the dC140 section to record the displayed values.

2.

Enter dC140 [Dicorotron Values]. Select Continue. Check the values returned for any outof-range readings. (Refer to the dC140 Diagnostic Table)

3.

Select [DC Bias Values]. Select Continue. Check the values returned for any out-of-range readings. (Refer to the dC140 Diagnostic Table)

4.

If any value is out-of-range ensure that the correct dC314 power supply calibration value has been entered.

5.

If a value is still out-of-range, replace any Dicorotrons and Shields associated with that value (PL 9.10 and PL 9.11).

6.

If any Control value is out-of-range, ensure that the appropriate NVM locations have the correct values.

7.

If any Monitor value is out-of-range, check the following voltages:

NOTE: Read this section completely before beginning the procedure. If any out-of-range values are noted, use the information given below, and the procedures and references provided in the table to troubleshoot. When using the fault code references, use the appropriate diagnostic procedure. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The Cleaner and Developer subsystems are high suspect causes. A Monitor value depends on its corresponding Control value being correct.

a.

+ and - 15 VDC +/- 0.25 VDC is present at the HVAC and HVDC PWBs (referenced to DC Common on the PWB being checked)

The Control and Monitor values for each corresponding input/output should be within +/- 0.2 VDC of each other.

b.

+ and - 34 VDC +/- 1.0 VDC is present at the HVAC and HVDC PWBs (referenced to DC Common on the PWB being checked)

The Required and Actual voltages in the [DC Bias Values] portion of dC140 should be within +/ - 5 VDC for their respective outputs. Also, the values for the Cleaner Brush, and the Lower and Upper Detoning Rollers may be as much as 30 VDC lower than the real voltages at the Cleaner.

8.

c.

48 KHz is present and stable at the HVDC PWB (2.5 to 9 VAC)

d.

24 KHz is present and stable at the HVAC PWB (2.5 to 9 VAC)

Use the PQ RAP references as additional sources of information to fix the out-of-range problem.

Table 1 dC140 Diagnostic Parameter

Range

Procedures 1. Check the dC131 [MIN] locations 146 (Dicor AC Voltage Reference) and 223 (Dicorotron AC Target).

References BSD 9.1 (Sheet 2) Fault Code: 9-202, 9328, 9-329 dC314: COR$$ACV IQ RAP: 9-626

Purpose This signal provides the control point voltage to the HVAC PWB. The actual value of this signal is determined during Power Up Convergence or the Initialization portion of dC951 (ACV Setpoint).

Coronode AC Voltage Control

8.0 to 9.8 VDC

Coronode AC Voltage Monitor

8.0 to 9.8 VDC

BSD 9.1 (Sheet 2) Fault Code: 9-202, 09- This is the signal returned to the ADA PWB that informs the control logic 328, 9-329 dC314: COR##ACV IQ RAP: about the AC Coronode voltage being produced. This value should be 9-626 within +/- 0.2 VDC of the Control Point.

Coronode AC Current Monitor

2.0 to 4.8 VDC

BSD 9.1 (Sheet 2) dC314: COR##ACI IQ This is the signal returned to the ADA PWB that informs the control logic RAP: 9-626 about the AC Coronode current being produced for the applied level of the AC Coronode voltage. This parameter is neither controlled or monitored for fault detection.

Charge 2 Voltage 3.4 to 4.6 VDC Control

BSD 9.2 (Sheet 1) Fault Code: 9-203, 9213, 9-325 dC314: CHG2$$SV IQ RAP: 9-626

Preliminary Working Document

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No Product Name Assigned

This signal provides the control point voltage to the HVDC PWB for the required shield bias of the Charge 2 Dicorotron. This value is also the initial charge voltage required on the PR Belt. Its value is dependent upon the amount of Dark Decay and Dark Dusting Target voltage required.

Section Name

DC140 Analog Display Diagnostic Procedure

Table 1 dC140 Diagnostic Parameter

Range

Procedures

References

Purpose This is the signal returned to the ADA PWB that informs the control logic about the amount of Charge 2 shield bias being produced. This value should be within +/- 0.2 VDC of the Control Point. The actual voltage that corresponds to the monitor is displayed in dC909.

Charge 2 Voltage 3.4 to 4.6 VDC Monitor

BSD 9.2 (Sheet 1) Fault Code: 9-203, 9213, 9-325 dC314: CHG2##SV IQ RAP: 9-626

Charge 1 Voltage 3.2 to 5.3 VDC Monitor

BSD 9.2 (Sheet 1) dC314: CHG1##SV IQ This is the signal returned to the ADA PWB that informs the control logic RAP: 9-626 about the amount of Charge 1 shield bias being produced. This parameter is not monitored for fault detection. The actual voltage that corresponds to the monitor is displayed in dC909.

Charge 2 Current 0 to 0.2 VDC Control

BSD 9.2 (Sheet 1) Fault Code: 9-203, 9213 dC314: CHG2$$SI IQ RAP: 9-626

Charge 2 Current 0 to 0.2 VDC Monitor

BSD 9.2 (Sheet 1) Fault Code: 9-203, 9- This is the signal returned to the ADA PWB that informs the control logic 213, 9-330 dC314: CHG2##SI IQ RAP: 9- about the amount of Charge 2 shield current being produced. This value 626 should be within +/- 0.2 VDC of the Control Point. The actual voltage that corresponds to the monitor is displayed in dC909.

Charge 1 Current 2.5 to 5.5 VDC Monitor

BSD 9.2 (Sheet 1) dC314: CHG1##SI IQ RAP: 9-626

This signal provides the control point voltage to the HVDC PWB required for the Charge 2 shield current. The required shield current is dependent on the potential difference between the Charge 2 shield bias and the PR Belt charge. If a potential difference is measured, the HVDC PWB will increase/decrease the Charge 1 shield bias until the potential between the PR Belt and the Charge 2 shield is equal.

This is the signal returned to the ADA PWB that informs the control logic about the amount of Charge 1 shield current being produced. There is no corresponding control point or ault detection for this parameter. The actual voltage that corresponds to the monitor is displayed in dC909.

Transfer Current 3.4 to 4.3 VDC Control

1. Check the dC131 [MIN] location BSD 9.2 (Sheet 1) Fault Code: 9-326 210 (Transfer Shield Current Normal). dC314: TRAN$$SI IQ RAP: 9-626

This signal provides the control point voltage to the HVDC PWB required for the Transfer shield current.

Transfer Current 3.4 to 4.3 VDC Monitor

BSD 9.2 (Sheet 1) Fault Code: 9-326 dC314: TRAN##SI IQ RAP: 9-626

This is the signal returned to the ADA PWB that informs the control logic about the amount of Transfer shield current being produced. This value should be within +/- 0.2 VDC of the Control Point.

Transfer Voltage 6.0 to 8.5 VDC Monitor

BSD 9.2 (Sheet 1) dC314: TRAN##SV IQ This is the signal returned to the ADA PWB that informs the control logic RAP: 9-626 about the amount of Transfer shield bias being produced. This parameter is not monitored for fault detection.

Detack Current Control

3.4 to 5.6 VDC

Detack Current Monitor

1. Check the dC131 [MIN] location 202 (Detack Shield Current Reference).

BSD 9.2 (Sheet 1) Fault Code: 9-327 dC314: DTAC$$SI IQ RAP: 9-626

This signal provides the control point voltage to the HVDC PWB required for the Detack shield current.

3.4 to 5.6 VDC

BSD 9.2 (Sheet 1) Fault Code: 9-327 dC314: DTAC##SI IQ RAP: 9-626

This is the signal returned to the ADA PWB that informs the control logic about the amount of Detack shield current being produced. This value should be within +/- 0.2 VDC of the Control Point.

Detack Voltage Monitor

3.4 to 5.6 VDC

BSD 9.2 (Sheet 1) dC314: DTAC##SV IQ This is the signal returned to the ADA PWB that informs the control logic RAP: 9-626 about the amount of Detack shield bias being produced. This parameter is not monitored for fault detection.

Preclean Current Control

5.9 to 6.7 VDC

Preclean Current Monitor

5.9 to 6.7 VDC

1. Check the dC131 [MIN] location 204 (Preclean Shield Current Reference).

Section Name

DC140 Analog Display Diagnostic Procedure

BSD 9.2 (Sheet 1) Fault Code: 9-328 dC314: PCLN$$SI IQ RAP: 9-626

This signal provides the control point voltage to the HVDC PWB required for the Preclean shield current.

BSD 9.2 (Sheet 1) Fault Code: 9-328 dC314: PCLN##SI IQ RAP: 9-626

This is the signal returned to the ADA PWB that informs the control logic about the amount of Preclean shield current being produced. This value should be within +/- 0.2 VDC of the Control Point.

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Table 1 dC140 Diagnostic Parameter

Range

Preclean Voltage Monitor

5.3 to 9.9 VDC

Dev Rolls 1 & 2 Voltage Control

4.0 to 7.5 VDC

Dev Rolls 1 & 2 160 to 300 VDC Voltage Required

Procedures

References

Purpose

BSD 9.2 (Sheet 1) dC314: PCLN##SV IQ This is the signal returned to the ADA PWB that informs the control logic RAP: 9-626 about the amount of Preclean shield bias being produced. This parameter is not monitored for fault detection. 1. Check the dC131 [MIN] location 217 (Developer Rolls 1 & 2 Unit Reference).

BSD 9.2 (Sheet 3) Fault Code: 9-320 dC314: DEV1$$BV IQ RAP: 9-616

This signal provides the control point voltage to the HVDC PWB needed for the Developer Rolls 1 and 2 Bias voltage. This bias voltage changes, based on print mode. In standard mode, the specification for this bias is 130 volts more negative than the background voltage.

1. Check the dC131 [MIN] location 217 (Developer Rolls 1 & 2 Unit Reference).

BSD 9.2 (Sheet 3) Fault Code: 9-320 dC314: DEV1$$BV IQ RAP: 9-616

This is the corresponding voltage required by the Control Point.

Dev Rolls 1 & 2 Voltage Monitor

4..0 to 7.5 VDC

BSD 9.2 (Sheet 3) Fault Code: 9-320 dC314: DEV1##VM IQ RAP: 9-616

This is the signal returned to the ADA PWB that informs the control logic about the amount of Developer Rolls 1 and 2 Bias voltage being produced. This value should be within +/- 0.2 VDC of the Control Point.

Dev Rolls 1 & 2 Voltage Actual

160 to 300 VDC

BSD 9.2 (Sheet 3) Fault Code: 9-320 dC314: DEV1##VM IQ RAP: 9-616

This is the actual voltage being produced at the Developer Rolls 1 and 2. This value should be within 5 VDC of the Required voltage. The value also is displayed in dC909.

Dev Roll 3 Voltage Control

5.0 to 9.5 VDC

1. Check the dC131 [MIN] location 218 (Developer Roll 3 Unit Reference).

BSD 9.2 (Sheet 3) Fault Code: 9-321 dC314: DEV2$$BV IQ RAP: 9-616

This signal provides the control point voltage to the HVDC PWB needed for the Developer Roll 3 Bias voltage. This bias voltage changes, based on print mode. In standard mode, the specification for this bias is 30 volts more negative than the Developer Rolls 1 and 2 voltage.

Dev Roll 3 Voltage Required

200 to 380 VDC

1. Check the dC131 [MIN] location 218 (Developer Roll 3 Unit Reference).

BSD 9.2 (Sheet 3) Fault Code: 9-321 dC314: DEV2$$BV IQ RAP: 9-616

This is the corresponding voltage required by the Control Point.

Dev Roll 3 Voltage Monitor

5.0 to 9.5 VDC

BSD 9.2 (Sheet 3) Fault Code: 9-321 dC314: DEV2##VM IQ RAP: 9-616

This is the signal returned to the ADA PWB that informs the control logic about the amount of Developer Roll 3 Bias voltage being produced. This value should be within +/- 0.2 VDC of the Control Point.

Dev Roll 3 Voltage Actual

200 to 380 VDC

BSD 9.2 (Sheet 3) Fault Code: 9-321 dC314: DEV2##VM IQ RAP: 9-616

This is the actual voltage being produced at the Developer Roll 3. This value should be within 5 VDC of the Required voltage. The value also is displayed in dC909.

Cleaner Brush Voltage Control

5.5 to 6.3 VDC

1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-322 200 (Cleaner Bias Reference for Nor- dC314: CLNR$$BV IQ RAP: 9-617 mal mode).

This signal provides the control point voltage to the HVDC PWB needed for the Cleaner Brush Bias voltage.

1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-322 200 (Cleaner Bias Reference for Nor- dC314: CLNR$$BV IQ RAP: 9-617 mal mode).

This is the corresponding voltage required by the Control Point.

Cleaner Brush 223 to 249 VDC Voltage Required Cleaner Brush Voltage Monitor

5.5 to 6.3 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-322 dC314: CLNR##VM IQ RAP: 9-617

This is the signal returned to the ADA PWB that informs the control logic about the amount of Cleaner Brush Bias voltage being produced. This value should be within +/- 0.2 VDC of the Control Point.

Cleaner Brush Voltage Actual

223 to 249 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-322 dC314: CLNR##VM IQ RAP: 9-617

This is the actual voltage being produced at the Cleaner Brush. This value should be within 5 VDC of the Required voltage. This voltage may be as much as 30 VDC lower than the real voltage at the Cleaner Brush.

Lower Detoning Roll Voltage Control

5.3 to 6.1 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-324 dC314: WAST$$BV IQ RAP: 9-617

This signal provides the control point voltage to the HVDC PWB needed for the Lower Detoning Roll.

Preliminary Working Document No Product Name Assigned

1. Check the dC131 [MIN] location 208 (Waste Bias Reference for Dead Cycle mode).

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Section Name

DC140 Analog Display Diagnostic Procedure

Table 1 dC140 Diagnostic Range

Procedures

Lower Detoning Roll Voltage Required

Parameter

539 to 601 VDC

1. Check the dC131 [MIN] location 208 (Waste Bias Reference for Dead Cycle mode).

Lower Detoning Roll Voltage Monitor

References

Purpose

BSD 9.1 (Sheet 1) Fault Code: 9-324 dC314: WAST$$BV IQ RAP: 9-617

This is the corresponding voltage required by the Control Point. During normal operation, the Lower Detoning Roll requirement is 600 VDC measured, with respect to the Cleaner Brush.

5.3 to 6.1 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-324 dC314: WAST##VM IQ RAP: 9-617

This is the signal returned to the ADA PWB that informs the control logic about the amount of Lower Detoning Roll Bias voltage being produced. This value should be within +/- 0.2 VDC of the Control Point.

Lower Detoning Roll Voltage Actual

539 to 601 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-324 dC314: WAST##VM IQ RAP: 9-617

This is the actual voltage being produced at the Lower Detoning Roll. This value should be within 5 VDC of the Required voltage. This voltage may be as much as 30 VDC lower than the real voltage at the Lower Detoning Roll.

Upper Detoning Roll Voltage Control

5.9 to 6.7 VDC

1. Check the dC131 [MIN] location BSD 9.1 (Sheet 1) Fault Code: 9-323 206 (Reclaim Bias Reference for Nor- dC314: RCLM$$BV IQ RAP: 9-617 mal mode).

This signal provides the control point voltage to the HVDC PWB needed for the Upper Detoning Roll.

Upper Detoning Roll Voltage Required

359 to 396 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-323 1. Check the dC131 [MIN] location 206 (Reclaim Bias Reference for Nor- dC314: RCLM$$BV IQ RAP: 9-617 mal mode).

This is the corresponding voltage required by the Control Point. During normal operation, the Upper Detoning Roll requirement is -400 VDC measured, with respect to the Cleaner Brush.

Upper Detoning Roll Voltage Monitor

5.9 to 6.7 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-323 dC314: RCLM##VM IQ RAP: 9-617

This is the signal returned to the ADA PWB that informs the control logic about the amount of Upper Detoning Roll Bias voltage being produced. This value should be within +/- 0.2 VDC of the Control Point.

Upper Detoning Roll Voltage Actual

359 to 396 VDC

BSD 9.1 (Sheet 1) Fault Code: 9-323 dC314: RCLM##VM IQ RAP: 9-617

This is the actual voltage being produced at the Upper Detoning Roll. This value should be within 5 VDC of the Required voltage. This voltage may be as much as 30 VDC lower than the real voltage at the Upper Detoning Roll.

Section Name

DC140 Analog Display Diagnostic Procedure

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Preliminary Working Document No Product Name Assigned

Figure 1 dC140 Analog Display Dicorotron Values

Preliminary Working Document No Product Name Assigned

0/0/00 ?-125

Section Name

DC140 Analog Display Diagnostic Procedure

Figure 2 dC140 Analog Display DC Bias Values

Section Name

DC140 Analog Display Diagnostic Procedure

0/0/00 ?-126

Preliminary Working Document No Product Name Assigned

Figure 3 dC140 Analog Display Fuser Values

Preliminary Working Document No Product Name Assigned

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Section Name

DC140 Analog Display Diagnostic Procedure

DC909 P/R Belt Seam And Xerographic Test PURPOSE NOTE: Prior to performing any of these procedures, ensure that all appropriate service call procedures have been completed (e.g., Initial Action, RAPs, NRDs, HFSIs due).

2.

Enter dC909. Select Continue. Check the values returned for any out-of-range readings. (Refer to the dC909 Diagnostic Table)

3.

Select [ESV-DSS Test]. Select Continue. Check the values returned for any out-of-range readings. (Refer to the dC909 Diagnostic Table, Table 1 and Figure 2)

4.

If any 09-3XX faults occur use the following procedure to mask them, and rerun dC909:

Use this procedure when isolating the causes of an out-of-range value in dC909.

a.

Enter dC131 [MIN]. Enter location 179. Note and record the present value. Change the value to 164.

General Troubleshooting Information

b.

Enter dC909. Select [Continue]. Check the values returned for any out-of-range readings. (Refer to the dC909 Diagnostic Table, Table 1 and Figure 1).

NOTE: Read this section completely before beginning the procedure.

c.

Select [ESV - DSS Test] Select Continue. Check the values returned for any out-ofrange readings (refer to the dC909 Diagnostic Table, Table 1 and Figure 2).

If any out-of-range values are noted, use the information given below, and the procedures and references provided in the table to troubleshoot.

NOTE: Ignore any other fault codes that may occur. Also be sure to reset the value in dC131 [MIN] location 179 to its original value before continuing.

If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The Cleaner and Developer subsystems are suspect causes.

5.

If a value is out-of-range, replace any Dicorotrons and Shields associated with that value (PL 9.10 & PL 9.11).

When using the fault code references, use the appropriate diagnostic procedure.

6.

If any value is out-of-range, ensure that the correct dC314 power supply calibration value has been entered.

PROCEDURE

7.

Use the PQ RAP references as additional sources of information to fix the out-of-range problem.

NOTE: The ranges given in the table are only valid during a normal (NORMAL) print run and with a Photoreceptor that has less than 500K prints on it. If the Printer is in a Power Up Convergence cycle, some dC909 values may not be within the ranges specified. If possible, wait for the Power Up Convergence cycle to complete. 1.

Enter dC909 section to record the displayed values. Table 1 dC909 Diagnostic Parameter

Range

Procedures

References

Purpose

Charge Ratio

55 to 75

Check the dC131 [MIN] loca- BSD 9.10 (sheet 2) Fault Code: 9-202 tion 223 (Dicorotron AC Tar- PQ RAP: 9-626 get)

Charge 1 (V)

1300 to 2100 VDC / 2000 to 3000 VDC W MICR

BSD 9.10 (SHEET 1) dC314: CHGO##SV PQ RAP: 9-626

This is the amount of shield voltage placed on the Charge 1 Dicorotron by the HVDC PWB. This voltage is the amount needed to charge the PR Belt to a voltage equal to the Charge 2 Voltage. The monitor voltage for this output is displayed in dC140.

Charge 1 (uA)

75 to 155 ua / 125 to 250 ua W MICR

BSD 9.10 (SHEET 1) dC314: CHGO##S1 PQ RAP: 9-626

This is the amount of Charge 1 shield current. This current is a result of the Charge 1 Shield voltage applied to the dicorotron and the AC Voltage on the coronode. The monitor voltage for this input is displayed in dC140.

Charge 2 (V)

750 to 950 VDC / 850 to 1000 VDC W MICR

BSD 9.10 (SHEET 1) dC314: This is the amount of shield voltage placed on the Charge 2 Dicorotron by the HVDC CHGO##S FAULT CODE:9-203, 9-213, PWB. This voltage is the initial charge that is placed on the PR Belt to obtain the cor9-325 PQ RAP: 9-626 rect Dark Dusting target voltage, and is based on the Dark Decay voltage. The control logic always assumes that the initial charge on the PR Belt is equal to the Charge 2 Shield voltage. The monitor voltage for this output is displayed in dC140.

Section Name

DC909 P/R Belt Seam And Xerographic Test

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This is a ratio of the Charge 1 Current divided by the Charge 1 Voltage. The level of the Coronode AC Voltage determines this ratio. The ratio increases as the coronode voltage increases.

Preliminary Working Document No Product Name Assigned

Table 1 dC909 Diagnostic Parameter Charge 2 (uA)

Range -5 to 5 ua

Procedures

References

Purpose

BSD 9.10 (SHEET 1) dC314: CHGO##SI Fault Code:9-203, 9-213 PQ RAP: 9-616

This is the amount of shield current flow from the Charge 2 Dicorotron. This current is a result of the potential difference between the Charge 2 Shield voltage and the charge placed on the PR Belt by the Charge 1 Dicorotron. If any current is detected, the HVDC PWB controls the Charge 1 Shield voltage to bring the current back to 0 ua. When this current is 0 ua, the control logic knows that the charge on the belt is equal to the Charge 2 Shield voltage. The monitor voltage for this output is displayed in dC140.

Dev Rolls 1 & 2 185 to 285 VDC Check The dC131 [MIN] loca- BSD 9.3 dC314: DEV1$$BV Fault Code:9-230 PQ RAP: 9-616 (V) tion 217 (Developer rolls 1 and 2 Unit)

This is the voltage applied to the Developer Rolls 1 and 2. There is a specification for this voltage in each print mode. These specifications are set automatically during dC951. This value also is displayed in dC140.

Dev Roll 3 (V)

235 to 335 VDC Check The dC131 [MIN] loca- BSD 9.3 dC314: DEV2$$BV Fault tion 218 (Developer roll 3 Unit Code:9-231 PQ RAP: 9-616 Reference)

This is the voltage applied to the Developer Roll 3. There is a specification for this voltage in each print mode. These specifications are set automatically during dC951. This value also is displayed in dC140.

ESV Target (V)

700 to 800 VDC / 800 to 900 VDC W MICR

BSD 9.9 (Sheet 1) Fault Code:9-203, 9- This is the expected ESV reading on the next patch (ID Zone 2,4 and 6), based on 213 PQ RAP: 9-619 the Charge 2 Shield voltage. The value depends on the Dark Dusting, Dark Decay, and Charge 2 Voltages.

Dark Dusting

670 to 770 VDC / 800 to 900 VDC W MICR

BSD 9.9 Fault Code:9-203, 9-213 PQ RAP: 9-616

This is the target voltage of the latent image on the PR Belt, when the image arrives at developer roll #1. This is the voltage the control logic is trying to maintain, based on the Dark Decay voltage. The High and Low contrast voltages are based on this value and the Exposure Setpoint. This value for each print mode is setup during dC951.

Dark Decay

50 to 150 VDC

BSD 9.9 Fault Code:9-203, 9-213 PQ RAP: 9-601

This value is the loss of charge between the Charge 2 Dicorotron and the ESV. The total dark decay is equal to the Charge 2 Voltage minus the ESV Target Voltage times (1.4). Then, Charge 2 Voltage is adjusted by subtracting the Dark Decay from the Charge 2 Voltage, and comparing it to the Dark Dusting.

Exposure Setpoint

72 to 182

PGEN Reference

1.2 to 2.2 VDC / 1.6 to 2.6 VDC W MICR

Preliminary Working Document No Product Name Assigned

Check the dC131 [MIN] loca- BSD 6.2 (Sheet 2) Fault Code: 6-357, 6- This is a digital value that represents the amount of ROS exposure intensity. This tions 152 (Printer Scan Detec- 363, 6-364 value is calculated during dC951. The High and Low contrast voltages are based on tion Calibration Normal) and this value and the Dark Dusting. 153 (Printer Scan Detection Calibration Print Darkness 1). The range given for this parameter is with a normal ROS. If the power output from the ROS is low, this value can be as high as 240. If the system is meeting PQ specifications, a higher value is not considered a problem and the ROS assembly should not be replaced. BSD 9.9 (SHEET 1) Fault Code: 9-211 PQ RAP: 9-621

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This is the reference voltage applied to the Patch Generator to control its output intensity: the higher the number, the brighter the Generator. The Patch Generator will not switch on unless this value is at least 1.0 VDC. This value is calculated during dC951 to ensure that the patch is always developed at approximately -300 volts. Thus any changes measured by the DSS of the developed patch must be due to the toner concentration. This value varies with each print mode.

Section Name

DC909 P/R Belt Seam And Xerographic Test

Table 1 dC909 Diagnostic Parameter

Range

Procedures

References

Purpose

ESV ID Zone Clean Frames (1, 3, 5)

50 to 170 VDC / 100 to 200 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the background voltage reading, after exposure by the ROS.

ESV ID Zone Patch Frames (2, 4, 6)

700 to 800 VDC / 850 to 950 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the charged patch values. This reading, along with the DSS readings in the Patch Frames is used for Charge Control and Toner Concentration Control by the control logic. This value should be about the same as the ESV Target Voltage.

ESV Test Pat150 to 250 VDC tern Position #1 / 200 to 300 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the reading by the ESV of the 0.2 density area block of the resident xerographic test pattern printer during dC909. The magnitude of the individual voltage is not important; however, the magnitude of the voltage compared to the other 4 ESV Test Pattern Positions is important.

ESV Test Pat50 to 170 VDC / tern Position #2 100 to 200 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the reading by the ESV of the background area block of the resident xerographic test pattern printer during dC909. The magnitude of the individual voltage is not important; however, the magnitude of the voltage compared to the other 4 ESV Test Pattern Positions is important.

ESV Test Pat700 to 800 VDC tern Position #3 / 850 to 950 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the reading by the ESV of the 1.2 density area block of the resident xerographic test pattern printer during dC909. The magnitude of the individual voltage is not important; however, the magnitude of the voltage compared to the other 4 ESV Test Pattern Positions is important.

ESV Test Pat250 to 450 VDC tern Position #4 / 400 to 500 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the reading by the ESV of the 0.35 density area block of the resident xerographic test pattern printer during dC909. The magnitude of the individual voltage is not important; however, the magnitude of the voltage compared to the other 4 ESV Test Pattern Positions is important.

ESV Test Pat450 to 650 VDC tern Position #5 / 570 to 670 VDC W/ MICR

BSD:9.9 Fault Code: 9-213 PQ RAP: 9-619

This is the reading by the ESV of the 0.7 density area block of the resident xerographic test pattern printer during dC909. The magnitude of the individual voltage is not important; however, the magnitude of the voltage compared to the other 4 ESV Test Pattern Positions is important.

DSS ID Zone Patch Frames (2, 4, 6)

BSD:9.9 (SHEET 2) Fault Code 9-215 This is the reflectance of the developed patch after exposure by the Patch Generator. PQ RAP: 9-620, 9-621 This reading along with the ESV readings in the Patch Frames, is used for Charge Control and Toner Concentration Control by the control logic. As toner concentration increases, the patch gets darker, and the DSS reading decreases.

85 to 105

DSS Test Pat190 to 240 tern Position #1

BSD 9.9 (Sheet 2) Fault Code 9-215 PQ This is the reading by the DSS of the 0.2 density area block of the resident xeroRAP 621 graphic test pattern printer during dC909.

DSS Test Pat210 to 270 / 218 tern Position #2 to 246 W/ MICR

BSD:9.9 (SHEET 2) Fault Code 9-215 This is the reading by the DSS of the background area after exposure by the ROS. PQ RAP: 9-620

DSS Test Pat55 to 70 tern Position #3

BSD 9.5 Fault Code 9-215 PQ RAP: 9- This is the reading by the DSS of the 1.2 density area block of the resident xero620 graphic test pattern printer during dC909.

DSS Test Pat190 to 240 / 150 tern Position #4 to 200 W/ MICR

BSD:9.9 (SHEET 2) Fault Cod 9-215 PQ RAP: 9-620

This is the reading by the DSS of the 0.35 density area block of the resident xerographic test pattern printer during dC909.

DSS Test Pat120 to 180 tern Position #5

BSD:9.9 (SHEET 2) Fault Cod 9-215 PQ RAP: 9-620

This is the reading by the DSS of the 0.7 density area block of the resident Xerographic Test Pattern printer during dC909.

Toner Dispensing

BSD:9.7 & 9.9 Fault Code 9-215 PQ RAP: 9-620

This is the command for the toner dispenser motor, based on the DSS readings. For a DSS reading less than 78, the command is off; between 78 and 81, the command is duty-cycle; between 82 and 88, the command is on; two consecutive readings higher than 88, the command is on, and the Printer enters the dead cycle mode. The Printer must return to the duty-cycle range within 18 PR Belt revolutions, after entering the dead cycle mode.

% Duty Cycle 20 BITS on two consecutive VDDP patches.

6.

The ESV reading is more than 300 Volts above the CHG 2 Shld bias on two consecutive VDDP patches.

Initial Actions

Ensure that the Charge Dicorotron Height (ADJ 9-7) and Charge Dicorotron Balance (ADJ 9-6) are correct. NOTE: Excessive removal of the Dicorotron housings, (not shields), can cause premature failure of the dicorotron and/or connectors. Do not remove the dicorotrons for cleaning or inspection unless directed to do so by HFSI requirements or RAP diagnostics. Dicorotrons: Inspect the circuits for open or loose connections. Check for contamination, arcing, and discoloration of the Dicorotrons, Shields, and connectors (PL 9.10). NOTE: Inspect the Dicorotrons and Shields, and their circuits thoroughly. High voltage arcing through these components is a major contributor to this fault. Ensure that the Patch Generator is positioned correctly on the mounting pins, and that the ESV is not skewed. Clean the ESV and Patch Generator with a clean, soft, dry cloth. Perform the ESV Height Adjustment (ADJ 9-12). Go to dC 909 and perform the [ESV-DSS Test]. Ensure that the ROS Assembly is correctly positioned, not skewed on the rails. Check the ROS Low Correction Factor (ADJ 6-3). Locate the HVAC and HVDC calibration tags. Enter dC314. Ensure that all AC PWB and DC PWB Power Supply Calibration Values programmed, match the calibration tag values for those PWBs. Ensure that the covers and inner panels are on.

Enter dC105, ensure [F10] is Deselected,

NOTE: If this RAP does not fix the problem or electrical noise is suspected go to the NonRepeatable Problem Entry Procedure (Service Call Procedures).

Verify Erase Lamp operation and PR Brush integrity. NOTE: In some software versions the dC107 counter had the units incorrectly labeled as pitches, the counter actually counts P/R Belt revolutions.

Procedure

Enter dC107, [Xero]. Replace the P/R Belt if greater than 100K revolutions (700K pitches) (PL 9.1). If less than 700 pitches, do not replace the PR Belt. Perform a complete Xerographic Setup (ADJ 9-3). Pay special attention to the following:

Laser Radiation. Avoid direct exposure to the beam. The ROS can and will reflect off the photoreceptor belt. DO NOT look down into the machine from the top with the machine top cover and the ROS safety cover removed.

•

Step 1: All HFSI Actions as listed in the HFSI TABLES

•

Step 12: Charge Dicor Balance (ADJ 9-6)

•

Step 14e: dC314 Power Supply Cal

Preliminary Working Document No Product Name Assigned

WARNING

Cover the Photoreceptor, under the ROS Assembly, inboard to outboard with white paper. Cheat the Printer Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press Continue. Observe the scan line on the paper. There is a continuous scan line across the paper.

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Section Name

9-203, 9-213

Y

N Go to the 6-701 RAP.

Table 1 MIN NVM Address

NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD). For detailed Operating Instructions of the RHHD, go to (GP 1). The scan line is of equal brilliance across the entire length of paper. Y N Go to the 6-701 RAP. Keep [Laser Write] energized. Select [Patch Exposure]. The inboard half of the beam should become dimmer than the outboard. Press Continue. NOTE: Toggle the output on/off several times while observing the scan line if you are unsure of the above check. The scan line is dimmer on the inboard side. Y N Go to the 6-701 RAP. Press Stop. Select [Laser Write] [Patch Enable]. Press Continue. The scan line is completely off in the patch area. Y N Go to the 6-701 RAP. CAUTION Ensure that all paper is removed from under the ROS Assembly to avoid Printer damage during operation. Exit dC330. Remove the paper from the Photoreceptor. Close the Printer Front Doors. -15 VDC is measured between P293-6 (+) and TP-2 (-) of the HVDC PWB. Y N -15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS. Y N Go to the 1-716 RAP. Go to wire 1010F, wirenet. -15 VDC is measured between TS55 (+) and TS56 (-) of the MIN ADA PWB #2 Y N Go to Flag 1. Check wire 1010D for an open circuit. If the wire is Ok, replace the MIN ADA PWB #2 (PL 1.8).

Arc Simulation/Fault Mask

223

Dicorotron AC Target

260

ESV Adjust

285

Patch Location

ACV Slope Convergence

Control

Observe the Pcln Shld Current display. The Control Point V and the Pcln SI Monitor are less than 9.5. Y N Replace the Preclean Dicorotron and Shield (PL 9.10). Enter dC951, [Initialize]. Press Continue. Observe the dC951 Screen. The ESV Monitor Current Reading is less than 36. Y N (Potential cause for MIN NVM 443=3.) Switch off Printer power. Clean the ESV with a soft, dry, clean cloth. Check the air lines to the ESV. Perform the ESV Height Adjustment (ADJ 9-12). If the problem continues, go to PQ 9-619, ESV RAP, and PQ 9-618, PR Ground RAP. If the problem continues, replace the HVDC PWB (PL 1.7). Observe the dC951 Screen. If a random number less than 22 is displayed answer no. The ESV Monitor Current Reading is always greater than 21 bits. Y N (Potential cause for MIN NVM 443=3.) Enter dC909, [ESV-DSS]. The ESV Monitor reading is 1 +/- 0.2 volts. Y N Clean the ESV and Patch Generator again. Enter dC909, [ESV-DSS]. If the ESV Monitor reading is not 1 +/- 0.2 volts, replace the ESV Assembly (PL 1.7). Enter dC106. +5 VDC is measured between TS7 (+) and TS20 (-) of the MIB PWB #1. Y N Disconnect the J2 connector at the MIB PWB #1. +5 VDC is measured between TS7 (+) and TS20 (-) of the MIB PWB #1. Y N Replace the MIB PWB #1 (PL 1.8).

Description

179

ACV Factor

354

Clear the faults and press Continue. Observe the Chg 2 Shld Voltage display. The Point V and the Chg 2 SV Monitor are less than 9.5. Y N Replace the appropriate Dicorotron and Shield (PL 9.10).

Table 1 MIN NVM Current Value

Description

(HVDC PWB leakage check.) Enter dC140, [Dicorotron Values]. Press Start. After 10 seconds all the dicorotron values should be stable. Open the Printer Right Front Door to interrupt operation. Observe the Dicorotron Monitor Voltages for 30 seconds. The Monitor values cycle down to less than 0.3 after 30 seconds. Y N HVDC PWB leakage problem, replace the HVDC PWB (PL 1.7).

Enter dC131 [MIN]. Ensure that the following MIN NVM Addresses are at the values as listed in the appropriate level Software dC 131 Table in General Procedures.

Address

Current Value

353

Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8). A

Section Name

9-203, 9-213

0/0/00 ?-714

Preliminary Working Document No Product Name Assigned

A

B +15 VDC is measured between TS12 (+) and TS20 (-) of the MIB PWB #1. Y N Disconnect the J2 connector of the MIB PWB #1. +15 VDC is measured between the disconnected wire P211-13 (+) and TS20 (-) of the MIB PWB #1. Y N +24 VDC is measured between P205-7 (+) and P205-6 (-) of the ESV Power Supply. Y N Go to wires 1038B and 1039B wirenets. Check for an open circuit. Go to Flag 5. Check for a short circuit. If the circuit is OK, replace the ESV Power Supply (PL 1.7). Replace the MIB PWB (PL 1.8).

C Go to Flag 4. Check for an open or a short circuit. If the circuit is OK, replace the HVDC PWB and/or the HVAC PWB (PL 1.7).

Enter dC909. Select [Charge Control], [Open], [Print Patch], [Yes]. Program a 50 print job. Press Continue. Record the value of the dC909 Dark Decay V for future reference, after prints are completed. NOTE: If faults occur and no reading is displayed in dC909 or dC912, go to PQ 9-621, Patch Gen/Patch Integrity RAP. A Patch is printed. Y N Go to PQ 9-621, Patch Gen/Patch Integrity RAP. Enter dC912. Press Continue. The All Panels (Range) is less than 70 VDC. Y N Go to the PQ 9-633, PR Belt Uniformity RAP.

Replace the Charge Dicorotrons and Shields (PL 9.10). Observe the dC951 Screen. The Hi Charge Dark Decay is less than 30. Y N Open the Printer Front Doors. Cheat the Door Interlocks. Enter dC330, [9]. Select [PreCharge/Prexfr Lamps]. Press Continue. All segments on the Precharge Lamp and the Pretransfer Lamp are lit. Y N Go to PQ 9-624, Precharge/Pretransfer Lamp RAP.

Look at the dC909 Dark Decay V previously recorded. The recorded dC909 Dark Decay V is within 50 VDC of the dC912 Dark Decay Volts. Y N +15 VDC is measured between TS12 (+) and TS20 (-) of the MIB PWB. Y N Go to Flag 5. Check for an open circuit. If the circuit is Ok, replace the ESV Power Supply (PL 1.7).

Enter dC909. Select [Charge Control], [Open Loop]. Press Continue. An Image is present on the prints. Y N Go to Flag 3. Check for an open circuit. Ensure that the Endblock Tab is making a good connection with the Shield. If the circuit is OK, replace the Charge Dicorotrons and Shields (PL 9.10). If the problem still exists, replace the following as required • HVDC PWB (PL 1.7).

+5 VDC is measured between TS43 (+) and TS37 (-) of the MIN DIO PWB. Y N Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the MIB PWB (PL 1.8).

•

HVAC PWB (PL 1.7).

•

High Voltage Output Module (PL 1.7).

Ensure that the DC Leads of the Charge Dicorotrons are connected to the proper dicorotron. If the problem continues, go to PQ 9-619, ESV RAP. Observe the dC951 Screen. The Lo Charge Dark Decay reading is less than 28 or greater than 0, and the Dark Decay Intercept is less than 35 or greater than 0. Y N Replace the Charge Dicorotrons and Shields (PL 9.10).

Go to the PQ 9-621, Patch Gen/Patch Integrity RAP. The dC912 Dark Decay Volts is less than 225 VDC. Y N Compare the printed patch to the DK:UM density on the XTP 564.001 (82E4161) test pattern. The exact density is not critical. The prints have a patch nearly as dark as the DK:UM. Y N Go to PQ 9-621, Patch Gen/Patch Integrity RAP. Go to PQ 9-618, PR Ground RAP. If 9-213 fault codes still recur, perform the following: • Replace the Photoreceptor Belt (PL 9.1).

Observe the dC951 Screen. The ACV Setpoint reading is less than 245. Y N Enter dC909. Select [Charge Control], [Open]. Press Continue. The prints are blank. Y N Replace the Charge Dicorotrons and Shields (PL 9.10).

•

B

D

C

Preliminary Working Document No Product Name Assigned

Run Initialization.

•

Clean the POP Sensor.

•

Clean the DSS. Use anti-static solution (8R90275) with a clean, soft, lint-free cloth.

•

Replace the Developer Material.

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Section Name

9-203, 9-213

D •

Reaching this point indicates proper printer operation. If there are continued problems, and electrical noise is suspected go to the Printer Electrical Noise Procedure NRD 3, or the Non-Repeatable Problem Entry Procedure NRD 1 (Service Call Procedures).

Section Name

9-203, 9-213

0/0/00 ?-716

Preliminary Working Document No Product Name Assigned

Figure 1 9-203 Circuit Diagram (709003)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-717

Section Name

9-203, 9-213

9-211 RAP Fault Code, 9-211, indicates a Patch Generator failure. The Patch Generator cannot generate the current required to produce the correct light output.

Procedure CAUTION DO NOT install an analog Patch Generator into a 4180 machine, damage to the MIN DIO PWB will result. 4180 machines use a digital Patch Generator. CAUTION The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. DO NOT leave the Patch Generator energized in dC330 for longer than two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for longer than two minutes, remove the photoreceptor from the belt module and place it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module. Clear the fault. Enter dC330, [9]. The Patch Generator Failure Detector display is H. Y N Disconnect P240/J1 at the Patch Generator. The display is H. Y N Connect P240. Disconnect P249/J6 at the MIN DIO PWB. The display is H. Y N Replace the MIN DIO PWB (PL 1.8). Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the Patch Generator (PL 9.10). Replace the Patch Generator (PL 9.10). Select [Patch Gen High (pulsed)]. Press Continue. The Patch Generator Failure Detect display goes L. Y N Go to Flag 1. Check for an intermittent short circuit. If no broken insulation or no intermittent short circuit is found, replace the Patch Generator (PL 9.10). Replace the Patch Generator (PL 9.10).

Section Name

9-211

0/0/00 ?-718

Preliminary Working Document No Product Name Assigned

Figure 1 9-211 Circuit Diagram (709004)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-719

Section Name

9-211

A Y

9-212 RAP Fault Code, 9-212, indicates a DSS failure. The reflectance of a clean patch is less than 75%, or more than 10%, of the reflectance of a normal clean patch. This fault will occur if the DSS Monitor signal is less than 25 for three or more consecutive reads, or during Power Up Convergence the clean belt reading is not 232 +/-14 after five attempts.

N Go to the 6-701 RAP.

Press Stop. Select [Laser Write] [Patch Enable]. Press Continue. The scan line is completely off in the patch area. Y N Go to the 6-701 RAP.

Initial Actions Pull out the Xerographic Drawer. Check the Photoreceptor Ground Brush for contamination and/or deformation (PL 9.7). CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean.

CAUTION Ensure that all paper is removed from under the ROS Assembly to avoid Printer damage during operation. Exit dC330. Remove the paper from the Photoreceptor. Close the Printer Front Doors. -15 VDC is measured between P293-6 (+) and TP-2 (-) of the HVDC PWB. Y N -15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS. Y N Go to the 1-716 RAP. Go to wire 1010F, wirenet.

Check the ROS Low Correction Factor (ADJ 6-3). Clean the DSS. Ensure that the Photoreceptor Belt over the DSS is clean. Enter dC909, [ESVDSS Tests]. Select [DSS Recalibrate]. Select [Patch Test] and press Continue. This will force a power up sequence to establish the new DSS calibration value. If experiencing multiple occurrences of DSS failures (replacements), go to Multiple DSS Failures at the end of this RAP.

Procedure WARNING Laser Radiation. Avoid direct exposure to the beam. Cover the Photoreceptor, under the ROS Assembly, inboard to outboard with white paper. Cheat the Printer Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press Continue. Observe the scan line on the paper. There is a continuous scan line across the paper. Y N Go to the 6-701 RAP.

Enter dC909, [ESV-DSS Test]. Observe variations during five DSS Recalibrations. Press [DSS Recalibrate] record the value each time. The DSS Reading is 232 +/- 12 after each recalibration, and the variation between any of the readings does not exceed 6. Y N +15 VDC is measured between IRD-5 (+) and IRD-2 (-) at the DSS. Y N +15 VDC is measured between IRD-5 (+) at the DSS and machine frame (-). Y N +15 VDC is measured between TH6 (+) and TH8 (-) at the LVPS. Y N Go to the 1-715 RAP. Go to Flag 4. Check the wire 1009N and 1009P, wirenets for an open circuit. Go to Flag 5. Check the wire, 1008P, wirenet for an open circuit. +15 VDC is measured between IRD-6 (+) and IRD-2 (-) of the DSS. Y N Go to Flag 4. Check the wire, 1009N, wirenet for an open circuit.

NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD). For detailed Operating Instructions of the RHHD, go to (GP 1). The scan line is of equal brilliance across the entire length of paper. Y N Go to the 6-701 RAP.

Greater than +3.0 VDC is measured between TS24 (+) and TS37 (-) of the MIN DIO PWB. Y N Disconnect the wire from P249-27. 5 VDC is measured between TS24 (+) and TS37 (-) of the MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8).

Keep [Laser Write] is energized. Select [Patch Exposure]. The inboard half of the beam should become dimmer than the outboard. Press Continue. NOTE: Toggle the output on/off several times while observing the scan line if you are unsure of the above check.

Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the DSS (PL 9.7).

The scan line is dimmer on the inboard side. +15 +/-.75 VDC is measured between TS10 (+) and TS56 (-) of the MIN ADA PWB #1. A Section Name

9-212

B 0/0/00 ?-720

C Preliminary Working Document No Product Name Assigned

B

C Y

N Disconnect the wire at P214-17, (J4) of the MIN ADA PWB #1. 4.0 to 5.5 VDC is measured between TS10 (+) and TS56 (-) the MIN ADA PWB #1. Y N Go to Flag 3. Check for a short circuit and replace the DSS (PL 9.7). Go to Flag 3. Check for an open or a short circuit. If the circuit is OK, replace the DSS (PL 9.7).

Greater than +1.0 VDC is measured between TS51 (+) and TS56 (-) of the MIN ADA PWB #1. Y N Disconnect the wire at P206-1 (J7) of the MIN ADA PWB #1. Greater than +1 VDC is measured between the disconnected wire and TS56 (-) of the MIN ADA PWB #1. Y N Go to Flag 1. Check for an open or a short circuit. If the circuit is OK, replace the DSS (PL 9.7).

CAUTION The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. If the belt module will be exposed to light for longer than two minutes, remove the photoreceptor from the belt module and place it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module. Open the Front Doors. Pull out the Photoreceptor Drawer. Raise the Photoreceptor Module at least 30 degrees from the horizontal and leave it there. The DSS Reading is less than 50. Y N Replace the DSS (PL 9.7). Select [DSS Recalibrate]. A 9-212 fault code is declared. Y N +15 VDC is measured between TS8 (+) and TS56 (-) of the MIN ADA PWB #1. Y N Go to Flag 2. Check for an open or short circuit. If the circuit is OK, replace the DSS (PL 9.7). Select [DSS Recalibrate]. Use Pulse Detection (Procedure at the end of this RAP). A negative going pulse is measured between TS8 (+) and TS56 (-) of the MIN ADA PWB #1 every time the DSS Recalibrate button is pressed. Y N Replace the MIN ADA PWB #1 (PL 1.8).

Replace the MIN ADA PWB #1 (PL 1.8). Use Pulse Detection. (The procedure is at the end of this RAP). A negative going pulse is measured approximately every 2 seconds between TS10 (+) and TS56 (-) of the MIN ADA PWB #1. Y N Replace the MIN ADA PWB #1 (PL 1.8). +15 is measured between TS8 (+) and TS56 (-) the MIN ADA PWB #1. Y N Disconnect the wire at P214-19, (J4) of the MIN ADA PWB #1. 4.0 to 5.5 VDC is measured between TS8 (+) and TS56 (-) the MIN ADA PWB #1. Y N Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the DSS (PL 9.7). Go to Flag 2. Check for an open or a short circuit. If the circuit is OK, replace the DSS (PL 9.7). Select [DSS Recalibrate]. Use Pulse Detection. A negative going pulse is measured between TS8 (+) and TS56 (-) of the MIN ADA PWB #1 every time the DSS Recalibrate button is pressed. Y N Replace the MIN ADA PWB #1 (PL 1.8). Replace the DSS (PL 9.7).

Replace the DSS (PL 9.7). Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8). If the above checks are OK, go to PQ 9-619, ESV RAP. If the problem continues, go to the Multiple DSS Failures checklist at the end of this procedure. DMM Pulse Detection Procedure: • Meter Probes in the Volt-Ohm (+) and the COM (-) Jacks •

Press in the Ohm Button.

•

Press in the 200K Button.

•

Press in the AC Button if Audible Pulse Detection is desired.

For the negative going pulses measured in this RAP: • The UP Arrow will be displayed. •

The DOWN Arrow will Flash with the negative going pulses.

•

If the Audible Pulse Detection is used, a BEEP will be heard when the Down Arrow Flashes. CAUTION

Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean.

Multiple DSS Failures •

Preliminary Working Document No Product Name Assigned

0/0/00 ?-721

Ensure that the Photoreceptor Ground Strip is not damaged.

Section Name

9-212

•

Ensure that there is a CP Connector by the DSS. If the CP Connector is not by the DSS, go to the ADA PWB #1 and find the CP Connector by J7. Remove the CP Connector and disconnect the wire at P206-3 (J7) of the ADA PWB #1. Connect the CP Connector by the DSS across pins 2 & 3 per the CD.

•

Ensure that the DSS Wires are tucked under the L-shaped Frame of the Photoreceptor Drawer.

•

Check the Ground Brush ground path back to the HV PWBs (PQ 9-618, PR Ground RAP).

•

Switch Off Printer power. Unplug the Printer. Check the ground between the Machine Frame and the Power Cord.

•

Ensure that all green ground wires in the Fuser area are connected and secure.

•

Ensure that the DSS wires are not against any AC high voltage wires.

•

Perform the Charge Dicorotron Balance (ADJ 9-6) and Height (ADJ 9-7) adjustments.

•

Replace the Transfer and Preclean Dicorotrons (PL 9.10).

•

Replace the Drawer Roll Up Ribbon Cable (PL 9.1).

•

If the failure is at first power up, replace the Position 3 (A) PWB of the LVPS (PL 1.10).

•

Clean the DSS. Ensure that the Photoreceptor Belt over the DSS is clean. Enter dC909, [ESV-DSS Tests]. Select [DSS Recalibrate]. Select [Patch Test] and press Continue. This will force a power up sequence to establish the new DSS calibration value.

Section Name

9-212

0/0/00 ?-722

Preliminary Working Document No Product Name Assigned

Figure 1 9-212 Circuit Diagram (7906)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-723

Section Name

9-212

A

9-215 RAP

WARNING

Fault Code, 9-215, indicates a toner dispense failure. Two consecutive DSS patch readings are above the Dead Cycle Set point of the Toner Dispense Motor. The machine will dead cycle with the Toner Dispense Motor switched on at 100% duty cycle. If, after 75 pitches, the DSS reading still exceeds the Full Dispense Set Point (and there is toner present), the fault is declared.

Initial Actions NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures). CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. Check/repair the following: •

Check for toner in the dry ink bottle. If there is no toner in the bottle, skip the rest of the Initial Action steps and go directly to the Procedure.

•

Ensure that [Precision Patch] is selected in dC105.

•

Ensure that the ROS Assembly is correctly positioned not skewed in the rails.

•

Check the ROS Low Correction Factor (ADJ 6-3).

•

Check the DSS Timing (ADJ 9-14).

•

Check the Patch Generator Timing (ADJ 9-5).

•

Clean the ESV, DSS, and the Patch Generator. Check the ESV Height (ADJ 9-12).

•

Developer Door Seal and Dump Door for excessive developer leakage (PL 9.17).

•

Metal chips in the developer from the Paddle Wheel Bearing.

•

Developer Drive Coupling for wear.

Laser Radiation when the PR Drawer is open. Avoid eye exposure to the beam. Cover the Photoreceptor Belt, under the ROS Assembly, inboard to outboard with white paper. Cheat the Printer Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press Continue. Observe the scan line on the paper. There is a continuous scan line across the paper. Y N Go to the 6-701 RAP. NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD). For detailed Operating Instructions of the RHHD, go to (GP 1). The scan line is of equal brilliance across the entire length of paper. Y N Go to the 6-701 RAP. Keep [Laser Write] energized. Select [Patch Exposure]. Observe the scan line when the Continue button is pressed. The inboard half of the beam should be dimmer than the outboard half. Press Continue. NOTE: The difference in beam intensity is not that great, press (Stop/Continue) several times while observing the scan line to verify check. The scan line is dimmer on the inboard side. Y N Go to the 6-701 RAP. Press Stop. Select [Patch Enable]. Press Continue. The scan line is completely off in the patch area. Y N Go to the 6-701 RAP. Select Clear Outputs. The Patch Generator LED's are off. Y N (Patch Gen problem). +5 VDC is measured between TS8 (+) and TS20 (-) of the MIB PWB. Y N Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8).

•

Ensure that the Photoreceptor is seated properly.

•

Ensure that all covers are installed and that there are no light leaks.

•

Ensure dC131, MIN NVM locations 243, 244, and 245 are at the proper values as listed in the appropriate level Software dC 131 Table in General Procedures.

CAUTION DO NOT install an analog Patch Generator into a 4180 machine, damage to the MIN DIO PWB will result. 4180 machines use a digital Patch Generator. Go to Flag 7. Check for a short circuit. If the circuit is ok, replace the MIB PWB (PL 1.8).

Procedure NOTE: MICR (DP180MX) Machines use a red Toner Bottle that is not compatible with DP180. Inspect the Developer Housing. Determine if there is abnormal developer flow (reverse developer flow) or excessive developer on the Input Chute of the BRD Roll. The developer flow is normal. Y N Go to PQ 9-616, Development RAP.

Pull out the Xerographic Drawer. Remove the paper from the Photoreceptor. Raise the Photoreceptor Module. Select [Precharge/Prexfr Lamps]. Press Continue. All segments of the Precharge and Pretransfer Lamps are lit. Y N If some, but not all of the segments, of a lamp are lit, replace that lamp (PL 9.4). If a lamp does not light, go to the PQ 9-624, Precharge/Pretransfer Lamps RAP.

A

B

Section Name

9-215

0/0/00 ?-724

Preliminary Working Document No Product Name Assigned

B Close and latch the Xerographic Drawer. Select [Main Drive Start/Run]. Press Continue. The Developer Rolls rotate. Y N Check the Developer Gear teeth for wear and/or breakage. The gears are OK. Y N Remove the Developer Housing from the Printer. Remove the gears. Rotate the rolls, the auger, and the paddle wheel. Check for bearing failures. Repair the components as required (PL 9.14).

C

Remove the Paddle Wheel Gear. Rotate each roll. Check for packed developer or debris. Ensure proper operation of the bearings. The rolls rotate. Y N Clean/replace the components as necessary (PL 9.18).

D Press Stop. 115 VAC is measured between P272-11 and P272-3 of the MIN AC Remote PWB #1. Y N This is a 60HZ Printer. Y N (50HZ). 115 VAC is measured between K102-9 (+) and K102-8 (-). Y N Go to the 1-709, AC Interlock Power RAP. Go to Flag 2. Check wires 4FF and 31 wirenets. Check for a open circuit. (60HZ). 115 VAC is measured between K102-5 (+) and 2A7TB1-15 (-). Y N Go to the 1-702, AC Power Interlock RAP.

Rotate the auger. Check for binding. The auger rotates. Y N Replace the Auger Bearing (PL 9.16).

Go to Flag 2. Check wires 4FF and 31 wirenets. Check for a open circuit. 115 VAC is measured between P272-5 (+) and P272-3 (-) of the MIN AC Remote PWB #1. Y N Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the Toner Dispense Motor, MOT902, (PL 9.19).

The Paddle Wheel rotates. Y N Check for binding and replace the Paddle Wheel (PL 9.18). Replace Developer Roll #2 (PL 9.15).

Press Continue. Less than 10 VDC is measured between P272-5 (+) and P272-3 (-) of the MIN AC Remote PWB #1. Y N Replace the MIN AC Remote PWB #1 (PL 1.7).

Select [Clear Outputs]. Open the Xerographic Drawer. Remove the dry ink bottle. NOTE: To avoid a toner spill, clean the area before reinstalling the dry ink bottle. There is dry ink in the hopper. Y N CAUTION Use care when handling the Low Toner Sensor Q903. Do not touch the sensor portion of Q903. Go to Flag 4. Check the circuit of the Low Toner Sensor, Q903 (GP 6-2, General Procedures, may be used as a guideline; however, notice the difference in the input voltage level). If the circuit checks OK, replace the Low Toner Sensor (PL 9.19). Enter dC330, [9], [Toner Dispenser]. Press Continue. Observe the Anti-Bridging Paddle action. The Toner Dispenser Motor rotates. Y N Press Stop. Ensure that the frame mounted connector, P256, is seated properly. +5 VDC is measured between TS47 (+) and TS37 (-) of the MIN DIO PWB. Y N Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN AC Remote PWB #1 (PL 1.7). Press Continue. Less than +1.0 VDC is measured between TS47 (+) and TS37 (-) of the MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8).

Replace the Toner Dispense Motor, MOT902, (PL 9.19). NOTE: The Toner Bottle may have to be removed to observe the Paddle. The Anti-Bridging Paddle appears to operate correctly. Y N Check for any clogged dry ink. If the dry ink is OK, replace the MIN AC Remote PWB (PL 1.7). Press Stop. Select [Toner Thumper]. Press Continue. NOTE: Listening for the Thumper may not be adequate. Cheat the Front Door Interlocks. Observe the Solenoid actuation. The Toner Thumper Solenoid actuates. Y N Go to Flag 5. Check the Toner Thumper Solenoid, SOL901, circuit. (GP 6-2, General Procedures). The Toner Thumper hits the toner bottle. Y N Adjust the Toner Thumper (ADJ 9-0). Check for any clogged dry ink. The LOW toner Sensor display is H.

C

D

Preliminary Working Document No Product Name Assigned

0/0/00 ?-725

Section Name

9-215

Y

N CAUTION Use care when handling the Low Toner Sensor Q903. Do not touch the sensor portion of Q903. Go to Flag 6. Check the circuit of the Low Toner Sensor circuit. (GP 6-2, General Procedures, may be used as a guideline; however notice the difference in the input voltage level).

Press Stop.Enter dC106. Select [Test Patterns and PQ], [Xerographic]. Program a 25 print job. Press Continue. Compare the prints to the Xerographic Test Pattern. The density of block #3 on the prints is less than or equal to the STD: Restore block on the 82E4161 test pattern. Y N Go to Flag 5. Check for an intermittent short circuit in the Toner Thumper Solenoid circuit. Adjust the Toner Thumper (ADJ 9-0). If the problem continues, go to the PQ 9-610, High Image Darkness RAP, the PQ 9-616, Development RAP, and PQ 9-620, DSS RAP as required. Enter dC131 [MIN]. Enter Address 250. Lower the Data value by 6 bits. Run 200 copies to detone the system. Perform the Xerographic Setup (ADJ 9-3). If the problem continues, go to PQ 9-610, High Image Darkness RAP. If the problem continues, go to PQ 9-616, Development RAP, and 9-620, DSS RAP.

Section Name

9-215

0/0/00 ?-726

Preliminary Working Document No Product Name Assigned

Figure 1 9-215 Circuit Diagram (7933)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-727

Section Name

9-215

Figure 2 9-215 Circuit Diagram (7908)

9-220, 9-222 RAP Section Name

9-215

0/0/00 ?-728

Preliminary Working Document No Product Name Assigned

Y

Fault Code, 9-220, indicates that the Belt Hole Sensor, Q901, did not detect the belt hole within 3152 milliseconds of the previous belt hole detection, or twice within one hundred average calculations of the time between belt holes, the average calculation was greater than 50 milliseconds above the last ten average calculations (Intermittent Slow Belt Hole Detection).

N Go to the 4-201 RAP.

The Photoreceptor Belt is rotating. Y N Press Stop. Troubleshoot the Photoreceptor Module Input Drives. Closely examine the Drive Coupling for wear.

Fault Code, 9-222, indicates that the Belt Hole Sensor, Q901, detected the belt hole less than 2840 milliseconds since the previous belt hole detection, or twice within one hundred average calculations of the time between belt holes, the average calculation was less than 50 milliseconds below the last ten average calculations (Intermittent Fast Belt Hole Detection).

CAUTION The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. If the belt module will be exposed to light for longer than two minutes, remove the Photoreceptor from the belt module and place it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module.

Initial Actions •

If the Photoreceptor Belt and/or the Machine Clock Sensor has just been replaced, clear the fault and run the printer to verify operation.

•

Ensure that the Belt Hole Sensor, Q901, and the Belt Hole LED are connected.

•

Ensure that the Photoreceptor Module is securely seated in the Drawer Assembly. Check the Drawer Roll-up Cable, (PL 9.1).

Press Stop. Remove the Photoreceptor Belt. Check the following: • Blocked Belt Hole

•

Enter dC131 EDN NVM ensure that location 392 is 180.

•

Photoreceptor Belt for edge damage or seam show-through

Procedure

•

Loose Machine Clock Sensor

Cheat the Printer Interlock Bypass Switch. Run a few prints to observe the system operation. Determine if the fault is intermittent. The fault code is consistently displayed during the print cycle. Y N (The fault is intermittent).

•

Tension Roll for damaged or binding bearings

•

Idler Roll for damaged or binding bearings

•

Stripper Roll for damaged or binding bearings

NOTE: The nominal value of Machine Clocks between Belt Holes is 5533. The nominal value of Milliseconds between Belt Holes is 3052. This may not be seen until after the displayed fault code is cleared, and the test restarted.

•

Loose Machine Clock Sensor

•

Tension Roll for damaged or binding bearings

•

Idler Roll for damaged or binding bearings

•

Stripper Roll for damaged or binding bearings

•

Broken Tension Roll Springs

•

Cleaner Module, Developer Housing, or Machine Drives for binding

Cleaner Module, Developer Housing, or Machine Drives for binding

Pull out the Xerographic Drawer. Lift the Photoreceptor Module. Reinstall the Photoreceptor Belt. +5 VDC is measured between TS15 (+) and TS18 (-) of the MIN Core PWB. Y N +5 VDC is measured between TB3-8A (+) and TS18 (-) of the MIN Core PWB. Y N Go to the wire, 1000L wirenet. Check for an open circuit.

Check the following: • Blocked Belt Hole Photoreceptor Belt for edge damage or seam show-through

Broken Tension Roll Springs

•

The above checks are Ok. Y N Repair the components as required.

Enter dC912, [Belt Hole]. Press Continue. The Milliseconds between Belt Holes values indicate that random Belt Holes are detected far outside the general range of readings. Y N Replace the Machine Clock Sensor (PL 9.3).

•

•

Clean the Belt Hole LED and the Sensor. Go to Flag 2. Check the circuit of the Belt Hole Sensor (GP 6-2, General Procedures). Rotate the Photoreceptor to uncover the Belt Hole LED. Lower the Photoreceptor Module. Less than +1 VDC is measured between TS15 (+) and TS18 (-) of the MIN Core PWB. Y N Clean the Belt Hole LED and the Sensor. Go to Flag 1 and Flag 2. Check the circuit of the Belt Hole LED and the Sensor (GP 6-2, General Procedures).

If the problem continues, replace the Belt Hole Sensor, Q901, (PL 9.7). A 9-222 fault code is displayed. Y N Enter dC330, [Main Drive Start/Run] Motor. Press Continue. The Main Drives (paper transports) are rotating. A Preliminary Working Document No Product Name Assigned

0/0/00 ?-729

B Section Name

9-220, 9-222

A

B

C NOTE: The nominal value of Machine Clocks between Belt Holes is 5533. The nominal value of Milliseconds between Belt Holes is 3052. This may not be seen until after the displayed fault code displayed is cleared and the test restarted.

•

Blocked Belt Hole

•

Photoreceptor Belt for edge damage

•

Loose Machine Clock Sensor

Enter dC912, [Belt Hole]. Press Continue. The Milliseconds between Belt Holes values, indicate random Belt Holes detected far outside the general range of readings. Y N Replace the Machine Clock Sensor (PL 9.3).

•

Tension Roll for damaged or binding bearings

•

Idler Roll for damaged or binding bearings

•

Stripper Roll for damaged or binding bearings

Replace the Belt Hole Sensor, Q901 (PL 9.7). Replace the MIN Core PWB (PL 1.8).

•

Broken Tension Roll Springs

•

Cleaner Module, Developer Housing, or Machine Drives for binding

•

If the above checks are OK, replace the Belt Hole Sensor, Q901, (PL 9.7).

Check the following: • Tension Roll Springs for damage

CAUTION

•

Tension Roll bearings and shafts for loosening or binding that could cause mistracking

The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. If the belt module will be exposed to light for longer than two minutes, remove the photoreceptor from the belt module and place it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module.

•

Stripper Roll bearings and shafts for loosening or binding that could cause mistracking

Open the front doors and slide the Xerographic Drawer out of the machine. Partially cover the Belt Hole Sensor, Q901, with black electrical tape. Inspect the PR Belt. The front edge of the Photoreceptor Belt is damaged. Y N Press the Red Test Button on the Photoreceptor Module. Rotate the Photoreceptor over the Precharge Lamp. Inspect the ground strip area of the belt. Look for any scratches that transmit light, or if the seam transmits light wider than 2mm. The Photoreceptor Belt Ground Strip is OK. Y N Replace the Photoreceptor Belt (PL 9.1). Check the following for possible causes of the damage: • Foreign material in the Developer Housing or in the Cleaner Housing •

Damaged or contaminated Ground Brush

•

Charge Dicorotron Height Adjustment (ADJ 9-7).

•

Loose Machine Clock Sensor

•

Loose Drive Belt Idler

•

Developer Housing for correct position

•

Photoreceptor Edge Guide

•

Check P/J 300 for rubbing on drives. P/J 300 is located by the Reg Servo PWB (PL 1.4).

The mistracking problem was corrected. Y N Replace the Photoreceptor Module and Photoreceptor Belt (PL 9.1). Replace the Photoreceptor Belt (PL 9.1).

Go to Flag 1 and Flag 2. Check the circuit of the Belt Hole LED, CR901, and the Belt Hole Sensor, Q901 (GP 6-2, General Procedures). The circuit is OK. Y N Repair the circuit as required (PL 9.2). NOTE: The nominal value of Machine Clocks between Belt Holes is 5533. The nominal value of Milliseconds between Belt Holes is 3052. This may not be seen until after the fault code displayed is cleared and the test restarted. Enter dC912, [Belt Hole]. Press Continue. The Milliseconds between Belt Holes values, indicate random Belt Holes detected far outside the general range of readings. Y N Replace the Machine Clock Sensor (PL 9.3). Press Stop. Remove the Photoreceptor Belt. Check the following: C Section Name

9-220, 9-222

0/0/00 ?-730

Preliminary Working Document No Product Name Assigned

Figure 1 9-220/222 Circuit Diagram (7910)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-731

Section Name

9-220, 9-222

9-221 RAP Fault Code, 9-221, indicates that the Ozone Vacuum Switch, S902, detected inadequate air flow.

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

9-221

0/0/00 ?-732

Preliminary Working Document No Product Name Assigned

Figure 1 9-221 Circuit Diagram (7911D)

Preliminary Working Document No Product Name Assigned

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Section Name

9-221

A

9-320 RAP

•

Check the Rear two Contact Points. If either Contact Point is damaged or broken, replace the Developer Assembly (PL 9.13).

Fault Code, 9-320, indicates that the Dev Rolls 1&2 Bias Monitor voltage is less the Dev Rolls 1&2 Bias Control voltage (dC140). The Monitor voltage is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

•

If the Contact Points are OK, perform the Developer Zone Roll Adjustment (ADJ 91).

•

If the above checks are OK, replace the Developer Drive Coupling (PL 4.17).

Initial Actions Ensure that the Ribbon Cable between the HVAC and HVDC PWBs is securely connected. If loose or damaged, replace the Ribbon Cable (PL 9.1). NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures). NOTE: If this RAP does not fix the problem, check the HV output module. NOTE: Except for missing or broken contact points on the Developer Housing, replacing the assembly will not repair the 9-320 faults.

Procedure Enter dC131 [MIN]. Enter address 125. Ensure that the Data value equals the value as listed in the appropriate level Software dC 131 Table in General Procedures. If address 125 does not equal the value listed in the appropriate table, ROS 6-3xx series faults may be masked and the 9-320 fault will result. MIN address 125 equals the table value. Y N Enter address 125. Enter the Data value listed in the appropriate level Software dC 131 Table (Section 6, General Procedures, of the Service Manual). Enter dC606. Run any job to determine what fault code displays. If any 6-3xx series fault occurs, go to the RAP for that fault. If the 9-320 fault occurs, continue with this RAP.

With dC140 still on. Observe the Dev Rolls 1&2 Bias displays. Compare the Required display and the measured voltage. The difference is greater than +/- 20 VDC. Y N (The measured voltage equals the Required display +/- 20 VDC). Measure the voltage between TS18 (+) and TS19 (-) of the MIN ADA PWB #2. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Measure the voltage between TP502 (+) and TP2 (-) of the HVDC PWB. Observe the Dev Rolls 1&2 Bias displays. Press the Continue button. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Press Stop. Disconnect the wire from P201-1 (J6) of the MIN ADA PWB #2. Measure the voltage between TP502 (+) and TP2 (-) of the HVDC PWB. Observe the Dev Rolls 1&2 Bias displays. Press the Continue button. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Reconnect the wire to P201-1 (J6) of the MIN ADA PWB #2. Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Reconnect the wire to P201-1 (J6) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8). Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8).

WARNING The Printer will not shutdown due to 9-3xx series faults in dC140. Select Stop between measurements, when checking for an open or a short circuit, and when removing or replacing parts.

Check the Developer Drive Assembly for the following problems: • Check the Contact Points for the Developer Zone Roll on the Developer Housing. If the Contact Points are broken or missing, replace the Developer Housing (PL 9.13).

Enter dC140, [DC Bias Values]. Open the Printer Front Doors. Cheat the Printer Interlock Bypass Switch. Measure the Dev Rolls 1&2 Bias voltage. (See the circuit diagram for the test point.) Measure between the Developer Housing left side extrusion, located under the Developer Catch Tray, and the Printer Frame (-).

•

NOTE: dC140 will not operate with a fault queued. Press R (reset) button on the Printer UI Control Panel to clear faults.

Separation of the Developer Drive Pulley Flange.

•

Wobble in the Drive Pulley during operation

•

Scrapping on the inside of the Developer Drive Clam Shell due to interference with the Developer Drive Pulley.

One of the above Developer Drive problems exist. Y N Replace the MIN ADA PWB #2 (PL 1.8).

Press Continue. NOTE: An intermittent short will not drop the voltage to 0 VDC.

Replace the Developer Drive Assembly (PL 9.14).

The measured voltage reading is stable +/- 2 VDC. Y N Press Stop. Check the following: • Flag 6 and Flag 7. Check Developer Roll 1&2 Bias wire for a short circuit. •

(The measured voltage does not equal the Required display +/- 20 VDC). Press Stop. -15 VDC is measured between TS55 (+) and TS56 (-) of the MIN ADA PWB #2

Check the Developer Housing, Front two Contact Points. If either Contact Point is damaged or broken, replace the Front Bearing Clamp Assembly (PL 9.15).

A Section Name

9-320

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Preliminary Working Document No Product Name Assigned

B Y

N Go to Flag 10. Check wire 1010D for an open circuit. If the wire is Ok, replace the MIN ADA PWB #2 (PL 1.8).

C

D Y

N Go to wire, 1009D, wirenet. Check for an open circuit.

Replace the MIN ADA PWB #2 (PL 1.8). +15 VDC is measured between P293-4 (J4) (+) and TP2 (-) on the HVDC PWB. Y N +15 VDC is measured between TH6 (+) and TH8 (-) on the LVPS. Y N Go to the 1-715 RAP.

Reconnect the wire to J5-14 of the MIN ADA PWB #2. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Press Stop. Measure the voltage between TP501 (+) and TP2 (-) of the HVDC PWB. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Go to Flag 2. Check for an open circuit.

Check wire, 1009K, wirenet. +15 VDC is measured between (P294) J1-4 (+) and TP1 (-) on the HVAC PWB. Y N Check wire, 1009J, wirenet.

Press Stop. +34 VDC is measured between P293-7 (+) and P293-10 (-) of the HVDC PWB. Y N +34 VDC is measured between TH16 (+) and TH18 (-) on the LVPS. Y N Disconnect J298 of the LVPS. +34 VDC is measured between TH16 (+) and TH18 (-) of the LVPS. Y N Go to the 1-717, +24, +34, -34 VDC RAP.

Greater than +8 VDC is measured between TP9 (+) and TP1 (-) on the HVAC PWB. Y N Go to Flag 8. Check for a short or an open circuit. If the wires are Ok, replace the MIN ADA PWB #1 (PL 1.8). Greater that +8 VDC is measured between TS16 (+) and TS56 (-) on the MIN ADA PWB #1. Y N Go to Flag 8. Check for an open circuit.

Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Press Continue. Less than 1 VDC is measured between TS16 (+) and TS56 (-) on the MIN ADA PWB #1. Y N Replace the MIN ADA PWB #1 (PL 1.8).

Go to Flag 3. Check for an open circuit. -34 VDC is measured between P294-2 (+) and P294-10 (-) of the HVAC PWB. Y N -34 VDC is measured between TH17 (+) and TH18 (-) on the LVPS. Y N Disconnect J298 of the LVPS. -34 VDC is measured between TH17 (+) and TH18 (-) of the LVPS. Y N Go to the 1-717, +24, +34, -34 VDC RAP.

Press Stop. Enter [dC] [Power Interrupt]. Disconnect P291 (J6) at the HVDC PWB. Press Continue. Enter dC140, [DC BiasValues]. Measure the voltage between J6-1 (+) and TP2 (-) at the HVDC PWB. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The measured voltage is within +/- 20 VDC of the Required display. Y N Press Stop. Enter [dC] [Power Interrupt]. Reconnect P291 at the HVDC PWB. Press Continue. Enter dC140, [DC Bias Values]. Measure the voltage between TS11 (+) and TS56 (-) of the MIN ADA PWB #2. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The voltage measured is within +/- 0.5 VDC of the Control display. Y N Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire from J5-14 of the MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Measure the voltage between TS11 (+) to TS56 (-) of the MIN ADA PWB #2. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The voltage measured is within +/- 0.5 VDC of the Control display. Y N Press Stop. Enter [dC] [Power Interrupt]. Reconnect the wire to J5-14 of the MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Press Continue. +15 VDC is measured between TS57 (+) and TS56 (-) of the MIN ADA PWB #2. B

C

D

Preliminary Working Document No Product Name Assigned

Go to Flag 4. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Go to Flag 4. Check for an open circuit. +24 VDC is measured between P294-5 (+) and TP1 (-) at the HVAC PWB. Y N Go to Flag 9. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Press Continue. Greater than +8 VDC is measured between TP5 (+) and TP1 (-) of the HVAC PWB.

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Section Name

9-320

B Y

N Press Stop. Unplug the ribbon cable between the HVDC and the HVAC PWBs. Press Continue. Ignore the displayed fault code. Greater than +8 VDC is measured between TP5 (+) and TP1 (-) of the HVAC PWB. Y N Between +14.15 and +15.85 VDC is measured between TH6 (+) and TH8 (-) of the LVPS. Y N Replace the POS.3 Output A PWB in the LVPS (PL 1.9). Replace the HVAC PWB (PL 1.7). Go to Flag 5. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Press Continue. Greater than +8 VDC is measured between TP4 (+) and TP2 (-) of the HVDC PWB. Y N Replace the Ribbon Cable (PL 9.1). Replace the HVDC PWB (PL 1.7). Press Stop. Enter [dC] [Power Interrupt]. Reconnect the P291 (J6) connector to the HVDC PWB. Disconnect the P/J204 connector by the Dry Ink Bottle. Press Continue. Observe the Dev Rolls 1&2 Bias displays. Press Continue. The Monitor display is within +/- 0.5 of the Control display. Y N Go to Flag 6. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Press Stop. Check the following potential causes of a short circuit: • Go to Flag 7. Check Developer Bias #1 and #2 wires for a short circuit. •

Excessive leakage of developer

•

Chips or cracks in the Developer Housing or the seals

•

Repair or replace the Paddle Wheel, bearings, seals, or Developer Housing as required (PL 9.14).

•

Check the Contact Points for the Developer Zone Roll on the Developer Housing. If the Contact Points are broken or missing, replace the Developer Housing (PL 9.15).

•

Developer Drive Pulley or Drive Coupling failures (PL 9.14).

Section Name

9-320

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Preliminary Working Document No Product Name Assigned

Figure 1 9-320 Circuit Diagram (7912)

Preliminary Working Document No Product Name Assigned

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Section Name

9-320

Figure 2 9-320 Circuit Diagram (7934A)

Section Name

9-320

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Preliminary Working Document No Product Name Assigned

A

B

9-321 RAP Fault Code, 9-321, indicates that the Dev Roll 3 Bias Monitor voltage is less the Dev Roll 3 Bias Control voltage (dC140). The Monitor voltage is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Press Stop. Reconnect P291 at the HVDC PWB. Disconnect P/J204 by the Dry Ink Bottle. Press Continue. Observe the Dev Roll 3 Bias displays. The Dev Roll 3 Bias Monitor is within +/- 0.5 VDC of the Control display. Y N Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Procedure NOTE: This RAP requires that temporary changes be made to the NVM values at certain Address locations. Ensure that a record is made of all NVM values that are being changed prior to the change. Ensure that all values changed during troubleshooting are reset back to their original values prior to completion of the service call.

Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Press Stop. Check the following possible causes: • Go to Flag 4. Check the Developer Roll #3 Bias wire for a short or an open circuit.

Enter dC131 [MIN]. Enter Address 125. Record the current Data value. Subtract 16 from the current Data value. Enter this temporary Data value at Address 125. This temporary value at MIN address 125 disables ROS Faults for diagnostics. Enter dC140, [DC Bias Values]. Open the front doors. Cheat the Printer Interlock Bypass Switch. Measure the Developer Roll 3 voltage between the hex head screw in metal extrusion on the right hand of the Developer Housing and the machine frame. (See the circuit diagram for test point.) Compare the measured voltage to the Dev Roll 3 Bias Required display. Press Continue. NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI Control Panel to clear the faults.

Preliminary Working Document No Product Name Assigned

D Reposition the wire in P202-18. Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Initial Actions

The measured voltage is within +/- 20 VDC of the Required display. Y N Press Stop. Enter [dC] [Power Interrupt]. Disconnect connector P291 (J6) at the HVDC PWB. Press Continue. Enter dC140, [DC Bias Values]. Measure the voltage between J6-6 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is within +/- 20 VDC of the Required display. Y N Press Stop. Enter [dC] [Power Interrupt]. Reconnect the P291 connector. Press Continue. Enter dC140, [DC Bias Values]. Measure the voltage between TS5 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire from P202-18 (J5) of the MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Measure between TS5 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Reposition the wire in P202-18. Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Replace the MIN ADA PWB #2 (PL 1.8). A B C D

C

•

Chips or cracks in the Developer Housing or the Seals, causing excessive leakage of Developer.

•

Repair or replace the Paddle Wheel, Bearings, Seals, or Developer Housing as required (PL 9.14).

•

Check the Developer Housing front two contact points. If either point is damaged or broken, replace the Front Bearing Clamp Assembly (PL 9.15).

•

Check the Developer Housing rear two contact points. If either point is damaged or broken, replace the Developer Housing Assembly (PL 9.14).

•

If all contact points are Ok, go to the Developer Zone Roll Adjustment (ADJ 9-1).

Press Stop. Measure the voltage between TS39 (+) and TS40 (-) of the MIN ADA PWB #2. Press Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is within +/0.5 VDC of the Control display. Y N Press Stop. Measure the voltage between TP801 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe the Dev Roll 3 Bias displays. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire from P201-21 (J6) of the MIN ADA PWB #2. Press Continue. Enter dC140, [DC Bias Values]. Press Continue. Observe dev roll 3 display. Measure the voltage between TP801 (+) and TP2 (-) of the HVDC PWB. The measured voltage is within +/- 0.5 VDC of the Control display. Y N Reposition the wire in P201-21. Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Reposition the wire in P201-21. Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Replace the MIN ADA PWB #2 (PL 1.8). E

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F Section Name

9-321

E

F Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8).

E Enter dC131 [MIN]. Enter address 125. Enter the current Data value recorded for Address 125. Replace the MIN ADA PWB #2 (PL 1.8).

E

Figure 1 9-321 Circuit Diagram (7913E)

Section Name

9-321

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Preliminary Working Document No Product Name Assigned

A

9-322 RAP

Y

Fault Code, 9-322, indicates that the Cleaner Brush Bias Monitor voltage is less than the Cleaner Brush Bias Control voltage (dC140). The Monitor voltage is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

N Go to Flag 3. Check for a short circuit. There is a short circuit in the Cleaner Brush Bias wire. Y N Go to the 9-706 RAP.

Initial Actions

Determine the cause of the short circuit. Repair the circuit.

Check [SCP] Queued Faults and [Last 50] shutdowns. If the fault codes alternate between any of the following; 9-325, 9-326, 9-327, 9-328, and/or 9-329, go to the 9-328 RAP first.

Press Stop. Check the following in order as needed: • Go to Flag 4. Check for a short circuit.

NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Procedure Enter dC140, [DC Bias Values]. Open the Printer Front Doors. Cheat the Printer Interlock Bypass Switch. Measure the voltage between the Cleaner Brush Shaft and the machine frame. Press Continue. NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI Control Panel to clear the faults. The measured voltage is within +/- 20.0 VDC of the Cleaner Brush Bias Required display. Y N Measure the voltage between TP17 (+) and TP1 (-) of the HVAC PWB. Press Continue. The measured voltage is within +/- 0.5 VDC of the Cleaner Brush Bias Control display. Y N Measure the voltage between TS1 (+) and TS56 (-) of the MIN ADA PWB #1. Press Continue. The measured voltage is within +/- 0.5 of the Cleaner Brush Bias Control display. Y N Press Stop. Disconnect the wire from P246-6 (J5-6) of the MIN ADA PWB #1. Measure the voltage between TS1 (+) and TS56 (-) of the MIN ADA PWB 1. Press Continue. The measured voltage is within +/- 0.5 VDC of the Cleaner Brush Bias control display. Y N Reconnect the wire to P246-6 (J5-6) of the MIN ADA PWB #1. Replace the MIN ADA PWB 1 (PL 1.8).

•

Check for a short in the Cleaner Assembly.

•

Check the Tension Roll/Springs for proper actuation.

•

Adjust the Photoreceptor Tension (ADJ 9-11).

Measure the voltage between TP18 (+) to TP1 (-) of the HVAC PWB. Press Continue. The voltage is within +/- 0.5 of the Cleaner Brush Bias Control display. Y N Press Stop. Disconnect the wire from P242-13 (J6) of the MIN ADA PWB 1. Measure the voltage between TP18 (+) and TP1 (-) of the HVAC PWB. Press Continue. The voltage is within +/- 0.5 of the Cleaner Brush Bias Control display. Y N Reconnect the wire to P242-13 (J6) of the MIN ADA PWB 1. Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Reconnect the wire to P242-13 (J6) of the MIN ADA PWB 1. Replace the MIN ADA PWB #1 (PL 1.8). Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #1 (PL 1.8).

Enter [dC] [Power Interrupt]. Reconnect the wire to P246-6 (J5-6) of the MIN ADA PWB #1. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Enter [dC] [Power Interrupt]. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Press Stop. Disconnect the Cleaner Brush Bias Wire P290-1 at the Cleaner Assembly. Press Continue. The Cleaner Brush Bias Monitor display is within +/- 0.5 of Cleaner Brush Bias Control display. A Preliminary Working Document No Product Name Assigned

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Section Name

9-322

Figure 1 9-322 Circuit Diagram (709005)

Section Name

9-322

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Preliminary Working Document No Product Name Assigned

A

9-323 RAP

Y

Fault Code, 9-323, indicates that the (Upper Detoning Roll) UDTR Bias Monitor voltage is less than the UDTR Bias Control voltage. The Monitor voltage is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

N Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).

Go to Flag 4. Check for a short circuit. If the circuit is OK, check for a short in the Cleaner Assembly.

Initial Actions Check [SCP] Queued Faults following the shutdown. If a combination of 9-325, 9-326, 9-327, 9-328,and/or 9-329 fault codes is indicated and this RAP does not repair the problem, go to the 9-328 RAP. NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Measure the voltage between TS30 (+) and TS31 (-) of the MIN ADA PWB #1. Press Continue. The voltage is within +/- 0.5 VDC of the UDTR Bias Control display. Y N Press Stop. Disconnect the wire from P242-9 (J6) of the MIN ADA PWB #1. Measure the voltage between TS30 (+) and TS31 (-) of the MIN ADA PWB #1. Press Continue. The voltage is within +/- 0.5 VDC of the UDTR Bias Control display. Y N Reconnect the wire to P242-9 (J6) of the MIN ADA PWB #1. Replace the MIN ADA PWB #1 (PL 1.8).

Procedure Enter dC140, [DC Bias Values]. Measure between the Upper Detoning Roll and the Cleaner Brush. Press the Continue button.

Reconnect the wire to P242-9 (J6) of the MIN ADA PWB #1. Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).

NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the IOT Control Panel to clear the faults.

Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #1 (PL 1.8).

The measured voltage is within +/- 20 VDC of the UDTR Bias Required display. Y N Press Stop. Measure the voltage between TP19 (+) and TP-1 (-) of the HVAC PWB. Press Continue. The measured voltage is within +/- 0.5 VDC of the UDTR Bias Control display. Y N Press Stop. Measure the voltage between TS4 (+) and TS56 (-) of the MIN ADA PWB #1. Press the Continue button. The measured voltage is within +/- 0.5 VDC of the UDTR Bias Control display. Y N Press Stop. Disconnect the wire from P246-8 (J5) of the MIN ADA PWB #1. Measure the voltage from TS4 (+) to TS56 (-) of the MIN ADA PWB #1. Press Continue. The measured voltage is within +/- 0.5 VDC of the UDTR Bias Control display. Y N Reconnect the wire to P246-8 (J5) of the MIN ADA PWB #1. Replace the MIN ADA PWB #1 (PL 1.8). Reconnect the wire to P246-8 (J5) of the MIN ADA PWB #1. Enter [dC] [Power Interrupt]. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Enter [dC] [Power Interrupt]. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Press Stop. Enter [dC] [Power Interrupt]. Disconnect the wire at P290-3. Press Continue. Enter [dC140], [DC Bias Values]. Press Continue. Observe the UDTR Bias displays. The Monitor is within +/- 0.5 of the Control display. A Preliminary Working Document No Product Name Assigned

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Section Name

9-323

Figure 1 9-323 Circuit Diagram (709006)

Section Name

9-323

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Preliminary Working Document No Product Name Assigned

9-324 RAP Fault Code, 9-324, indicates that the (Lower Detoning Roll) LDTR Bias Monitor voltage is less than the LDTR Bias Control voltage. The Monitor is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

Initial Actions NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Procedure Enter dC140, [DC Bias Values]. Cheat the Printer Interlock Bypass Switch. Measure between P290-2 (+) and P290-3 (-) of the Cleaner Assembly. Press Continue.

A Measure the voltage between TP16 (+) and TP1 (-) of the HVAC PWB. Press Continue. The measured voltage is within +/- 0.5 VDC of the LDTR Bias Control display value. Y N Press Stop. Disconnect the wire from the P242-11 (J6) of the MIN ADA PWB #1. Measure between TP16 (+) and TP1 (-) of the HVAC PWB. Press Continue. The voltage is within +/- 0.5 VDC of the LDTR Bias Control display value. Y N Reconnect the wire to P242-11 (J6) of the MIN ADA PWB #1. Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Reconnect the wire to P242-11 (J6) of the MIN ADA PWB #1. Replace the MIN ADA PWB #1 (PL 1.8). Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #1 (PL 1.8).

NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the IOT Control Panel to clear the faults. The measured voltage is within +/- 20 VDC of the LDTR Bias Required display. Y N Measure the voltage between TP15 (+) and TP1 (-) of the HVAC PWB. Press Continue. The measured voltage is within +/- 0.5 VDC of the LDTR Bias Control display value. Y N Measure the voltage between TS3 (+) and TS56 (-) of the MIN ADA PWB #1. Press Continue. The measured voltage is within +/- 0.5 of the LDTR Bias Control display value. Y N Press Stop. Disconnect the wire P246-4 (J5) of the MIN ADA PWB #1. Measure between TS3 (+) and TS56 (-) of the MIN ADA PWB #1. Press Continue. The measured voltage is within +/- 0.5 VDC of the LDTR Bias Control display value. Y N Reconnect the wire to P246-4 (J5) of the MIN ADA PWB #1. Replace the MIN ADA PWB #1 (PL 1.8). Reconnect the wire to P246-4 (J5) of the MIN ADA PWB #1. Enter [dC] [Power Interrupt]. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Enter [dC] [Power Interrupt]. Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Press Stop. Disconnect the LDTR Bias wire from P290-2. Press Continue. The LDTR Bias Monitor display is within +/- 0.5 of the LDTR Bias Control display value. Y N Reconnect the LDTR Bias wire to P290-2. Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Reconnect the LDTR Bias wire to P290-2. Go to Flag 4. Check for a short circuit in the wire and the Cleaner Assembly. A Preliminary Working Document No Product Name Assigned

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Section Name

9-324

Figure 1 9-324 Circuit Diagram (709007)

Section Name

9-324

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Preliminary Working Document No Product Name Assigned

9-325 RAP

Y

Fault Code, 9-325, indicates that the Chg2 SV Monitor voltage is less than the Chg2 Shld Voltage Control Point V (dC140). The Monitor is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

Initial Actions Check [SCP] Queued Faults following the shutdown. If the Fault Codes include any combination of the following; 9-325, 9-326, 9-327, 9-328, and/or 9-329, go to the 9-328 RAP first. NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures). Inspect for opens, loose connections, contamination, arcing, and discoloration of the following: •

Dicorotrons and connectors (PL 9.10).

•

Ozac System and connectors (PL 9.8).

•

HVDC Cables (PL 1.7).

N Press Stop. Disconnect the wire at P201-9 (J6) of the MIN ADA PWB #2. Press Continue. Greater than 0 VDC is measured between TS30 (+) and TS31 (-) of the MIN ADA PWB #2. Y N Reconnect the wire to P201-9 of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8). Reconnect the wire to P201-9 of the MIN ADA PWB #2. Go to Flag 1 and Flag 3. Check for a short circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).

Observe the Chg2 Shld Voltage displays. The Charge 1 SV Monitor is greater than 0. Y N Go to Flag 4. Check for a short in the Charge 1 Shield Bias. Observe the Chg2 Shld Current displays. The Charge 2 SI Monitor is less than 10. Y N Clean or replace all of the Charge Dicorotrons and Shields (PL 9.10). Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8).

Procedure Enter dC140, [Dicorotron Values]. Cheat the Printer Interlock Bypass Switch. Press Continue. Observe the Coronode ACV displays. NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the IOT Control Panel to clear the faults. The ACV Monitor display is within +/- 0.5 of the Control Point V. Y N Go to the 9-329 RAP. Press Continue. Greater than 0 VDC is measured between TS12 (+) and TS56 (-) of the MIN ADA PWB #2. Y N Press Stop. Disconnect the wire at P202-22 (J5) of the MIN ADA PWB #2. Press Continue. Greater than 0 VDC is measured between TS12 (+) and TS56 (-) of the MIN ADA PWB #2. Y N Reconnect the wire to P202-22 (J5) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8). Reconnect the wire to P202-22 (J5) of the MIN ADA PWB #2. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Press Continue. Greater than 0 VDC is measured between TP201 (+) and TP2 (-) of the HVDC PWB. Y N Go to Flag 2. Check for an open circuit. Press Continue. Greater than 0 VDC is measured between TS30 (+) and TS31 (-) of MIN ADA #2.

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Section Name

9-325

Figure 1 9-325 Circuit Diagram (709008)

Section Name

9-325

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Preliminary Working Document No Product Name Assigned

A

9-326 RAP

B Y

Fault Code, 9-326; indicates that the Tran SI Monitor voltage is less than the Tran Shld Current Control Point V (dC140). The Monitor is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

N Reconnect the wire at P202-20 (J5) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8).

Reconnect the wire at P202-20 (J5) of the MIN ADA PWB #2. Go to Flag 2. Check for an open or short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Initial Actions Measure between TP303 (+) and TP2 (-) of the HVDC PWB. Observe the Tran Shld Current displays. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P201-25 (J6) of the MIN ADA PWB #2. Measure between TP303 (+) and TP2 (-) of the HVDC PWB. Observe the Tran Shld Current displays. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Reconnect the wire at P201-25 (J6) of the MIN ADA PWB #2. Go to Flag 1 and 3. Check for a short or an open circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).

Check [SCP] Queued Faults following the shutdown. If combinations of 9-325, 9-326, 9-327, 9-328, and/or 9-329 codes are indicated, go to the 9-328 RAP first. NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Procedure Enter dC140, [Dicorotron Values]. Press Continue. Observe the Coronode ACV displays. NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the Printer UI Control Panel to clear faults.

Reconnect the wire at P201-25 (J6) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8).

The ACV Monitor is within +/- 0.5 of the Control Point V. Y N Go the 9-329 RAP. Press Stop. Open the Printer Front Doors. Bypass the Processor Interlocks. Press Continue. The Transfer Dicorotron glows. Y N Press Stop. Remove the Transfer Dicorotron. Install the Preclean Dicorotron in the Transfer position. Press Continue. The new Transfer Dicorotron glows. Y N (HVAC problem). Install the Preclean Dicorotron into it's original position. Inspect for open or loose connection of the Transfer Dicorotron coronode wire. Inspect the following for contamination, arcing, and discoloration: • All Dicorotrons and connectors (PL 9.10). •

Ozac System and connectors (PL 9.8).

•

HVDC Cables (PL 1.7).

Go to Flag 1. Check for an open circuit. Go to Flag 3. Check for an open or a short circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8). Replace the Transfer Dicorotron (PL 9.11).

Install the Preclean Dicorotron into its original position. Replace the Transfer Dicorotron (PL 9.10). A hot spot or arc is observed. Y N Measure between TP301 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe the Tran Shld Current displays. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P202-20 (J5) of the MIN ADA PWB #2. Measure between TS7 (+) and TS56 (-) of the MIN ADA PWB #2. Observe the Tran Shld Current displays. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. A

B

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Section Name

9-326

Figure 1 9-326 Circuit Diagram (709009)

Section Name

9-326

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Preliminary Working Document No Product Name Assigned

A

B

9-327 RAP

Y

Fault Code, 9-327; indicates that the Dtac SI Monitor voltage is less than the Dtac Shld Current Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive samples or 75% less for five consecutive samples.

Go to Flag 2. Check for an open or a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Initial Actions

N Replace the MIN ADA PWB #2 (PL 1.8).

Measure between TP602 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P201-23 (J6) of the MIN ADA PWB #2. Measure between TP602 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Control Point V. Y N Go to Flag 1. Check for a short circuit. Go to Flag 3. Check for an open or a short circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).

Check [SCP] Queued Faults following the shutdown. If combinations of 9-325, 9-326, 9-327, 9-328, and/or 9-329 codes are indicated, go to the 9-328 RAP first. NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Procedure Enter dC140, [Dicorotron Values]. Press Continue. Observe the Coronode ACV displays. NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the Printer UI Control Panel to clear the faults.

Replace the MIN ADA PWB #2 (PL 1.8). Go to Flag 1. Check for an open circuit. Go to Flag 3. Check for an open or a short circuit. If the circuits are OK, replace the MIN ADA PWB #2 (PL 1.8).

The ACV Monitor is within +/- 0.5 of the Control Point V. Y N Go to the 9-329 RAP.

Replace the Detack Dicorotron (PL 9.11).

Press Stop. Open the Printer Front Doors. Cheat the Printer Interlock Bypass Switch. Press Continue. The Detack Dicorotron glows. Y N Press Stop. Remove the Detack Dicorotron. Install the Preclean Dicorotron into the Detack position. Press Continue. The new Detack Dicorotron glows. Y N (HVAC problem). Install the Preclean Dicorotron into its original position. Inspect for an open or a loose connection of the Detack Dicorotron Coronode wire. Inspect the following for contamination, arcing, and discoloration: • All Dicorotrons and connectors (PL 9.10). •

Ozac System and connectors (PL 9.8).

•

HVDC Cables (PL 1.7).

Install the Preclean Dicorotron into its original position. Replace the Detack Dicorotron (PL 9.11). A hot spot or arc is observed. Y N Measure between TP601 (+) and TP2 (-) of the HVDC PWB. Press Continue. Observe the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P202-12 (J5) of the MIN ADA PWB #2. Measure between TS9 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. Observe the Dtac Shld Current displays. The measured voltage is within +/- 0.5 of the Control Point V. A

B

Preliminary Working Document No Product Name Assigned

0/0/00 ?-751

Section Name

9-327

Figure 1 9-327 Circuit Diagram (709010)

Section Name

9-327

0/0/00 ?-752

Preliminary Working Document No Product Name Assigned

A

B

9-328 RAP

Y

Fault Code, 9-328, indicates that the Pcln SI Monitor voltage is less than the Pcln Shld Current Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

Go to Flag 3. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).

Initial Actions Enter [dC] [Power Interrupt]. Reseat the HVDC PWB and HVAC PWB. Thoroughly inspect the following for open or loose connections, contamination, arcing, and discoloration: •

Dicorotrons and connectors (PL 9.10).

•

Ozac System/connectors (PL 9.8).

•

HVDC Cables (PL 1.7).

NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Procedure

Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Enter dC140, [Dicorotron Values]. Press Continue. Observe the Coronode ACV displays. The ACV Monitor is within +/- 0.7 of the Control Point V. Y N Go to the 9-329 RAP. The Preclean Dicorotron glows. Y N Other Dicorotrons glow. Y N Check the Ozac Twist-Lock Connector P2. If the connector is OK, replace the HVAC Output Module (PL 1.7).

+24 VDC is measured between P294-1 (+) and TP1 (-) of the HVAC PWB. Y N +24 VDC is measured between TH13 (+) and TH8 (-) on the LVPS. Y N Go to the 1-717, +24, +34, -34 VDC RAP.

Press Stop. Install the Transfer Dicorotron into the Preclean position. Press Continue. The new Preclean Dicorotron glows. Y N Replace the Ozac System (PL 9.8). Return the Transfer Dicorotron to its original position. Replace the Preclean Dicorotron (PL 9.11).

Go to the wire, 1021, wirenet. Check for an open circuit. Enter dC140, [Dicorotron Values]. Measure between TP3 (+) and TP2 (-) of the HVDC PWB (15 VDC in standby). Press Continue. NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI Control Panel to clear the faults. 3.0 +/- 0.5 VDC is measured between TP3 (+) and TP2 (-) of the HVDC PWB. Y N Press Continue. Less than 1.0 VDC is measured between TP12 (+) and TP1 (-) of the HVAC PWB. Y N Press Continue. 14 to 26 VAC is measured between TP10 (+) and TP1 (-) of the HVAC PWB. Y N Go to Flag 4. Check for an open circuit. If the circuit is OK, replace the HVAC Output Module (PL 1.7). Replace the HVAC PWB (PL 1.7). Press Continue. +15 VDC is measured between TP3 (+) and TP2 (-) of the HVDC PWB. Y N Unplug the Ribbon Cable Between the HVDC and the HVAC PWBs. +15 VDC is measured between TP3 (+) and TP2 (-) of the HVDC PWB. A

B

Preliminary Working Document No Product Name Assigned

N Replace the HVDC PWB (PL 1.7).

There is a normal even glow without arcing or hot spots. Y N Arcing observed, replace the Preclean Dicorotron (PL 9.10). Observe the Pcln Shld Current display. The Pcln SI Monitor display is within +/- 0.5 of the Control Point V. Y N The Pcln SV Monitor is greater than 2.0. Y N Measure between TS15 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P202-24 (J5) of the MIN ADA PWB #2. Measure between TS15 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Reconnect the wire at P202-24 (J5) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8). Reconnect the wire at P202-24 (J5) of the MIN ADA PWB #2. Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

C 0/0/00 ?-753

D

E Section Name

9-328

C

D

E Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

Measure between TP403 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is within +/- 0.5 of the Pcln Control Point V. Y N Press Stop. Disconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Measure between TP403 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is within +/- 0.5 of the Pcln Control Point V. Y N The Pcln SI Monitor is greater than 0 VDC. Y N Reconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Go to Flag 1 and Flag 5. Check for a short circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7). Reconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Replace the Preclean Dicorotron and Shield (PL 9.10). Reconnect the wire at P201-5 (J6) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8). Go to Flag 1 and Flag 5. Check for an open circuit. If the circuits are OK, replace the MIN ADA PWB #2 (PL 1.8). Go to Flag 1 and Flag 5. Check for a short circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).

Section Name

9-328

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Preliminary Working Document No Product Name Assigned

Figure 1 9-328 Circuit Diagram (709011)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-755

Section Name

9-328

A

9-329 RAP Fault Code, 9-329, indicates that the Coronode ACV Monitor voltage is less than the Coronode ACV Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive samples, or 75% less for five consecutive samples.

Initial Actions Check [SCP] Queued Faults following the shutdowns. If combinations of 9-325, 9-326, 9-327, 9-328, and/or 9-329 fault codes are indicated, go to the 9-328 RAP first. NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

B

C Enter [dC] [Power Interrupt]. Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).

Replace the HVAC PWB (PL 1.7). Measure the voltage between TS27 (+) and TS28 (-) of the MIN ADA PWB #1. Press Continue. The voltage is within +/- 0.5 VDC of the Coronode ACV Control Point V. Y N Go to Flag 4. Check for an open circuit. Replace the MIN ADA PWB #1 (PL 1.8).

Ensure that all connectors on the HVAC PWB and MIN ADA PWB #1 are secure. Inspect for opens, loose connections, contamination, arcing, and discoloration of the following: •

Dicorotrons and connectors (PL 9.10).

•

Ozac System and connectors (PL 9.8).

•

HVDC Cables (PL 1.7).

Procedure Enter dC140, [Dicorotron Values]. Measure the voltage between TP13 (+) and TP1 (-) of the HVAC PWB. Press Continue. Observe the Coronode ACV displays. NOTE: dC140 will not operate with a fault queued. Press the R (reset) button on the Printer UI Control Panel to clear the fault. The measured voltage is within +/- 0.5 VDC of the Control Point V. Y N Measure the voltage between TP11 (+) and TP1 (-) of the HVAC PWB. Press Continue. The measured voltage is within +/- 0.5 VDC of the Coronode ACV Control Point V. Y N Measure the voltage between TS2 (+) and TS56 (-) of the MIN ADA PWB #1. Press Continue. The measured voltage is within +/- 0.5 VDC of the Coronode ACV Control Point V. Y N Press Stop. Disconnect the wire from P246-2 (J5) of the MIN ADA PWB #1. Measure the voltage between TS2 (+) and TS56 (-) of the MIN ADA PWB #1. Press Continue. The measured voltage is within +/ - 0.5 VDC of the Coronode ACV Control Point V. Y N Reconnect the wire to P246-2 (J5) of the MIN ADA PWB #1. Replace the MIN ADA PWB #1 (PL 1.8). Reconnect the wire to P246-2 (J5) of the MIN ADA PWB #1. Enter [dC] [Power Interrupt]. Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).

A

B

C

Section Name

9-329

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Preliminary Working Document No Product Name Assigned

Figure 1 9-329 Circuit Diagram (7921E)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-757

Section Name

9-329

A

B

9-330 RAP Fault Code, 9-330, indicates that the Chg2 SI Monitor voltage is less than the Chg2 Shld Current Control Point V (dC140). The Monitor voltage is either 50% less for two consecutive samples or 75% less for five consecutive samples. The fault is not declared unless the Chg2 Current Control Point V is greater than 0.4 VDC.

Initial Actions Check [SCP] Queued Faults following the shutdown. If combinations of 9-325, 9-326, 9-327, 9-328, and/or 9-329 faults are indicated, go to the 9-328 RAP first.

Reconnect the wire at P201-7 (J6) of the MIN ADA PWB #2. Replace the MIN ADA PWB #2 (PL 1.8).

NOTE: Enter [SCP] [Last 50] shutdowns. If 09-201, 09-203, 09-213, 09-215,or other 09-3xx faults are listed with 03-xxx or 06-xxx faults as "pairs" at the same print count, and if this RAP does not fix the problem or electrical noise is suspected, go to the Non-Repeatable Problem Entry Procedure (Service Call Procedures).

Go to Flag 1. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8).

Inspect for open circuits, loose connections, contamination, arcing, and discoloration of the following: •

Dicorotrons and connectors (PL 9.10).

•

Ozac System and connectors (PL 9.8).

•

HVDC Cables (PL 1.7).

C Measure the voltage between TP204 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P201-7 (J6) of the MIN ADA PWB #2. Measure the voltage between TP204 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Go to Flag 1. Check for a short circuit. Go to Flag 3. Check for an open circuit. If the circuits are OK, replace the HVDC PWB (PL 1.7).

Press Stop. Check the following: • Go to Flag 2. Check for an open or short circuit. •

Go to Flag 1. Check for a short circuit.

•

If both checks are OK, replace the MIN ADA PWB #2 (PL 1.8).

Press Stop. Enter dC140. Do not press Continue.

Perform the Charge Dicorotron Balance (ADJ 9-6) and Height (ADJ 9-7) adjustments.

NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the IOT Control Panel to clear the faults.

Procedure Enter dC909, [Printer Options], [Test Patterns and PQ], [Lighter 1], [Patch Test]. Program a 500 print job. Press Continue. Observe the Control Values displays. Run a few prints until the Charge 2 ua and the Dark Decay V stabilizes. The Charge 2 ua display is greater than 50. Y N Press Stop. Enter dC140. Press Continue. Observe the Chg2 Shld Current displays.

The Chg2 Shld Current Control Point V is 0. Y N The Chg2 Shld Current Control Point V is not=0, go to the 9-203, 9-213 RAP. The Chg2 Shld Current Control Point V is=0, go to the Printer Electrical Noise Procedure NRD 3 (Service Call Procedures).

NOTE: dC140 will not operate with a queued fault. Press the R (reset) button on the IOT Control Panel to clear the faults. The Chg2 SI Monitor is 0.0 +/- 0.1. Y N Press Stop. Measure the voltage between TP202 (+) and TP2 (-) of the HVDC PWB. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Press Stop. Disconnect the wire at P202-16 (J5) of the MIN ADA PWB #2. Measure the voltage between TS14 (+) and TS56 (-) of the MIN ADA PWB #2. Press Continue. The measured voltage is within +/- 0.5 of the Control Point V. Y N Replace the MIN ADA PWB #2 (PL 1.8). Go to Flag 2. Check for an open or a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). A

B

C

Section Name

9-330

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Preliminary Working Document No Product Name Assigned

Figure 1 9-330 Circuit Diagram (709012)

Preliminary Working Document No Product Name Assigned

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Section Name

9-330

9-332 RAP

9-353 RAP

Fault code, 9-332, indicates a failure to complete Cycle Up Convergence after power up.

Fault Code, 9-353, indicates that the control logic sensed a failure to converge contrast potentials during dC951 Setup.

Procedure Initial Actions CAUTION •

Ensure that the Cleaner Zone Roll is engaged.

•

Check the PR Ground Strip for damage.

•

Check the Ground brush for contamination, deformation, or loss of fibers. Replace as required (PL 9.7).

The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. If the belt module will be exposed to light for longer than two minutes, remove the photoreceptor from the belt module and place it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module.

•

Check the ESV Height Adjustment (ADJ 9-12).

•

Ensure that the Cleaner Zone Roll is engaged.

•

Check the Charge Dicorotron Height (ADJ 9-6) and Charge Dicorotron Balance (ADJ 97).

•

Check ROS Low Correction Factor (ADJ 6-3).

•

Enter dC107, [Xero]. Check the P/R Belt life. If greater than threshold, replace the Photoreceptor Belt.

•

Check the ESV Monitor voltage in dC909 ESV/DSS Test for 1.0 +/- 0.2 Volts.

•

Perform the Xerographic Set-up (ADJ 9-3). If the fault continues, go to the PQ 9-633, PR Uniformity RAP.

Procedure WARNING Laser Radiation. Avoid direct exposure to the beam. Cover the Photoreceptor Belt, under the ROS Assembly, inboard to outboard with white paper. Cheat the Printer Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press Continue. Observe the scan line on the paper. There is a continuous scan line across the paper. Y N Go to the 6-701 RAP. NOTE: Scan line observations are easily made using the Remote Hand Held Device (RHHD). For detailed Operating Instructions of the RHHD, go to (GP 1). The scan line is of equal brilliance across the entire length of paper. Y N Go to the 6-701 RAP. Keep [Laser Write] energized. Select [Patch Exposure]. The inboard half of the beam should become dimmer than the outboard. Press Continue. NOTE: Toggle the output on/off several times while observing the scan line if you are unsure of the above check. The scan line is dimmer on the inboard side. Y N Go to the 6-701 RAP. Press Stop. Remove the paper from the Photoreceptor Belt. Close the Printer Front Doors. Select [Laser Write]. Press Continue. +5 VDC is measured between TH4 (+) and TH15 (-) on the ROS Distribution PWB. Y N Go to the 6-701 RAP.

CAUTION

ing operation.

Ensure that all paper is removed from under the ROS Assembly to avoid Printer damage dur-

+5 VDC is measured between TS30 (+) and TSPWR GND (-) on the RCM PWB. A

Section Name

9-332, 9-353

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A Y

N Go to the 6-701 RAP.

Go to PQ 9-633, PR Uniformity RAP. Return to this RAP after completing the PQ 9-633 procedure. Adjust the ROS Low Correction Factor (ADJ 6-3). Perform the Xerographic Setup (ADJ 9-3). If the problem continues, the ROS assembly may have been miscalibrated for the ROS Patch Exposure setup. There is no field adjustment for the ROS Patch Exposure, replace the ROS Assembly (PL 6.1), adjust the ROS Low Correction Factor (ADJ 6-3) and perform the Xerographic Setup (ADJ 9-3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-761

Section Name

9-353

Figure 1 9-353 Circuit Diagram (7929B)

9-354 RAP Section Name

9-353

Fault Code, 9-354, indicates that the control logic sensed a failure to set toner concentration during the dC951 Automatic Xerographic Setup. 0/0/00 ?-762

Preliminary Working Document No Product Name Assigned

A

Initial Actions

NOTE: The correlation between DSS readings and output density is as follows: The DSS reading range is 234 +/- 14. The higher the reading the lighter the density should be. Example: If the DSS reading is 248 the patch density should be about STD/LT:UM. If the DSS reading is 220 the patch density should be about STD:Restore.

CAUTION The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. If the belt module will be exposed to light for longer than two minutes, remove the photoreceptor from the belt module and place it immediately into the protective photoreceptor bag. or place the bag over the Photoreceptor with it on the belt module. •

Ensure that the Photoreceptor area is clean and that all the covers and inner panels are in place.

•

Check the DSS Timing (ADJ 9-14).

•

Check the DSS Timing (ADJ 9-14).

•

Enter dC1311, MIN NVM. Ensure that locations 220=51, 251=101 and 125=252.

•

Enter dC105. Ensure the Precision Patch is Enabled.

The correlation between output density and DSS reading is correct. Y N Perform the DSS Timing (ADJ 9-14), then repeat the output density correlation check. If no correlation is seen, replace the DSS (PL 9.7). The Patch is 17.5 mm wide in the process direction, and is 20 to 25 mm high, centered top-to-bottom, on a 14 inch sheet of paper. Y N Go to PQ 9-621, Patch Gen/Patch Integrity RAP.

Procedure Enter dC131 [MIN]. Select Address 348 (TC detone). Enter the Data value listed in the appropriate level Software dC 131 Table in General Procedures. Enter dC951. Select [TC/PGen]. Press Continue. A 9-354 fault is declared. Y N If another fault presents continued problems go to the RAP for that fault code. If the Xerographic Setup was successfully completed, exit this procedure.

Go to the 9-215 RAP. The DSS has been calibrated with a dirty belt. Go to PQ 9-617, Cleaner RAP.

Pull out the Xerographic Drawer. Raise the Photoreceptor Module. Select [Precharge/Prexfr Lamps]. Press Continue. Examine the lamps closely. All segments of both lamps are lit. Y N If some, but not all of the segments, of a lamp are lit, replace that lamp (PL 9.4). If an entire lamp does not light, go to PQ 9-624, Precharge/Pretransfer Lamps RAP. Select [TC/Patch Gen]. Press Continue. When the Setting Toner Concentration screen appears, observe the Average DSS display. The Average DSS Current Reading is greater than the DSS Target Reading. (The Printer thinks the patch is too light). Y N Press Stop. Enter dC909. Select [Print Patch] (Yes). Press Continue. Compare the patch density to the STD:Restore on the XTP 564.001 (82E4161). The patches are darker than STD:Restore. Y N Replace the DSS (PL 9.7). Go to the 9-215 RAP. Enter dC951, [Initialize]. Press Continue. Hardstop the printer as soon as a DSS reading is displayed, about 10 seconds after the Continue button is pressed. Slide out the PR Module and inspect the PR Belt. Toner is present on the PR Belt before and after the Cleaner. Y N Enter dC909. Select [Patch Test], [Patch Print (Yes). Press Continue. Observe the DSS readings during operation.

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Section Name

9-354

Figure 1 9-354 Circuit Diagram (7935)

Section Name

9-354

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A

9-355 RAP

Y

Fault Code, 9-355, indicates that the control logic sensed a failure to set the Patch Generator during the dC951 Automatic Xerographic setup.

Measure between TS53 (+) and TS37 (-) of the MIN DIO PWB. Select [Patch Gen High]. Press Continue.

Initial Actions

NOTE: When [Patch Gen High] is energized in dC330, [9]. The signal is pulsed as a square wave. Use Peak Hold (-) to measure the low pulse as required. The DMM Peak Hold Procedure is located at the end of this RAP.

•

Ensure that the Cleaner Zone Roll is engaged.

•

Ensure that all covers and inner panels are in place.

•

Check the Patch Generator Timing (ADJ 9-5).

•

Enter dC105. Ensure that the Digital Patch Generator is Enabled.

The voltage pulses between 5 VDC and 0 VDC. Y N Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8).

Procedure CAUTION DO NOT install an analog Patch Generator into a 4180 machine, damage to the MIN DIO PWB will result. 4180 machines use a digital Patch Generator.

Measure between TS8 (+) and TS20 (-) of the MIB PWB. The voltage pulses between 5 VDC and 0 VDC. Y N Go to Flag 1. Check for an open circuit.

CAUTION The Photoreceptor is extremely sensitive to light. Limit the Photoreceptor exposure to light to under two (2) minutes. Also, DO NOT leave the Patch Generator energized for longer than two minutes. Severe xerographic problems may result. If the belt module will be exposed to light for longer than two minutes, remove the photoreceptor from the belt module and place it immediately into the protective photoreceptor bag or place the bag over the Photoreceptor with it on the belt module. Cheat the Printer Interlock Bypass Switch. Pull out the Xerographic Drawer. Raise the Photoreceptor Module. Enter dC330, [9]. Select [Precharge/Prexfr Lamps]. Press Continue. Observe the Precharge and the Pretransfer Lamps. All segments of each lamp are lit. Y N If some, but not all of the segments, of a lamp are lit, replace that lamp (PL 9.3). If an entire lamp does not light, go to PQ 9-624, Precharge/Pretransfer Lamps RAP. Press Stop. Enter dC131 [MIN]. Ensure that the following MIN NVM Addresses are at the values as listed in the appropriate level Software dC 131 Table in General Procedures. Change the data as required. Table 1 Address

Current Value

Description

135

PGen Increment

250

PGen Intercept

254

PGen Normal

Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the Patch Generator (PL 9.10). All 4 LEDs are lit. Y N Replace the Patch Generator (PL 9.10). Close the Xerographic Drawer. Cheat the Printer Interlock Bypass Switch. Observe the Patch Generator during operation. Enter dC606, [Printer Options]. Program a 25 print job. Press Continue. The Patch Generator LED's flash on and off during printer operation. Y N Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the MIN ADA PWB #2 (PL 1.8).

NOTE: When [Patch Gen High] is energized in dC330, [9]. The signal is pulsed as a square wave. Use Peak Hold (-) to measure the low pulse as required. The DMM Peak Hold Procedure is located at the end of this RAP.

Select [Patch Gen High]. Use a mirror to observe the Patch Generator light. Press Continue. At least one LED is lit. Y N Press Stop. +5 VDC is measured between P240-2 (+) and P240-4 (-) of the Patch Generator connector. A No Product Name Assigned

Measure between TS13 (+) and TS20 (-) of the MIB PWB. The voltage pulses between 2.5 VDC and 0 VDC. Y N Replace the MIB PWB (PL 1.8).

Enter dC330, [9], [Patch Gen High]. Measure the voltage between TS32 (+) and TS37 (-) of the MIN DIO PWB. Press Continue.

Enter dC951. Select [TC/Patch Gen]. Press Continue. A 9-355 fault is declared. Y N The Xerographic Setup was successfully completed. Exit this procedure.

Preliminary Working Document

N Go to Flag 4. Check for an open circuit.

The voltage pulses between 5 VDC and 0 VDC. Y N Go to Flag 5. Check for an open or a short circuit. If the circuit is OK, replace the Patch Generator (PL 9.10).

B

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Section Name

9-355

B Enter dC606, [Printer Options], [Test Patterns and PQ]. Using Peak Hold (+), measure between TS2 (+) and TS56 (-) of the MIN ADA PWB #2 for each Print Darkness measurement. Press Continue. NOTE: The measured voltage may vary from the voltage listed below, but the relative voltage from mode to mode should change as shown: •

+1.8 VDC is measured in [Normal]

The voltages are OK. Y N Replace the MIN ADA PWB #2 (PL 1.8). After the Initialization Screen is completed and the Toner Concentration Setup is operating, observe the Average DSS displays. After 10 updates, press Stop. NOTE: There should not be greater than +/- 5 bits variation in readings from one update to another. The Readings are consistent. Y N Go to PQ 9-630, Toner/Charge Control RAP and PQ 9-633, PR Uniformity RAP as required. Replace the MIN DIO PWB (PL 1.8). DMM Peak Hold Procedure: • Select V or mA as required. •

Select AC or DC and range as required.

•

Place Meter Probes in the Volt-Ohm (+) and the COM (-) Jacks

•

Press (+) or (-) polarity.

NOTE: To measure for negative peaks on a positive voltage, first select (+) peak polarity, press the Peak Hold button then switch polarity to (-) peak polarity. For further information, go to the DMM operators Manual. •

To make a new measurement, release the Peak Hold button to clear previous reading and repeat procedure.

Section Name

9-355

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Figure 1 9-355 Circuit Diagram (709002)

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Section Name

9-355

9-356 RAP

9-360 RAP

The Fault Code 9-356 indicates a failure to converge charge in toner concentration setup during dC951.

The Fault Code 9-360 indicates that the ROS Low Correction Factor adjustment failed to converge in dC951.

Initial Actions

Procedure WARNING

Check the following components: •

Cleaner Zone Roll for proper engagement

•

PR Belt Ground Strip for damage

•

Ground Brush for contamination and/or damage

•

ESM Timing, dC951 MIN location 260=40

•

ROS Patch Exposure, dC330. If not OK, go to the 9-360 RAP

Avoid direct exposure to the beam. Laser Radiation is present. Cover the Photoreceptor, under the ROS Assembly, outboard to inboard with white paper. Cheat the Processor Interlock Bypass Switch. Enter dC330, [6]. Select [Laser Write]. Press the Continue button. Observe the scanline on the paper. (The scanline should not be missing in the middle of the PR Belt area). There is a full scanline across the paper. Y N Go to the 6-701 RAP.

Procedure Enter dC909. Select [Charge Control], [Open]. Press the Continue button. Check the ESV readings for stability after 40 prints. The readings for ID Zones 2, 4, and 6 are within +/-25 VDC of themselves. Y N Select [Stop]. Check the Charge Dicorotrons for arcing. Clean the shields and reseat the Dicorotrons. If the problem is still present, go to PQ 9-619, ESV RAP.

NOTE: If you are not sure, continue with the [Yes] path.

Go to PQ 9-624, Precharge/Pretransfer Erase Lamps RAP. If the PQ 9-624 RAP is OK, go to PQ 9-617, Cleaner RAP.

With [Laser Write] on, select [Patch Enable]. Press the Continue button. The scanline is completely off in the patch area (approximately the middle of the PR Belt). Y N Go to the 6-701 RAP.

With [Laser Write] on, the scanline appears to be of equal brilliance across the paper (the inboard half of the beam should not be dimmer than the outboard half). Y N Go to the 6-701 RAP.

Press the Stop button to turn off the [Patch Enable] output. With [Laser Write] on, select [Patch Exposure]. While observing the scanline, press the Continue button. The scanline is visible dimmer on the inboard side of the paper, compared to the outboard side (approximately from the middle of the belt to the inboard end of the beam should be about half the brightness of the outboard end). HINT: Toggle the output several times on/off while observing the scanline, if you are unsure of the above check. Y N Go to the 6-701 RAP. Replace the following, one at a time and in the order given, until the problem is resolved: • Pixel Clock PWB (PL 1.11).

Section Name

9-356, 9-360

•

SLB/RDR PWB (PL 1.11).

•

ROS Assembly (PL 6.1).

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9-361 RAP Fault Code 9-361 indicates that the ROS adjustment was out of range in dC951.

Procedure Cover the Photoreceptor, under the ROS assembly, outboard to inboard with white paper. Cheat the Processor Interlock Bypass Switch. Enter dC330, [6]. Select [Write Laser]. Press the Continue button. Observe the scanline on the paper. There is a full scanline across the paper (the scanline should not be missing in the middle of the page). Y N Go to the 6-701 RAP. With the (Write Laser) on. The scanline appears to be equal in brilliance across the paper (the inboard half of the beam should be not dimmer than the middle of the PR Belt). Y N Go to the 6-701 RAP. With the (Laser Write) on, select (Patch). Press the CONTINUE button. The scanline is completely off in the middle of the Patch area (approximately the middle of the PR Belt). Y N Go to the 6-701 RAP. Press the STOP button to turn off the (Patch) output. With (Laser Write) on, select (Patch Exposure). While observing the scanline, press the CONTINUE button. NOTE: If your not sure, continue with the (YES) path. The scanline is visibly dimmer on the inboard side of the paper, compared to the outboard side (approximately from the middle of the belt to the inboard end of the beam should be about half the brightness of the outboard end) Y N Go to the 6-701 RAP. NOTE: Toggle the output several times ON and OFF while observing the scanline if your not sure of the above check. Check for excessive dirt in the Xerographic area of the printer. If there is a excessive build up of dirt, find the cause of the build up and repair it. If dirt was found clean in the Xerographic subsystem, The likely cause of the dirt are the Cleaner and developer area of the machine. If the problem continues, replace the ROS Assembly.

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Section Name

9-361

9-702 Dry Ink Level Low Message RAP Message indicates that the Low Toner Sensor, Q903, sensed no toner.

Procedure NOTE: MICR (DP180MX) Machines use a red Toner Bottle that is not compatible with DP180. Enter dC330, [9]. Select [Toner Thumper]. Press Continue. NOTE: Listening for the Thumper may be inadequate. Cheat the Front Door Interlocks. Observe the solenoid actuation. The Toner Solenoid Thumper is working. Y N Go to Flag 2. Check the circuit of the Toner Thumper Solenoid. (Generic Solenoid RAP GP 6-3, General Procedures). The Thumper hits the bottle. Y N Adjust the Toner Thumper (ADJ 9-10). Replace the Thumper Assembly as required (PL 9.19). The Low Toner Sensor is H. Y N +24 VDC is measured between MT10-1 (+) of the Low Toner Sensor and TS37 (-) of the MIN DIO PWB. Y N Go to wire, 1005M/1005H wirenet. Check for a short or an open circuit. Go to Flag 1. Check the circuit of the Low Toner Sensor. (GP 6-2, General Procedures). Remove Toner Bottle. Check the operation of the cross mix baffle.

Section Name

9-702

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Figure 1 9-702 Circuit Diagram (7925)

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Section Name

9-702

9-703 Replace the Waste Bottle Message RAP Initial Actions Ensure that a Waste Container is in the printer. Ensure that the Waste Bottle Full Sensor is clean and mounted properly.

Procedure Inspect the PR Drawer Ribbon Cable connections. Ensure that the plugs are secure at the back of the Xerographic Drawer and at the frame near the HVAC/HVDC PWBs Enter dC330, [9]. Move the Waste Bottle to actuate the sensor. The Waste Bottle Full Sensor display goes L. Y N Go to Flag 1. Check the circuit of the Waste Bottle Full Sensor, Q906. (GP 6-2, General Procedures). Check the following: • Sensor Band for damage or burrs (PL 9.7). •

Bottle Guide Bracket for proper orientation

•

Waste Bottle for damage in area of the Sensor Band

•

If the above checks are OK, replace the Waste Container (PL 9.22).

Section Name

9-703

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Figure 1 9-703 Circuit Diagram (7926)

Preliminary Working Document No Product Name Assigned

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Section Name

9-703

9-704 Toner Filter Blower Motor RAP Initial Actions Check the Toner Filter Blower O-Rings for damage (PL 9.20). Ensure that the wires are connected to the Toner Filter Blower Motor Capacitor.

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

Section Name

9-704

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Figure 1 9-704 Circuit Diagram (7930B)

Preliminary Working Document No Product Name Assigned

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Section Name

9-704

9-705 MIN Cooling Fan RAP This procedure is used to diagnose MIN Cooling Fan failures.

Initial Actions Ensure that the fan connector is not damaged and is securely fastened. Clear any obstructions from the fan area that may restrict air flow.

Procedure WARNING When the Main Drive is running, use Caution when working in the vicinity of the Toner Filter Blower Motor and the MIN Compressor. 115 VAC is measured between JBT-1 and JBT-2 of the MIN Cooling Fan Connector. Y N 115 VAC is measured between 1TB1-3 and 1TB-5. Y N (60HZ) Go to the 1-703, AC Switched On Power RAP. (50HZ) Go to the 1-710, AC Switched On Power RAP. Go to Flag 1. Repair the open circuit. Enter [dC] [Power Interrupt] Disconnect the two pin connector on the MIN Cooling Fan. Press Continue. 115 VAC is measured between PBT1-1 and PB1-2 at the Cooling Fan. Y N Go to Flag 1. Check for an open circuit. Replace the MIN Cooling Fan (PL 4.9).

Section Name

9-705

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Figure 1 9-705 Circuit Diagram (7931C)

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Section Name

9-705

A

9-706 Power

B

C Go to Flag 2. Check for a short circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7).

This RAP is used to diagnose standby power to the HVAC and HVDC PWBs. Go to Flag 2. Check for an open circuit.

Procedure 7.3 +/- 0.2 VAC is measured between TP1 (+) and TP2 (-) of the HVDC PWB. Y N Greater than 7.6 VAC is measured between TP1 (+) and TP2 (-) of the HVDC PWB. Y N Disconnect the Ribbon Cable between the HVDC and HVAC PWB. Greater than 6.6 VAC is measured between TP1 (+) and TP2 (-) of the HVDC PWB. Y N Replace the HVDC PWB (PL 1.7).

+15 VDC is measured between P294-4 (+) and P294-9 (-), (J1) of the HVAC PWB. Y N +15 VDC is measured between TH6 (+) and TH8 (-) on the LVPS. Y N Go to the 1-715 RAP. Go to the wire, 1009J, wirenet. -15 VDC is measured between P294-6 (+) and P294-9 (-), (J1) of the HVAC PWB. Y N -15 VDC is measured between TH7 (+) and TH8 (-) on the LVPS. Y N Go to the 1-716 RAP.

Go to Flag 3. Check for an short circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7). Go to Flag 3. Check for an open circuit. If the circuit is OK, replace the HVAC PWB (PL 1.7).

Go to the wire, 1010H, wirenet.

Replace the HVAC PWB (PL 1.7).

+24 VDC is measured between P294-5 (+) and P294-9 (-), (J1) of the HVAC PWB. Y N Go to Flag 1. Check for an open circuit. +34 VDC is measured between P294-7 (+) and P294-10 (-) of the HVAC PWB. Y N +34 VDC is measured between TH16 (+) and TH18 (-) on the LVPS. Y N Go to the 1-717, +24, +34, -34 VDC RAP. Check the +34 VDC wirenet 1018A/1018C for an open. +15 VDC is measured between P293-4 (+) and P293-9 (-), (J1) of the HVDC PWB. Y N +15 VDC is measured between TH6 (+) and TH8 (-) on the LVPS. Y N Go to the 1-715 RAP. Go to the wire, 1009H, wirenet. 3.5 +/- 0.5 VAC is measured between P293-3 (+) and P293-8 (-) of the HVDC PWB. Y N 3.5 +/- 0.5 VAC is measured between TH19 (+) and TH20 (-) on the LVPS. Y N Switch Off Printer power. Wait for the LVPS LEDs to go off. Disconnect P354 from the LVPS. Switch on Printer power. 3.5 +/- 0.5 VAC is measured between TH19 (+) and TH20 (-) of the LVPS. Y N Replace the LVPS (PL 1.9). A

B

C

Section Name

9-706

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Figure 1 9-706 Circuit Diagram (7932D)

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Section Name

9-706

Section Name

9-706

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A

B

10-101 RAP Fault Code, 10-101, indicates that a print did not actuate the Prefuser Sensor, Q1009, within the specified number of clock counts after it arrived at the Registration Sensor.

C Place a sheet of paper (8 1/2 x 11 or A3 if available) on the Prefuser Transport. The vacuum holds the sheet on the Prefuser Transport. Y N Check the Prefuser Transport Assembly for vacuum leaks and restricted or damaged air ducts (PL 8.12).

Initial Actions Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue button. The Prefuser Transport Belts rotate. Y N Check the Prefuser Transport Drive system for damaged or worn components (PL 4.16).

•

Ensure that the Prefuser Sensor and Reflector are not obstructed and that the Prefuser Sensor and Reflector are clean and in proper position.

•

Ensure that the Prefuser Transport is in the normal operating position.

•

Check the Prefuser Transport adjustment (ADJ 10-18).

•

The Fault Code, 10-101, occurring at machine start may be due to a dirty or defective Registration Transport Sensor, Q861.

•

Ensure that the paper path is free from obstructions.

•

Load fresh paper and run the machine. If the fault is no longer present advise the Key Operator about the storage and use of paper.

•

Binding Prefuser Transport Bearings (part of the drive roll) (PL 8.12).

•

Worn Prefuser Transport Drive Coupling (part of the drive coupling) (PL 8.12).

Ensure that the paper is loaded correctly and that curl is not excessive.

•

Check the following: • Damaged or contaminated Prefuser Transport Drive Belts (PL 4.16).

•

Obstructed Prefuser Transport Manifold holes

Procedure

•

Check the Prefuser Transport adjustment (ADJ 10-18).

Enter dC106. Run the machine until Fault Code, 10-101, is declared. Inspect the image on the jammed print. The image is skewed or misregistered. Y N Enter dC330, [8]. Block and then clear the Registration Sensor, Q861. The display changes from H to L. Y N Go to the 8-155.

•

If all other checks are good refer to the Generic Sensor GP 6-2, (General Procedures) and ensure that the sensor voltages for the Registration Transport Sensor and Prefuser Sensor are correct.

Select [10]. Open, then close the Fuser Drawer. The Prefuser Sensor display changes from L to H. Y N Measure the voltage at TS24 (+) and TS37 (-) on the PHN DIO PWB #2. If the voltage is greater than +0.5 VDC, clean the Prefuser Sensor. Check the Prefuser Sensor Reflector for damage or contamination (ensure that the sensor and reflector are aligned). If +0.5 VDC or less cannot be obtained, replace the Prefuser Sensor (PL 8.12). Y N Go to Flag 1. Check the circuit of the Prefuser Sensor.

Check the following: • Obstructions in the paper path •

Condition of the paper

•

Operation and condition of the Transfer and Detack Dicorotrons (REP 9-39 and REP 9-49).

•

Condition of the Pretransfer Baffle (PL 8.11).

•

Condition of the Stripper Finger Assembly (PL 9.3).

•

Condition and operation of the Transfer Assist Blade (PL 9.11).

•

Condition of the Detack Guide (PL 9.11).

Go to the 8-706 PHM Misregistration and Skew RAP.

Rerun the machine to ensure that the problem is resolved. If the problem reoccurs go to the beginning of this RAP. Clear the Fault Code. If Fault Code, 10-101, can not be cleared, switch off and then reset all printer circuit breakers. Enter dC106. Run the machine until Fault Code, 10-101, is declared (if Fault Code, 10-101, is not declared, go to the declared fault). The print is jammed or stopped before the Prefuser Transport. Y N Install a cheater in the Printer Interlock Bypass Switch. Select [Prefuser Vacuum] motor. Press the Continue button. The Prefuser Vacuum Motor comes on. Y N Go to the 10-706 Prefuser Vacuum Motor RAP. A

B

C

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Section Name

10-101

Figure 1 10-101 Circuit Diagram (8001A)

10-102 RAP Fault Code, 10-102, indicates that a print did not reach the Fuser Jam Sensor, Q1010, within the specified number of clock counts after it arrived at the Prefuser Jam Sensor, Q1009, and that the Prefuser Jam Sensor, Q1009, is still blocked after machine cycle-down. Section Name

10-101

Fault Code, 10-102, can also be declared if the specified number of clock counts is exceeded (during seven pitch mode) after actuating the Fuser Sensor, Q1010, the Prefuser Sensor, Q1009, is still blocked.

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Initial Actions

Measure the voltage between TS21 (+) and TS37 (-) on the PHN DIO PWB #2. If voltage is greater than +0.5 VDC, clean the Fuser Sensor. Check the Fuser Sensor Reflector for damage or contamination. If +0.5 VDC or less cannot be obtained, replace the Fuser Sensor (PL 10.5 Y N Go to Flag 1. Check the circuit of the Fuser Sensor (GP 6-2 General Procedures).

WARNING Whenever the IOT Compressor is running keep hands and clothing away from the compressor area. Use extreme caution when performing service in this area. If the Compressor Motor is in an overheat condition it will run automatically when cool and the internal thermal switch resets.

Clear the Fault Code. If the Fault Code, 10-102, can not be cleared, switch off and then reset all printer circuit breakers. Check the Fuser Roll Temperature (ADJ 10-6). The Fuser Temperature is in specification. Y N Ensure that the Fuser and Metering Roll Thermistors are clean and making proper contact. Enter dC701. Adjust the Fuser Roll Temperature (ADJ 10-6).

CAUTION Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to the cover may occur. Perform the following: •

Check SCP HFSI due for the Fuser Module (10-800 series) and perform as necessary.

•

Ensure that the Prefuser Sensor and Reflector are clean and are not obstructed. Ensure that the sensor and reflector are correctly aligned. Fault Code, 10-102, occurring at print cycle up may be due to a dirty or defective Prefuser Sensor.

•

Ensure that the Prefuser Transport is in the normal operating position.

•

Check the Prefuser Transport adjustment (ADJ 10-18).

Install a cheater in the Printer Interlock By-pass Switch. Enter dC330, [10]. Select [Prefuser Vacuum] motor. Press the Continue button. The Prefuser Vacuum Motor comes on. Y N Go to the 10-706 Prefuser Vacuum Motor RAP.

NOTE: Use only Fuser Agent for the DP180. •

Check the Fuser Agent level. If the reservoir is empty and the machine has not detected this condition, go to the 10-705 Low Fuser Agent Level RAP.

•

Enter dC131. Ensure that the PHN NVM locations 180, 181, 182, and 183 are at the values given in the appropriate level Software dC 131 Table in General Procedures.

•

Ensure that the print paper is loaded correctly and that paper curl is not excessive (refer to the Decurler section in the Operators Manual).

•

Load fresh paper and run the machine. If the fault is no longer present advise the Operator about the storage and use of paper.

•

Image that extends to the edge of the prints can cause an increased frequency of jams. Avoid dense images at the lead and trail edges of the print for superior performance. Notify operator of the lead edge lightening operation as described in the Operators Manual.

•

Ensure the PR Drive coupling is properly lubricated with Moly Grease (PL 25.1). See Rollovers (PC 3676, RO 177643) in the Service Information section for additional information on the lubricant and a tool for its application.

Place a sheet of paper (8 1/2 x 11 or A3 if available) on the Prefuser Vacuum Transport. The vacuum holds the sheet on the Prefuser Transport. Y N Check the Prefuser Transport for vacuum leaks and restricted or damaged air ducts. The image on the jammed print is completely and correctly fused. Y N Run the machine. The Fuser Heat Roll rotates. Y N Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Fuser Drive Coupling (at rear of machine) rotates. Y N The Fuser / Developer Drive Motor Comes on. Y N Go to the 4-705 Fuser Developer Drive Motor RAP. Check the Fuser Drive assembly for damaged or worn components (PL 4.17).

Procedure Enter dC606. Run the machine until Fault Code, 10-102, is declared (if Fault Code, 10-102, is not declared go to the declared fault). Inspect the image on the jammed print. The image is skewed or misregistered. Y N Enter dC330, [10]. Open, then close the Fuser Drawer. The Prefuser Sensor display changes from L to H. Y N Go to Flag 2. Check the circuit of the Prefuser Sensor (GP 6-2, General Procedures).

Inspect Fuser Drive Gears and Fuser Drive Coupling for wear. The gears or coupling are worn. Y N Move the Fuser Drive Coupling in and out. The Fuser Drive Coupling moves in and out freely. Y N Clean, repair, or replace the Fuser Drive Coupling (PL 4.17). Enter dC606. Run the machine. Inspect the Fuser Idler Gear while the machine is running. Intermittent Fuser drive is observed. Y N Clean, repair, or replace the Fuser Roll (REP 10-1). A

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B

C

D Section Name

10-102

A

B

C

D

A

B

Clean, repair, or replace the Fuser Drive Coupling (PL 4.17).

Y

Replace the Fuser Drive Gear or Fuser Drive Coupling (PL 4.17). Enter dC106. Run the machine. The Pressure Roll cams in. Y N Check for binding or worn components in the Pressure Roll Camming system (PL 10.2). Enter dC330, [10], [Compressor] motor. Press the Continue button. The pressor Motor comes on. Y N Go to the 10-703, Printer Compressor Motor RAP.

N Check for a blocked or damaged Air Line between the Air Gauge and Air Knife Solenoid. If OK, replace the Air Knife Solenoid (PL 10.5).

Check for a blocked or damaged Air Knife Manifold or Air Line to the Air Knife Manifold. Check the Air Knife Manifold condition and adjustment (ADJ 10-4). The Air Knife Manifold is OK. Y N Repair or replace the Air Knife Manifold (PL 10.5).

Com-

Check the Stripper Finger Baffle Assembly (ADJ 10-15). The Stripper Finger Baffle Assembly is adjusted correctly. Y N Adjust the Stripper Finger Baffle Assembly (ADJ 10-15).

The Air Knife Pressure is at 20 +/- 1 PSI (ADJ 10-5). Y N The Air Knife Pressure can be adjusted to 20 +/- 1 PSI (ADJ 10-5). Y N Go to the 10-702 Fuser Air System Checkout and check for an air leak.

Check the following: • Condition of the Fuser Entrance Baffle (PL 10.4). •

Select [Air-Knife], [Cycle]. Press the Continue Button. The Air Knife Solenoid cycles on and off. Y N Go to Flag 3. Check the circuit of the Air Knife Solenoid.

Check the following: • Condition and operation of the Air Knife Solenoid (PL 10.5). Adjustment of the Air Knife Manifold (ADJ 10-4).

•

Damaged or kinked air line between the Pressure Regulator and the Air Knife Manifold

•

Go to the 10-702 RAP and perform the check for the Moisture Trap / Air Filter

Ensure that the Fuser Drive Coupling moves in and out freely

•

The Fuser Drive Coupling (ensure to check both the drive side and the mating side on the fuser) for wear, damage, and proper engagement (PL 4.17).

Inspect the Fuser Roll and Pressure Roll surfaces for damage. Either roll is damaged. Y N The jammed print has completely exited the Fuser Exit Baffle. Y N Enter dC330, [10], [Compressor] motor. Press the Continue button. The Compressor Motor comes on. Y N Go to the 10-703, Printer Compressor Motor RAP.

There is less than a 2 PSI momentary decrease in air pressure as the air knife solenoid energizes. Y N Check for a leak in the air line between the Pressure Regulator and the Air Knife Manifold.

•

The Pressure Roll Contact Arc (ADJ 10-2).

•

The Air Knife Pressure is at 20 +/- 1 PSI (ADJ 10-5). Y N The Air Knife Pressure can be adjusted to 20 +/- 1 PSI (ADJ 10-5). Y N Go to the 10-702 Fuser Air System Checkout and check for an air leak.

Pull out the Fuser Drawer. Bypass the Processor Interlocks. Select [Air Knife], [Cycle]. Press the Continue button. A pulsating Air jet can be felt at all the Air Knife Manifold openings. Y N The Air Knife Solenoid is energized. Y N Go to Flag 3. Check the circuit of the Air Knife Solenoid.

The Air Knife Solenoid energizes. Y N Go to Flag 3. Check the circuit of the Air Knife Solenoid. There is less than a 2 PSI momentary decrease in air pressure as the air knife solenoid energizes. Y N Check for a leak in the air line between the Pressure Regulator and the Air Knife Manifold.

Disconnect the Air Line from the Air Knife side of the Air Knife Solenoid. Air is discharged from the Air Knife Solenoid.

Check the following: A

B

Section Name

10-102

A 0/0/00 ?-784

E

F

G

H Preliminary Working Document No Product Name Assigned

A

E

F

G

H •

Condition and operation of the Air Knife Solenoid (PL 10.5).

A

•

Adjustment of the Air Knife Manifold (ADJ 10-4).

•

Damaged or kinked air line between the Pressure Regulator and the Air Knife Manifold

E

F

Pull out the Fuser Drawer. Bypass the Processor Interlocks. Select [Air Knife] solenoid. Press the Continue button. Air jet can be felt at all the Air Knife Manifold openings. Y N The Air Knife Solenoid is energized. Y N Go to Flag 3. Check the circuit of the Air Knife Solenoid.

J Ensure that the PHN NVM location 188 =18. Place the output hose from the Fuser Agent Pump into the cap from a Fuser Agent bottle (bottle part number is 8R2955). Enter dC330, [10] [Fuser Agent] Pump [Cycle]. Press the Continue button. Count the number of strokes, of the Fuser Agent Pump Solenoid, necessary to fill the cap. Press the Stop button. The cap filled in 15 or less strokes. NOTE: The Fuser Agent Solenoid should be run for a few minutes to ensure that all air is removed from the fuser agent lines prior to the test. Y N Replace the Fuser Agent Pump Assembly (PL 10.8). Exit dC330. Manually rotate the Donor Roll. The Donor Roll rotates freely and is not damaged. Y N Clean or replace the Donor Roll or Donor Roll Bearings (PL 10.8).

Disconnect the Air Line from the Air Knife side of the Air Knife Solenoid. Air is discharged from the Air Knife Solenoid. Y N Check for a blocked or damaged Air Line between the Air Gauge and Air Knife Solenoid. If OK, replace the Air Knife Solenoid (PL 10.5).

Remove the Metering Roll and check the following: • Metering Roll and Metering Roll Bearings (PL 10.7).

Check for a blocked or damaged Air Knife Manifold or Air Line to the Air Knife Manifold. Check the Air Knife Manifold condition and adjustment (ADJ 10-4). The Knife Manifold is OK. Y N Repair or replace the Air Knife Manifold (PL 10.5).

I

Air

•

Metering Blade for damage or wear (PL 10.7).

•

Condition of the Fuser Wick (PL 10.7).

•

Condition of the Fuser Drives for noise or wear (PL 4.17).

•

Fuser Static Brush for damage (PL 10.4).

Repair or replace the Fuser Entrance Baffle (PL 10.3). Check the following: • Condition of the Fuser Exit Baffle (PL 10.4).

Check the Stripper Finger Baffle Assembly (ADJ 10-15). The Stripper Finger Baffle Assembly is adjusted correctly. Y N Adjust the Stripper Finger Baffle Assembly (ADJ 10-15). Select [Camming] motor. Press the Continue button. The Fuser Roll, Donor Roll, and Metering Roll cam in properly. Y N Check the Camming System for damaged or worn components (PL 10.2). Enter dC106. Run the machine. Observe the prints entering the Fuser nip. The prints are catching on the Fuser Entrance Baffle. Y N Enter dC330, [10], [Fuser Agent Pump] solenoid [Cycle]. Press the Continue button. The Fuser Agent Pump Solenoid cycles on and off. Y N Go to the 10-708, Fuser Agent Dispense RAP.

•

Condition of the Fuser Static Brush (PL 10.4).

•

Air Knife Pressure (especially with lightweight paper) (ADJ 10-5), if the Air Knife pressure cannot be adjusted properly go to the 10-702, Fuser Air System Checkout and check for an air leak

•

Condition of the Fuser Drives for noise or wear (PL 4.17).

•

Condition of the Donor Roll loading hardware (PL 10.8).

•

Ensure that the Vacuum Manifold and the Air Knife Manifold (ADJ 10-4) are adjusted correctly

Determine, and repair the cause of the damage, then replace the damaged Fuser Roll (REP 10-1). Go to the 8-706 PHM Misregistration and Skew RAP.

Fuser Agent is being dispensed. Y N Check the input and output Fuser Agent Lines for obstruction or damage. Repair or replace as required (PL 10.8).

A

E

F

I

J

Preliminary Working Document No Product Name Assigned

0/0/00 ?-785

Section Name

10-102

Figure 1 10-102 Circuit Diagram (8002)

Section Name

10-102

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Preliminary Working Document No Product Name Assigned

Figure 2 10-102 Circuit Diagram (8003)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-787

Section Name

10-102

10-104 RAP

Y

Fault Code, 10-104, indicates that a print did not actuate the Decurler Sensor, Q1011, within the specified number of clock counts after it arrived at the Fuser Sensor, Q1010.

Initial Actions •

Check SCP HFSI due for Fuser Module (10-800 series) actions and perform as necessary.

•

Ensure that the Decurler Sensor is not obstructed and that the Decurler Sensor Actuator is not damaged.

•

Ensure that the Decurler paper path is free from obstructions.

•

Ensure that the Decurler Jam Clearance baffle is positioned correctly.

•

If the problem occurs only with high humidity or just after machine power-up, check for condensed water vapor on Decurler or Top Transport.

•

Check the Fuser Vacuum Manifold for proper installation.

•

Fault Code, 10-104, during print cycle-up may be due to a dirty or failed Fuser Sensor, Q1011.

• •

N Enter dC330, [10], [Compressor] motor. Press the Continue button. The Air Gauge can be adjusted to 20 +/-1 PSI (ADJ 10-5). Y N Check for damaged or restricted air lines. If OK, go to the 10-703 MIN Compressor Motor RAP. Select [Air-Knife] [Cycle]. Press the Continue Button. The air pressure momentarily decreases about 2 to 3 PSI as the Air Knife Solenoid energizes. Y N The Air Knife Solenoid energizes. Y N Go to Flag 3. Check the circuit of the Air Knife Solenoid, go to (GP 6-3) (Generic Solenoid RAP, General Procedures). Check the following: • If there is less than a 2 to 3 PSI decrease: •

Ensure that the paper is loaded correctly and that the curl is not excessive (refer to the Operator Manual, Decurler section). Image that extends to the edge of prints may cause an increased frequency of jams. Avoid dense images at the lead and trail edges of the print for superior performance. Notify operator of lead edge density suppression (Jam Bypass Operation) (refer to the Operator Manual, Options section). NOTE: Use only Fuser Agent for the DP180.

Condition and operation of the Air Knife Solenoid (PL 10.5).

•

Adjustment of the Air Knife Manifold (ADJ 10-4).

•

Damaged or kinked air lines between the Pressure Regulator and the Air Knife Manifold.

•

If there is a greater than 2 to 3 PSI decrease:

•

Check for a leak in the air line between the Pressure Regulator and the Air Knife Manifold.

Check the condition (PL 10.5).

•

If Fuser Agent is not being dispensed go to the 10-708 Fuser Agent Dispense RAP.

•

Enter dC131. Ensure that the PHN NVM locations 180, 181, 182, and 183 are at the values given in the appropriate level Software dC 131 Table in General Procedures.

Procedure Cheat the Printer Door Interlocks. Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Measure the voltage between TS21 (+) and TS37 (-) on the PHN DIO PWB #2. If voltage is greater than +0.5 VDC, clean the Fuser Sensor. Check the Fuser Sensor Reflector for damage or contamination. If + 0.5 VDC or less cannot be obtained, replace the Fuser Sensor (PL 10.5 Y N Go to Flag 2. Check the circuit of the Fuser Sensor (GP 6-2,General Procedures). Select [Camming] motor. Press the Continue button. The Pressure Roll cams in. Y N Go to the 10-707 Camming Motor RAP.

Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Decurler Belts rotate. Y N Check the following: • Damaged or contaminated Decurler Belts (PL 10.12). •

Binding or worn Decurler Drive Belts or Pulleys (PL 10.12).

•

Perform Panic Stop Procedure.

Select [Clear Outputs]. Enter [SCP] [HFSI] [Print Transport] [10-813]. The prints on Decurler Belts is over threshold. Y N Check the following: • Worn or damaged parts •

Air Knife is adjusted correctly (ADJ 10-4).

•

Vacuum Manifold is adjusted correctly.

•

If the above checks are OK, replace the Decurler Clutch (PL 10.12).

number

of

Replace the Decurler Belts (PL 10.12).

Clear the Fault Code. If Fault Code, 10-104, can not be cleared, switch off and then reset all printer circuit breakers). Run the machine until Fault Code, 10-104, is declared (if Fault Code, 10-104, is not declared, go to the declared fault). The jammed print is started into the Decurler. Section Name

10-104

0/0/00 ?-788

Preliminary Working Document No Product Name Assigned

Figure 1 10-104 Circuit Diagram (8004A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-789

Section Name

10-104

A Go to the 8-705 PHM Copy Damage RAP.

10-105 RAP Fault Code, 10-105, indicates that the trail edge of the print did not leave the Decurler Sensor, Q1011, within the specified number of clock counts after actuating the sensor, and that the sensor is still actuated after the machine cycle-down.

Table 1 HISTOGRAM RESULTS Distribution

Probable Cause

Random Distribution

Check: sensors, drives, loose or worn belts and pulleys in the Top Transport and Decurler, obstructions in the paper path, damaged paper path components, excessive paper curl.

Normal Distribution

Check: sensors, drives, loose or worn belts and pulleys in the Top Transport or Decurler, obstructions in the paper path, damaged paper path components, excessive paper curl. Also check the Hardware Induced Crash checklist (Service Call Procedures). If the problem continues replace the Top Transport Slip Clutch (PL 10.14).

Late Distribution

Replace the Top Transport Clutch and check the following: drives, loose or worn belts or pulleys in the Decurler and Top Transport drives, proper Decurler Sensor, Q1011, actuation.

Initial Actions •

Ensure that the Decurler Jam Clearance Baffle is properly seated and that the Jam Clearance Baffle Handle is not bent.

•

Check that the paper path and the Decurler Sensor are not obstructed, and that the Decurler Sensor Actuator is not damaged or binding.

Procedure Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Enter dC726, [53]. Select [100 prints], [Top Tray]. Use the same paper that the customer was using. Run the machine. A 10-105 fault is declared. Y N Enter dC330, [10]. The Decurler Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the post Decurler assembly (proper overtravel). Y N Replace the Decurler Sensor (PL 10.16). Enter dC726, [53]. Select [100 prints], [Top Tray]. Use the heaviest paper the customer has available. Refer to the chart below and perform the appropriate action based on the results of the histogram. Observe the jammed print without opening the Decurler Jam Clearance Baffle. The Decurler Sensor is covered. Y N Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Examine the prints in the Top Tray and all the prints in the paper path. The prints are damaged. Y N Check the following: • The Decurler Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the Post Decurler assembly (proper overtravel) (PL 10.16). •

Obstructions in the paper path

•

All Top Transport idlers and rollers are clean and correctly positioned (all springs are present and correctly located) (PL 10.15).

•

Loose or worn Top Transport drive belts and pulleys (PL 10.14).

•

Paper for excessive curl, refer to the Print Paper Diagnostics (Service Call Procedures).

•

Loose or worn belts and pulleys in the Decurler Transport Drives (PL 4.16).

•

Decurler belts for wear or damage (PL 10.12).

•

Replace the Top Transport Slip Clutch (PL 10.14).

A Section Name

10-105

0/0/00 ?-790

Preliminary Working Document No Product Name Assigned

Figure 1 10-105 Circuit Diagram (8005A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-791

Section Name

10-105

A Go to the 8-705 Print Damage RAP.

10-106 RAP Fault Code, 10-106, indicates that the trail edge of the print did not leave the Decurler Sensor, Q1011, within the specified number of clock counts after actuating the sensor, and that the sensor is not actuated after the machine cycle-down.

Table 1 HISTOGRAM RESULTS Distribution

Probable Cause

Random Distribution

Check: sensors, drives, loose or worn belts and pulleys in the Top Transport and Decurler, obstructions in the paper path, damaged paper path components, excessive paper curl.

Normal Distribution

Check: sensors, drives, loose or worn belts and pulleys in the Top Transport or Decurler, obstructions in the paper path, damaged paper path components, excessive paper curl. Also check the Hardware Induced Crash Checklist (Service Call Procedures). If the problem continues replace the Top Transport Slip Clutch (PL 10.14).

Late Distribution

Replace the Top Transport Clutch (PL 10.14).

Initial Actions •

Ensure that the Decurler Jam Clearance Baffle is properly seated and that the Jam Clearance Baffle Handle is not bent.

•

Check that the paper path and the Decurler Sensor are not obstructed and that the Decurler Sensor Actuator is not damaged.

Procedure Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Enter dC726, [53]. Select [100] prints, [Top Tray]. Use the same paper that the customer was using. Fault Code, 10-106, is declared. Y N Enter dC330, [10]. The Decurler Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the Post Decurler assembly (proper overtravel). Y N Replace the Decurler Sensor (PL 10.16). Enter dC726, [53]. Select [100] prints, [Top Tray]. Use the heaviest weight paper the customer has available. Refer to the chart below and perform the appropriate action based on the results of the histogram. Examine the prints in the Top Tray and all the prints in the paper path. The prints are damaged. Y N Enter dC726, [53]. Select [100] prints, [Top Tray]. Use the heaviest paper the customer has available. The Histogram indicates times approaching the yellow arrow or beyond (late). Y N Check the following: • Paper path for obstructions •

Paper path components for damage

•

Loose or worn belts or pulleys in the Decurler Transport drives (P L 4.16)

•

Decurler Exit Baffle Adjustment (ADJ 10-8).

•

Loose or worn belts or pulleys in the Top Transport Drives (PL 10.14).

•

Top Transport rollers and idlers are clean and properly seated, and that all springs are properly installed

Replace the Top Transport Slip Clutch (PL 10.14).

A Section Name

10-106

0/0/00 ?-792

Preliminary Working Document No Product Name Assigned

Figure 1 10-106 Circuit Diagram (8006A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-793

Section Name

10-106

A

B

10-107 RAP

•

Fault Code, 10-107, indicates that a print lead edge did not actuate the Top Transport Sensor, Q1012, within the specified number of clock counts after the print lead edge arrived at the Decurler Sensor, Q1011.

Initial Actions

If the problem continues replace the Top Transport Slip Clutch (PL 10.16).

Replace the Top Transport Slip Clutch (PL 10.14). Enter dC330, [1-4] [Main Drives/Start/Run]. Press the Continue button. All the Top Transport Idlers and Rollers rotate. Y N Check the following: • Drive belts and pulleys

•

Ensure that the Decurler Sensor, Top Transport Sensor, and Top Transport paper path are free from obstructions.

•

Ensure that the Decurler Sensor Actuator is not damaged.

•

Rollers and Idlers for binding or wear

•

Ensure that the Top Transport Sensor is not damaged or binding.

•

Drive clutches

•

Ensure that the Top Transport Baffles are seated properly.

•

Ensure that the Top Transport Idler Rolls and springs are seated properly and that the rolls turn freely.

•

Ensure that the paper is loaded correctly, and that curl is not excessive (refer to the Decurler Section of the Operators Manual).

The jammed print is damaged. Y N Check the following: • Drive belts and pulleys •

Rollers and Idlers for binding or wear

Procedure

•

Drive clutches

Enter dC330, [10]. Actuate the Top Transport Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Top Transport Sensor (GP 6-2, General Procedures).

•

Circuit of the Top Transport Sensor

Go to the 8-705 Print Damage RAP to determine the cause of the paper damage.

The Top Transport Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the Top Transport (proper overtravel). Y N Replace the Top Transport Sensor (PL 10.16). The Decurler Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the Post Decurler Transport (proper overtravel). Y N Replace the Decurler Sensor (PL 10.16). Actuate the Decurler Sensor. The display changes from H to L. Y N Go to Flag 2. Using the Generic Sensor RAP GP 6-2,General Procedures, check the circuit of the Decurler Sensor. Use the paper that the customer was using. Enter dC726, [55]. Press the Continue button. The Fault Code, 10-107, occurs. Y N Load the heaviest weight paper the customer has available. Enter dC106. Select [100] prints, [Top Tray]. Press the Continue button. Observe the histogram. The histogram indicates times approaching the yellow arrow or beyond (late). Y N Check the following: • Top Transport Drive Rolls and Idlers are clean, rotate freely, and that all springs are installed correctly (PL 10.14).

A

•

Top Transport Drive Belts (PL 10.14).

•

All drive belts are installed correctly, are properly tensioned and are not worn

B

Section Name

10-107

0/0/00 ?-794

Preliminary Working Document No Product Name Assigned

Figure 1 10-107 Circuit Diagram (8007A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-795

Section Name

10-107

Figure 2 PWB Location (7313)

Section Name

10-107

0/0/00 ?-796

Preliminary Working Document No Product Name Assigned

A

B

10-108, 10-109 RAP

Y

Fault Code, 10-108, indicates that the trail edge of a print going to the Duplex Tray, did not leave the Top Transport Sensor, Q1012, within the specified number of clock counts after the print lead edge actuated the sensor, and that the Top Transport Sensor, Q1012, is still actuated after the machine cycle-down.

The Duplex Gate is adjusted correctly (ADJ 10-9). Y N Perform the Duplex Gate Adjustment (ADJ 10-9).

Fault Code, 10-109, indicates that the trail edge of a print going to the Duplex Tray, did not leave the Top Transport Sensor, Q1012, within the specified number of clock counts after the print lead edge actuated the sensor, and that the Top Transport Sensor, Q1012, is not actuated after the machine cycle-down.

N Repair or replace the Duplex Gate (PL 10.14).

Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue button. The Top Transport Rolls rotate. Y N Check for binding or worn components in the Top Transport drive system (PL 4.19).

Initial Actions •

Ensure that the Top Transport Sensor and Turn Roll area of the paper path are not obstructed.

Check the following: • Worn or dirty Top Transport Rolls (PL 10.15).

•

Ensure that the Top Transport Sensor Actuator is not damaged, or binding.

•

Worn or dirty Top Transport Clutch (PL 10.14).

Ensure that the Top Transport Baffles are attached to the cover and are properly seated.

•

Decurler Setting

•

Worn or damaged Top Transport drive system components (PL 4.19).

•

Worn or damaged Top Transport pulleys and belts (PL 10.14).

•

Damaged Top Transport Springs (PL 10.15).

•

Procedure Enter dC330, [10]. The Decurler Sensor actuates before going below the upper baffle, and, the actuator goes below the cutout in the Post Decurler Transport (proper Overtravel). Y N Replace the Decurler Sensor (PL 10.16).

•

Worn or damaged Duplex drive system components (PL 10.14).

•

Duplex Gate Solenoid Adjustment (ADJ 10-9).

Enter dC330, [10], [Duplex Gate] solenoid. Press the Continue button. Press the Stop button. The Duplex Gate Solenoid comes on and then goes off. Y N Go to Flag 2. Check the circuit of the Duplex Gate Solenoid.

Actuate the Decurler Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Actuate the Top Transport Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Top Transport Sensor (GP 6-2, General Procedures).

Manually actuate and deactuate the Duplex Gate. The Duplex Gate moves freely. Y N Repair or replace the Duplex Gate (PL 10.14). The Duplex Gate is adjusted correctly (ADJ 10-9). Y N Perform the Duplex Gate Adjustment (ADJ 10-9).

Select SCP [Last 50] Fault Code listing. 10-110 Faults are also present. Y N Using the same paper that the customer used, run the same duplex job that the customer ran when the fault occurred. There is paper damage. Y N The Top Transport Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the Top Transport (proper overtravel). Y N Replace the Top Transport Sensor (PL 10.16). Enter dC330, [10], [Duplex Gate] solenoid. Press the Continue button. Press the Stop button. The Duplex Gate Solenoid comes on and then goes off. Y N Go to Flag 2. Check the circuit of the Duplex Gate Solenoid.

Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue button. The Top Transport Rolls rotate. Y N Check for binding or worn components in the Top Transport Drive system (PL 4.19). Go to the 8-705, Copy Damage RAP, to determine the cause of the paper damage. Go to the 10-110.

Manually actuate and deactuate the Duplex Gate. The Duplex Gate moves freely. A

B

Preliminary Working Document No Product Name Assigned

0/0/00 ?-797

Section Name

10-108, 10-109

Figure 1 10-108/10-109 Circuit Diagram (8008A)

Section Name

10-108, 10-109

0/0/00 ?-798

Preliminary Working Document No Product Name Assigned

Figure 2 PWB Location (7313)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-799

Section Name

10-108, 10-109

A

10-110 RAP Fault Code, 10-110, indicates that the trail edge of a print going to the Inverter Feeder/Stacker, did not leave the Top Transport Sensor, Q1012, within the specified number of the specified number of clock counts after the print lead edge actuated the sensor.

•

Worn or damaged Top Transport Pulleys and Belts (PL 10.14).

•

Worn or damaged Duplex Drive system components (PL 10.14).

Go to the 8-705, Print Damage RAP, to determine the cause of the paper damage.

Initial Actions •

Ensure that the Top Transport Sensor and Turn Roll area of the paper path are not obstructed.

•

Ensure that the Top Transport Sensor Actuator is not damaged, or binding.

•

Ensure that the Top Transport Baffles are attached to the cover and are properly seated.

Procedure Enter dC330, [10]. Actuate the Top Transport Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Top Transport Sensor (GP 6-2, General Procedures). The Top Transport Sensor actuates before going below the upper baffle, and the actuator goes below the cutout in the Top Transport (proper overtravel). Y N Replace the Top Transport Sensor (PL 10.16). Enter dC330, [10], [Duplex Gate] solenoid. Press the Continue button and then the Stop button. The Duplex Gate Solenoid energizes and then deenergizes. Y N Go to Flag 2. Check the circuit of the Duplex Gate Solenoid. Manually actuate and deactuate the Duplex Gate. The Duplex Gate moves freely. Y N Repair or replace the Duplex Gate (PL 10.14). The Duplex Gate is adjusted correctly (ADJ 10-9). Y N Perform the Duplex Gate Adjustment (ADJ 10-9). Enter dC330, [1-4], [main Drive/Start/Run] motor. Press the Continue button. The Top Transport Idlers and Rollers rotate. Y N Check for binding or worn components in the Top Transport drive system (PL 4.19). Enter dC726, [54]. Select [100] prints, [Top Tray]. Use the same paper that the customer was using. Press Continue. Examine the prints in the Top Tray. The prints are damaged. Y N Check the following: • Duplex Gate Solenoid adjustment (ADJ 10-9). •

Worn or dirty Top Transport Rolls (PL 10.15).

•

Worn or dirty Top Transport Slip Clutch (PL 10.14).

•

Decurler Setting

•

Worn or damaged Top Transport Drive system components (PL 4.19).

A Section Name

10-110

0/0/00 ?-800

Preliminary Working Document No Product Name Assigned

Figure 1 10-110 Circuit Diagram (8010A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-801

Section Name

10-110

Figure 2 Run Control PWB Location

Section Name

10-110

0/0/00 ?-802

Preliminary Working Document No Product Name Assigned

A

10-111 RAP Fault Code, 10-111, indicates that the trail edge of the print (A3 Mode) did not leave the Decurler Sensor, Q1011, within the specified number of clock counts after actuating the sensor.

B Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Transport Rolls rotate. Y N Check the following for wear or damage: • Top Transport Drive system (PL 10.14).

Initial Actions

•

Top Transport Clutch (PL 10.14).

•

Ensure that the Top Transport Baffles are attached to the cover and are seated properly.

•

Top Transport Pulleys and Belts (PL 10.14).

•

Ensure that the Decurler Sensor Actuator is not damaged and moves freely.

•

Top Transport Springs (PL 10.14).

•

Ensure that the paper path is not obstructed.

•

Decurler Drive system (PL 4.16).

Procedure

Check the following: • Decurler Jam Sensor is adjusted all the way into the paper path and the switch actuator moves freely

Enter dC330, [10]. Actuate the Decurler Sensor. The display changes from H to L. Y N Go to Flag 1. Check the circuit of the Decurler Sensor (GP 6-2, General Procedures). Clear the Fault Code. If Fault Code, 10-111, can not be cleared, switch off and then reset all the printer circuit breakers. Select A3 Mode. Enter dC106 and run the machine until Fault Code, 10-111, is declared (if Fault Code, 10-111, is not declared, go to the declared fault). A jammed print is observed. Y N Check the following: • Obstructed paper path •

Damaged paper path components

•

Loose or worn belts and pulleys in the Decurler Transport Drives (PL 4.16).

•

Decurler Setting

•

Decurler Exit Baffle Adjustment (ADJ 10-8).

Top

•

Obstructed paper path

•

Worn or dirty Top Transport Rolls (PL 10.14).

•

Worn or dirty Top Transport Slip Clutch (PL 10.14).

Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Decurler Belts rotate. Y N Check the Decurler Drive system for wear or damage (PL 4.16). Check the following: • Decurler Setting

The lead edge of the print arrived at the first Top Transport Drive Roll. Y N The jammed print is damaged. Y N Enter dC330, [Main Drive/Start Run] motor. Press the Continue button. The Decurler Belts rotate. Y N Check the Decurler Drive system and Decurler One-way Clutch for wear or dirt (PL 10.14).

•

Worn or damaged Top Transport Drive Belts (PL 10.14).

•

Worn or dirty Top Transport Slip Clutch (PL 10.14).

•

Worn or damaged Top Transport Pulleys and Belts (PL 10.14).

•

Damaged or missing Top Transport Springs (PL 10.14).

•

Worn or damaged Decurler Drives (PL 4.16).

Check the Decurler Setting. Check the following: • Obstructed paper path •

Damaged or worn paper path components

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

B

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Section Name

10-111

Figure 1 10-111 Circuit Diagram (8011A)

Section Name

10-111

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Preliminary Working Document No Product Name Assigned

A

B

10-112 RAP Fault Code, 10-112, indicates that a print did not actuate the Prefuser Sensor, Q1009, within the specified number of clock counts after it arrived at the Registration Sensor, in 3 pitch mode.

Initial Actions •

Ensure that the Prefuser Sensor and Reflector are not obstructed and that the Prefuser Sensor and Reflector are clean and in proper position.

•

Ensure that the Prefuser Transport is in the normal operating position.

•

The Fault Code, 10-112, occurring at print cycle-up may be due to a dirty or defective Registration Transport Sensor, Q861.

•

Ensure that the paper path is free from obstructions.

Damaged or contaminated Prefuser Transport Belts (PL 8.12).

•

Binding Prefuser Transport Bearings (part of the drive roll and idler shaft) (PL 8.12).

•

Worn Prefuser Transport Drive Coupling (PL 8.12).

•

Obstructed Prefuser Transport Manifold holes

•

If the above checks are good, go to GP 6-2 (Generic Sensor RAP, General Procedures) and ensure that all the sensor voltages are correct.

Check the following: • Obstructions in the paper path •

Condition of the paper

•

Operation and condition of the Transfer and Detack Dicorotrons (REP 9-39 and REP 9-49).

Procedure Enter dC106. Run the machine until Fault Code, 10-112 is declared. Inspect the image on the jammed print. The image is skewed or misregistered. Y N Enter dC330, [8]. Block and then clear the Registration Transport Sensor. The display changes from H to L. Y N Go to the 8-155.

•

•

Condition of the Pretransfer Baffle (PL 8.11).

•

Condition of the Stripper Finger Assembly (PL 9.3).

•

Condition and operation of the Transfer Assist Blade (PL 9.11).

•

Condition of the Detack Guide (PL 9.11).

Go to the 8-706 Printer Misregistration and Skew RAP.

Select [10]. Open, then close the Fuser Drawer. The Prefuser Sensor display changes from H to L. Y N Go to Flag 1. Check the circuit of the Prefuser Sensor (GP 6-2, General Procedures). Clear the Fault Code. If Fault Code, 10-112, can not be cleared, switch off and then reset all the printer circuit breakers. Enter dC106. Run the machine until Fault Code, 10-112, is declared (if Fault Code, 10-112, is not declared, go to the declared fault). The print is jammed or stopped before the Prefuser Transport. Y N Install a cheater in the Processor Interlock Bypass Switch. Select [Prefuser Vacuum] motor. Press the Continue button. The Prefuser Vacuum Motor comes on. Y N Select [Clear Outputs]. Go to the 10-706 Prefuser Vacuum Motor RAP. Place a sheet of paper (8 1/2 x 11 or A3 if available) on the Prefuser Transport. The vacuum holds the sheet on the Prefuser Transport. Y N Check the Prefuser Transport Assembly for vacuum leaks and restricted or damaged air ducts (PL 8.12). Select [Clear Outputs] [1-4] [Main Drive/Start Run] motor. Press the Continue button. The Prefuser Transport Belts rotate. Y N Select [Clear Outputs]. Check the Prefuser Transport Drive system for damaged or worn components (PL 4.16). Select [Clear Outputs]. Check the following: A

B

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Section Name

10-112

Figure 1 10-112 Circuit Diagram (8012A)

Section Name

10-112

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10-201 RAP Fault Code, 10-201, indicates that one of the following conditions exists: the Fuser did not reach the operating temperature within eight and one half minutes of start-up; that no change (decrease) in the Fuser Thermistor resistance has been detected for five and one half minutes; or no change (decrease) in Fuser Thermistor resistance was detected within 10 seconds after clearing Fault Code, 10-204.

Initial Actions •

Inspect the Fuser Roll Thermistors for debris or damage, and ensure that they are making proper contact with the Fuser Roll.

•

Ensure that the Fuser Roll Thermostat is adjusted correctly (ADJ 10-0).

•

Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1).

Procedure The Cavity Cooling Fan is turning. Y N Go to Flag 22. Check the circuit of the Cavity Cooling Fan. If there is a problem with the Cavity Fan return line go to wirenet 3DD. If the inputs to the Print Power Relay, K403, are missing go to the 4-703 (60 Hz), or go to the 4-704 (50 Hz), Print Power RAPs. The Cavity Cooling Fan is clean and has good airflow. Y N Clean or replace the Cavity Cooling Fan and Screen (PL 9.8). Enter then exit diagnostics (Press button R). If fault code 10-201 can not be cleared, switch off and then reset the machine circuit breakers. Open the Fuser drawer. Enter dC140, [Fuser Values]. Wait until the Thermistor value for the Inboard and Outboard Thermistors are both 10. DO NOT place any cheaters in any interlock switches. Close the fuser drawer ensuring that the fuser interlock switch is properly actuated. The fuser rod turns on. Y N Go to the 10-714. The Inboard or Outboard Thermistor value drops below 10 before a 10-201 fault is declared. Y N Open the fuser drawer. Go to the 10-714. The value for the Outboard Thermistor is less then 10. Y N Open the fuser drawer. Go to the 10-714. Open the fuser drawer. Go to the 10-711.

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Section Name

10-201

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

Section Name

10-201

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

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Section Name

10-201

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

Section Name

10-201

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10-202 RAP

Y

Fault Code, 10-202, indicates that the Fuser has reached a temperature of 455° F (overtemperature).

Procedure Ensure that the fuser is below operating temperature before beginning this RAP. +15 VDC is available at P287-2 of MIB PWB#1. Y N Go to Flag 3. Check the wire 1009A. If ok, go to the 1-715 +15 VDC RAP.

N Go to Flag 34 and Flag 35. Check the wires for a short, if no short is found replace the MIN ADA PWB #1 (PL 1.8).

DO NOT place a cheater in the Printer Interlock Bypass switch. Disconnect the Inboard Fuser Roll Thermistor, RT1003. Measure resistance of the Inboard Fuser Roll Thermistor, RT1003. Resistance is 2 Megohms at room temperature or 8.5K to 11.5K Ohms at operating temperature (410° to 425°F). Y N Replace the Inboard Fuser Roll Thermistor, RT1003, (PL 10.4). Reconnect the Inboard Fuser Roll Thermistor, RT1003. Disconnect P259 from J-3 at the MIB PWB#2. DO NOT place a cheater in the Printer Interlock Bypass switch. Resistance is 2 Megohms at room temperature or 8.5K to 11.5K Ohms at operating temperature 410° to 425°F). Y N Go to Flag 30 and Flag 31. Check the wires for a short.

+15 VDC is available from P287-2 to P287-5 of MIB PWB#1. Y N Go to Flag 4. Check the wire 1008A. -15 VDC is available at P 287-3 of the MIB PWB#1. Y N Go to Flag 5. Check the wire 1010A. If ok, go to the 1-716 -15 VDC RAP. Inspect the Outboard Fuser Roll Thermistor, RT1001, for debris and proper contact to the Fuser Roll. The Outboard Fuser Roll Thermistor, RT1001, is making proper contact. Y N Clean, repair, or replace the Fuser Roll Thermistor, RT1001 (PL 10.4). Check the Fuser Roll Thermostat adjustment (ADJ 10-0). The Fuser Roll Thermostat adjustment is within specification. Y N Adjust the Fuser Roll Thermostat (ADJ 10-0). DO NOT place a cheater in the Printer Interlock Bypass switch. Disconnect the Outboard Fuser Roll Thermistor, RT1001. Measure resistance of the Outboard Fuser Roll Thermistor, RT1001. Resistance is 2 Megohms at room temperature or 8.5K to 11.5K Ohms at operating temperature (410° to 425°F). Y N Replace the Outboard Fuser Roll Thermistor, RT1001, (PL 10.4). Reconnect the Outboard Fuser Roll Thermistor, RT1001. Disconnect P208 from J-3 at the MIB PWB#1. DO NOT place a cheater in the Printer Interlock Bypass switch. Resistance is 2 Megohms at room temperature or 8.5K to 11.5K Ohms at operating temperature (410° to 425°F). Y N Go to Flag 36 and Flag 37. Check the wires for a short.

Reconnect P259 and clear any faults. 2 VDC to +9.5 VDC is available at J3-7 (+) to J3-8 (-) of the MIB PWB#2. Y N Replace the MIB PWB#2 (PL 1.8). 2 to +9.5 VDC is available at TS45 (+) to TS46 (-) of the MIN ADA PWB #2. Y N Go to Flag 32 and Flag 33. Check the wires for a short, if no short is found replace the MIN ADA PWB #2 (PL 1.8). Open the fuser Drawer and allow the fuser to cool below operating temperature. Disconnect HR12/P1. Refer to GP 7, Section 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter dC701, [Fuser Roll Temp]. Close the fuser drawer. The Fuser Heat Rod is on. Y N Open the fuser drawer. Reconnect HR12/P1. Disconnect HR14/P1. Refer to GP 8, Section 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter dC701, [Thermistor Cal]. Close the fuser drawer. The fuser heat rod comes on. Y N Open the fuser drawer. Reconnect HR14/P1. Check the following for intermittent operation: • Thermistor CAL ADJ 10-17

Reconnect P208 and clear any faults. 2 VDC to +9.5 VDC is available at J3-7 (+) to J3-8 (-) of the MIB PWB#1. Y N Replace the MIB PWB#1 (PL 1.8). 2 to +9.5 VDC is available at TS39 (+) to TS40 (-) of the MIN ADA PWB #1.

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•

Fuser Roll Thermostat Adjustment (ADJ 10-0) and operation

•

Metering Roll Thermostat Adjustment (ADJ 10-1) and operation

•

Fuser Roll Thermistors (RT1001 and RT1001)

•

Metering Roll Thermistor

•

Fuser Relay, K1007

•

The MIN ADA PWB #1

•

The MIN ADA PWB #2

•

The MIB#1 PWB

•

Wiring and connectors

•

Fuser Heat Rod

B Section Name

10-202

A

B Open the fuser drawer. Reconnect HR14/P1. Close the Fuser and all doors and covers. Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Fuser Relay, K1002. Y N +5 VDC is available at TS 60 of the MIN ADA PWB #2. Y N Go to wirenet 1005N. Check the wires for an open circuit. +5 VDC is available at pin 3 of the Fuser Relay, K1002. Y N Go to Flag 6. Check the yellow wires. +5 VDC is available at pin 4 of the Fuser Relay, K1002. Y N Replace the Fuser Relay, K1002 (PL 1.3).

C Y

N Replace the Fuser Relay, K1007 (PL 1.3).

Go to Flag 123. Check the orange wires. Go to Flag 123. Check the orange wires for a short. There is a short in the orange wires. Y N Disconnect P233 from J2 on the MIN DIO PWB. Greater then 100 ohms is measured from J2-7 on the MIN DIO PWB to machine frame. Y N Replace the Fuser Relay, K1007 PL 1.3. Replace the MIN DIO PWB PL 1.8. Replace or repair the orange wires.

+ 5 VDC is available at TS 16 of the MIN ADA PWB #2. Y N Go to Flag 2. Check for an open circuit. Replace the MIN ADA PWB #2 (PL 1.8). Go to Flag 2, Flag 7, and Flag 10. Check the wires for a short circuit to ground. A short circuit to ground exists. Y N Go to Flag 1. Check the wiring of the Fuser Roll Thermistor for a short circuit to ground. A short circuit to ground exists. Y N Replace the Fuser Relay, K1002 (PL 1.3). Go to Flag 1. Repair or replace the Fuser Thermistor wiring. Repair or replace the wire. Close the Fuser and all doors and covers. Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Fuser Relay, K1007. Y N +5 VDC is available from TS 60 of the MIN ADA PWB #2 to TS44 of the MIN DIO PWB. Y N +5 VDC is available at TS60 of the ADA PWB #2. Y N If +5 VDC is available at J1-10, replace the MIN ADA PWB #1. If +5 VDC is not available, go to Flag 25 and check the wire 1000N. Go to the 10-709, MIB PWB RAP. +5 VDC is available at pin 4 of the Fuser Relay, K1007. Y N Go to Flag 1. Check the yellow wires. +5 VDC is available at pin 3 of the Fuser Relay, K1007. C Section Name

10-202

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

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Section Name

10-202

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

Section Name

10-202

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

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Section Name

10-202

A +15 VDC is available at P287-2 of MIB PWB. Y N Go to Flag 9. Check the wire 1009A.

10-203 (60HZ) RAP Fault Code, 10-203, indicates that the voltage to the Fuser is less than 170 VAC.

Procedure

-15 VDC is available at P287-3 of MIB PWB. Y N Go to Flag 10. Check the wire 1010A.

WARNING Performing service actions in the vicinity of the Printer Compressor represents a safety hazard. Use caution when performing service in this area. When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when performing service in this area. +15 VDC is available at TS57 of the MIN ADA PWB #1. Y N Go to Flag 12. Check the wire 1009C. If ok, go to the 1-715 +15 VDC RAP.

+15 VDC is available from P287-2 to P287-5 of MIB PWB. Y N Go to Flag 11. Check the wire 1008A. +1.0 to 7.0 VDC is available from P242-17 to P242-16 of MIN ADA PWB. Y N +1.0 to 7.0 VDC is available at TS6 of MIB PWB. Y N Replace the MIB PWB (PL 1.8).

+15 VDC is available from TS57 to TS56 of MIN ADA PWB#1. Y N Go to Flag 13. Check the wire 1008C.

+1.0 to 7.0 VDC is available from P208-11 to P208-12 of MIB PWB. Y N Go to Flag 5. Check the red wire.

-15 VDC is available at TS55 of the MIN ADA PWB#1. Y N Go to Flag 14. Check the wire 1010C. If ok, go to the 1-716 -15 VDC RAP.

Go to Flag 6. Check the brown wire. Greater than 170 VAC is available from pin B to pin D of Circuit Breaker, CB102. Y N Go to the 1-700 AC Input Power RAP.

Enter dC140. Select [Fuser Values]. The Fuser Analog Voltage is within specification. Y N Replace the MIN ADA PWB #1 (PL 1.8).

Greater than 170 VAC is available from pin 1 to pin 2 of Fuser Power Relay, K1001. Y N Disconnect wire 6 (pin 2) at Fuser Power Relay, K1001. Greater than 85 VAC is available on wire 6. Y N Go to Flag 4. Check the wire 6.

Assume a momentary low line voltage condition occurred.

Go to Flag 2. Check the wire 5. Greater than 85 VAC is available at pin 2 of Fuser Transformer, T1001. Y N Go to Flag 1. Check the wire 5A. Greater than 85 VAC is available at pin 1 of Fuser Transformer, T1001. Y N Go to Flag 3. Check the wire 6A. 10 to 15 VAC is available from pin 3 to pin 4 of Fuser Transformer, T1001. Y N Replace the Fuser Transformer (PL 1.1). 10 to 15 VAC is available from J3-6 to J3-5 on MIB PWB. Y N Go to Flag 7 and Flag 8. Check the violet and gray wires. A Section Name

10-203

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Figure 1 10-203 Circuit Diagram (8023A)

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Section Name

10-203

A 10 to 15 VAC is available from J3-6 to J3-5 on MIB PWB. Y N 10 to 15 VAC is available at J3-6 of the MIB PWB. Y N Go to Flag 7. Check the violet wire.

10-203 (50HZ) RAP Fault Code, 10-203, indicates that the voltage to the Fuser is less than 170 VAC.

Procedure WARNING

Go to Flag 8. Check the gray wire.

Performing service actions in the vicinity of the Printer Compressor, represents a safety hazard. Use caution when performing service in this area. When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when performing service in this area. +15 VDC is available at TS57 of the MIN ADA PWB #1. Y N Go to Flag 12. Check the wire 1009C. If ok, go to the 1-715 +15 VDC RAP.

+15 VDC is available at P287-2 of MIB PWB. Y N Go to Flag 9. Check the wire 1009A. -15 VDC is available at P287-3 of MIB PWB. Y N Go to Flag 10. Check the wire 1010A.

+15 VDC is available from TS57 to TS56 of MIN ADA PWB#1. Y N Go to Flag 13. Check the wire 1008C.

+15 VDC is available from P287-2 to P287-5 of MIB PWB. Y N Go to Flag 11. Check the wire 1008A.

-15 VDC is available at TS55 of the MIN ADA PWB#1. Y N Go to Flag 14. Check the wire 1010C. If ok, go to the 1-716 -15 VDC RAP. Greater than Phase to Phase minimum voltage is available from pin H to pin B of Circuit Breaker, CB104. Y N Go to the 1-707 AC Input Power RAP (50HZ). Greater than Phase to Phase minimum voltage is available from pin 1 to pin 2 of Fuser Power Relay, K1001. Y N Disconnect wire 4A (pin 2) at Fuser Power Relay, K1001. Greater than Phase to Earth minimum voltage is available at wire 4A. Y N Go to Flag 4. Check the wire 4A.

+1.0 to 7.0 VDC is available from P242-17 to P242-16 of MIN ADA PWB. Y N +1.0 to 7.0 VDC is available at TS6 of MIB PWB. Y N Replace the MIB PWB (PL 1.8). +1.0 to 7.0 VDC is available from P208-11 to P208-12 of MIB PWB. Y N Go to Flag 6. Check the brown wire. Go to Flag 5. Check the red wire. Enter dC140. Select [Fuser Values]. The Fuser Analog Voltage is within specification. Y N Replace the MIN ADA PWB #1 (PL 1.8). Assume a momentary low line voltage condition occurred.

Go to Flag 2. Check the wire 5C. Greater than Phase to Earth minimum voltage is available at pin 2 of Fuser Transformer, T1001. Y N Go to Flag 1. Check the wire 5C. Greater than Phase to Earth minimum voltage is available at pin 1 of Fuser Transformer, T1001. Y N Go to Flag 3. Check the wire 4E. 10 to 15 VAC is available from pin 3 to pin 4 of Fuser Transformer, T1001. Y N Replace the Fuser Transformer (PL 1.1). A Section Name

10-203

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

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Section Name

10-203

10-204, 10-206 RAP Fault Code, 10-204, indicates that the Fuser temperature is 35 degrees below operating temperature after the Fuser had reached operating temperature. Fault Code, 10-206, indicates that the Fuser temperature momentarily dropped 35 degrees below operating temperature after the Fuser reached operating temperature. This is not a declared fault but is logged in NVM.

Procedure WARNING When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when performing service in this area. CAUTION Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to the cover may occur. The system can fault with an undertemp problem while it is in standby mode, or while the system is printing. The system faults in standby mode. Y N

WARNING AC Power is present in the Line Interface Assembly whenever the printer power cord is plugged into the wall outlet. Use caution when working in this area. Disconnect the printer power cord(s). Open the Line Interface Assembly. Pull out the Fuser Drawer. Disconnect HR11 (at the outboard end of the Fuser Roll). Check for continuity between K1001-5 (in the Line Interface Assembly) and HR11. The wiring is correct. Y N Go to Flag 6. Check the wiring from HR11 to K1001-5. Ensure that the connectors P252-1, and P/J4-1 are properly connected.

A Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Thermistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at operating temperature. Y N Replace the Metering Roll Thermistor (PL 10.7). Inspect the Outboard Fuser Roll Thermistor, RT1001, for debris and proper contact to the Fuser Roll. The Outboard Fuser Roll Thermistor, RT1001, makes proper contact. Y N Clean, repair, or replace the Outboard Fuser Roll Thermistor, RT1001, (PL 10.4). Disconnect the Outboard Fuser Roll Thermistor, RT1001. Measure the resistance of the Fuser Roll Thermistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at operating temperature. Y N Replace the Fuser Roll Thermistor (PL 10.7). Check the last 50 Fault Code Listing. Fault Code, 10-210, is listed at the same copy count as this Fault Code. Y N Enter dC606. Select [10] prints. Press the Continue button, wait 10 seconds and press the Stop button. The Cavity Cooling Fan comes on at low speed. Y N Go to Flag 22. Check the circuit of the Cavity Cooling Fan. If there is a problem with the Cavity Fan return line go to the 3DD wirenet. If the inputs to the Print Power Relay, K403, are missing go to the 4-703 (60 Hz), or go to the 4-704 (50 Hz), Print Power RAPs. Enter then exit diagnostics (Press button R). If fault code 10-201/10-204 can not be cleared, switch off and then reset the machine circuit breakers. Open the Fuser drawer. Enter dC140, [Fuser Values]. Wait until the Thermistor value for the Inboard and Outboard Thermistors are both 10. DO NOT place any cheaters in any interlock switches. Close the Fuser Drawer ensuring that the Fuser Interlock Switch is properly actuated. The fuser rod turns on. Y N Go to the 10-714 RAP.

Reconnect HR11. Disconnect HR12 (at the inboard end of the Fuser Roll). Check for continuity between K1002-2 (in the Line Interface Assembly) and HR12. The wiring is correct. Y N Go to Flag 5. Check the wiring from HR12 to K1002-2. Ensure that connectors P2531, and P/J3-1 are properly connected.

The Inboard or Outboard Thermistor value drops below 10 before a 10-201 fault is declared. Y N Open the fuser drawer. Go to the 10-714 RAP.

Reconnect HR12. Disconnect HR14 (at the inboard end of the Fuser Roll). Check for continuity between K1007-2 (in the Line Interface Assembly) and HR14. The wiring is correct. Y N Go to Flag 111. Check the wiring from HR14 to K1007-2 to HR14. Ensure that the connectors P/J255-1, and P/J11-1 are properly connected.

The value for the Outboard Thermistor is less then 10. Y N Open the fuser drawer. Go to the 10-714 RAP.

Reconnect HR14. Restart this RAP and follow the Yes path in the first statement. Inspect the Metering Roll Thermistor for debris and proper contact to the Metering Roll. The Metering Roll Thermistor makes proper contact. Y N Clean, repair, or replace the Metering Roll Thermistor (PL 10.7). A Section Name

10-204, 10-206

Open the fuser drawer. Go to the 10-711 RAP Go to the 10-210 or go to the 10-210.

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

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Section Name

10-204, 10-206

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

Section Name

10-204, 10-206

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

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Section Name

10-204, 10-206

A

10-205 RAP Fault Code, 10-205, indicates that the voltage to the Fuser is greater than 265 VAC.

Initial Actions •

Inspect the Fuser System for overheat damage.

•

Troubleshoot this fault by using peak hold on the meter, and switching off and then resetting all the printer circuit breakers for each step of this RAP.

B

C Less than +7.0 VDC is available from P242-17 to P242-16 of MIN ADA PWB. Y N Less than +7.0 VDC is available at TS6 of MIB PWB. Y N Replace the MIB PWB (PL 1.8). Less than +7.0 VDC is available from P208-11 to P208-12 of MIB PWB. Y N Go to Flag 5. Check the red wire.

Procedure Go to Flag 6. Check the brown wire.

WARNING Performing service actions in the vicinity of the Printer Compressor represents a safety hazard. Use caution when performing service in this area.

Replace the MIN ADA PWB #1 (PL 1.8).

When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when performing service in this area.

60Hz - Go to the 1-700 AC Input Power RAP. 50Hz - Go to the 1-707 AC Input Power RAP.

Greater than 130 VAC is available at pin 4 of Fuser Power Relay, K1001. Y N Greater than 130 VAC is available at pin 5 of Fuser Power Relay, K1001. Y N Less than 130 VAC is available at pin 2 of Fuser Transformer, T1001. Y N Go to Flag 1. Check the wire 5A.

60Hz - Go to the 1-700 AC Input Power RAP. 50Hz - Go to the 1-707 AC Input Power RAP.

Less than 130 VAC is available at pin 1 of Fuser Transformer, T1001. Y N Go to Flag 2. Check the wire 6A. Less than 15 VAC is available from pin 3 to pin 4 of Fuser Transformer, T1001. Y N Replace the Fuser Transformer (PL 1.1). Less than 15 VAC is available from pin 6 to pin 5 of J3 on MIB PWB. Y N Less than 15 VAC is available at TS3 of MIB PWB. Y N Go to Flag 4. Check the violet wire. Go to Flag 3. Check the gray wire. +15 VDC is available at P287-2 of MIB PWB. Y N Go to Flag 7. Check the wire 1009A. -15 VDC is available at P287-3 of MIB PWB. Y N Go to Flag 8. Check the wire 1010A. +15 VDC is available from P287-2 to P287-5 of MIB PWB. Y N Go to Flag 9. Check the wire 1008A. A

B

C

Section Name

10-205

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Preliminary Working Document No Product Name Assigned

Figure 1 10-205 Circuit Diagram (8052A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-825

Section Name

10-205

A

10-210 (60HZ) RAP Fault Code, 10-210, indicates that the Metering Roll did not reach a temperature of 250°F within 7 minutes of start-up or that the Metering Roll temperature is below 250°F in Print (Under-Temperature).

C

D

E +5 VDC is available at pin 4 of the Metering Roll Relay, K1004. Y N Replace the Metering Roll Relay K1004 (PL 1.3). Go to Flag 8. Check the green wire.

Initial Actions •

B

Replace the Metering Roll Relay K1004 (PL 1.3).

Inspect the Fuser Roll Thermistor for debris or damage, and ensure that it is making proper contact with the Fuser Roll.

•

Ensure that the Fuser Roll Thermostat is adjusted correctly (ADJ 10-0).

•

Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1).

Go to Flag 4. Check the wire 17. 115 VAC is available at P1-1 (Metering Roll Heater side of HT2). Y N 115 VAC is available at HT2-2. Y N 115 VAC is available at pin 2 of Fuser Power Relay, K1001. Y N 115 VAC is available at pin D of CB102. Y N Go to the 1-700 AC Input Power RAP.

Procedure Place a cheater in the Printer Interlock Bypass Switch. Check the Metering Roll Heater (use Temperature Tape). The Metering Roll Heater is heating up. Y N Remove pin 1 from HT2 of the Metering Roll Heater. Measure the voltage to the Metering Roll Heater. 115 VAC is available at HT2-1. Y N Open the Line Interface Box. 115 VAC is available at pin 1 of Metering Roll Relay, K1004. Y N 115 VAC is available at pin 1 of Fuser Power Relay, K1001. Y N 115 VAC is available at pin B of CB102. Y N Go to the 1-700 AC Input Power RAP.

Go to Flag 2. Check the wire 6. 115 VAC is available at pin 5 of Fuser Power Relay, K1001. Y N Replace the Fuser Power Relay K1001 (PL 1.3). Go to Flag 5. Check the wire 14. Replace the Metering Roll Heater (PL 10.7).

Go to Flag 7. Check the wire 5.

Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of the Metering Roll Relay, K1004. Y N +5 VDC is at TS13 to TS60 of the MIN ADA PWB #2. Y N +5 VDC is at TS 60 of the MIN ADA PWB #2. Y N Replace the MIN ADA PWB #2 (PL 1.3).

115 VAC is available at pin 4 of Fuser Power Relay, K1001. Y N Replace the Fuser Power Relay K1001 (PL 1.3). Go to Flag 3. Check the wire 13. 115 VAC is available at pin 2 of Metering Roll Relay, K1004. Y N Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of the Metering Roll Relay, K1004. Y N +5 VDC is at TS13 to TS60 of the MIN ADA PWB #2. Y N Check for +5 VDC at TS 60 of the MIN ADA PWB #2, if +5 VDC is present, go to the 10-709, MIB PWB RAP. If +5 VDC is not present, replace the MIN ADA PWB #2 (PL 1.8).

Go to the 10-709 MIB PWB RAP. +5 VDC is available at pin 3 of the Metering Roll Relay, K1004. Y N Go to Flag 1. Check the blue wire. +5 VDC is available at pin 4 of the Metering Roll Relay, K1004. Y N Replace the Metering Roll Relay K1004 (PL 1.3).

+5 VDC is available at pin 3 of the Metering Roll Relay, K1004. Y N Go to Flag 1. Check the blue wire.

Go to Flag 8. Check the green wire. Replace the Metering Roll Relay K1004 (PL 1.3).

A

B

C

Section Name

10-210

D

E

A 0/0/00 ?-826

Preliminary Working Document No Product Name Assigned

A Remove the cheater from the Printer Interlock Bypass Switch. Inspect the Metering Roll Thermistor for debris and proper contact to the Metering Roll. The Metering Roll Thermistor makes proper contact. Y N Clean, repair, or replace the Metering Roll Thermistor (PL 10.7). Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Thermistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at operating temperature. Y N Replace the Metering Roll Thermistor (PL 10.7). Enter dC701. Select [Fuser Adjustments]. Adjust the Metering Roll Temperature (ADJ 10-7).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-827

Section Name

10-210

Figure 1 10-210 Circuit Diagram (8053A)

Section Name

10-210

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Preliminary Working Document No Product Name Assigned

Figure 2 10-210 Circuit Diagram (8027A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-829

Section Name

10-210

A

10-210 (50HZ) RAP Fault Code, 10-210, indicates that the Metering Roll did not reach a temperature of 250°F within 7 minutes of start-up or that the Metering Roll temperature is below 250°F in Print (Under-Temperature).

C

D

E +5 VDC is available at pin 4 of the Metering Roll Relay, K1004. Y N Replace the Metering Roll Relay, K1004 (PL 1.2). Go to Flag 8. Check the green wire.

Initial Actions •

B

Replace the Metering Roll Relay, K1004 (PL 1.2).

Inspect the Fuser Roll Thermistor for debris or damage, and ensure that it is making proper contact to the Fuser Roll.

•

Ensure that the Fuser Roll Thermostat is adjusted correctly (ADJ 10-0).

•

Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1).

Go to Flag 4. Check the wire, 17. Phase to Earth voltage is available at P1-1 (Metering Roll Heater side of HT2). Y N Phase to Earth voltage is available at HT2-2. Y N Phase to Earth voltage is available at pin 2 of Fuser Power Relay, K1001. Y N Phase to Earth voltage is available at pin H of CB104. Y N Go to the 1-707 AC Input Power RAP.

Procedure Place a cheater in the Printer Interlock Bypass Switch. Check the Metering Roll Heater (use Temperature Tape (ADJ 10-7). The Metering Roll Heater is heating up. Y N Remove pin 1 from HT2 of the Metering Roll Heater. Measure the voltage to the Metering Roll Heater. Phase to Earth voltage is available at HT2-1. Y N Open the Line Interface Box. Phase to Earth voltage is available at pin 1 of Metering Roll Relay, K1004. Y N Phase to Earth voltage is available at pin 1 of Fuser Power Relay, K1001. Y N Phase to Earth voltage is available at pin B of CB104. Y N Go to the 1-707 AC Input Power RAP.

Go to Flag 2. Check the wire 4A. Phase to Earth voltage is available at pin 5 of Fuser Power Relay, K1001. Y N Replace the Fuser Power Relay, K1001 (PL 1.2). Go to Flag 5. Check the wire 14. Replace the Metering Roll Heater (PL 10.7).

Go to Flag 7. Check the wire 5.

Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Metering Roll Relay, K1004. Y N +5 VDC is available at TS 13 to TS60 of the MIN ADA PWB #2. Y N +5 VDC is at TS60 of the MIN ADA PWB #2. Y N Replace the MIN ADA PWB #2 (PL 1.8).

Phase to Earth voltage is available at pin 4 of Fuser Power Relay, K1001. Y N Replace the Fuser Power Relay, K1001 (PL 1.2). Go to Flag 3. Check the wire 13. Phase to Earth voltage is available at pin 2 of Metering Roll Relay, K1004. Y N Use Peak + Voltage. Greater than + 4 VDC is available from pin 3 to pin 4 of the Metering Roll Relay, K1004. Y N +5 VDC is available at TS13 to TS60 of the MIN ADA PWB #2. Y N Check for +5 VDC at TS60 of the MIN ADA PWB#2. If +5 VDC is present, go to the 10-709 MIB PWB RAP. If +5 VDC is not present, replace the MIN ADA PWB #2 (PL 1.8).

Go to the 10-709 MIB PWB RAP. +5 VDC is available at pin 3 of Metering Roll Relay, K1004. Y N Go to Flag 1. Check the blue wire. +5 VDC is at pin 4 of the Metering Roll Relay,K1004. Y N Replace the Metering Roll Relay, K1004 (PL 1.2).

+5 VDC is available at pin 3 of the Metering Roll Relay, K1004. Y N Go to Flag 1. Check the blue wire.

Go to Flag 8. Check the green wire. Replace the Metering Roll Relay, K1004 (PL 1.2).

A

B

C

Section Name

10-210

D

E

A 0/0/00 ?-830

Preliminary Working Document No Product Name Assigned

A Remove the cheater from the Printer Interlock Bypass Switch. Inspect the Metering Roll Thermistor for debris and proper contact to the Metering Roll. The Metering Roll Thermistor makes proper contact. Y N Clean, repair, or replace the Metering Roll Thermistor (PL 10.7). Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Thermistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at operating temperature. Y N Replace the Metering Roll Thermistor (PL 10.7). Enter [dC701] Adjust the Metering Roll Temperature (ADJ 10-7).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-831

Section Name

10-210

Figure 1 10-210 (50 HZ) Circuit Diagram (8019A)

Section Name

10-210

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Preliminary Working Document No Product Name Assigned

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

Preliminary Working Document No Product Name Assigned

0/0/00 ?-833

Section Name

10-210

10-211 RAP Fault Code, 10-211, indicates that the Metering Roll has exceeded a temperature of 380°F (Over-Temperature).

Procedure Inspect the Metering Roll Thermistor for debris and proper contact to the Metering Roll. The Metering Roll Thermistor makes proper contact. Y N Clean, repair, or replace the Metering Roll Thermistor (PL 10.7). DO NOT bypass any Printer Interlock. Disconnect the Metering Roll Thermistor. Measure the resistance of the Metering Roll Thermistor. Resistance is 2 Megohms at room temperature or 17K to 75K Ohms at operating temperature. Y N Replace the Metering Roll Thermistor (PL 10.7). Greater than +4 VDC is available from pin 3 to pin 4 of Metering Roll Relay, K1004. Y N Replace the Metering Roll Relay, K1004 (PL 1.3). Go to Flag 2. Check the green wire for a short circuit to ground. A short circuit to ground exists. Y N Go to Flag 1. Check the wiring of the Metering Roll Thermistor for a short circuit to ground. A short circuit to ground exists. Y N Replace the Metering Roll Relay, K1004 (PL 1.3). Go to Flag 1. Check the wiring in the Metering Roll Thermistor circuit. The checks ok. Y N Repair the wiring.

wiring

Go to the 10-709 MIB PWB RAP. Go to Flag 2. Repair or replace the green wire.

Section Name

10-211

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Preliminary Working Document No Product Name Assigned

Figure 1 10-211 Circuit Diagram (8029A)

10-212, 10-217 RAP

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

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

Preliminary Working Document No Product Name Assigned

0/0/00 ?-835

Section Name

10-211

10-213, 10-218 RAP

Initial Actions Perform the following:

Fault Code, 10-213, indicates that the Cam-Out Sensor, Q1003, was unblocked during cycle down.

•

Ensure that the Cam-In Sensor is clean and not obstructed.

•

Ensure that the Fuser Camming Brake is not being actuated when the fuser drawer is closed. Be sure to check the Ozac tubes and or Cleaner vacuum duct as these items have been known to contact the brake.

Fault Code, 10-218, indicates that the Cam-Out Sensor, Q1003, was unblocked during machine initialization.

•

If the Camming Motor runs continuously, Go to the 10-710 Camming Motor Runs Continuously RAP.

Initial Actions

Procedure Enter dC330, [10], [Camming] Motor. Press the Continue button. The Cam-In Sensor display changes from L to H. Y N Check the Camming Flag. The Camming Flag is OK. Y N Repair or replace the Camming Flag (PL 10.5). Go to Flag 1. Check the circuit of the Cam-In Sensor, Q1002, GP 6-2 (Generic Sensor Rap, General Procedures). Check the Cam-In Sensor and Camming Flag for debris and or damage. Clean, repair, or replace the Cam-In Sensor or Camming Flag (PL 10.5).

Perform the following: •

Ensure that the Cam-Out Sensor is clean and not obstructed.

•

Ensure that the Fuser Camming Brake is not being actuated when the fuser drawer is closed. Be sure to check the Ozac tubes and or Cleaner vacuum duct as these items have been known to contact the brake.

•

If the Camming Motor runs continuously, go to the 10-710 Camming Motor Runs Continuously RAP.

Procedure Enter dC330, [10], [Camming] Motor. Press the Continue button. The Cam-Out Sensor display changes from L to H. Y N Check the Camming Flag. The Camming Flag is OK. Y N Repair or replace the Camming Flag (PL 10.5). Go to Flag 2. Check the circuit of the Cam-Out Sensor, Q1003, (GP 6-2, General Procedures). Check the Cam-Out Sensor and Camming Flag for debris and or damage. Clean, repair, or replace the Cam-Out Sensor or Camming Flag (PL 10.5).

Section Name

10-212, 10-217, 10-213, 10-218

0/0/00 ?-836

Preliminary Working Document No Product Name Assigned

A Check the Cam-Out and Cam-In Sensors for debris or damage. Clean, repair, or replace the Sensors (PL 10.5).

10-214, 10-215, 10-219 RAP Fault Code, 10-214, indicates that the Camming Motor, MOT1004, failed to stop during cam-in while in Print. Fault Code, 10-215, indicates that the Camming Motor, MOT1004, failed to stop during camout while in Print. Fault Code, 10-219, indicates that the Camming Motor, MOT1004, failed to stop during camout at machine initialization.

Initial Actions Perform the following: •

Inspect the Camming Flag, Camming Motor Brake, Cam-In Sensor, and Cam-Out Sensor for debris or damage.

•

Ensure that the Fuser Camming Brake is not being actuated when the fuser drawer is closed. Be sure to check the Ozac tubes and or Cleaner vacuum duct as these items have been known to contact the brake.

•

If the Camming Motor runs continuously, go to the 10-710 Camming Motor Runs Continuously RAP.

Procedure Enter dC330, [10], [Camming] motor. Press the Continue button. The Cam-In Sensor display changes from L to H. Y N Go to Flag 1. Check the circuit of the Cam-In Sensor, Q1002, GP 6-2 Generic Sensor RAP, General Procedures). Press the Stop button. Inspect the Camming Flag for damage or wear. The Camming Flag is OK. Y N Repair or replace the Camming Flag (PL 10.5). Inspect the Camming Motor Brake. Camming Motor Brake is OK. Y N Clean, repair, or replace the Camming Motor Brake (part of the Camming Motor assembly) (PL 10.3). Press the Continue button, then the Stop button. The Camming Motor Brake operates correctly. (The Camming Motor stops in the correct location, the flag is covering the Cam Out Sensor and the Pressure Roll is cammed out.) Y N Replace the Camming Motor Brake (part of the Camming Motor Assembly) (PL 10.3). Press the Continue button, then the Stop button. The Cam-Out Sensor display changes from H to L. Y N Go to Flag 2. Check the circuit of the Cam-Out Sensor, Q1003, (GP 6-2, General Procedures). A Preliminary Working Document No Product Name Assigned

0/0/00 ?-837

Section Name

10-214, 10-215, 10-219

Figure 1 10-212/10-213/10-214/10-215/10-217/10-218/10-219 Circuit Diagram (8030A)

10-216 RAP Section Name

10-214, 10-215, 10-219

0/0/00 ?-838

Preliminary Working Document No Product Name Assigned

A Fault Code, 10-216, indicates that the Camming Motor, MOT1004, failed to operate when commanded to do so. This fault code will cause the machine to disable the +24 VDC section of the Low Voltage Power Supply. A loss of +24 VDC from the LVPS will declare a false, 10-216, during Power-Up.

Initial Actions

Check the Camming Motor Brake (part of the Camming Motor Assembly), if the brake is OK or cannot be repaired, replace the Camming Motor Assembly (PL 10.3). Select [Clear Outputs]. Inspect the Camming Flag for damage or wear. The Camming Flag is OK. Y N Repair or replace the Camming Flag (PL 10.5).

WARNING If the Camming Motor is in a thermal overheat condition it will run when it resets itself. Perform the following: •

Ensure that the Pressure Roll is not partially cammed in.

•

Ensure that the Camming Motor Brake (part of the Camming Motor assembly) is not on, or that the Camming Assembly is not binding.

•

If the Camming Motor runs continuously go to the 10-710 Camming Motor Runs Continuously RAP.

•

Ensure that all power cords are correctly installed and that all circuit breakers are on.

•

Ensure that the Air Knife Solenoid is not shorted (has a resistance of 3 to 5 ohms). A good Solenoid should measure 30 to 40 ohms.

Procedure

Select [Camming] motor. Press the Continue button. The Cam-In Sensor display changes from H to L. Y N Go to Flag 1. Check the circuit of the Cam-In Sensor, Q1002, (GP 6-2, General Procedures). The Cam-Out Sensor display changes from H to L. Y N Go to Flag 2. Check the circuit of the Cam-Out Sensor, Q1003, (GP 6-2, General Procedures). Check the Cam-In Sensor for debris or damage. Clean, repair, or replace the Cam-In Sensor or Camming Flag (PL 10.5).

Connect a jumper wire between TS 53 and TS37 on the PHN DIO PWB #2 to re-enable +24 VDC from the LVPS. Leave this jumper in place until the problem is resolved, even if referenced to other RAPs. Remove the Fuser Front Cover. Ensure that the Fuser Drawer is closed correctly. Do not place a cheater in the Printer Interlock Bypass Switch. Open the Processor left and right front doors and place a cheater in the left and right door interlock switches. Enter dC330, [10], [Camming] motor. Press the Continue button. The Cams rotate, the Fuser and Pressure Rolls engage and disengage. Y N The Camming Motor comes on, or tries to come on. Y N +24VDC is measured between TH12(+) and TH14(-)on the LVPS. Y N Go to the 1-717 +24, +34, -34 VDC RAP. Open the Fuser drawer and place a cheater in the Fuser Interlock Switch. Do not place a cheater in the Printer Interlock By-pass Switch. 115VAC is available from P1-1 to P1-2 of the Camming Motor (ensure Camming Motor is selected and has not timed out). Y N Go to the 10-707 Camming Motor RAP. Check the Camming Motor Brake (part of the Camming Motor Assembly), if the brake is OK or cannot be repaired, replace the Camming Motor Assembly (PL 10.3). Inspect the Camming Motor Coupling for damage or wear. The Camming Motor Coupling is OK. Y N Repair or replace the Camming Motor Coupling (PL 10.3). A Preliminary Working Document No Product Name Assigned

0/0/00 ?-839

Section Name

10-216

Figure 1 10-216 Circuit Diagram (8031B)

Section Name

10-216

0/0/00 ?-840

Preliminary Working Document No Product Name Assigned

Figure 2 10-216 Circuit Diagram (8032C)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-841

Section Name

10-216

Figure 3 Component Location (8054A)

Section Name

10-216

0/0/00 ?-842

Preliminary Working Document No Product Name Assigned

10-601 Fuser Lead Edge Smear RAP

10-602 Fuser Print Gloss RAP

Procedure

Procedure

Check the following:

CAUTION

•

Load fresh paper and run the machine. If the defect is no longer present advise the Key Operator about the storage and use of paper.

•

Ensure that the paper is loaded correctly and that curl is not excessive (refer to the Decurler section of the Operators Manual).

•

Remove the Prefuser Transport. Clean the Prefuser Transport Vent Holes and the Prefuser Transport.

•

Check the condition of the Fuser Entrance Baffle.

Preliminary Working Document No Product Name Assigned

Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to the cover may occur. Overall Print Gloss •

Repetitive prints of the same document may cause a differential gloss defect.

•

Ensure that the Fuser Roll Thermistor is clean and is making proper contact.

•

Enter dC701, check the Fuser Roll Temperature (ADJ 10-6).

•

Replace the Fuser Roll (REP 10-1).

0/0/00 ?-843

Section Name

10-601, 10-602

10-603 Wrinkle RAP Initial Actions CAUTION Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to the cover may occur. Perform the following: •

Ensure that the Fuser Entrance Baffle is installed correctly (all four screws are installed and are tight) and in good condition.

•

Wrinkle caused by the Fuser is seen most often on the first 10 to 15 sheets of A3 (11x17) paper when the machine has been started from a cold condition (the pressure roll is cold).

•

Check the HSFIs for the Fuser.

Procedure Enter dC701. Select [Contact Arc Setup]. The Fuser Contact Arc is correct (ADJ 10-2). Y N Perform the Contact Arc Adjustment (ADJ 10-2). Select [Temperature Setups]. The Fuser Roll Temperature is in specification (ADJ 10-6). Y N Perform the Fuser Roll Temperature Adjustment (ADJ 10-6). Using a fresh (unopened) ream of paper, load the largest size paper that the customer uses into the appropriate tray. Enter dC106. Run the machine. Wrinkles still occur. Y N Advise the customer about the correct storage and use of paper. The wrinkles are only at the trail edge of the print. Y N Run the machine. Observe the prints entering the fuser. The sheets are skewed or damaged. Y N Check the Fuser Entrance Baffle for debris or damage, and ensure that all four of the mounting screws are present and are tight. Go to the 8-706 PHM Skew and Misregistration RAP. Replace the Pressure Roll (PL 10.4).

Section Name

10-603

0/0/00 ?-844

Preliminary Working Document No Product Name Assigned

Figure 1 10-603 Circuit Diagram (8034A)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-845

Section Name

10-603

10-604 Fuser Agent On Print RAP

10-605 Lead Edge To Trail Edge Streaks (Unfused Print) RAP

Initial Actions •

If there is a large build up of clay in the Fuser Agent Module in the vicinity of the Fuser Wick, or the Metering Blade, clean the area, replace the Fuser Wick (PL 10.7).

Procedure

•

Go to the HFSI TABLES, and perform all 10-800 HFSI actions due.

•

Excess Fuser Agent may be noticed on the first few prints when using colored stock (the Fuser Agent on the prints should evaporate after a few days).

Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to the cover may occur.

NOTE: Use only Fuser Agent for the DP180.

Procedure Inspect the Stripper Finger Baffle. There is a build up of Fuser Agent and paper dust on the Stripper Finger Baffle caused by the baffle scraping the Pressure Roll. Y N Inspect the Metering Blade for damage or debris. The Metering Blade is OK and properly located. Y N The Metering Roll is damaged. Y N Clean the Metering Roll of any toner build-up and clean, rotate, or replace the Metering Blade (PL 10.7).

CAUTION

Inspect the Fuser Roll for damage. Inspect the Fuser Roll for wear, especially wear in the 11" (A4) area. The Fuser Roll is damaged, or worn. Y N Inspect the Pressure Roll for damage, or wear in the 11" (A4) area, and replace if necessary (PL 10.4). Replace the Fuser Roll (REP 10-1).

Replace the Metering Roll (PL 10.7). Inspect the Donor Roll for damage or debris. Discoloration and banding of the donor roll is considered normal. The Donor Roll is OK. Y N Clean or replace the Donor Roll (PL 10.8). Clean or replace the Metering Roll (PL 10.7). Clean the Stripper Finger Baffle and perform the Stripper Finger Baffle Clearance ADJ 10-15.

Section Name

10-604, 10-605

0/0/00 ?-846

Preliminary Working Document No Product Name Assigned

10-606 Dry Ink Spots On Prints/Spot Deletions RAP

10-607 Unable to Type on Prints RAP

Initial Actions

Initial Actions CAUTION

Do not place a hot Fuser Roll or Pressure Roll on any machine cover as damage or warping to the cover may occur. Perform a panic stop (General Procedures) and check to see if the defect is present before the fuser. If the defect is not being caused by the fuser go to the appropriate area to troubleshoot the cause.

Procedure Inspect the Fuser Roll for damage. The Fuser Roll is OK. Y N Replace the Fuser Roll (REP 10-1).

Determine whether this is a machine, paper, or typewriter problem. Proceed with this RAP only if the problem is caused by the machine.

Procedure The problem occurs ONLY on cold start-up of machine (first 30 prints out after Power On). Y N Enter dC701, [Fuser Roll Temp]. Check the Fuser Roll Temperature. The Fuser Roll Temperature is in specification. Y N Adjust Fuser Roll Temperature (ADJ 10-6). Replace the Metering Blade and the Fuser Wick (PL 10.7).

Inspect the Pressure Roll for damage and replace if necessary (PL 10.4).

Check the Last 50 Faults in SCP for Metering Roll Undertemperature Faults (10-210). Metering Roll Undertemperature Faults have occurred. Y N Enter dC701, [Metering Roll Temp]. The Metering Roll Temperature is in specification. Y N Adjust Metering Roll Temperature (ADJ 10-7). Replace the Metering Blade and the Fuser Wick (PL 10.7). Go to the 10-210 RAP or the 10-210.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-847

Section Name

10-606, 10-607

10-608 Dry Ink Not Fixed RAP Procedure The problem occurs only on cold start-up of machine (first 30 prints out after Power On). Y N Enter dC701, [Fuser Roll Temp]. The Fuser Roll Temperature is in specification. Y N Adjust Fuser Roll Temperature (ADJ 10-6). Enter dC701, [Contact Arc]. The Contact Arc is in specification. Y N Adjust Contact Arc (ADJ 10-2) Replace the Metering Blade and the Fuser Wick (PL 10.7). If the problem has not been resolved, go to the 10-201. Check the Last 50 Faults in SCP for Metering Roll Undertemperature Faults, 10-210. Metering Roll Undertemperature Faults have occurred. Y N Enter dC701, [Metering Roll Temp]. The Metering Roll Temperature is in specification. Y N Adjust Metering Roll Temperature (ADJ 10-7). Ensure that the Metering Roll Heater comes on. Replace the Metering Blade and the Fuser Wick (PL 10.7). If the problem has not been resolved, go to the 10-201. Check the following and then go to the 10-210 or go to the 10-210. • The Metering Roll Blade (PL 10.7). •

The Metering Blade Bracket Support Assembly is properly mounted to the Metering Assembly Housing (it is necessary to remove the Metering Roll and the Blade Support to ensure that it is located properly)

•

The correct Dry Ink is being used, especially if this is a MIRC Machine.

•

The correct Fuser Agent is being used.

Section Name

10-608

0/0/00 ?-848

Preliminary Working Document No Product Name Assigned

10-701 Bent Corners RAP Initial Actions •

Check for damaged or obstructed paper path components.

•

Check the area from the Registration Transport to the Prefuser Transport for damaged components.

•

Go to the HFSI TABLES, and perform all 10-800 HFSI actions due.

•

Ensure that the paper is loaded in the appropriate tray correctly and that curl is within specification (Decurler section of the Operator Manual).

Procedure Enter dC701, [Stripper]. The Fuser Air Knife Manifold Air Pressure is in specification. Y N Adjust Air Manifold and the Air Knife Pressure (ADJ 10-5). Enter dC106. Select [Job Setup], [Sample Tray], [Simplex], [Test Patterns and PQ], [Halftone], and [100] prints. Run prints to the Sample Tray until a bent corner is observed. The bent corner is (away from the image). Y N The image is distorted. Y N Perform the following: • Adjust the Air Knife Manifold (ADJ 10-4). •

Check the Fuser Roll condition

•

Condition and operation of the Decurler

Check the condition and operation of the Pre Fuser Baffle. Adjust the Stripper Finger Baffle Clearance (ADJ 10-15).

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Section Name

10-701

Figure 1 10-607/608/701 Circuit Diagram (8036A)

Section Name

10-701

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Preliminary Working Document No Product Name Assigned

10-702 Fuser Air System Checkout Procedure Use the Fuser Air System Checkout schematics on the following pages as an aid to locate and determine the operation of the various Fuser air components. Most air leaks in the Manhattan air system should be audible and not require a directive procedure to repair. The following procedure is intended to be used when there is an air system problem that is not obvious. Check the Air Gauge (PL 10.9).

NOTE: The internal air filter element (part of the Moisture Trap / Air Filter) should not be removed from the Moisture Trap / Air Filter. If a problem is found, the filter should be replaced not removed. If the filter is removed, it can result in excess moisture in the ESV, Prefuser Sensor, and Fuser Sensor. This moisture can cause failure of these components. Dirt and dust can also be sent to these components that could cause problems, or clogging of the Air Knife Manifold holes. To check the Air Filter for internal contamination perform the following: 1.

Remove the air line at the quick disconnect at the 90 degree fitting where the air hose exits the umbilical cord by the fuser left rail.

2.

Enter dC330, [10], [Compressor]. Press [Continue] and observe the Air Gauge. If the gauge reads above 8 PSI the Moisture Trap / Air Filter (PL 10.10) should be replaced.

The MIM Compressor should turn on in dC330. Enter dC330, [10]. Select [Compressor]. Press [Continue]. If the MIM Compressor does not turn on, go to 10-703, Compressor Motor RAP. The Manhattan Printer requires 20 PSI of air for proper operation. Since the MIM Compressor is capable or supplying greater amounts of air, the pressure in excess of 29 PSI is vented through a Relief Valve. The Relief Valve should be adjusted to 29 PSI (ADJ 10-16). If the Relief Valve cannot be adjusted to 29 PSI, check for the following: •

A leak in the air system

•

A failed Bleed Off Solenoid (PL 10.10) (or the wiring, the Timer Relay and the software that controls it)

•

A failed Air Gauge (PL 10.9)

•

A failed compressor (PL 10.9)

•

A failed Relief Valve (PL 10.10)

•

A failed Moisture Trap / Air Filter. See the Moisture Trap / Air Filter procedure later in this RAP to check the Moisture Trap / Air Filter operation

•

A failed Compressor Intake Air Filter (PL 10.9)

•

A restriction in the air system between the Compressor and the Air Gauge

The Air Knife Pressure / Pressure Regulator should be adjusted to 20 PSI (ADJ 10-5). The Air Knife Pressure should not be adjusted until the Relief Valve has been properly adjusted (ADJ 10-16). The Moisture Trap / Air Filter (PL 10.10) should be checked for proper operation. Ensure that the vent on the bottom moves freely. Cut the tie wrap and remove the foam from the bottom of the vent. Under pressure (with the compressor turned on in dC330) the vent should be in the down position. The vent should move up when pushed up. The vent should move back down and close when released. If the vent does not close, an air loss will result. If the vent does not open, moisture will not be removed. The internal air filter element (part of the Moisture Trap / Air Filter) should also be checked for proper operation. Reinstall the foam when the check has been finished.

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Section Name

10-702

Figure 1 10-702 Fuser Air System Checkout (8037B)

Section Name

10-702

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Preliminary Working Document No Product Name Assigned

Figure 2 10-702 Fuser Air System Checkout (8039B)

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Section Name

10-702

A

10-703 (60HZ) Compressor Motor RAP

B Y

N Go to Flag 2. Check the wire 59.

Procedure Go to Flag 5. Check the wire 4F.

WARNING Performing service actions in the vicinity of the Compressor represents a safety hazard. Use caution when servicing in this area.

115 VAC is available at P270-3. Y N Go to Flag 4. Check the wire 59A.

When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when servicing in this area.

Go to Flag 3. Check the wire 3S.

If the Compressor Motor is in a thermal overheat condition it will run when it resets itself. Enter dC330, [10], [Compressor] motor. Press the Continue button. 115 VAC is available from P270-3 to P270-1. Y N 115 VAC is available from J268-16 to J268-7. Y N 115 VAC is available at pin 7 of Power On Relay, K101. Y N Go to the 1-701 AC Standby Power RAP. 115 VAC is available at pin 1 of Compressor Relay, K1005. Y N Go to Flag 1. Check the wire 21C.

There is greater than 170 VAC across the terminals of the Compressor Motor Run Capacitor. Y N Check the wires to the Compressor Motor Run Capacitor, if ok replace the Compressor Motor Run Capacitor (PL 10.9). Select [Clear Outputs]. Air can be heard from the Bleed Off Solenoid. Y N Press the Continue button. The Compressor Motor attempts to start (hum or rotate). Y N Replace the Compressor Motor (PL 10.9). Go to the 10-704 Bleed Off Solenoid RAP.

115 VAC is available at pin 2 of Compressor Relay, K1005. Y N Less than +4 VDC is available from pin 3 to pin 4 of Compressor Relay, K1005. Y N Replace the Compressor Relay, K1005 (PL 1.3).

Replace the Compressor Motor (PL 10.9).

+5 VDC is available at pin 3 of Compressor Relay, K1005. Y N +5 VDC is available at TS35 of the MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8). Go to Flag 6. Check the brown wire. +5 VDC is available at pin 4 of Compressor Relay, K1005. Y N Replace the Compressor Relay, K1005 (PL 1.3). +5 VDC is available at TS46 of MIN DIO PWB. Y N Go to Flag 7. Check the red wire. Replace the MIN DIO PWB (PL 1.8). 115 VAC is available at J268-16. A

B

Section Name

10-703

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Preliminary Working Document No Product Name Assigned

Figure 1 10-703 Circuit Diagram (8040A)

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Section Name

10-703

A

10-703 (50HZ) Compressor Motor RAP

B Y

N Go to Flag 2. Check the wire 59.

Procedure Go to Flag 5. Check the wire 21A.

WARNING Performing service actions in the vicinity of the Compressor represents a safety hazard. Use caution when working in this area.

The Phase to Earth voltage is available at P270-3. Y N Go to Flag 4. Check the wire 59A.

When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when servicing in this area.

Go to Flag 3. Check the wire 3S.

If the Compressor Motor is in a thermal overheat condition it will run when it resets itself. Enter dC330, [10], [Compressor] motor. Press the Continue button. The Phase to Neutral voltage is available from P270-1 to P270-3. Y N The Phase to Neutral voltage is available from J268-16 to J268-7. Y N The Phase to Earth voltage is available at pin 8 of Power On Relay, K101. Y N Go to the 1-708 AC Standby Power RAP.

Select [Clear Outputs]. Air can be heard from the Bleed Off Solenoid. Y N Go to the 10-704 Bleed Off Solenoid RAP. Replace the Compressor Motor (PL 10.9).

The Phase to Earth voltage is available at pin 1 of Printer Compressor Relay, K1005. Y N Go to Flag 1. Check the wire 54A. The Phase to Earth voltage is available at pin 2 of Compressor Relay, K1005. Y N Less than +4 VDC is available from pin 3 to pin 4 of Compressor Relay, K1005. Y N Replace the Compressor Relay, K1005 (PL 1.2). +5 VDC is available at pin 3 of Compressor Relay, K1005. Y N +5 VDC is available at J3-20 of the MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8). Go to Flag 6. Check the brown wire. +5 VDC is available at pin 4 of Compressor Relay, K1005. Y N Replace the Compressor Relay, K1005 (PL 1.2). +5 VDC is available at TS46 of MIN DIO PWB. Y N Go to Flag 7. Check the red wire. Replace the MIN DIO PWB (PL 1.8). The Phase to Earth voltage is available at J268-16. A

B

Section Name

10-703

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Preliminary Working Document No Product Name Assigned

Figure 1 10-703 (50 HZ) Circuit Diagram (8041A)

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Section Name

10-703

10-704 Bleed-Off Solenoid RAP Procedure WARNING Performing service in the vicinity of the Compressor Motor represents a safety hazard. Use caution when servicing in this area. Enter dC330, [10], [Compressor] Motor. Press the Continue button. The Motor starts, or attempts to start (hum or rotate). Y N Go to the 10-703 Compressor Motor RAP.

Compressor

115 VAC is measured between P2002-1 and P2002-3. Y N +5 VDC is measured between TS47 (+) and TS37 (-) on the MIN DIO PWB. Y N +5 VDC is measured between TS35 (+) and TS37 (-) on the MIN DIO PWB Y N Go to 1-713 and troubleshoot a +5 VDC problem. Replace the MIN DIO PWB (PL 1.8). Press Stop. +5 VDC is measured between TS13 (+) and TS56 (-) on the MIN ADA PWB #1. Y N Go to Flag 1 and Flag 2. Check for Open circuits. If OK, replace the MIN AC Remote PWB #1 (PL 1.7). Press Continue. Measure between TS13 (+) and TS56 (-) on the MIN ADA PWB #1. The voltage drops from +5 VDC to less than 1 VDC. Y N Replace the MIN ADA PWB #1 (PL 1.8). Go to Flag 3. Check or an Open circuit. If OK, replace the MIN AC Remote PWB #1 (PL 1.7). Replace the Bleed Off Solenoid, SOL1003 (PL 10.11).

Section Name

10-704

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Figure 1 10-704 Circuit Diagram (8050)

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Section Name

10-704

10-705 Low Fuser Agent Level RAP Initial Actions •

Check the Fuser Agent level. Fill Fuser Agent Reservoir, if required.

•

After the Fuser Agent Reservoir has been filled, the machine must cycle for at least 30 seconds before the Operator Message, Fuser Agent Is Low, or Add Fuser Agent, message will be removed. NOTE: Use only Fuser Agent for the DP180.

Procedure Enter dC330, [10]. Actuate and deactuate the Fuser Agent Level Switch. The changes from H to L. Y N +5 VDC is available from L1-1 to L1-2. Y N +5 VDC is available at L1-2. Y N +5 VDC is available at P248-2 of MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8).

display

Go to Flag 1. Check the wire. +5 VDC is available at P248-1 of MIN DIO PWB. Y N Go to Flag 2. Check the wire. Replace the MIN DIO PWB (PL 1.8). Replace the Fuser Agent Level Switch (PL 10.1). Check for binding of the Fuser Agent Level Switch actuator.

Section Name

10-705

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Preliminary Working Document No Product Name Assigned

Figure 1 10-705 Circuit Diagram (8042A)

Preliminary Working Document No Product Name Assigned

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Section Name

10-705

A

10-706 (60HZ) Prefuser Vacuum Motor RAP Procedure

B Go to Flag 5. Check the wire 117.

Replace the Prefuser Vacuum Motor (PL 8.12).

WARNING Performing service actions in the vicinity of the Compressor represents a safety hazard. Use caution when servicing in this area. When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when servicing in this area. Enter dC330, [10], [Prefuser Vacuum] motor. Press the Continue button. 115 VAC is available from P271-1 to P271-2. Y N 115 VAC is available from J1-18 to J1-6 on MIN AC Remote PWB #1. Y N 115 VAC is available at 2A7TB2-18. Y N Go to the 1-701 AC Standby Power RAP. 115 VAC is available at J1-17 on MIN AC Remote PWB #1. Y N Go to Flag 2. Check the wires, 16AA and 16AB. 115 VAC is available from J1-8 to J1-17 on MIN AC Remote PWB #1. Y N Go to Flag 1. Check the wires 3LL and 3LM. +5 VDC is available from J2-5 to J2-6 on MIN AC Remote PWB #1. Y N +5 VDC is available at J2-5 on MIN AC Remote PWB #1. Y N +5 VDC is available at TS 35 on MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8). Go to Flag 3. Check the green wire. +5 VDC is available at J2-6 on MIN AC Remote PWB #1. Y N Replace the MIN AC Remote PWB #1 (PL 1.7). +5 VDC is available at TS39 on MIN DIO PWB. Y N Go to Flag 4. Check the blue wire. Replace the MIN DIO PWB (PL 1.8). Replace the MIN AC Remote PWB #1 (PL 1.7). 115 VAC is available at P271-1. Y N Go to Flag 6. Check the wire 110H. A

B

Section Name

10-706

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Figure 1 10-706 Circuit Diagram (8043A)

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Section Name

10-706

A

10-706 (50HZ) Prefuser Vacuum Motor RAP

Y

N Go to Flag 6. Check the wire 110H.

Procedure Go to Flag 5. Check the wire 117.

WARNING Performing service actions in the vicinity of the Compressor represents a safety hazard. Use caution when servicing in this area.

Replace the Prefuser Vacuum Motor (PL 8.12).

When performing service in the vicinity of the cleaner, the moving pulleys and belts represent a safety hazard. Use caution when servicing in this area. Enter dC330, [10], [Prefuser Vacuum] motor. Press the Continue button. The Phase to Neutral voltage is available from P271-1 to P271-2. Y N The Phase to Neutral voltage is available from J1-18 to J1-6 on MIN AC Remote PWB #1. Y N The Phase to Earth voltage is available at 2A7TB2-12. Y N Go to the 1-708 AC Standby Power (50HZ) RAP. The Phase to Earth voltage is available at J1-17 on MIN AC Remote PWB #1. Y N Go to Flag 2. Check the wires 16AA and 16AB. The Phase to Neutral voltage is available from J1-17 to J1-8 on MIN AC Remote PWB #1. Y N Go to Flag 1. Check the wires 3LL and 3LM. +5 VDC is available from J2-5 to J2-6 on MIN AC Remote PWB #1. Y N +5 VDC is available at J2-5 on MIN AC Remote PWB #1. Y N +5 VDC is available at TS35 of the MIN DIO PWB. Y N Replace the MIN DIO PWB (PL 1.8). Go to Flag 3. Check the green wire. +5 VDC is available at J2-6 on MIN AC Remote PWB #1. Y N Replace the MIN AC Remote PWB #1 (PL 1.7). +5 VDC is available at TS39 on MIN DIO PWB. Y N Go to Flag 4. Check the blue wire. Replace the MIN DIO PWB (PL 1.8). Replace the MIN AC Remote PWB #1 (PL 1.7). The Phase to Earth voltage is available at P271-1. A Section Name

10-706

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Preliminary Working Document No Product Name Assigned

Figure 1 10-706 (50 HZ) Circuit Diagram (8044A)

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Section Name

10-706

A

10-707 (60HZ) Camming Motor RAP Initial Actions NOTE: When performing checks during this procedure ensure that the camming motor has been selected and has not timed out.

Procedure Enter dC330, [10], [Camming] motor. Open the Fuser Drawer. Place a cheater in the Printer Interlock Bypass switch. Press the Continue button. The Camming Motor fails to come on. (If the Camming Motor does not come on follow the yes path.) Y N Press the Stop button. Remove the cheater from the Printer Interlock Bypass Switch. Place a cheater in the left door, right door and Fuser Interlock switches. Press the Continue button. The Camming Motor comes on. Y N +24 VDC is available at pin 1 of the Fuser Interlock Switch. Y N +24 VDC is available at 1TB4-1A. Y N There is +24 VDC available between TH12 (+) and TH14 (-) of the Low Voltage Power Supply. Y N Go to the 1-717 +24, +34, -34 RAP.

B Allow the Camming Motor to cool down and then go to the start of this RAP.

115 VAC is available from pin 1 to pin 2 of the Fuser Camming Relay, K1006. Y N 115 VAC is available from J1-5 to J1-13 on PHN AC Remote PWB #2. Y N 115 VAC is available from J1-11 to J1-3 on PHN AC Remote PWB #2. Y N 115 VAC is available at pin 19 of 2A7TB1. Y N Go to the 1-701 AC Standby Power RAP. 115 VAC is available at J1-11 on the PHN AC Remote PWB #2. Y N Go to Flag 3. Check the wires. Go to Flag 11. Check the wire 3MM for an open circuit. The wire 3MM shows an open circuit. Y N Go to the 1-701 AC Standby Power RAP. Repair or replace the wire. +5 VDC is available from J2-3 to J2-4 on PHN AC Remote PWB #2. Y N +5 VDC is available at 2TB4-12A. Y N Go to Wirenets (Wiring Data) Check the wire #538 for an open circuit.

Go to the +24VDC Distribution wirenet. Check the wire 1028 for an open circuit. Go to Flag 8. Check the wiring between 1TB4 and the Fuser Interlock Switch.

+5 VDC is available from 2TB4-12A to PHN DIO PWB #2 J2-11. Y N Replace the PHN DIO PWB #2 (PL 1.4).

Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the and the Fuser Camming Relay. If the wiring checks good replace the Fuser Interlock Switch (PL 10.1).

+5 VDC is available from 2TB4-12A to PHN AC Remote PWB #2 J2-4. Y N Go to Flag 5. Check the brown wire.

Check or adjust the actuator of the Fuser Interlock Switch. If the camming Motor came on in the previous step this is not the correct path, start the procedure over. Less than 90 VAC is available from B2-1 to B2-2. Y N The Camming Motor is hot to the touch. Y N Manually operate the Camming Motor. Check for binding in the Camming mechanism. Binding of the Camming mechanism is present. Y N There is pitting on the contacts of the Camming Motor Relay, K1006. Y N Replace the Camming Motor (PL 10.3).

+5 VDC is available from 2TB4-12 to PHN AC Remote PWB #2 J2-3. Y N Replace the PHN AC Remote PWB #2 (PL 1.4). Go to Flag 4. Check the red wire. Replace the PHN AC Remote PWB #2 (PL 1.4). 115 VAC is available at pin 2 of Fuser Camming Relay, K1006. Y N Go to Flag 6. Check the wire.

Replace the Camming Motor Relay, K1006 (PL 1.3). Go to Flag 7. Check the wire. Repair or replace the cause of the binding. Less than 90 VAC is available from pin 4 to pin 5 of the Fuser Camming Relay, K1006. A

B

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10-707

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Y

N 115 VAC is available at B2-2. Y N Go to Flag 1. Check the wires. Go to Flag 2. Check the wires.

+24 VDC is available from pin A to pin B on Fuser Camming Relay, K1006. Y N +24 VDC is available at pin A on Fuser Camming Relay, K1006. Y N +24 VDC is available at pin 1B of Fuser Interlock Switch. Y N +24VDC is available at 1TB4-1A. Y N There is +24VDC available between TH12 (+) and TH14 (-) of the Low Voltage Power Supply. Y N Go to the 1-717 +24, +34, -34 VDC RAP. Go to the +24VDC Distribution wirenet. Check the wire 1028 for an open circuit. Go to Flag 8. Check the wiring between 1TB4-1A and the Fuser Interlock Switch. Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the Fuser Camming Relay. If the wiring checks good replace the Fuser Interlock Switch (PL 10.1). Go to Flag 10. Check the wire for an open circuit. The wire shows an open circuit. Y N Go to the +24VDC Return Distribution wirenet. Check the wire 1029 for an open circuit. Go to Flag 10. Repair or replace the wire. Replace the Fuser Camming Relay, K1006 (PL 1.3).

Preliminary Working Document No Product Name Assigned

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Section Name

10-707

Figure 1 10-707 Circuit Diagram (8045A)

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10-707

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Preliminary Working Document No Product Name Assigned

10-707 (50HZ) Camming Motor RAP Initial Actions NOTE: When performing checks in this procedure ensure that the Camming Motor has been selected and has not timed out.

Procedure Enter dC330, [10], [Camming] motor. Open the Fuser Drawer. Place a cheater in the Printer Interlock Bypass Switch. Press the Continue button. The Camming Motor fails to come on. (If the Camming Motor does not come on follow the yes path.) Y N Press the Stop button. Remove the cheater from the Printer Interlock bypass Switch. Place a cheater in the left door, right door and the Fuser Interlock switches. Press the Continue button. The Camming Motor comes on. Y N +24 VDC is available at pin 1 of the Fuser Interlock Switch. Y N +24 VDC is available at pin 1A of 1TB4. Y N There is +24 VDC available between TH12 (+) and TH14 (-) of the LVPS. Y N Go to the 1-717 +24, +34, -34 VDC RAP.

A 115VAC is available from pin 1 to pin 2 of the Fuser Camming Relay, K1006. Y N 115VAC is available from J1-5 to J1-13 on PHN AC Remote PWB #2. Y N 115VAC is available from J1-11 to J1-3 on PHN AC Remote PWB #2. Y N 115VAC is available from pin 14 of 2A7TB2 to pin 6 of MIM Power Relay K107. Y N Go to the 1-711-1 Inverter/Stacker A Standby AC Power (50HZ) RAP (The AC Power for the Camming Relay is controlled through the IFS Power Relay, K107, which is checked in the 1-711-1 RAP). 115VAC is available at J1-11 on the PHN AC Remote PWB #2. Y N Go to Flag 3. Check the wires 16CC and 16FF. Go to Flag 11. Check the wires, 3FF and 3MM for an open circuit. The wire 3FF or 3MM shows an open circuit. Y N Go to the 1-711-1 Inverter/Stacker Standby AC Power (50HZ) RAP (The AC Power for the Camming Relay is controlled through the IFS Power Relay, K107, which is checked in the 1-711-1 RAP). Repair or replace the wire.

Go to the +24 VDC Distribution wirenet. Check the wire 1028 for an open circuit.

+5 VDC is available from J2-3 to J2-4 on PHN AC Remote PWB #2. Y N +5 VDC is available at 2TB4-12A. Y N Go to the Wirenets (Wiring Data) and check the wire #538 for an open circuit.

Go to Flag 8. Check for an open circuit between 1TB4 and the Fuser Interlock Switch. Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the Fuser Camming Relay. If the wires check good replace the Fuser Interlock Switch (PL 10.1).

+5 VDC is available from 2TB4-12A to PHN DIO PWB #2 J2-11. Y N Replace the PHN DIO PWB #2 (PL 1.4).

Check or adjust the actuator of the Fuser Interlock Switch. (If the Camming Motor came on in the previous step, this is not the correct path. Start the procedure over.) Less than 90 VAC is available from B2-1 to B2-2. Y N The Camming Motor is hot to the touch. Y N Manually release the Camming motor brake and operate the Camming Motor. Check for binding in the Camming mechanism. Binding of the Camming mechanism is present. Y N Replace the Camming Motor (PL 10.3).

+5 VDC is available from 2TB4-12A to PHN AC Remote PWB #2 J2-4. Y N Go to Flag 5. Check the brown wire. +5 VDC is available from 2TB4-12 to PHN AC Remote PWB #2 J2-3. Y N Replace the PHN AC Remote PWB #2 (PL 1.4). Go to Flag 4. Check the red wire. Replace the PHN AC Remote PWB #1 (PL 1.4).

Repair or replace the cause of the binding. Allow the Camming Motor to cool, then go to the start of this RAP. A Preliminary Working Document No Product Name Assigned

B 0/0/00 ?-869

115VAC is available at pin 2 of Fuser Camming Relay, K1006. Y N Go to Flag 6. Check the wire. C Section Name

10-707

B

C Go to Flag 7. Check the wire.

Less than 90 VAC is available from pin 4 to pin 5 of the Fuser Camming Relay, K1006. Y N 115VAC is available at B2-2. Y N Go to Flag 2. Check the wire. Go to Flag 1. Check the wire. +24 VDC is available from pin A to pin B on Fuser Camming Relay, K1006. Y N +24 VDC is available at pin A on Fuser Camming Relay, K1006. Y N +24 VDC is available at pin 1 of Fuser Interlock Switch. Y N +24 VDC is available at pin 1A of 1TB4. Y N +24 VDC is available between TH12 (+) and TH14 (-) with of the LVPS. Y N Go to the 1-717 +24, +34, -34 VDC RAP. Go to the +24 VDC Distribution wirenet. Check the wire 1028 for an open circuit. Go to Flag 8. Check the wiring between 1TB4-1A and the Fuser Interlock Switch. Go to Flag 9. Check the wiring between the Fuser Interlock Switch and the Fuser Camming Relay. If the wiring checks good replace the Fuser Interlock Switch. Go to Flag 10. Check the wire for an open circuit. The wire shows an open circuit. Y N Go to the 24 VDC Return Distribution wirenet. Check the wire 1029. Go to Flag 10. Repair or replace the wire. Replace the Fuser Camming Relay, K1006 (PL 1.2).

Section Name

10-707

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Figure 1 10-707 (50 HZ) Circuit Diagram (8046A)

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Section Name

10-707

10-708 Fuser Agent Dispense RAP Procedure Enter dC330, [10], [Fuser Agent Pump] solenoid. Place a cheater in the Printer Interlock Bypass switch. Press the Continue button. The Fuser Agent Pump Solenoid cycles on and off. Y N The Fuser Agent solenoid energizes and remains energized. Y N +24 VDC is available at J1-7 of the PHN DIO PWB #2. Y N Go to Flag 1. Check wire 516.

NOTE: If a new Fuser Agent Pump is not available, change PHN NVM location 188 to 36. (This is only a temporary attempt to increase the flow rate). Be sure to change the PHN NVM location 188 back to 18 when a new pump has been installed. It may be helpful to leave a note in the machine log as a reminder to reset the NVM back to default when the pump is replaced.

+24VDC is available at J3-8 of the PHN DIO PWB #2. Y N Replace the PHN DIO PWB #2 (PL 1.4). +24VDC is available B1-2 of the Fuser Agent Pump Solenoid. Y N Go to Flag 2. Check the wires for an open. +24 VDC is available at B1-1 of the Fuser Agent Pump Solenoid. Y N Replace the Fuser Agent Pump Solenoid (PL 10.8). +24VDC is available at J3-7 of the PHN DIO PWB#2. Y N Go to Flag 3. Check the wires for an open. +24VDC is available at TS51 of the PHN DIO PWB #2. Y N Replace the PHN DIO PWB #2 (PL 1.4). Go to the 24VDC Return Distribution wirenet. Check for an open. Go to Flag 3. Check for a short to ground. If no short is found replace the PHN DIO PWB #2 (PL 1.4). Fuser Agent is being dispensed. Y N Check for damaged, loose, or obstructed lines. If no problems are found replace the Fuser Agent Pump Solenoid (PL 10.8). Check the PHN NVM location 188 =18. Place the output hose from the Fuser Agent Pump into the cap from a Fuser Agent bottle (bottle part number is 8R2955). Enter dC330, [10] [Fuser Agent] Pump [Cycle]. Press the Continue button. Count the number of strokes, of the Fuser Agent Pump Solenoid, necessary to fill the cap. Press the Stop Button. If less than 15 strokes, the pump is operating correctly. If 16 to 20 strokes the pump is marginal and should be replaced (PL 10.8).

Section Name

10-708

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Figure 1 10-708 Circuit Diagram (8047A)

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Section Name

10-708

A Replace the MIN ADA PWB #1 (PL 1.8).

10-709 MIB PWB RAP Procedure +15 VDC is available at P287-2 of MIB PWB. Y N Go to Flag 10. Check the wire, 1009A. If ok, go to the 1-715 +15 VDC RAP. -15 VDC is available at P287-3 of MIB PWB. Y N Go to Flag 9. Check the wire, 1010A. If ok, go to the 1-716 -15 VDC RAP. +15 VDC is available from P287-2 to P287-5 of MIB PWB. Y N Go to Flag 8. Check the wire, 1008A. This RAP was entered from the 10-210 RAP. Y N Enter dC330, [LVPS 24VDC]. Press the Start button (ensure that the LVPS has been reset and that 24VDC is enabled). 0 to 10 VDC is available between TS 39 and TS 40 of the MIN ADA PWB #1. (It may be necessary to wait up to 4 minutes for the voltage to register the temperature change.) Y N 0 to 10 VDC is at J3-7 to J3-8 of the MIB PWB. Y N 0 to 10 VDC available at J3-1 to J3-2 of the MIB PWB. Y N Go to Flag 7, and check the wires of the Fuser Roll Thermistor circuit. If the wires check OK, replace the Fuser Roll Thermistor (PL 10.4). Replace the MIB PWB (PL 1.8). Go to Flag 3 and Flag 4, and check the blue and green wires. Replace the MIN ADA PWB #1 (PL 1.8). Enter dC330, [LVPS 24VDC]. Press the Start button (ensure that the LVPS has been reset and that 24VDC has been enabled). 0 to 10 VDC is available between TS 37 and TS 38 of the MIN ADA PWB #1. (It may be necessary to wait up to 4 minutes for the voltage to register the temperature change.) Y N 0 to 10 VDC is available at J3-9 to J3-10 of the MIB PWB. Y N 0 to 10 VDC is at J3-4 to J3-3 of the MIB PWB. Y N Go to Flag 6, and check the wires of the Metering Roll Thermistor circuit. If OK, replace the Metering Roll Thermistor (PL 10.7). Replace the MIB PWB (PL 1.8). Go to Flag 1 and Flag 2, and check the Yellow and Orange wires. A Section Name

10-709

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Preliminary Working Document No Product Name Assigned

Figure 1 10-709 Circuit Diagram (8048A)

Preliminary Working Document No Product Name Assigned

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Section Name

10-709

10-710 Camming Motor Runs Continuously RAP Initial Actions Perform the following: •

If in the service mode, ensure that the Camming Motor is not selected.

•

Ensure that the problem is present (motor runs continuously) while performing this RAP.

Procedure + 5 VDC is available at TS 43 (+) and TS 37 (-) on PHN DIO PWB #2. Y N Go to Flag 5, and check for a short. If no short is found replace the PHN DIO PWB #2 (PL 1.4). Go to Flag 7, and 2, and check for a short. If no short is found replace the PHN AC Remote PWB #2 (PL 1.4).

Section Name

10-710

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Preliminary Working Document No Product Name Assigned

Figure 1 10-710 Circuit Diagram (8049A)

Preliminary Working Document No Product Name Assigned

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Section Name

10-710

10-711 RAP

Y

Fault Code, 10-711, indicates that a 10-201 or 10-204 fault code has been declared. The 10711 RAP troubleshoots a problem with the either the 115VAC supply or the lamp switching portion of the circuit.

Initial Actions •

Inspect the Fuser Roll Thermistor for debris or damage, and ensure that it is making proper contact with the Fuser Roll.

•

Ensure that the Fuser Roll Thermostat is adjusted correctly (ADJ 10-0).

•

Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1).

+24 VDC is available at pin 1 (Com) of Printer Interlock Bypass Switch. Y N Replace the Printer Interlock Bypass Switch (PL 1.15).

Procedure

+24 VDC is available at ST2-2 of Fuser Roll Thermostat. Y N Go to Flag 11 and Flag 18. Check the wires.

+15 VDC is available at P257-2 of the MIB#2 PWB. Y N Go to Flag 29. Check the wire 1009T. If ok, go to the 1-715 +15 VDC RAP.

+24 VDC is available at pin 1 of Fuser Roll Thermostat. Y N Replace the Fuser Roll Thermostat (PL 10.4).

-15 VDC is available at P257-3 of the MIB#2 PWB. Y N Go to Flag 28. Check the wire 1010K. If ok, go to the 1-716 -15 VDC RAP.

+24 VDC is available at pin 1 of Metering Roll Thermostat. Y N Go to Flag 12. Check the white wires.

+15 VDC is available from P257-2 to P257-5 of the MIB#2 PWB. Y N Go to Flag 27. Check the wire 1008U.

+24 VDC is available at pin 2 of Metering Roll Thermostat. Y N Replace the Metering Roll Thermostat (PL 10.7).

Enter then exit diagnostics (Press button R). If Fault Code, 10-201/10-204, can not be cleared, switch off and then reset the machine circuit breakers. Open the Fuser Drawer. Disconnect HR12/P1 at the rear of the Fuser. Refer to GP 8, Section 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter dC701, [Thermistor Cal]. Place a cheater in the Printer Interlock Bypass Switch. The Fuser Heat Rod is off. Y N Check the Fuser Roll Temperature (ADJ 10-6). The Fuser Temperature is below specification. Y N Check the Fuser Roll Thermistor, RT1003, for debris or damage. The Fuser Thermistor is clean and making proper contact. Y N Clean or replace the Fuser Roll Thermistors, RT1001 and RT1003, (PL 10.4).

+24 VDC is available at pin 1 (diode input side) of CR1. Y N Go to Flag 10. Check the wires. +24 VDC is available at pin 1 (diode output side) of CR1. Y N Replace the Diode CR1 (PL 24.5). Go to Flag 16. Check the orange wire. Remove the Cheater from the Printer Interlock Bypass Switch. Make sure the Fuser Drawer is closed. +24 VDC is available at pin 1 of the Fuser Interlock Switch. Y N Go to Flag 13. Check the wires, 1005F, 1005R and 1005T. If OK, go to the 1-717 +24, +34, and -34 VDC RAP.

Go to Flag 124. Check the circuit of the Fuser Roll Thermistor, RT1003. Remove the cheater from the Printer Interlock Bypass Switch. Reconnect HR14/P1. Go to Flag 7. Check the circuit of the Fuser Roll Thermistor, RT1003. Check the Metering Roll (ADJ 10-1) and Fuser Roll (ADJ 10-0) Thermostats for adjustment and condition. Inspect the Metering Roll Thermistor (PL 10.7). Perform the Thermistor Cal adjustment (ADJ 10-13). If the problem continues replace the Fuser Relays, K1002, K1007 (PL 1.3).

+24 VDC is available at pin 2 of the Fuser Interlock Switch. Y N Check the alignment of the Fuser Interlock Switch Actuator. If ok, replace the Fuser Interlock Switch (PL 10.1).

Remove the cheater from the Printer Interlock Bypass Switch. Reconnect HR12/P1. Ensure that the Fuser drawer is closed and that the Fuser Interlock switch is properly actuated. +24 VDC is available at pin A of Fuser Power Relay, K1001. A Section Name

10-711

N Place a cheater in the Printer Interlock Bypass Switch. +24 VDC is available at pin A of Fuser Power Relay, K1001. Y N +24 VDC is available at pin 1 (N.O.) of Printer Interlock Bypass Switch. Y N Go to Flag 14. Check the orange wires.

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+24 VDC is available at ST2-2 of the Fuser roll thermostat. Y N Go to Flag 11 and Flag 17. Check the wires. B Preliminary Working Document No Product Name Assigned

A

B Go to Flag 17. Check the orange wire.

C

D Y

+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin B (-) of the Power On Relay, K101. Y N +24 VDC is available from pin A (+) to Pin B (-) of the Fuser Power Relay, K1001. Y N +24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin 2 (diode output side) of CR1. Y N +24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin 2 (-) (diode input side) of CR1. Y N Go to Flag 15. Check the violet wire and connections. If OK, replace the Power On Relay, K101 (PL 1.3).

N +5VDC is available from TS60 of the ADA PWB #2 to TS44 of the MIN DIO PWB. Y N +5VDC is available at TS60 of the MIN ADA PWB #2. Y N If +5VDC is available at J1-10 replace the MIN ADA PWB #2 (PL 1.8). Go to the 10-709 MIB PWB RAP +5VDC is available at pin 4 of the Fuser Relay, K1007. Y N Go to Flag 1. Check the yellow wires. +5VDC is available at pin 3 of the Fuser Relay, K1007. Y N Replace the Fuser Relay, K1007, (PL 1.3).

Replace the Diode, CR1 (PL 24.5). Go to Flag 9. Check the violet wire and connections for an Open.

Go to Flag 123. Check the orange wires. Replace the Fuser Power Relay, K1001 (PL 1.3). Replace the Fuser Relay, K1007, (PL 1.3). NOTE: During the next procedure the voltage will only be available when the lamp pulses. The description of the operation of the lamp is contained in GP 8. Open the Fuser Drawer. Disconnect HR14/P1 at rear of Fuser Heat Rod. Refer to GP 8, Section 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter dC701, [Thermistor Cal]. Place a cheater in the Printer Interlock Bypass switch. 115 VAC is available at HR14-1 (at rear of Fuser Heat Rod). NOTE: After the cause of the problem has been identified in the following steps, reconnect HR14/P1. Y N Open the Line Interface Box. 115 VAC is available at pin 1 of Fuser Relay, K1007. Y N 115 VAC is available at pin 1 of the Fuser Relay, K1002. Y N 115 VAC is available at pin 1 of Fuser Inductor, L1001. Y N Go to Flag 3. Check the wire 13C.

115 VAC is available at P1-1 (at the rear of Fuser Heat Rod). Y N 115 VAC is available at HR11-1 (at front of Fuser Heat Rod). Y N Go to Flag 6. Check the wires 14A, and 19A. Replace the Fuser Heat Rod (REP 10-1). An intermittent 10-201 is suspected. Check the following for intermittent operation: • Fuser Roll Thermostat Adjustment (ADJ 10-0) and operation •

Metering Roll Thermostat Adjustment (ADJ 10-1) and operation

•

Fuser Roll Thermistors (RT1001 and RT1003)

•

Metering Roll Thermistor

115 VAC is available at pin 2 of Fuser Inductor, L1001. Y N Replace the Fuser Inductor, L1001 (PL 1.3).

•

Thermistor CAL ADJ 10-17

•

Fuser Relay, K1007 and K1002

•

The MIN ADA PWB #1

Go to Flag 4. Check the wire 18.

•

The MIN ADA PWB #2

•

The MIB#2 PWB

Go to Flag 123. Check the wire 18A. 115 VAC is available at pin 2 of Fuser Relay, K1007. Y N Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Fuser Relay, K1007. C

Go to Flag 111. Check the wires 82A, 82C, and 82E.

•

Fuser Heat Rod

•

Wiring and connectors

D

Preliminary Working Document No Product Name Assigned

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Section Name

10-711

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

Section Name

10-711

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

Preliminary Working Document No Product Name Assigned

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Section Name

10-711

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

Section Name

10-711

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Preliminary Working Document No Product Name Assigned

10-714 RAP

Y

Fault Code, 10-714, indicates that a 10-201 or 10-204 fault code has been declared. The 10714 RAP troubleshoots a problem with either the 115VAC supply or the temperature control portion of the circuit.

Initial Actions •

Inspect the Fuser Roll Thermistor for debris or damage, and ensure that it is making proper contact with the Fuser Roll.

•

Ensure that the Fuser Roll Thermostat is adjusted correctly (ADJ 10-0).

•

Ensure that the Metering Roll Thermostat is adjusted correctly (ADJ 10-1).

+24 VDC is available at pin 1 (Com) of Printer Interlock Bypass Switch. Y N Replace the Printer Interlock Bypass Switch (PL 1.15).

Procedure

+24 VDC is available at ST2-2 of Fuser Roll Thermostat. Y N Go to Flag 11 and Flag 18. Check the wires.

+15 VDC is available at P287-2 of the MIB#1 PWB. Y N Go to Flag 19. Check the wire 1009A. If ok, go to the 1-715 +15 VDC RAP.

+24 VDC is available at pin 1 of Fuser Roll Thermostat. Y N Replace the Fuser Roll Thermostat (PL 10.4).

-15 VDC is available at P287-3 of the MIB#1 PWB. Y N Go to Flag 20. Check the wire 1010A. If ok, go to the 1-716 -15 VDC RAP.

+24 VDC is available at pin 1 of Metering Roll Thermostat. Y N Go to Flag 12. Check the white wires.

+15 VDC is available from P287-2 to P287-5 of the MIB#1 PWB. Y N Go to Flag 21. Check the wire 1008A.

+24 VDC is available at pin 2 of Metering Roll Thermostat. Y N Replace the Metering Roll Thermostat (PL 10.7).

Check the Fuser Roll Temperature (ADJ 10-6). The Fuser Temperature is below specification. Y N Check the Fuser Roll Thermistor, RT1001, for debris or damage. The Fuser Thermistor is clean and making proper contact. Y N Clean or replace the Fuser Roll Thermistor, RT1001, (PL 10.4).

+24 VDC is available at pin 1 (diode input side) of CR1. Y N Go to Flag 10. Check the wires. +24 VDC is available at pin 1 (diode output side) of CR1. Y N Replace the Diode CR1 (PL 24.5).

Go to Flag 7. Check the circuit of the Fuser Roll Thermistor, RT1001. Enter then exit diagnostics (Press button R). If Fault Code, 10-201, can not be cleared, switch off and then reset the machine circuit breakers. Open the Fuser Drawer. Ensure that the Fuser temperature is below operating temperature. Disconnect HR14/P1 at the rear of the Fuser. Refer to GP 7, Section 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter dC701, [Fuser Roll Temp]. Place a cheater in the Printer Interlock Bypass Switch. Observe the Fuser Heat Rod. The Fuser Heat Rod is off. Y N Open the fuser drawer. Reconnect HR14/P1. Check the Metering Roll (ADJ 10-1) and Fuser Roll (ADJ 10-0) Thermostats for adjustment and condition. Inspect the Metering Roll Thermistor (PL 10.7). Perform the Thermistor Cal adjustment (ADJ 10-17). If the problem continues, replace the Fuser Relays K1001, K1003 (PL 1.3).

Go to Flag 16. Check the orange wire. Remove the Cheater from the Printer Interlock Bypass Switch. Make sure the Fuser Drawer is closed. +24 VDC is available at pin 1 of the Fuser Interlock Switch. Y N Go to Flag 13. Check the wires, 1005F, 1005R and 1005T. If OK, go to the 1-717 +24, +34, and -34 VDC RAP. +24VDC is available at pin 2 of the Fuser Interlock Switch. Y N Check the alignment of the Fuser Interlock Switch Actuator. If ok, replace the Fuser Interlock Switch (PL 10.1).

Remove the cheater from the Printer Interlock Bypass Switch. Reconnect HR14/P1. Ensure that the Fuser drawer is closed and that the Fuser Interlock switch is properly actuated. +24 VDC is available at pin A of Fuser Power Relay, K1001. A Preliminary Working Document No Product Name Assigned

N Place a cheater in the Printer Interlock Bypass Switch. +24 VDC is available at pin A of Fuser Power Relay, K1001. Y N +24 VDC is available at pin 1 (N.O.) of Printer Interlock Bypass Switch. Y N Go to Flag 14. Check the orange wires.

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+24 VDC is available at ST2-2 of the Fuser roll thermostat. Y N Go to Flag 11 and Flag 17. Check the wires. B Section Name

10-714

A

B Go to Flag 17. Check the orange wire.

C

D Y

+24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin B (-) of the Power On Relay, K101. Y N +24 VDC is available from pin A (+) to Pin B (-) of the Fuser Power Relay, K1001. Y N +24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin 2 (diode output side) of CR1. Y N +24 VDC is available from pin A (+) of the Fuser Power Relay, K1001, to pin 2 (-) (diode input side) of CR1. Y N Go to Flag 15. Check the violet wire and connections. If OK, replace the Power On Relay, K101 (PL 1.3).

N +5VDC is available from TS16 to TS60 of the ADA PWB #2. Y N +5VDC is available at TS60 of the MIN ADA PWB #2. Y N If +5VDC is available at J1-10 replace the MIN ADA PWB #2 (PL 1.8). Go to the 10-709 MIB PWB RAP. +5VDC is available at pin 3 of the Fuser Relay, K1002. Y N Go to Flag 1. Check the yellow wires. +5VDC is available at pin 4 of the Fuser Relay, K1002. Y N Replace the Fuser Relay, K1002, (PL 1.3).

Replace the Diode, CR1 (PL 24.5). Go to Flag 9. Check the violet wire and connections for an Open.

Go to Flag 2. Check the orange wires.

Replace the Fuser Power Relay, K1001 (PL 1.3).

Replace the Fuser Relay, K1002, (PL 1.3).

NOTE: During the next procedure the voltage will only be available when the lamp pulses. The description of the operation of the lamp is contained in GP 8. Open the Fuser Drawer. Ensure that the Fuser temperature is below operating temperature. Disconnect HR12/P1 at the rear of the Fuser. Refer to GP 7, Section 6 General Procedures, for the correct procedure to pulse the lamp in the next step. Enter dC701, [Fuser Roll Temp]. Place a cheater in the Printer Interlock Bypass Switch. Measure voltage to the Fuser Heat Rod.

Go to Flag 5. Check the wires 19 and 14C. 115 VAC is available at P1-1 (at the rear of Fuser Heat Rod). Y N 115 VAC is available at HR11-1 (at front of Fuser Heat Rod). Y N Go to Flag 6. Check the wires 14A, and 19A. Replace the Fuser Heat Rod (REP 10-1).

NOTE: Ensure that after the cause of the fault has been repaired, in the following steps, the heat rod is reconnected.

An intermittent 10-201 is suspected. Check the following for intermittent operation: • Thermistor CAL ADJ 10-17

115 VAC is available at HR12-1 (at rear of Fuser Heat Rod). Y N Open the Line Interface Box. 115 VAC is available at pin 1 of Fuser Relay, K1002. Y N 115 VAC is available at pin 1 of Fuser Inductor, L1001. Y N Go to Flag 3. Check the wire 13C. 115 VAC is available at pin 2 of Fuser Inductor, L1001. Y N Replace the Fuser Inductor, L1001 (PL 1.3). Go to Flag 4. Check the wire 18.

•

Fuser Roll Thermostat Adjustment (ADJ 10-0) and operation

•

Metering Roll Thermostat Adjustment (ADJ 10-1) and operation

•

Fuser Roll Thermistors (RT1001 and RT1001)

•

Metering Roll Thermistor

•

Fuser Relay, K1007

•

The MIN ADA PWB #1

•

The MIN ADA PWB #2

•

The MIB#1 PWB

•

Wiring and connectors

•

Fuser Heat Rod

115 VAC is available at pin 2 of Fuser Relay, K1002. Y N Use Peak + Voltage. Greater than +4 VDC is available from pin 3 to pin 4 of Fuser Relay, K1002. C

D

Section Name

10-714

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Preliminary Working Document No Product Name Assigned

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

Preliminary Working Document No Product Name Assigned

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Section Name

10-714

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

Section Name

10-714

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Preliminary Working Document No Product Name Assigned

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

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Section Name

10-714

Section Name

10-714

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11-100 RAP Fault Code, 11-100, indicates that a print arrived at the Inverter Entrance Sensor, Q1155, early. The print missed the Printer Duplex Gate, or a stray print arrived at the Inverter Entrance Sensor.

Initial Actions Check the following: •

Inverter Entrance Sensor is clean and not obstructed.

•

Paper path is not obstructed.

•

The Printer Duplex Gate pivots freely and is not damaged.

Procedure Enter dC330, [10], [Duplex Gate] solenoid. Insert a cheater into the Printer Top Cover Interlock Switch. Press Continue. The Duplex Gate Solenoid energizes and the gate actuates. Y N Press Stop. Check the following: • Gate to solenoid linkage (PL 10.14). •

Duplex Gate and Solenoid RAP Adjustment (ADJ 10-9).

If OK, go to Flag 2. Check the Printer Duplex Gate Solenoid circuit GP 6-3 (Generic Solenoid RAP, General Procedures). Press Stop. Check the (ADJ 10-9), Duplex Gate Solenoid adjustment. The correct. Y N Perform (ADJ 10-9), Duplex Gate and Solenoid RAP adjustment.

adjustment

is

Enter dC330, [10]. Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L to H. Y N Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures). (PL 11.24) Go to the 10-108, 10-109.

Preliminary Working Document No Product Name Assigned

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Section Name

11-100

Figure 1 11-100 Circuit Diagram (8100)

Section Name

11-100

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Preliminary Working Document No Product Name Assigned

Figure 2 Run Control PWB Location

11-102 RAP Preliminary Working Document No Product Name Assigned

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Section Name

11-100

Fault Code, 11-102 indicates that the lead edge of the print delivered from the Printer Top Transport Sensor, Q1012, did not arrive at the Inverter Entrance Sensor, Q1155, within the specified amount of time.

Initial Actions Check the following: •

Inverter Entrance Sensor is clean and is not obstructed

•

Paper path is not obstructed

•

Transport jam clearance baffles for damage and that they are seated correctly

•

Printer Top Transport drive rolls, idlers, belts, and bearings for wear, damage, or contamination

Diagnostic Tools: •

dC226, Inverter/Stacker Paper Path Timing Diagnostics, interval #1, LE from Top Transport Sensor Q1012, to LE at Inverter Entrance Sensor Q1155

•

dC227, Inverter/Stacker Jam Bypass

Procedure Observe the Prints entering the Inverter. The prints are free from damage, skew, and excessive curl. Y N Check the following: • Paper path for obstructions •

IF/S to Printer Alignment/Leveling

•

Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14)

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [10]. Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L to H. Y N Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures). (PL 11.24) Insert a cheater into the Top Cover Interlock Switch. Select [1-4] [Main Drive Start/Run]. Press Continue. The Top Transport Drive Rolls are rotating. Y N Press the Stop button. Check the PHM Top Transport Drives for loose, defective or damaged components (PL 10.14). Press Stop. Check the following: • Drive belts for wear, damage, or contamination and that they are set to the correct tension. •

Drive Pulley for damage and that it is not slipping on the shaft (PL 10.14).

•

Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14).

Section Name

11-102

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Preliminary Working Document No Product Name Assigned

Figure 1 11-102/103 Circuit Diagram (8101)

Preliminary Working Document No Product Name Assigned

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Section Name

11-102

Figure 2 Run Control PWB Location

11-104, 11-105 RAP Section Name

11-102

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Preliminary Working Document No Product Name Assigned

A The Inverter Transport Motor Fan is running. Y N CAUTION

Fault Code, 11-104, indicates that the trail edge of a print arrived later than the specified amount of time at the Inverter Entrance Sensor, Q1155. When this fault is declared, the sensor is unblocked.

Before removing the Inverter Motor Cooling Fan from the mounting bracket, note the orientation of the Fan and the direction of the air flow.

Fault Code, 11-105, indicates that the trail edge of a print arrived later than the specified amount of time at the Inverter Entrance Sensor, Q1155. When this fault is declared, the sensor is blocked.

Loosen the screws (2) securing the Fan bracket to the Inverter Assembly Motor and replace the Inverter Transport Motor Fan (PL 11.22).

Initial Actions

Press Stop. Check the following; • Drive belts for wear, damage, or contamination. (PL 11.22).

Check the following:

•

Drive Rolls for wear, damage, or contamination. (PL 11.22).

•

Inverter Pivot Assembly is latched properly.

•

All jam clearance baffles are latched.

•

Inverter Entrance Sensor is clean and is not obstructed

•

Drive belts broken, loose, or damaged.

•

Paper path is not obstructed.

•

Idler Rolls rotate without binding. (PL 11.22).

•

IF/S is aligned properly with printer

•

Idler Springs are mounted properly.

•

Inverter Gate pivots freely and is not damaged.

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #2, LE at Inverter Entrance Sensor to TE at Inverter Entrance Sensor

•

dC227 - Inverter/Stacker Jam Bypass

Procedure

Observe the Inverter Gate Solenoid, SOL1108 (with Printer power on in a standby condition). The Inverter Gate Solenoid is actuated. Y N The problem only occurs in duplex mode. Y N Press Stop. Check the following: • Drive belts for wear, damage, or contamination. (PL 10.14) and (PL 11.22).

Observe the prints entering the Inverter. The prints are free from damage, skew, and excessive curl. Y N Check the following: • Paper path for obstruction. •

If OK, go to the 8-705 Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [10]. Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L to H. Y N Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures). (PL 11.24)

No Product Name Assigned

Inverter Gate for missing or damaged Gate Return Spring (PL 11.24)

Press Stop. Check the following: • Drive belts for wear, damage, or contamination (PL 11.24). After replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).

The Inverter Main Drive Motor may run automatically. There is an internal thermal sensor in the motor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Use caution when working near the motor.

A

Inverter Gate for damage or (PL 11.23)

•

Press Stop. Select [Inverter REV] motor. Press Continue. The Inverter Motor comes on in the reverse direction (clockwise viewed from rear). Y N Press Stop. Go to the 11-707, Inverter Drive Motor RAP.

WARNING

Preliminary Working Document

Drive Rolls and Idlers for binding or wear (PL 11.23)

•

Select [Inverter FWD] motor. The Inverter Motor comes on in the forward direction (Counterclockwise viewed from rear). Y N Press Stop. Go to the 11-707, Inverter Drive Motor RAP.

Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14).

Press Stop. Select [Inverter Start/Run] motor. Press Continue. The Inverter Drive Rolls and Idlers rotate. Y N The Inverter Main Drive Motor comes on. Y N Press Stop. Go to the 11-708 Inverter Main Drive Motor RAP.

•

•

Drive Rolls and Idlers for binding or wear (PL 11.23) and PL 11.25).

•

Inverter Gate for damage (PL 11.23)

•

Inverter Gate for missing or damaged Gate Return Spring (PL 11.24)

•

IF/S to Printer Alignment/Leveling

•

Proper pulley on reversing Shaft (60Hz-24 teeth, 50Hz-20 teeth)

Go to Flag 3. Check the wire for a short circuit. If OK, replace the PHN DIO PWB #5 (PL 1.17).

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Section Name

11-104, 11-105

B

Figure 1 11-104/105 Circuit Diagram (8102) l

Section Name

11-104, 11-105

0/0/00 ?-896

Preliminary Working Document No Product Name Assigned

Figure 2 Run Control PWB Location

11-106 RAP Preliminary Working Document No Product Name Assigned

0/0/00 ?-897

Section Name

11-104, 11-105

Fault Code, 11-106, indicates that the lead edge of an inverted print arrived earlier than the specified amount of time at the Post Inverter Sensor, Q1156, from the Inverter Entrance Sensor, Q1155. The duplex print missed the Inverter Gate.

A •

Proper Inverter Main Drive Motor is present (60Hz, 21 teeth on pulley), (50Hz, 25 teeth on pulley).

Initial Actions Check the following: •

Post Inverter Sensor actuator is not obstructed or damaged.

•

Inverter Gate is not obstructed.

•

Inverter Gate Solenoid Return Spring is not damaged, missing, or stretched.

•

Inverter Gate Solenoid plunger moves freely.

Diagnostic Tools: dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #3, LE from Inverter Entrance Sensor to LE at Post Inverter Sensor

Procedure Enter dC330, [10]. Actuate the Post Inverter Sensor. The Post Inverter Sensor display changes from L to H. Y N Go to Flag 1. Check the Post Inverter Sensor circuit (GP 6-2, General Procedures). (PL 11.2) Select [Inverter Gate] solenoid. Press Continue. The Inverter Gate actuates. Y N The Inverter Gate Solenoid energizes. Y N Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit. Go to Flag 2. Check the Inverter Gate Solenoid circuit (Generic Solenoid RAP GP 6-3, General Procedures), (PL 11.24). Press Stop. Check the following: • Inverter Gate for damage or binding (PL 11.23) •

Gate pivot for damage or binding (PL 11.23)

•

Bearing for binding (PL 11.23)

•

(ADJ 11-1), Inverter Gate Solenoid adjustment

•

Solenoid RAP plunger for binding

Press Stop. Select [Cycle Mode]. Press Continue. Let the solenoid cycle for several minutes. The Inverter Solenoid RAP energizes and deenergizes without binding. Y N Press Stop. Replace the Inverter Gate Solenoid (PL 11.24). Press Stop. Check the following: • (ADJ 11-1), Inverter Gate Solenoid adjustment. A Section Name

11-106

0/0/00 ?-898

Preliminary Working Document No Product Name Assigned

Figure 1 11-106 Circuit Diagram (8104)

11-107 RAP Preliminary Working Document No Product Name Assigned

0/0/00 ?-899

Section Name

11-106

Fault Code, 11-107, indicates that the lead edge of an inverted print from the Inverter Entrance Sensor, Q1155, arrived earlier than the specified amount of time at the Sample Tray Sensor, Q1157. The print missed the Inverter Gate.

A •

(ADJ 11-1), Inverter Gate Solenoid adjustment.

•

Proper Inverter Main Drive Motor is present (60Hz, 25 teeth on pulley), (50Hz, 21 teeth on pulley).

0/0/00 ?-900

Preliminary Working Document

Initial Actions Check the following: •

Sample Tray Sensor is clean and not obstructed.

•

Paper path is clear.

•

Inverter Gate pivots freely and is not damaged.

•

Inverter Gate Solenoid Return Spring is not damaged, missing, or stretched.

•

Inverter Gate Solenoid plunger moves freely.

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #7, LE from Inverter Entrance Sensor to LE at Sample Tray Sensor.

Procedure Enter dC330, [10]. Actuate the Sample Tray Sensor. The Sample Tray Sensor display changes from L to H. Y N Go to Flag 1. Check the Sample Tray Sensor circuit (GP 6-2, General Procedures). (PL 11.26) Select [Inverter Gate] solenoid. Press Continue. The Inverter Gate actuates. Y N The Inverter Gate Solenoid energizes. Y N Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit. Go to Flag 2. Check the Inverter Gate Solenoid circuit (Generic Solenoid RAP, GP 63 General Procedures) (PL 11.24). Press Stop. Check the following: • Inverter Gate for damage or binding (PL 11.23) •

Gate pivot for damage or binding (PL 11.23)

•

Bearing for binding (PL 11.23)

•

(ADJ 11-1), Inverter Gate Solenoid adjustment

•

Check the solenoid plunger for binding

Press Stop. Select [Cycle Mode]. Press Continue. Let the solenoid cycle for several minutes. The Inverter Solenoid RAP energizes and deenergizes without binding. Y N Press Stop. Replace the Inverter Gate Solenoid (PL 11.24). Press Stop. Check the following: A Section Name

11-107

No Product Name Assigned

Figure 1 11-107 Circuit Diagram (8103)

11-108 RAP

Preliminary Working Document No Product Name Assigned

Fault Code, 11-108, indicates that the lead edge of a print delivered from the Inverter Entrance Sensor, Q1155, did not arrive at the Post Inverter Sensor, Q1156, within the specified amount of time.

0/0/00 ?-901

Section Name

11-107

A Observe the Sample Tray Gate Solenoid, SOL1110. The solenoid is NOT actuated. Y N The solenoid IS actuated. Check the following: • Sample Tray Gate and linkage for binding (PL 11.27).

Initial Actions Check the following: •

Inverter Entrance Sensor is clean and not obstructed.

•

Post Inverter Sensor actuator is not obstructed or damaged.

•

Paper path for obstructions or burrs. Jam clearance baffles are not damaged and that they are latched correctly.

•

Inverter Gate and Sample Tray Gate are not damaged and that they are free to move.

•

Gate return springs for damage or missing.

•

IF/S is aligned and leveled properly with the Printer

•

Ensure the PR Drive coupling is properly lubricated with Moly Grease (PL 25.1). See Rollovers (PC 3676, RO 177643) in the Service Information for additional information on the lubricant and a tool for its application. SCP HFSI 11-803 Table 4, or HFSI TABLES to see all of HFSI.

•

Check FSN AC Remote #2 for damaged components.

Flag 4. Check the wire for a short circuit.

WARNING

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #3, LE from Inverter Entrance Sensor to LE at Post Inverter Sensor

•

dC227 - Inverter/Stacker Jam Bypass

The Inverter Main Drive Motor, Inverter Drive Motor, or the Stacker Main Drive Motor may run automatically. There is an internal thermal sensor in each of these motors that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Use caution when working near the motor. Select [Inverter Start/Run] motor. Press Continue. The Inverter Transport Drive Rolls rotate. Y N The Inverter Main Drive Motor comes on. Y N Press Stop. Go to the 11-708, Inverter Main Drive Motor RAP. The Inverter Transport Motor Fan is running. Y N CAUTION

Procedure Observe the prints entering the Inverter. The prints are free from damage and are not skewed or have excessive curl. Y N Check the following: • Paper path for obstructions •

Sample Gate Return Spring

•

If OK, replace the PHN DIO PWB #5 (PL 1.17).

•

•

•

Before removing the Inverter Motor Cooling Fan from the mounting bracket, note the orientation of the Fan and the direction of the air flow. Loosen the screws (2) securing the Fan bracket to the Inverter Assembly Motor and replace the Inverter Transport Motor Fan (PL 11.22).

Drive Rolls and Idlers for wear, damage, or contamination (PL 10.14).

If OK, go to the 8-705, PHM Print Damage RAP or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information.

Press Stop. Check the following: • Drive Belts for wear, damage, or contamination and that they are set to the correct tension (PL 11.22).

Enter dC330, [10]. Actuate the Post Inverter Sensor. The Post Inverter Sensor display changes from H to L. Y N Go to Flag 1. Check the Post Inverter Sensor circuit (GP 6-2, General Procedures) (PL 11.2). Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L to H. Y N Go to Flag 2. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures) (PL 11.24).

•

Drive shaft bearings for binding (PL 11.24) and (PL 11.25) After replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).

•

Drive belt idlers for binding (PL 11.27).

•

Drive pulleys for damage and they are not slipping on the shaft (PL 11.21), (PL 11.26).

Press Stop. Select [Inverter FWD] motor. Press Continue. The Inverter Motor operates in the forward direction (Counterclockwise viewed from rear). Y N Press Stop. Go to the 11-707, Inverter Motor RAP.

Check that the Passive Gate is straight and that the fingers are lined up with the baffle cutouts. The Passive Gate is OK. Y N Check the Top and Bottom Hinge Adjustment (ADJ 11-4). If OK, replace the Passive Gate (PL 11.25).

Press Stop. Select [Inverter REV] motor. Press Continue. The Inverter Motor operates in the reverse direction (Clockwise viewed from rear). Y N Press Stop. Go to the 11-707, Inverter Motor RAP.

A

B

Section Name

11-108

0/0/00 ?-902

Preliminary Working Document No Product Name Assigned

B Press Stop. Select [11A1] [Stacker Start/Run]. Press Continue. The Preregistration Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

•

Proper Inverter Bottom Drive Shaft is present (60Hz, 24 teeth on pulley), (50Hz, 20 teeth on pulley).

0/0/00 ?-903

Section Name

The Preregistration Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, or contamination and that they are set to the correct tension (PL 11.2). •

Flexible Drive Cable for damage, loose, coupling, or missing or loose setscrew (PL 11.2).

Press Stop. Check the following: • Preregistration Drive and Idler rolls for wear, damage, or contamination (PL 11.2). •

Idler springs for wear or damage (PL 11.2).

•

(ADJ 11-6), Stacker Preregistration Corrugator Rolls Adjustment.

Press Stop. Select [10] [Inverter Gate]. Press Continue. The Inverter Gate actuated. Y N The Inverter Gate Solenoid energized. Y N Go to Flag 3. Check the Inverter Gate Solenoid circuit (Generic Solenoid RAP GP 63, General Procedures), (PL 11.24). Press Stop. Check the following: • (ADJ 11-1), Inverter Gate Solenoid adjustment. •

Gate bushings for damage (PL 11.23).

•

Gate linkage for damage (PL 11.24).

•

Check the solenoid plunger for binding (PL 11.23)

Press Stop. Check the following: • Ensure that the A3 Nip Release Solenoid RAP is not actuated. •

Passive Gate is straight (PL 11.25).

•

Drive Shaft bearings for binding (PL 11.26).

•

Drive Belt idlers for binding (PL 11.27).

•

Drive Rolls and Idlers for wear, damage, or contamination (PL 11.25), (PL 11.26).

•

(ADJ 11-2), Gate Flat Spring adjustment.

•

(ADJ 11-3), Inverter Output Baffle adjustment.

•

(ADJ 11-4), Top and Bottom Hinge adjustment.

•

(ADJ 11-7), Inverter Pivoting Assembly adjustment.

•

(ADJ 11-12), Post Inverter Latch Adjustment.

•

Baffles for damage (PL 11.24), (PL 11.25).

•

Processor Top Transport Exit Drive Rolls for wear, damage, or contamination (PL 10.14).

•

Drive belts for wear, damage, or contamination and that they are set to the correct tension (PL 10.14).

Preliminary Working Document No Product Name Assigned

11-108

Figure 1 11-108/109 Circuit Diagram (8105)

11-110 RAP Section Name

11-108

0/0/00 ?-904

Preliminary Working Document No Product Name Assigned

A Fault Code, 11-110, indicates that the trail edge of a print did not arrive at the Post Inverter Sensor, Q1156, within the specified amount of time after the lead edge of the print arrived at the sensor.

B Y

N Press Stop. Check the following: • Drive belts for wear, damage, or contamination and correct tension (PL 11.2). •

Initial Actions Check the following: •

Press Stop. Check the following: • Preregistration Drive and Idler rolls for wear, damage, or contamination (PL 11.2).

Post Inverter Sensor actuator is not bent, damaged, or interfering with baffle. The Sensor can be installed incorrectly and possibly interfere with the baffle. Refer to (REP 11-25) Post Inverter Sensor for correct positioning.

•

Paper path is not obstructed.

•

Jam clearance baffle is latched correctly and is not damaged.

•

IF/S is aligned and leveled properly with the Printer.

Flexible Drive Shaft for damage, loose, coupling, or missing or loose setscrew (PL 11.2).

•

Idler springs for wear or damage (PL 11.2).

•

(ADJ 11-6), Stacker Preregistration Corrugator Roll Adjustment.

Press Stop. Check the following: • Drive Shaft bearings for binding (PL 11.2). •

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #5, LE at Post Inverter Sensor to TE at Post Inverter Sensor

•

dC227 - Inverter/Stacker Jam Bypass

Procedure

Drive Belt idlers for binding (PL 11.2).

•

Drive Rolls for wear, damage, or contamination (PL 11.2).

•

Baffles for damage (PL 11.2).

•

Preregistration Drive Rolls for wear, damage, or contamination (PL 11.2).

•

Drive belts for wear, damage, or contamination and correct tension (PL 11.1, PL 11.2).

•

Preregistration Transport Pivot baffle is latched properly

Observe the prints entering the Preregistration Transport. The prints are free from damage, skew, and excessive curl. Y N Check the following: • Paper path for obstructions •

Drive Rolls and Idlers for wear, damage, or contamination (PL 11.2)

•

Idler roll retaining springs for damage or missing (PL 11.2)

Go to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information on paper problems. Enter dC330, [10]. Actuate the Post Inverter Sensor. The Post Inverter Sensor display changes from H to L. Y N Go to Flag 1. Check the Post Inverter Sensor circuit (GP 6-2, General Procedures) (PL 11.2).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11A1] [Stacker Start/Run]. Press Continue. The Preregistration Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. The Preregistration Transport Drive Rolls operate correctly. A

B

Preliminary Working Document No Product Name Assigned

0/0/00 ?-905

Section Name

11-110

Figure 1 11-110 Circuit Diagram (8106)

11-112 RAP Section Name

11-110

0/0/00 ?-906

Preliminary Working Document No Product Name Assigned

Fault Code, 11-112, indicates that the lead edge of the print delivered from the Post Inverter Sensor, Q1156, did not arrive at the Prestacker Sensor, Q1158, within the specified amount of time. When this fault is declared the Prestacker Sensor is unblocked.

A Y

Initial Actions

The Preregistration Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, or contamination and correct tension (PL 11.2).

Check the following: •

Post Inverter Sensor and the Prestacker Sensor are clean and are not obstructed.

•

Registration Edge on the Preregistration Transport for build up of adhesive from non-spec label stock.

•

Paper path is not obstructed.

•

Jam clearance baffles for damage and that they are correctly seated.

•

SCP, HFSI 11-805 Table 4, or HFSI TABLES to see all of HFSI.

•

•

dC227 - Inverter/Stacker Paper Path Timing Diagnostics, interval 6, LE at Post Inverter Sensor to LE at Prestacker Sensor. dC227 - Inverter/Stacker Jam Bypass

Procedure

•

Inverter Gate or Sample Gate for damage or incorrect position (PL 11.23), (PL 11.25). Drive Rolls, idlers, and idler springs for wear, damage or contamination (PL 11.2), (PL 11.26).

If OK, go to the 8-705, PHM Print Damage RAP or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [10]. Block the Post Inverter Sensor. The Post Inverter Sensor display changes from L to H Y N Go to Flag 2. Check the Post Inverter Sensor circuit (GP 6-2, General Procedures) (PL 11.2).

•

Drive belts for wear, damage, or contamination and correct tension (PL 11.2), (PL 11.23).

•

Drive Roll for slipping on shaft (PL 11.2).

•

Idler Roll bearings for binding (PL 11.28).

•

Idler Roll for springs missing or damaged (PL 11.28).

•

(ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.

•

Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, and the motor may restart. The outside surfaces of the motor could also be very hot. Select [11A1] [Stacker Start/Run]. Press Continue. The Preregistration Drive Rolls rotate.

No Product Name Assigned

(ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.

The original problem only occurs in the 3 pitch mode. Y N Press Stop. Check the following: • Registration Edge on the Preregistration Transport for wear (PL 11.2)

WARNING

A

Idler springs for wear or damage (PL 11.2).

•

Select [10]. Block the Prestacker Sensor. The Prestacker Sensor display changes from L to H. Y N Go to Flag 1. Check the Prestacker Sensor circuit (GP 6-2, General Procedures) (PL 11.2).

The Preregistration Transport baffle is seated and latched correctly. Y N Check the baffle for nicks, burrs, or other damage (PL 11.28). Reseat the baffle.

Preliminary Working Document

•

The Preregistration Drive Rolls and Idlers rotate correctly. Y N Press Stop. Check the following: • Drive Rolls and Idlers for correct installation (PL 11.2), (PL 11.28).

Observe the prints entering the Preregistration Transport. The prints are free from damage, skew, and excessive curl. Y N Check the following: • Idler Rolls for binding or retaining springs loose or missing (11.2). •

Flexible Drive Shaft for damage, loose, coupling, or missing or loose setscrew (PL 11.2).

Press Stop. Check the following: • Preregistration Drive and Idler rolls for wear, damage, or contamination (PL 11.2).

Diagnostic Tools: •

N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Drive Rolls for slipping on shaft (PL 11.2).

•

Drive Belt idlers for binding (PL 11.28).

•

(ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.

•

Drive or Preregistration Rolls for wear, damage, or contamination (PL 11.2)

•

Baffles for damage (PL 1.2).

•

Bypass Transport Drive Rolls and Idlers for wear, damage, or contamination (PL 11.11), (PL 11.15).

•

Drive belts for wear, damage, or contamination and correct tension (PL 11.2), (PL 11.11).

•

Bypass Transport grounded correctly.

B 0/0/00 ?-907

Section Name

11-112

B Press Stop. Select [Cycle Mode] [Nip Release A3]. Press Continue. The A3 Inverter Nip Release Rolls operate. Y N The A3 Inverter Nip Release Solenoid RAP energizes. Y N Press Stop. +24 VDC is measured at TS34. Y N Go to the Wirenets (Wiring Data) and check wire #64F for an open circuit. Press Stop. Go to Flag 4. Check the A3 Inverter Nip Release Solenoid RAP circuit (Generic Solenoid RAP GP 6-3, General Procedures), (PL 11.28). Press Stop. Check the following: • (ADJ 11-9), A3 Nip Release Solenoid RAP adjustment. •

Lift linkage for binding or damaged, loose, or missing hardware (PL 11.28).

•

A3 Nip Release solenoid on all the time

Press Stop. Check the following: • Registration edge on the Preregistration Transport for wear. •

Drive Rolls for slipping on shaft (PL 11.2).

•

Drive Belt idlers for binding (PL 11.28).

•

(ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.

•

Drive or Preregistration Rolls for wear, damage, or contamination (PL 11.2)

•

Baffles for damage (PL 11.2), (PL 11.28).

•

Bypass Transport Drive Rolls and Idlers for wear, damage, or contamination (PL 11.11), (PL 11.28).

•

Drive belts for wear, damage, or contamination and correct tension (PL 11.2), (PL 11.11).

Section Name

11-112

0/0/00 ?-908

Preliminary Working Document No Product Name Assigned

Figure 1 11-112 Circuit Diagram (8107)

11-114 RAP Preliminary Working Document No Product Name Assigned

0/0/00 ?-909

Section Name

11-112

A Fault Code, 11-114, indicates that the trail edge of a print did not arrive at the Prestacker Sensor, Q1158, within the specified amount of time after the lead edge of the print arrived at the sensor. The valid destination for the sheet is beyond Stacker A.

B The Preregistration Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, or contamination and correct tension (PL 11.2). •

Initial Actions Check the following:

Flexible Drive Cable for damage, loose, coupling, or missing or loose setscrew (PL 11.2).

•

Prestacker Sensor is clean and is not obstructed.

Press Stop. Check the following: • Preregistration Drive and Idler rolls for wear, damage, or contamination (PL 11.2).

•

Registration edge on the Preregistration Transport for a build up of adhesive from nonspec label stock.

•

Idler retaining springs damaged or missing (PL 11.28).

•

(ADJ 11-6), Stacker Preregistration Corrugator Roll adjustment.

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and not damaged.

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #8, LE at Prestacker Sensor to TE at Prestacker Sensor.

•

dC227 - Inverter/Stacker Jam Bypass

The Bypass Transport Drive Rolls and Idlers rotate correctly. Y N Press Stop. Check the following: • Drive Rolls and Idlers installed correctly (PL 11.11), (PL 11.15). •

Drive belts for wear, damage, contamination, and correct tension (PL 11.11).

•

Drive Roll for slipping on shaft (PL 11.11).

Procedure

•

Idler Roll bearings for binding (PL 11.15).

Observe the prints entering the Bypass Transport. The prints are free from damage, skew, and excessive curl. Y N Check the following: • Jam clearance baffles for wear or damage and they are seated correctly (PL 11.4), (PL 11.22), (PL 11.25), (PL 11.26), (PL 11.28).

•

Idler retaining springs damaged or missing (PL 11.15).

•

Paper path for obstructions

•

Drive Rolls and Idlers for wear, damage, or contamination (PL 11.2).

•

Idler retaining springs damaged or missing (PL 11.2).

Press Stop. Check the following: • Drive Rolls for slipping on shaft (PL 11.2), (PL 11.11). •

Drive Belt idlers for binding (PL 11.2), (PL 11.15).

•

Baffles for damage (PL 11.2), (PL 11.15).

•

Bypass Transport Drive Rolls and Idlers for wear, damage, or contamination (PL 11.11), (PL 11.15).

•

Drive belts for wear, damage, contamination, and correct tension (PL 11.11).

•

Bypass Gate is positioned properly. Ensure that the Gate Return Spring is functioning properly and that the Gate is closing fully. Check the Bypass Transport Gate Solenoid adjustment, (ADJ 11-11).

0/0/00 ?-910

Preliminary Working Document

If OK, go to the 8-705, PHM Print Damage RAP or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [10]. Block the Prestacker Sensor. The Prestacker Sensor display changes from L to H. Y N Go to Flag 1. Check the Prestacker Sensor circuit (GP 6-2, General Procedures) (PL 11.2). The Preregistration Transport pivot baffle is seated and latched correctly. Y N Check the following: • Pivot baffle for damage (PL 11.28) •

Latch assembly (PL 11.28)

Select [11A1] [Stacker Start/Run]. Press Continue. The Preregistration Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. A

B

Section Name

11-114

No Product Name Assigned

Figure 1 11-114 Circuit Diagram (8108)

11-116, 11-117 RAP Preliminary Working Document No Product Name Assigned

0/0/00 ?-911

Section Name

11-114

A Y

Fault Code, 11-116, indicates that the lead edge of a print delivered from the Inverter Entrance Sensor, Q1155, did not arrive at the Sample Tray Sensor, Q1157, within the specified amount of time. When this fault is declared, the sensor is unblocked.

Check the solenoid plunger for binding, (ADJ 11-8) Sample Tray Gate Solenoid. Go to Flag 4. Check the Sample Tray Gate Solenoid circuit (Generic Solenoid RAP GP 6-3, General Procedures) (PL 11.26).

Fault Code, 11-117, indicates that the lead edge of a print delivered from the Inverter Entrance Sensor, Q1155, did not arrive at the Sample Tray Sensor, Q1157, within the specified amount of time. When this fault is declared, the sensor is blocked.

Press Stop. Check the following: • (ADJ 11-8), Sample Tray Gate Solenoid adjustment.

Initial Actions Check the following: •

Inverter Entrance Sensor and the Sample Tray sensors are clean and are not obstructed.

•

Paper path is not obstructed

•

Jam clearance baffles are latched correctly and are not damaged.

•

Inverter Gate and Sample Tray Gate for damage and that they are free to move. Check the gate return springs for damage.

•

Drive Belts for wear, damage, contamination, and correct tension.

•

SCP, HFSI 11-803 Table 4, or HFSI TABLES to see all of HFSI

N Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit.

•

Gate bushings damaged (PL 11.27).

•

Gate linkage for damage (PL 11.27).

•

Gate Actuator positioned properly (PL 11.27).

Press Stop. Select [Inverter Gate]. Press Continue. The Inverter Gate actuates. Y N The Inverter Gate Solenoid energized. Y N Press Stop. Go to Flag 3. Check the circuit of the Inverter Gate Solenoid.

Diagnostic Tools:

Press Stop. Check the following: • (ADJ 11-1), Inverter Gate Solenoid adjustment.

•

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #7, LE from Inverter Entrance Sensor to LE at Sample Tray Sensor.

•

Solenoid RAP plunger for binding (PL 11.24).

•

Gate bushings damaged or contaminated (PL 11.23).

dC227 - Inverter/Stacker Jam Bypass

•

Gate linkage for damage or binding (PL 11.24).

•

Procedure Observe the prints entering the Inverter. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Paper path for obstructions •

IF/S to Printer alignment/leveling

•

Idler Rolls and retaining springs binding or loose (PL 10.14).

•

Processor Top Transport Exit Drive Rolls for wear, damage, or contamination (PL 10.14).

Press Stop. Select [Inverter Start/Run]. Press Continue. The Inverter Upper Rolls rotate. Y N The Inverter Main Drive Motor comes on. Y N Press Stop. Go to the 11-708, Inverter Main Drive Motor RAP.

Select [Sample Tray Gate] solenoid. Press Continue. The Sample Tray Gate actuated. Y N The Sample Tray Gate Solenoid energized. Y N Press Stop. +24 VDC is measured at TS35 (+) on the PHN DIO PWB #5. A Section Name

11-116, 11-117

Drive

Press Stop. Check the following: • Drive Belts for wear, damage, contamination, and correct tension (PL 11.26).

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [10]. Block the Sample Tray Sensor. The Sample Tray Sensor display changes from L to H. Y N Go to Flag 2. Check the Sample Tray Sensor circuit (GP 6-2, General Procedures) (PL 11.26).

Transport

•

Drive shaft bearings and Drive Belt Idlers for binding (PL 11.26).

•

Drive pulley for damage and that it is not slipping on the shaft (PL 11.26).

Block the Inverter Entrance Sensor. The Inverter Entrance Sensor display changes from L to H. Y N Go to Flag 1. Check the Inverter Entrance Sensor circuit (GP 6-2, General Procedures) (PL 11.24). The fault only occurs when running in the duplex mode. Y N Check the following: • Drive Shaft bearings and Drive Belt Idlers for binding (PL 11.26). •

Sample Tray Gate to Solenoid RAP linkage (PL 11.27).

•

Drive Rolls, idlers, and belts for wear, damage, or contamination (PL 11.26).

B 0/0/00 ?-912

Preliminary Working Document No Product Name Assigned

B •

(ADJ 11-4), Inverter Top and Bottom Hinge Adjustment

•

(ADJ 11-3), Inverter Output Baffle Adjustment

•

(ADJ 11-7), Inverter Pivot Assembly Adjustment

Press Stop. Select [Inverter FWD] motor. Press Continue. The Inverter Motor operates in the forward direction (Counterclockwise from rear). Y N Press Stop. Go to the 11-707, Inverter Motor RAP. Press Stop. Select [Inverter REV] motor. Press Continue. The Inverter Motor operates in the reverse direction (Clockwise from rear). Y N Press Stop. Go to the 11-707, Inverter Motor RAP. Press Stop. Observe the Inverter Gate Solenoid, SOL1108. The solenoid is actuated in the standby condition. Y N Press Stop. Check the following: • Inverter Passive Gate is straight (PL 11.25). •

(ADJ 11-2), Gate Flat Spring Adjustment

•

Drive Shaft bearings and Drive Belt Idlers for binding (PL 11.24), (PL 11.26). After replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ 1114).

•

Drive Rolls and belts for wear, damage, or contamination (PL 11.24), (PL 11.26). After replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).

•

Paper path for obstructions.

•

Baffles for damage (PL 11.23), (PL 11.24).

Go to Flag 3. Check the wire for a short circuit. If OK, replace the PHN DIO PWB #5 (PL 1.17).

Preliminary Working Document No Product Name Assigned

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Section Name

11-116, 11-117

Figure 1 11-116/117 Circuit Diagram (8109)

11-118, 11-119 RAP Section Name

11-116, 11-117

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Preliminary Working Document No Product Name Assigned

A Y

Fault Code, 11-118, indicates that the trail edge of a print did not arrive at the Sample Tray Sensor, Q1157, within the specified amount of time after the lead edge of the sheet arrived at the sensor. When the fault is declared, the sensor is unblocked.

Go to Flag 2. Check the Sample Tray Gate Solenoid circuit (Generic Solenoid RAP GP 6-3, General Procedures).

Fault Code, 11-119, indicates that the trail edge of a print did not arrive at the Sample Tray Sensor, Q1157, within the specified amount of time after the lead edge of the sheet arrived at the sensor. When the fault is declared, the sensor is blocked.

Press Stop. Check the following: • (ADJ 11-8), Sample Tray Solenoid RAP adjustment. •

Initial Actions NOTE: The Sample Tray utilizes corrugated rolls to decelerate the sheets to allow adequate stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm.

Maximum of 100 prints are in the Sample Tray.

•

Sample Tray sensor is clean and is not obstructed.

Gate bushings for damage (PL 11.27)

•

Gate linkage for damage (PL 11.27)

•

Check the solenoid plunger for binding (PL 11.27)

Press Stop. Select [Inverter Start/Run]. Press Continue. The Inverter Transport Upper Drive Rolls rotate. Y N The Inverter Main Drive Motor comes on. Y N Press Stop. Go to the 11-708, Inverter Main Drive Motor RAP.

Check the following: •

N Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit.

•

Idler rolls positioned properly and retaining springs not loose.

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Drive Belts for wear, damage, contamination, and correct tension.

Press Stop. Check the following: • Drive Belts for wear, damage, contamination, and correct tension (PL 11.26)

•

Sample Tray is installed correctly.

•

•

Check the Sample Tray Corrugation Roll adjustment (ADJ 11-13).

•

Drive belt idlers for binding (PL 11.28)

•

Drive pulley for damage and that it is not slipping on the shaft (PL 11.26)

Diagnostic Tools:

Drive shaft bearings for binding (PL 11.26)

•

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #41, LE at Sample Tray Sensor to TE at Sample Tray Sensor.

Press Stop. Check the following: • Drive Shaft bearings for binding (PL 11.26)

•

dC227 - Inverter/Stacker Jam Bypass

•

Drive Belt idlers for binding (PL 11.28)

Procedure

•

Drive Rolls for wear, damage, or contamination (PL 11.26)

Observe the prints entering the Inverter. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Paper path for obstructions

•

Drive belts for wear, damage, contamination, and correct tension (PL 11.26)

•

Sample Tray corrugating idler is seated correctly and that the springs are in place (PL 11.27)

•

Idler Rolls and retaining springs for binding.

•

Processor Top Transport Exit Drive Rolls for wear, damage, or contamination.

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [10]. Block the Sample Tray Sensor. The display changes from L to H. Y N Go to Flag 1. Check the Sample Tray Sensor circuit (GP 6-2, General Procedures). Select [Sample Tray] solenoid. Press Continue. The Sample Tray Gate actuated. Y N The Sample Tray Gate Solenoid energized. Y N Press Stop. +24 VDC is measured at TS35 (+) on the PHN DIO PWB #5. A Preliminary Working Document No Product Name Assigned

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Section Name

11-118, 11-119

Figure 1 11-118/119 Circuit Diagram (8110)

11-130 RAP Section Name

11-118, 11-119

Stacker A Fault Code, 11-130-1, indicates that the lead edge of a print was detected at the Disk Sheet Sensor, Q1106A, when it was not expected.

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Preliminary Working Document No Product Name Assigned

Stacker B Fault Code, 11-130-2, indicates that the lead edge of a print was detected at the Disk Sheet Sensor, Q1106B, when it was not expected. Stacker C Fault Code, 11-130-3, indicates that the lead edge of a print was detected at the Disk Sheet Sensor, Q1106C, when it was not expected. Stacker D Fault Code, 11-130-4, indicates that the lead edge of a print was detected at the Disk Sheet Sensor, Q1106D, when it was not expected.

Initial Actions Check the following: •

Disk Sheet Sensor is clean and is not obstructed.

•

Bypass Transport Gate is not obstructed and is operating correctly.

•

Bypass Transport baffle is seated correctly.

Procedure Enter dC330, [Stacker X], [11X1]. Block the Disk Sheet Sensor. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 1. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Observe the Bypass Gate Solenoid. The Bypass Solenoid RAP is actuated in a standby condition. Y N Press Stop. Check the following: • (ADJ 11-10), Bypass Transport adjustment •

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment

Go to Flag 2. Check the wire for a short circuit. If OK, replace the FSN DIO PWB #3 (PL 1.17).

Preliminary Working Document No Product Name Assigned

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Section Name

11-130

Figure 1 11-130 Circuit Diagram (8150)

Section Name

11-130

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Preliminary Working Document No Product Name Assigned

Figure 2 11-130 Circuit Diagram (8111)

Preliminary Working Document No Product Name Assigned

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Section Name

11-130

11-131-1, 11-132-1, 11-133-1 RAP

Y

Stacker A Fault Code, 11-131-1, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106A, within the specified amount of time after the Prestacker Sensor, Q1158 sensed the lead edge. When this fault is declared, the Prestacker Sensor is unblocked and the Disk Sheet Sensor is unblocked. Stacker A Fault Code, 11-132-1, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106A, within the specified amount of time after the Prestacker Sensor, Q1158 sensed the lead edge. When this fault is declared, the Prestacker Sensor is blocked and the Disk Sheet Sensor is unblocked.

N Go to Flag 3. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.14).

Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated. Y N The Bypass Gate Solenoid energized. Y N Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3A. Y N Go to the Wirenets (Wiring Data) and check wire #63M for an open circuit.

Stacker A Fault Code, 11-133-1, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106A, within the specified amount of time after the Prestacker Sensor, Q1158 sensed the lead edge. When this fault is declared, the Prestacker Sensor is unblocked and the Disk Sheet Sensor is blocked.

Check the solenoid plunger for binding (PL 11.11). Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 63, General Procedures).

Initial Actions

Press Stop. Check the following: • Bypass Gate for wear, damage, or binding (PL 11.14).

Check the following:

•

Press Stop. Select [Stacker Start/Run]. Press Continue. The Bypass Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

•

Prestacker Sensor and the Disk Sheet Sensor are clean and are not obstructed.

•

Paper path for obstructions.

•

Jam clearance baffles for damage and that they are seated correctly.

•

Drive rolls and Idlers for wear, damage or contamination.

•

Disks are positioned correctly.

•

Disk Gate moves freely.

•

Ensure that the Stacker Tray is stopping at the correct height, indexing down in the proper sequence of intervals, and is not interfering with disk rotation.

•

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #9, LE at Prestacker Sensor to LE at Stacker A Disk Sheet Sensor.

•

dC227 - Inverter/Stacker Jam Bypass

•

Obstructions in the paper path

•

(ADJ 11-6) Stacker Preregistration Corrugator Rolls Adjustment

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [11A1]. Block the Disk Sheet Sensor. The changes from L to H.

Section Name

11-131-1, 11-132-1, 11-133-1

Disk

Sheet

Sensor

display

Drive

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.11).

Press Stop. Check the following: • Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.11), (PL 11.15).

Procedure Observe the prints entering the Disk Module. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Drive Rolls and Idlers for damage or binding (PL 11.2, PL 11.32).

Transport

The Bypass Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.11).

Diagnostic Tools:

•

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

•

Idler springs for wear or damage (PL 11.15).

Press Stop. Select [10]. Block the Prestacker Sensor. The Prestacker Sensor display changes from L to H. Y N Go to Flag 1. Check the Prestacker Sensor circuit (GP 6-2, General Procedures) (PL 11.2). Press Stop. Check the following: • Drive Shaft bearings for binding (PL 11.2, PL 11.11, PL 11.32). •

Drive Belt idlers for binding (PL 11.2, PL 11.11).

•

Drive Rolls for wear, damage, or contamination (PL 11.2, PL 11.11)

•

Paper path for obstructions.

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Preliminary Working Document No Product Name Assigned

•

Baffles for damage (PL 11.2, PL 11.11, PL 11.15, PL 11.32).

•

Processor Top Transport Exit Drive Rolls for wear, damage, or contamination.

•

Drive belts for wear, damage, contamination, and correct tension (PL 11.2 PL 11.11).

•

A3 Nip Release Solenoid RAP for proper operation

•

Bypass Gate for binding

Preliminary Working Document No Product Name Assigned

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Section Name

11-131-1, 11-132-1, 11-133-1

Figure 1 11-131-1/132-1/133-1 Circuit Diagram (8112)

Section Name

11-131-1, 11-132-1, 11-133-1

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Preliminary Working Document No Product Name Assigned

11-131-2, 11-132-2, 11-133-2 RAP Stacker B Fault Code, 11-131-2, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106B, within the specified amount of time after the Bypass Transport Sensor, Q1158A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is unblocked. Stacker B Fault Code, 11-132-2, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106B, within the specified amount of time after the Bypass Transport Sensor, Q1158A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is blocked and the Disk Sheet Sensor is unblocked. Stacker B Fault Code, 11-133-2, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106B, within the specified amount of time after the Bypass Transport Sensor, Q1158A sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is blocked.

A Enter dC330, [11B1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 3. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated. Y N The Bypass Gate Solenoid energized. Y N Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3B. Y N Go to the Wirenets (Wiring Data) and check wire #86A for an open circuit. Check the solenoid plunger for binding (PL 11.13). Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 63, General Procedures) (PL 11.13).

Initial Actions Check the following:

Press Stop. Check the following: • Bypass Gate for wear, damage, or binding (PL 11.13).

•

Bypass Transport Sensor and the Disk Sheet Sensor are clean and are not obstructed.

•

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Drive rolls and Idlers for wear, damage or contamination.

•

Bypass Transport Gate is operating correctly

•

Disks are positioned correctly.

•

Disk Gate moves freely.

•

Ensure that the Stacker Tray is stopping at the correct height, indexing down in the proper sequence of intervals, and is not interfering with disk rotation.

•

F/S is aligned/leveled properly with the IF/S

•

SCP, HFSI 11-806-1 Table 4, or HFSI TABLES to see all of HFSI

•

Ensure that F/S Tag-36 is installed (improved Bypass Gate).

Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker B Bypass Transport Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. The Bypass Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.13). •

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #13, LE at Stacker A Bypass Transport Sensor to LE at Stacker B Disk Sheet Sensor.

•

dC227 - Inverter/Stacker Jam Bypass

•

Observe the prints entering the Disk Module. The prints are free from damage, skew, or excessive curl. Y N Check the following: • (ADJ 11-10), Stacker A Bypass Transport Adjustment Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL 11.32).

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information.

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.13).

Press Stop. Check the following: • Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13), (PL 11.32).

Procedure

•

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

Idler springs for wear or damage (PL 11.11), (PL 11.32).

Press Stop. Select [11A1]. Block the Stacker A Bypass Transport Sensor. The Bypass Transport Sensor display changes from L to H Y N Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Press Stop. Check the following: • Drive Shaft bearings for binding (PL 11.13). •

Drive Belt idlers for binding (PL 11.13).

•

Drive Rolls for wear, damage, or contamination (PL 11.13).

A Preliminary Working Document No Product Name Assigned

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Section Name

11-131-2, 11-132-2, 11-133-2

•

Paper path for obstructions.

•

Baffles for damage (PL 11.32).

•

Drive belts for wear, damage, contamination, and correct tension (PL 11.13).

•

Bypass Transport Gate for binding.

Observe the prints entering the Disk Module. The prints are free from damage, skew, or excessive curl. Y N Check the following: • (ADJ 11-10), Stacker A Bypass Transport Adjustment •

Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL 11.32).

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [11B1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 3. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated.

Section Name

11-131-2, 11-132-2, 11-133-2

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Preliminary Working Document No Product Name Assigned

Figure 1 11-131-2/132-2/133-2 Circuit Diagram (711004)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-925

Section Name

11-131-2, 11-132-2, 11-133-2

Figure 2 11-131-2/132-2/133-2 Component Location (711005)

Section Name

11-131-2, 11-132-2, 11-133-2

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Preliminary Working Document No Product Name Assigned

A

11-131-3, 11-132-3, 11-133-3 RAP

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information.

Stacker C Fault Code, 11-131-3, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106C, within the specified amount of time after the Bypass Transport Sensor, Q1158B sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is unblocked. Stacker C Fault Code, 11-132-3, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106C, within the specified amount of time after the Bypass Transport Sensor, Q1158B sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is blocked and the Disk Sheet Sensor is unblocked. Stacker C Fault Code, 11-133-3, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106C, within the specified amount of time after the Bypass Transport Sensor, Q1158B sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is blocked.

Enter dC330, [Stacker C], [11C1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 3. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated. Y N The Bypass Gate Solenoid energized. Y N Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3C. Y N Go to the Wirenets (Wiring Data) and check wire #86A for an open circuit.

Initial Actions

Check the solenoid plunger for binding (PL 11.13). Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 63, General Procedures) (PL 11.13).

Check the following: •

In a 3 or 4 Module System, ensure that P/J4230 are connected between Module 2 and Module 3 and the wires show continuity.

•

Bypass Transport Sensor and the Disk Sheet Sensor are clean and are not obstructed.

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Drive rolls and Idlers for wear, damage or contamination.

•

Bypass Transport Gate is operating correctly

•

Disks are positioned correctly.

•

Disk Gate moves freely.

•

Ensure that the Stacker Tray is stopping at the correct height, indexing down in the proper sequence of intervals, and is not interfering with disk rotation.

•

IF/S to MM to F/S is aligned and leveled properly.

•

SCP, HFSI 11-806-3 Table 4, or HFSI TABLES to see all of HFSI

•

Ensure that F/S Tag-36 is installed (improved Bypass Gate).

Press Stop. Check the following: • Bypass Gate for wear, damage, or binding (PL 11.13). •

Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker C Bypass Transport Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. The Bypass Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.13). •

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #13, LE at Stacker A Bypass Transport Sensor to LE at Stacker B Disk Sheet Sensor.

•

dC227 - Inverter/Stacker Jam Bypass

•

Observe the prints entering the Disk Module. The prints are free from damage, skew, or excessive curl. Y N Check the following: • (ADJ 11-10), Stacker C Bypass Transport Adjustment Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL 11.32).

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.13).

Press Stop. Check the following: • Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13), (PL 11.32).

Procedure

•

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

Idler springs for wear or damage (PL 11.11), (PL 11.32).

Press Stop. Select [11C1]. Block the Stacker C Bypass Transport Sensor. The Bypass Transport Sensor display changes from L to H Y N Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Press Stop. Check the following:

A Preliminary Working Document No Product Name Assigned

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Section Name

11-131-3, 11-132-3, 11-133-3

•

Drive Shaft bearings for binding (PL 11.13).

•

Drive Belt idlers for binding (PL 11.13).

•

Drive Rolls for wear, damage, or contamination (PL 11.13).

•

Paper path for obstructions.

•

Baffles for damage (PL 11.32).

•

Drive belts for wear, damage, contamination, and correct tension (PL 11.13).

•

Bypass Transport Gate for binding.

Section Name

11-131-3, 11-132-3, 11-133-3

0/0/00 ?-928

Preliminary Working Document No Product Name Assigned

Figure 1 11-131-3/132-3/133-3 Circuit Diagram (8147)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-929

Section Name

11-131-3, 11-132-3, 11-133-3

A

11-131-4, 11-132-4, 11-133-4 RAP

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information.

Stacker D Fault Code, 11-131-4, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106D, within the specified amount of time after the Bypass Transport Sensor, Q1158C sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is unblocked. Stacker D Fault Code, 11-132-4, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106D, within the specified amount of time after the Bypass Transport Sensor, Q1158C sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is blocked and the Disk Sheet Sensor is unblocked. Stacker D Fault Code, 11-133-4, indicates that the lead edge of print did not arrive at the Disk Sheet Sensor, Q1106D, within the specified amount of time after the Bypass Transport Sensor, Q1158C sensed the lead edge. When this fault is declared, the Bypass Transport Sensor is unblocked and the Disk Sheet Sensor is blocked.

Enter dC330, [Stacker D], [11D1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 3. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated. Y N The Bypass Gate Solenoid energized. Y N Press Stop. +24 VDC is measured at TS34 (+) on the FSN DIO PWB #3D. Y N Go to the Wirenets (Wiring Data) and check wire #86A for an open circuit.

Initial Actions

Check the solenoid plunger for binding (PL 11.13). Go to Flag 4. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 63, General Procedures) (PL 11.13).

Check the following: •

In a 3 or 4 Module System, ensure that P/J4230 are connected between Module 2 and Module 3 and the wires show continuity.

•

Bypass Transport Sensor and the Disk Sheet Sensor are clean and are not obstructed.

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Drive rolls and Idlers for wear, damage or contamination.

•

Bypass Transport Gate is operating correctly

•

Disks are positioned correctly.

•

Disk Gate moves freely.

•

Ensure that the Stacker Tray is stopping at the correct height, indexing down in the proper sequence of intervals, and is not interfering with disk rotation.

•

IF/S to MM to F/S is aligned and leveled properly.

•

SCP, HFSI 11-806-3 Table 4, or HFSI TABLES to see all of HFSI

•

Ensure that F/S Tag-36 is installed (improved Bypass Gate).

Press Stop. Check the following: • Bypass Gate for wear, damage, or binding (PL 11.13). •

Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker D Bypass Transport Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. The Bypass Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.13). •

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #13, LE at Stacker A Bypass Transport Sensor to LE at Stacker B Disk Sheet Sensor.

•

dC227 - Inverter/Stacker Jam Bypass

•

Observe the prints entering the Disk Module. The prints are free from damage, skew, or excessive curl. Y N Check the following: • (ADJ 11-10), Stacker D Bypass Transport Adjustment Drive Rolls and Idlers for damage or binding (PL 11.2), (PL 11.11), (PL 11.15), (PL 11.32).

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.13).

Press Stop. Check the following: • Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13), (PL 11.32).

Procedure

•

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

Idler springs for wear or damage (PL 11.11, (PL 11.32).

Press Stop. Select [11D1]. Block the Stacker D Bypass Transport Sensor. The Bypass Transport Sensor display changes from L to H Y N Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Press Stop. Check the following:

A Section Name

11-131-4, 11-132-4, 11-133-4

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Preliminary Working Document No Product Name Assigned

•

Drive Shaft bearings for binding (PL 11.13).

•

Drive Belt idlers for binding (PL 11.13).

•

Drive Rolls for wear, damage, or contamination (PL 11.13).

•

Paper path for obstructions.

•

Baffles for damage (PL 11.32).

•

Drive belts for wear, damage, contamination, and correct tension (ADJ 11-13).

•

Bypass Transport Gate for binding.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-931

Section Name

11-131-4, 11-132-4, 11-133-4

Figure 1 11-131-4/132-4/133-4 Circuit Diagram (8147)

Section Name

11-131-4, 11-132-4, 11-133-4

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Preliminary Working Document No Product Name Assigned

11-138, 11-139 RAP

•

Ensure that the Stacker Bypass Transport Gate is not bowed down (more than 1 mm) in the center (PL 11.14).

Stacker A Fault Code, 11-138-1, indicates that the lead edge of the print delivered from the Prestacker Sensor, Q1158, did not arrive at the Bypass Transport Sensor, Q1107A, within the specified amount of time and the Bypass Transport Sensor, Q1107A, is unblocked.

•

SCP, HFSI 11-806-1 Table 4, or HFSI TABLES to see all of HFSI

Stacker B Fault Code, 11-138-2, indicates that the lead edge of the print delivered from the Bypass Transport Sensor, Q1107A, did not arrive at the Bypass Transport Sensor, Q1107B, within the specified amount of time and the Bypass Transport Sensor, Q1107B, is unblocked. This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration. Stacker C Fault Code, 11-138-3, indicates that the lead edge of the print delivered from the Bypass Transport Sensor, Q1107B, did not arrive at the Bypass Transport Sensor, Q1107C, within the specified amount of time and the Bypass Transport Sensor, Q1107C, is unblocked. This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration. Stacker D Fault Code, 11-138-4, indicates that the lead edge of the print delivered from the Bypass Transport Sensor, Q1107C, did not arrive at the Bypass Transport Sensor, Q1107D, within the specified amount of time and the Bypass Transport Sensor, Q1107D is unblocked. This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration.

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #11, LE at Prestacker Sensor to LE at Stacker A Bypass Transport Sensor.

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. Observe the prints entering the Bypass Transport. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Drive Rolls and Idlers for wear, damage or contamination (PL 11.11. •

Stacker A Fault Code, 11-139-1, indicates that the lead edge of the print delivered from the Prestacker Sensor, Q1158, did not arrive at the Bypass Transport Sensor, Q1107A, within the specified amount of time and the Bypass Transport Sensor, Q1107B, is blocked. Stacker B Fault Code, 11-139-2, indicates that the lead edge of the print delivered from the Prestacker Sensor, Q1107A, did not arrive at the Bypass Transport Sensor, Q1107B,within the specified amount of time and the Bypass Transport Sensor, Q1107B, is blocked. This Fault is valid for modules 3, 4, or for a Transition Module configuration. Stacker C Fault Code, 11-139-3, indicates that the lead edge of the print delivered from the Prestacker Sensor, Q1107B, did not arrive at the Bypass Transport Sensor, Q1107C,within the specified amount of time and the Bypass Transport Sensor, Q1107C, is blocked. This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration. Stacker D Fault Code, 11-139-4, indicates that the lead edge of the print delivered from the Prestacker Sensor, Q1107C, did not arrive at the Bypass Transport Sensor, Q1107D,within the specified amount of time and the Bypass Transport Sensor, Q1107D, is blocked. This Fault is valid for modules 3, 4, 5, 6 or for a Transition Module configuration.

Initial Actions Check the following: •

Prestacker Sensor is clean and not obstructed.

•

Paper path is not obstructed.

Idler retaining springs for damage or missing (PL 11.11.

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [Stacker X], [11X1]. Block the Bypass Transport Sensor, Q1107X. The display changes from L to H. Y N Go to Flag 2. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.29).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Press Stop. Select [Stacker Start/Run]. Press Continue. The Stacker X Bypass Transport Drive Rolls rotate. Y N The Stacker X Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. The Bypass Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.11).

•

Jam clearance baffles are seated correctly and are not damaged.

•

Idler springs missing or idlers that are bound.

•

Stacker A Bypass Transport Gate is operating correctly and is not obstructing the paper path.

•

Flexible Drive Cable for damage, loose coupling, or missing or loose setscrew (PL 11.11).

Press Stop. Check the following: A Preliminary Working Document No Product Name Assigned

0/0/00 ?-933

Section Name

11-138, 11-139

A

B •

Bypass Transport Drive and Idler rolls for wear, damage or contamination (PL 11.11).

•

Idler springs for wear or damage (PL 11.11).

Y

Press Stop. Select [11X1] [Stacker Start/Run]. Press Continue. The Stacker X Entrance Drive Rolls rotate. Y N The Stacker X Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Press Stop. Check the following: • Purge Gate for wear or damage •

(ADJ 13-1), Stacker Output Gate adjustment

Press Stop. Check the following: • Drive rolls for wear, damage, or contamination (PL 11.12).

The Stacker X Entrance Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.12). •

N Press Stop. Check the solenoid plunger for binding. If no binding is found, go to Flag 4. Check the circuit of the Stacker Output Gate Solenoid (Generic Solenoid RAP GP 6-3, in General Procedures.

Flexible Drive cable for damage, loose coupling, or missing or loose setscrew (PL 11.12).

•

Drive belt idler for binding (PL 11.13).

•

If the problem continues, go to the 13-131 RAP.

(ADJ 13-1), Stacker Output Gate adjustment.

Press Stop. Check the following: • Entrance drive rolls and idlers for wear, damage, or contamination (PL 11.12). •

Idler springs for wear or damage (PL 11.12).

Press Stop. Select [IOT Paper Path], [10]. Block the Prestacker Sensor, Q1158. The display change from L to H. Y N Go to Flag 1. Check the Prestacker Sensor circuit (GP 6-2, General Procedures) (PL 11.2). Select [11X1] [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated. Y N The Bypass Gate Solenoid energized. Y N Press Stop. Go to Flag 3. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 6-3, General Procedures) (PL 11.11). Press Stop. Check the following: • Bypass Gate for wear or damage (PL 11.13). •

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

Press Stop. The machine has a Transition Module/Enablement Kit installed. Y N Check the following: • Drive shaft bearings for binding (PL 11.13) •

Drive idlers for binding (PL 11.13)

•

(ADJ 11-10), Stacker A Bypass Transport Adjustment

Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Continue. The Stacker Output Gate actuates. Y N The Stacker Output Gate Solenoid Energizes. B Section Name

11-138, 11-139

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Preliminary Working Document No Product Name Assigned

Figure 1 11-138/139 Circuit Diagram (8512)

Preliminary Working Document No Product Name Assigned

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Section Name

11-138, 11-139

Figure 2 11-138/139 Circuit Diagram (8513)

Section Name

11-138, 11-139

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Preliminary Working Document No Product Name Assigned

11-140, 11-141 RAP

Procedure

Stacker A Fault Code, 11-140-1, indicates that the trail edge of the print did not arrive at the Bypass Transport Sensor, Q1107A, within the specified amount of time after the lead edge of the print arrived at the Bypass Transport Sensor, Q1107A,. When the fault is declared the Bypass Transport Sensor is blocked. The valid destination for this print is beyond Stacker A.

NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes.

Stacker A Fault Code, 11-141-1, indicates that the trail edge of the print did not arrive at the Bypass Transport Sensor, Q1107A, within the specified amount of time after the lead edge of the print arrived at the Bypass Transport Sensor, Q1107A. When the fault is declared the Bypass Transport Sensor is unblocked. The valid destination for this sheet is beyond Stacker A.

Enter dC330, [Stacker X], [11X1]. Block the Stacker X Bypass Transport Sensor. The Bypass Xport Sensor display changes from L to H. Y N Go to Flag 1. Check the Stacker X Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.30).

WARNING

Stacker B Fault Code, 11-140-2, indicates that the trail edge of the print did not arrive at the Bypass Transport Sensor, Q1107B, within the specified amount of time after the lead edge of the print arrived at the Bypass Transport Sensor, Q1107B,. When the fault is declared the Bypass Transport Sensor, Q1107B, is blocked. The valid destination for this print is beyond Stacker B.

Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

Stacker B Fault Code, 11-141-2, indicates that the trail edge of the print did not arrive at the Bypass Transport Sensor, Q1107B, within the specified amount of time after the lead edge of the print arrived at the Bypass Transport Sensor, Q1107B. When the fault is declared the Bypass Transport Sensor, Q1107B, is unblocked. The valid destination for this sheet is beyond Stacker B.

Select [Stacker Start/Run]. Press Continue. Observe the Bypass Transport Exit Roll. The Exit Roll rotates. Y N The Stacker X Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. Press Stop. Check the following: • Drive belts wear, damage, contamination, and correct tension (PL 11.11), (PL 11.30).

Stacker C Fault Code, 11-140-3, indicates that the trail edge of the print did not arrive at the Bypass Transport Sensor, Q1107C, within the specified amount of time after the lead edge of the print arrived at the Bypass Transport Sensor, Q1107C,. When the fault is declared the Bypass Transport Sensor is blocked. The valid destination for this print is beyond Stacker C. Stacker C Fault Code, 11-141-3, indicates that the trail edge of the print did not arrive at the Bypass Transport Sensor, Q1107C, within the specified amount of time after the lead edge of the print arrived at the Bypass Transport Sensor, Q1107C. When the fault is declared the Bypass Transport Sensor is unblocked. The valid destination for this sheet is beyond Stacker C.

Initial Actions Check the following: •

Bypass Transport Sensor is clean and is not obstructed

•

Bypass Transport for obstructions.

•

Bearings for binding (PL 11.11, (PL 11.30).

•

Drive Rolls for wear, damage, or contamination and that they are not slipping on shaft (PL 11.11, (PL 11.30).

•

Idler Rolls for binding and for missing idler roll springs (PL 11.15).

Press Stop. Select [11X1] [Stacker Start/Run]. Observe the Stacker X Bypass Transport Entrance Drive Roll. Press Continue. The Drive Roll rotates. Y N The Stacker X Main Drive motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

•

Jam clearance baffles for damage and that they are seated correctly.

Press Stop. Check the following: • Drive belts and idlers for wear, damage, contamination, and correct tension (PL 11.13).

•

Transport Drive Rolls and Nip Springs for binding or contamination.

•

Bearings for binding (PL 11.13).

SCP, HFSI 11-806-1 Table 4, or HFSI TABLES to see all of HFSI.

•

Drive Rolls for wear, damage, or contamination and that they are not slipping on shaft (PL 11.13).

•

Idler Rolls for binding and for missing idler roll springs (PL 11.13).

•

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #12, LE at Stacker A Bypass Transport Sensor to TE at Bypass Transport Sensor.

•

dC227 - Inverter/Stacker Jam Bypass

Preliminary Working Document No Product Name Assigned

Press Stop. Select [Bypass Gate] solenoid. Press Continue. The Stacker X Bypass Gate actuates.

0/0/00 ?-937

Section Name

11-140, 11-141

Y

N The Bypass Gate Solenoid energized. Y N Press Stop. Check the solenoid plunger for binding. Go to Flag 2. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 63, General Procedures) (PL 11.12). Press Stop. Check the following: • Bypass Gate for wear or damage (PL 11.14). •

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

Press Stop. Check the following: • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.12) and (PL 11.15). •

(ADJ 11-10), Bypass Transport adjustment.

•

Bypass Transport for binding (PL 11.12).

•

Static in any of the transports.

•

Jam clearance baffles are seated correctly and are not damaged.

•

If the problem is occurring at the last Bypass Transport and a Transition Module is enabled, go to the 13-131 RAP and the 13-132 RAP.

Section Name

11-140, 11-141

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Preliminary Working Document No Product Name Assigned

Figure 1 11-140-1/141-1 Circuit Diagram (8518)

Preliminary Working Document No Product Name Assigned

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Section Name

11-140, 11-141

11-142-2, 11-143-2, 11-144-2 RAP

Y

Stacker B fault Code, 11-142-2, indicates that the lead edge of the print delivered from the Stacker A Bypass Transport Sensor, Q1107A, did not arrive at the Stacker B Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker B Purge Transport Sensor is unblocked and the Stacker A Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray. Stacker B fault code, 11-143-2, indicates that the lead edge of the print delivered from the Stacker A Bypass Transport Sensor, Q1107A, did not arrive at the Stacker B Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker B Purge Transport Sensor is unblocked and the Stacker A Bypass Transport Sensor is blocked. The valid destination for the print is the Purge Tray. Stacker B fault code, 11-144-2, indicates that the lead edge of the print delivered from the Stacker A Bypass Transport Sensor, Q1107A, did not arrive at the Stacker B Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker B Purge Transport Sensor is blocked and the Stacker A Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray.

N Go to Flag 2. Check the Purge Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.12).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11B1] [Stacker Start/Run]. Press Continue. The Purge Transport rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Drive Rolls

The Purge Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.13).

Initial Actions

•

Check the following:

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.13).

•

Purge Tray is too full or obstructed.

•

Stacker A Bypass Transport Sensor is clean and not obstructed.

Press Stop. Check the following: • Purge Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13).

•

Purge Transport Sensor is clean and is not obstructed.

•

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Idler springs missing or idlers that are bound or contaminated.

•

Bypass Transport Gate is operating correctly and is not obstructing the paper path.

•

SCP, HFSI 11-806-2 Table 4, or HFSI TABLES to see all of HFSI.

Idler springs for wear or damage (PL 11.16).

Press Stop. Select [11A1]. Block the Stacker A Bypass Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.30).

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #15, LE

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure Observe the prints entering the Bypass Transport. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Drive Rolls for wear, damage or contamination (PL 11.11). •

Observe the Bypass Transport Gate. The Gate is actuated in standby. Y N The machine has a Transition Module installed. Y N Check the following: • Drive Shaft bearings for binding (PL 11.13).

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. display

A Section Name

11-142-2, 11-143-2, 11-144-2

Drive Belt idlers for binding (PL 11.13).

•

(ADJ 11-10), Bypass/Purge Transport Adjustment

Press Stop. Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Continue. The Stacker Output Gate Solenoid actuates. Y N The Stacker Output Gate Solenoid energizes. Y N Press Stop. Check the solenoid plunger for binding. If no binding is present, go to Flag 4. Check the circuit of the Purge Gate Solenoid, (Generic Solenoid RAP GP 6-3, General Procedures).

Idler Rolls and retaining springs for damage or binding (PL 11.15).

Enter dC330, [Stacker A/B], [11B2]. Block the Purge Transport Sensor. The changes from L to H.

•

0/0/00 ?-940

B

C Preliminary Working Document No Product Name Assigned

A

B

C Press Stop. Check the following: • Purge gate for wear or damage. •

(ADJ 13-1), Stacker Output Gate adjustment.

Press Stop. Check the following: • Drive rolls and idlers for wear, damage, or contamination (PL 11.12). •

Drive belt idler for binding (PL 11.13).

Go to Flag 3. Check the wire for a short circuit. If OK, replace the FSN DIO PWB 3B (PL 1.17).

Preliminary Working Document No Product Name Assigned

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Section Name

11-142-2, 11-143-2, 11-144-2

Figure 1 11-142/143/144-2 Circuit Diagram (8514)

Section Name

11-142-2, 11-143-2, 11-144-2

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Preliminary Working Document No Product Name Assigned

Figure 2 11-142/143/144-2 Circuit Diagram (8515)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-943

Section Name

11-142-2, 11-143-2, 11-144-2

11-142-3, 11-143-3, 11-144-3 RAP

Y

Stacker C fault Code, 11-142-3, indicates that the lead edge of the print delivered from the Stacker B Bypass Transport Sensor, Q1107B, did not arrive at the Stacker C Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker C Purge Transport Sensor is unblocked and the Stacker B Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray. Stacker C fault code, 11-143-3, indicates that the lead edge of the print delivered from the Stacker B Bypass Transport Sensor, Q1107B, did not arrive at the Stacker C Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker C Purge Transport Sensor is unblocked and the Stacker B Bypass Transport Sensor is blocked. The valid destination for the print is the Purge Tray. Stacker C fault code, 11-144-3, indicates that the lead edge of the print delivered from the Stacker B Bypass Transport Sensor, Q1107B, did not arrive at the Stacker C Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker C Purge Transport Sensor is blocked and the Stacker B Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray.

N Go to Flag 2. Check the Purge Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.12).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11C1] [Stacker Start/Run]. Press Continue. The Purge Transport rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Drive Rolls

The Purge Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.13).

Initial Actions

•

Check the following:

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.13).

•

Purge Tray is too full or obstructed.

•

Stacker B Bypass Transport Sensor is clean and not obstructed.

Press Stop. Check the following: • Purge Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13).

•

Purge Transport Sensor is clean and is not obstructed.

•

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Idler springs missing or idlers that are bound or contaminated.

•

Bypass Transport Gate is operating correctly and is not obstructing the paper path.

•

SCP, HFSI 11-806-2 Table 4, or HFSI TABLES to see all of HFSI.

Idler springs for wear or damage (PL 11.16).

Press Stop. Select [11B1]. Block the Stacker B Bypass Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.30).

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #15, LE

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure Observe the prints entering the Bypass Transport. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Drive Rolls for wear, damage or contamination (PL 11.11). •

Observe the Bypass Transport Gate. The Gate is actuated in standby. Y N The machine has a Transition Module installed. Y N Check the following: • Drive Shaft bearings for binding (PL 11.13).

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [Stacker C], [11C2]. Block the Purge Transport Sensor. The display changes from L to H. A

11-142-3, 11-143-3, 11-144-3

Drive Belt idlers for binding (PL 11.13).

•

(ADJ 11-10), Bypass/Purge Transport Adjustment

Press Stop. Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Continue. The Stacker Output Gate Solenoid actuates. Y N The Stacker Output Gate Solenoid energizes. Y N Press Stop. Check the solenoid plunger for binding. If no binding is present, go to Flag 4. Check the circuit of the Purge Gate Solenoid, (Generic Solenoid RAP GP 6-3, General Procedures).

Idler Rolls and retaining springs for damage or binding (PL 11.15).

Section Name

•

0/0/00 ?-944

B

C Preliminary Working Document No Product Name Assigned

A

B

C Press Stop. Check the following: • Purge gate for wear or damage. •

(ADJ 13-1), Stacker Output Gate adjustment.

Press Stop. Check the following: • Drive rolls and idlers for wear, damage, or contamination (PL 11.12). •

Drive belt idler for binding (PL 11.13).

Go to Flag 3. Check the wire for a short circuit. If OK, replace the FSN DIO PWB 3C (PL 1.17).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-945

Section Name

11-142-3, 11-143-3, 11-144-3

Figure 1 11-142/143/144-3 Circuit Diagram (8514)

Section Name

11-142-3, 11-143-3, 11-144-3

0/0/00 ?-946

Preliminary Working Document No Product Name Assigned

Figure 2 11-142/143/144-3 Circuit Diagram (8515)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-947

Section Name

11-142-3, 11-143-3, 11-144-3

11-142-4, 11-143-4, 11-144-4 RAP

Y

Stacker D fault Code, 11-142-4, indicates that the lead edge of the print delivered from the Stacker C Bypass Transport Sensor, Q1107C, did not arrive at the Stacker D Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker D Purge Transport Sensor is unblocked and the Stacker C Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray. Stacker D fault code, 11-143-4, indicates that the lead edge of the print delivered from the Stacker C Bypass Transport Sensor, Q1107C, did not arrive at the Stacker D Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker D Purge Transport Sensor is unblocked and the Stacker C Bypass Transport Sensor is blocked. The valid destination for the print is the Purge Tray. Stacker D fault code, 11-144-4, indicates that the lead edge of the print delivered from the Stacker C Bypass Transport Sensor, Q1107C, did not arrive at the Stacker D Purge Transport Sensor, Q1164, within the specified amount of time. When the fault is declared, the Stacker D Purge Transport Sensor is blocked and the Stacker C Bypass Transport Sensor is unblocked. The valid destination for the print is the Purge Tray.

N Go to Flag 2. Check the Purge Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.12).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11D1] [Stacker Start/Run]. Press Continue. The Purge Transport rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Drive Rolls

The Purge Transport Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.13).

Initial Actions

•

Check the following:

Telescopic Drive Shaft for damage, loose coupling, or missing or loose setscrew (PL 11.13).

•

Purge Tray is too full or obstructed.

•

Stacker C Bypass Transport Sensor is clean and not obstructed.

Press Stop. Check the following: • Purge Transport Drive and Idler rolls for wear, damage or contamination (PL 11.13).

•

Purge Transport Sensor is clean and is not obstructed.

•

•

Paper path is not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Idler springs missing or idlers that are bound or contaminated.

•

Bypass Transport Gate is operating correctly and is not obstructing the paper path.

•

SCP, HFSI 11-806-2 Table 4, or HFSI TABLES to see all of HFSI.

Idler springs for wear or damage (PL 11.16).

Press Stop. Select [11C1]. Block the Stacker C Bypass Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.30).

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #15, LE

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure Observe the prints entering the Bypass Transport. The prints are free from damage, skew, or excessive curl. Y N Check the following: • Drive Rolls for wear, damage or contamination (PL 11.11). •

Observe the Bypass Transport Gate. The Gate is actuated in standby. Y N The machine has a Transition Module installed. Y N Check the following: • Drive Shaft bearings for binding (PL 11.13).

If OK, go to the 8-705, Print Damage RAP, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for additional information. Enter dC330, [Stacker D], [11D2]. Block the Purge Transport Sensor. The display changes from L to H. A

11-142-4, 11-143-4, 11-144-4

Drive Belt idlers for binding (PL 11.13).

•

(ADJ 11-10), Bypass/Purge Transport Adjustment

Press Stop. Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Continue. The Stacker Output Gate Solenoid actuates. Y N The Stacker Output Gate Solenoid energizes. Y N Press Stop. Check the solenoid plunger for binding. If no binding is present, go to Flag 4. Check the circuit of the Purge Gate Solenoid, (Generic Solenoid RAP GP 6-3, General Procedures).

Idler Rolls and retaining springs for damage or binding (PL 11.15).

Section Name

•

0/0/00 ?-948

B

C Preliminary Working Document No Product Name Assigned

A

B

C Press Stop. Check the following: • Purge gate for wear or damage. •

(ADJ 13-1), Stacker Output Gate adjustment.

Press Stop. Check the following: • Drive rolls and idlers for wear, damage, or contamination (PL 11.12). •

Drive belt idler for binding (PL 11.13).

Go to Flag 3. Check the wire for a short circuit. If OK, replace the FSN DIO PWB 3D (PL 1.17).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-949

Section Name

11-142-4, 11-143-4, 11-144-4

Figure 1 11-142/143/144-4 Circuit Diagram (8514)

Section Name

11-142-4, 11-143-4, 11-144-4

0/0/00 ?-950

Preliminary Working Document No Product Name Assigned

Figure 2 11-142/143/144-4 Circuit Diagram (8515)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-951

Section Name

11-142-4, 11-143-4, 11-144-4

A

11-145-2 RAP

•

Stacker B Fault Code, 11-145-2, indicates that the trail edge of the print did not arrive at the Purge Transport Sensor, Q1164, within the specified amount of time after the lead edge of the print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge Tray.

The machine has a Transition Module installed. Y N Check the following: • Drive shaft bearings for binding (PL 11.13).

Initial Actions NOTE: The Purge Tray utilizes corrugated rolls to decelerate the sheets to allow adequate stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm. Check the following: •

Purge Transport Sensor is clean and is not obstructed.

•

Purge Tray is not obstructed.

•

Paper path is not obstructed.

•

Bypass Transport is not obstructed.

•

Jam Clearance baffles are seated correctly and are not damaged.

•

Check the Purge Tray Corrugation Roll adjustment (ADJ 11-13).

Idler Rolls for binding and for missing idler roll springs (PL 11.16).

•

Drive idlers for binding (PL 11.13).

•

Bypass Purge Transport adjustment (ADJ 11-10).

Press Stop. Select [Third Party] [Fin 1] [Stacker Output Gate] Solenoid RAP. Press Continue. The Stacker Output Gate Solenoid actuates. Y N Press Stop. Check the solenoid plunger for binding. If no binding is found, go to Flag 4. Check the circuit of the Stacker Output Gate Solenoid, (Generic Solenoid RAP GP 6-3, General Procedures). Press Stop. Check the following: • Stacker Output Gate for wear or damage. •

(ADJ 13-1), Stacker Output Gate adjustment.

Press Stop. Check the following: • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.13) and (PL 11.16).

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #16, LE at Purge Transport Sensor to TE at Purge Transport Sensor.

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure

•

(ADJ 11-10), Bypass/Purge Transport adjustment.

•

Bypass Transport for binding (PL 11.12).

•

Static in the I F/S

•

(ADJ 13-1), Stacker Output Gate Adjustment.

•

Jam clearance baffles are seated correctly and are not damaged.

Enter dC330, [11B2]. Block the Purge Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the circuit of the Purge Transport Sensor (GP 6-2, General Procedures) (PL 11.12).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11B1] [Stacker Start/Run]. Press Continue. Observe the Purge Transport Exit Roll. The Exit Roll rotates. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. Press Stop. Check the following: • Drive belts and idlers for wear, damage, contamination, and correct tension (PL 11.13). •

Bearings for binding (PL 11.13).

•

Drive Rolls for wear, damage, or contamination and that they are not slipping on shaft (PL 11.13).

A Section Name

11-145-2

0/0/00 ?-952

Preliminary Working Document No Product Name Assigned

Figure 1 11-145-2 Circuit Diagram (8516)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-953

Section Name

11-145-2

Figure 2 11-145-2 Circuit Diagram (8517)

Section Name

11-145-2

0/0/00 ?-954

Preliminary Working Document No Product Name Assigned

A

11-145-3 RAP

•

Drive Rolls for wear, damage, or contamination and that they are not slipping on shaft (PL 11.13).

Stacker C Fault Code, 11-145-3, indicates that the trail edge of the print did not arrive at the Purge Transport Sensor, Q1164, within the specified amount of time after the lead edge of the print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge Tray.

•

Idler Rolls for binding and for missing idler roll springs (PL 11.16).

Initial Actions

The machine has a Transition Module installed. Y N Check the following: • Drive shaft bearings for binding (PL 11.13).

NOTE: The Purge Tray utilizes corrugated rolls to decelerate the sheets to allow adequate stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm. Check the following: •

Purge Transport Sensor is clean and is not obstructed.

•

Purge Tray is not obstructed.

•

Paper path is not obstructed.

•

Bypass Transport is not obstructed.

•

Jam Clearance baffles are seated correctly and are not damaged.

•

Check the Purge Tray Corrugation Roll adjustment (ADJ 11-13).

•

Drive idlers for binding (PL 11.13).

•

Bypass Purge Transport adjustment (ADJ 11-10).

Press Stop. Select [Third Party], [Fin 1], [Stacker Output Gate] Solenoid RAP. Press Continue. The Stacker Output Gate Solenoid actuates. Y N Press Stop. Check the solenoid plunger for binding. If no binding is found, go to Flag 4. Check the circuit of the Stacker Output Gate Solenoid, (Generic Solenoid RAP GP 6-3, General Procedures). Press Stop. Check the following: • Stacker Output Gate for wear or damage. •

(ADJ 13-1), Stacker Output Gate adjustment.

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #16, LE at Purge Transport Sensor to TE at Purge Transport Sensor.

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure Enter dC330, [Stacker C], [11C2]. Block the Purge Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the circuit of the Purge Transport Sensor (GP 6-2, General Procedures) (PL 11.12).

Press Stop. Check the following: • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.13) and (PL 11.16). •

(ADJ 11-10), Bypass/Purge Transport adjustment.

•

Bypass Transport for binding (PL 11.12).

•

Static in the I F/S

•

(ADJ 13-1), Stacker Output Gate Adjustment.

•

Jam clearance baffles are seated correctly and are not damaged.

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11C1], [Stacker Start/Run]. Press Continue. Observe the Purge Transport Exit Roll. The Exit Roll rotates. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. Press Stop. Check the following: • Drive belts and idlers for wear, damage, contamination, and correct tension (PL 11.13). •

Bearings for binding (PL 11.13).

A Preliminary Working Document No Product Name Assigned

0/0/00 ?-955

Section Name

11-145-3

Figure 1 11-145-3 Circuit Diagram (8516)

Section Name

11-145-3

0/0/00 ?-956

Preliminary Working Document No Product Name Assigned

Figure 2 11-145-3 Circuit Diagram (8517)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-957

Section Name

11-145-3

A

11-145-4 RAP

•

Drive Rolls for wear, damage, or contamination and that they are not slipping on shaft (PL 11.13).

Stacker D Fault Code, 11-145-4, indicates that the trail edge of the print did not arrive at the Purge Transport Sensor, Q1164, within the specified amount of time after the lead edge of the print arrived at the Purge Transport Sensor. The valid destination for this print is the Purge Tray.

•

Idler Rolls for binding and for missing idler roll springs (PL 11.16).

Initial Actions NOTE: The Sample Tray utilizes corrugated rolls to decelerate the sheets to allow adequate stacking at high speeds. Corrugation Rolls should be set to a nominal penetration of 1.6 mm.

Press Stop. Check the following: • Drive Rolls and Idlers for wear, damage, or contamination (PL 11.13) and PL 11.16). •

(ADJ 11-10), Bypass/Purge Transport adjustment.

•

Bypass Transport for binding (PL 11.12).

•

Static in the I F/S

•

Jam clearance baffles are seated correctly and are not damaged.

Check the following: •

Purge Transport Sensor is clean and is not obstructed.

•

Purge Tray is not obstructed.

•

Paper path is not obstructed.

•

Bypass Transport is not obstructed.

•

Jam Clearance baffles are seated correctly and are not damaged.

•

Check the Purge Tray Corrugation Roll adjustment (ADJ 11-13).

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #16, LE at Purge Transport Sensor to TE at Purge Transport Sensor.

•

dC227 - Inverter/Stacker Jam Bypass.

Procedure Enter dC330, [Stacker D], [11D2]. Block the Purge Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the circuit of the Purge Transport Sensor (GP 6-2, General Procedures) (PL 11.12).

WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [11D1] [Stacker Start/Run]. Press Continue. Observe the Purge Transport Exit Roll. The Exit Roll rotates. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP. Press Stop. Check the following: • Drive belts and idlers for wear, damage, contamination, and correct tension (PL 11.13). •

Bearings for binding (PL 11.13).

A Section Name

11-145-4

0/0/00 ?-958

Preliminary Working Document No Product Name Assigned

Figure 1 11-145-4 Circuit Diagram (8516)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-959

Section Name

11-145-4

Figure 2 11-145-4 Circuit Diagram (8517)

Section Name

11-145-4

0/0/00 ?-960

Preliminary Working Document No Product Name Assigned

11-146, 11-147 RAP

Procedure

Stacker A fault code, 11-146-1, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166A, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106A. This fault only occurs in the 7 pitch mode.

NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes.

Stacker B fault code, 11-146-2, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166B, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106B. This fault only occurs in the 7 pitch mode. Stacker C fault code, 11-146-3, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166C, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106C. This fault only occurs in the 7 pitch mode. Stacker D fault code, 11-146-4, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166D, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106D. This fault only occurs in the 7 pitch mode. Stacker A fault code, 11-147-1, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166A, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106A. This fault only occurs in the 3 pitch mode. Stacker B fault code, 11-147-2, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166B, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106B. This fault only occurs in the 3 pitch mode.

Enter dC330, [Stacker X], [11X1]. Rotate the Disks. The Disk Home Sensor display changes from L to H. Y N Ensure that the Disk flag is aligned with the sensor and not loose. If OK, go to Flag 3. Check the Disk Home Sensor circuit (GP 6-2, General Procedures) (PL 11.30). Block the Disk Lead Edge Sensor. The Disk Lead Edge Sensor display changes from H to L. Y N Go to Flag 2. Check the Disk Lead Edge Sensor circuit (GP 6-2, General Procedures) (PL 11.30). Enter dC203, [Stacker Disk], [Stacker X], [7 Pitch or 3 Pitch], [Continuous Run]. Press Continue. Compare the measured times with the expected range. The Disk module cycles smoothly and the measured times are within the expected range. Y N The Disk Motor comes on. Y N Press Stop. Go to the 11-700, Disk Motor RAP.

Stacker C fault code, 11-147-3, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166C, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106C. This fault only occurs in the 3 pitch mode.

Press Stop. Perform the Disk Home Position Adjustment (ADJ 11-25). Check the Disk Module components for wear, damage, and proper location (PL 11.30).

Stacker D fault code, 11-147-4, indicates that the lead edge of a print did not arrive at the Disk Lead Edge Sensor, Q1166D, within the specified amount of time after the lead edge of the print actuated the Disk Sheet Sensor, Q1106D. This fault only occurs in the 3 pitch mode.

Press Stop. Check the Disk Entrance Gate hardware for wear, damage, and proper operation. The Disk Gate hardware is OK. Y N Repair, replace the Disk Entrance Gate hardware as necessary (PL 11.14, (PL 11.30).

Initial Actions

Enter dC330, [Stacker X], [11X1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 1. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.30).

Check the following: •

Disk Sheet Sensor and Disk Lead Edge Sensor are clean and not obstructed.

•

Disk entrance and stacker areas are not obstructed.

•

Jam clearance baffles are seated correctly and are not damaged.

•

Disk Entrance Gate for binding or damage.

•

Disk Entrance Gate Cam Follower for binding or damage.

•

Disks are positioned correctly.

•

Stack is not interfering with Disk.

Select [Stacker Start/Run]. Observe the Disk Entrance Drive Roll. Press Continue. The Disk Entrance Drive Roll rotates. Y N Press Stop. Check the Disk Entrance Drive Roll for a loose or broken belt or pulley (PL 11.30).

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #29 or 30, LE at Disk Sheet Sensor to LE at Disk Lead Edge Sensor

•

dC227 - Inverter/Stacker Jam Bypass

The Trail Edge Assist belts are turning. Y N Press Stop. Check the Stacker Main Drives for broken belts, gears, or loose pulleys (PL 11.11). A

Preliminary Working Document No Product Name Assigned

0/0/00 ?-961

Section Name

11-146, 11-147

A Observe the prints entering the stacker. The prints are free of curl. Y N Curled prints, especially in heavy or lightweight papers may cause this fault. Upward curl as prints enter the disk area can cause the prints to miss the disk fingers or jam in the Disk Entrance Gate area. Upward curl on prints in a stack may interfere with the disks, stalling them. Go to the Physical Checks, Print Paper Diagnostics (Service Call Procedures) for more information on curl. The prints are free of skew and paper damage. Y N Check the following: • (Stacker X) - Preregistration Transport and Inverter area for obstructions •

(Stacker X) - Bypass Transport area for obstructions

•

Drive Rolls for contamination (PL 11.11) and (PL 11.13).

•

Idler Rolls for proper tension

•

Baffles seated or latched properly

•

Bypass Gate for binding (PL 11.14)

Press Stop. Check the following: • (ADJ 11-25), Disk Home Position adjustment. •

(ADJ 11-26), Disk Entrance Gate Height adjustment.

•

(ADJ 11-27), Stack Height Adjustment.

•

Disk Entrance Drive Roll idler (PL 11.14)

•

Bypass Gate for binding (PL 11.14)

Section Name

11-146, 11-147

0/0/00 ?-962

Preliminary Working Document No Product Name Assigned

Figure 1 11-146/147 Circuit Diagram

Preliminary Working Document No Product Name Assigned

0/0/00 ?-963

Section Name

11-146, 11-147

11-148, 11-149 RAP

Procedure

Stacker A fault code, 11-148-1, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166A, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is blocked.

NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes.

Stacker B fault code, 11-148-2, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166B, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is blocked. Stacker C fault code, 11-148-3, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166C, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is blocked.

Enter dC330, [Stacker X], [11X1]. Block the Disk Lead Edge Sensor. The Disk Lead Edge Sensor display changes from H to L. Y N Go to Flag 1. Check the circuit of the Disk Lead Edge Sensor (GP 6-2, General Procedures) (PL 11.30).

WARNING

Stacker D fault code, 11-148-4, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166D, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is blocked.

Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

Stacker A fault code, 11-149-1, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166A, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is unblocked.

Select [Stacker Start/Run]. Press Continue. The Stacker Main Drives come on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Stacker B fault code, 11-149-2, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166B, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is unblocked.

The Trail Edge Assist Belts are all turning. Y N Press Stop. Check the Telescopic Drive Shaft for proper operation and the belts, pulleys, and gears that drive the Trail Edge Assist Belts (PL 11.11).

Stacker C fault code, 11-149-3, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166C, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is unblocked. Stacker D fault code, 11-149-4, indicates that the trail edge of a print did not actuate the Disk Lead Edge Sensor, Q1166D, after the lead edge of the print actuated the sensor. When the fault is declared, the sensor is unblocked.

Press Stop. Check the Front and rear Tampers for proper operation. Enter dC203, [Tamper Fingers], [Stacker X], [Back Tamper], [Continuous Run]. Press Continue. Check the measured times against the expected range. Repeat the test for the Front Tamper. The measured times are within the expected range. Y N Press Stop. Check the following: • Tamper components for damage or wear (PL 11.5).

These faults are only declared in the 7 pitch mode.

Initial Actions

•

Right Guide Adjustments (ADJ 11-28).

•

Back Guide Adjustment (ADJ 11-29).

Check the following:

Press Stop. Check the following: • Trail Edge assist belts are tracking properly (PL 11.14).

•

Disk Entrance Gate or Stacker areas are not obstructed.

•

Trail edge assist belts not loose or slipping (PL 11.14).

•

Disk Lead Edge Sensor is clean and not obstructed.

•

Disk Entrance Gate hardware for proper operation (PL 11.14).

•

The upper transport is seated properly.

•

Disk Entrance Gate Height adjustment, (ADJ 11-26).

•

Stack is not interfering with Disk.

•

Disk Home Position Adjustment (ADJ 11-25).

•

SCP, HFSI 11-802 Table 4, or HFSI TABLES to see all of HFSI.

Diagnostic Tools: •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #31 or 32, LE at Disk Lead Edge Sensor to TE at Disk Lead Edge Sensor

•

dC227 - Inverter/Stacker Jam Bypass

Section Name

11-148, 11-149

0/0/00 ?-964

Preliminary Working Document No Product Name Assigned

Figure 1 11-148/149 Circuit Diagram (8145)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-965

Section Name

11-148, 11-149

A

11-150 RAP

WARNING

Stacker A fault code, 11-150-1, indicates that the trail edge of a print did not arrive at the A3 Trail Edge Sensor, Q1167A, within the specified amount of time after the trail edge was detected at the Disk Lead Edge Sensor, Q1166A.

Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

Stacker B fault code, 11-150-2, indicates that the trail edge of a print did not arrive at the A3 Trail Edge Sensor, Q1167B, within the specified amount of time after the trail edge was detected at the Disk Lead Edge Sensor, Q1166B.

Select [Stacker Start/Run]. Press Continue. The Stacker Main Drives come on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor RAP.

Stacker C fault code, 11-150-3, indicates that the trail edge of a print did not arrive at the A3 Trail Edge Sensor, Q1167C, within the specified amount of time after the trail edge was detected at the Disk Lead Edge Sensor, Q1166C.

The Trail Edge Assist Belts are all turning. Y N Press Stop. Check the following: • Telescopic Drive Shaft for proper operation (PL 11.11, PL 11.13).

Stacker D fault code, 11-150-4, indicates that the trail edge of a print did not arrive at the A3 Trail Edge Sensor, Q1167D, within the specified amount of time after the trail edge was detected at the Disk Lead Edge Sensor, Q1166D.

•

Bypass Drive Belts for damage, wear, and contamination (PL 11.11, PL 11.13).

•

Gears and pulleys for damage, wear, and contamination (PL 11.11, PL 11.13).

Press Stop. Check the Front and rear Tampers for proper operation. Enter dC203, [Tamper Fingers], [Stacker X], [Back Tamper], [Continuous Run]. Press Continue. Check the measured times against the expected range. Repeat the test for the Front Tamper. The measured times are within the expected range. Y N Press Stop. Check the following: • Tamper components for damage or wear (PL 11.5).

This fault only occurs in the 3 pitch mode.

Initial Actions Check the following: •

A3 Trail Edge Sensor is clean and not obstructed.

•

Stacker and Disk Entrance Gate areas are not obstructed.

•

Back Guide Adjustment, (ADJ 11-29).

Guides are positioned properly.

•

Right Guide Adjustment, (ADJ 11-28).

• •

Ensure that the paper stock is within the specifications for the printing system.

•

Upper Transport is seated properly.

Press Stop. Check the following: • Trail Edge assist belts are tracking properly (PL 11.14).

•

SCP, HFSI 11-802 Table 4, or HFSI TABLES to see all of HFSI.

•

Trail Edge assist belts not loose or slipping (PL 11.14).

•

Disk Entrance Gate hardware for proper operation (PL 11.14).

•

Disk Entrance Gate Height adjustment, (ADJ 11-26).

Diagnostic Tools: • •

dC226 - Inverter/Stacker Paper Path Timing Diagnostics, interval #33 or 34, TE at Disk Lead Edge Sensor to TE at A3 Trail Edge Sensor dC227 - Inverter/Stacker Jam Bypass

•

Stack Height Adjustment, (ADJ 11-27).

•

A3 Nip Release Mechanism for proper operation (PL 11.28)

Procedure NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. Enter dC330, [Stacker X], [11X1]. Block the A3 Trail Edge Sensor. The A3 Trail Edge sensor display changes from H to L. Y N Go to Flag 1. Check the A3 Trail Edge Sensor circuit (GP 6-2, General Procedures) (PL 11.14).

A Section Name

11-150

0/0/00 ?-966

Preliminary Working Document No Product Name Assigned

Figure 1 11-150 Circuit Diagram (8146)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-967

Section Name

11-150

11-200 RAP Fault Code, 11-200, indicates that the Inverter Front Door Interlock Switch, S1153, opened with the High Capacity Feeder 3 or Stacker A Main Drive Motor on.

Procedure Open the Inverter Front Door. Enter dC330. Manually actuate the Inverter Front Door Interlock Switch. The Inverter Door INTLK SW display changes from H to L. Y N Go to Flag 1. Check the Inverter Front Door Interlock circuit (Generic Switch RAP GP 6-1, General Procedures) (PL 4.11). Close and open the door several times. The Inverter Door INTLK SW display changes from H to L as the door is closed and opened. Y N Check the following: • Inverter Front Door Interlock adjustment, (ADJ 4-5). •

Inverter Front Door is not damaged or obstructed (PL 4.11).

•

Door hinges and pins are in place and intact (PL 4.11).

•

Pre-registration transport is seated correctly

•

Interlock mounting bracket is not damaged (PL 4.11).

Check the Inverter Front Door Interlock Switch and its associated wires for intermittent operation.

Section Name

11-200

0/0/00 ?-968

Preliminary Working Document No Product Name Assigned

Figure 1 11-200 Circuit Diagram (8118)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-969

Section Name

11-200

A

11-220 RAP

WARNING

Stacker A Fault Code, 11-220-1, indicates that the Elevator failed to leave the home position (max down). The Stacker Elevator Down Sensor, Q1135A, failed to deactuate within the specified amount of time after the UP winding of the Elevator Motor, MOT1106A, was energized to raise the Elevator. Stacker B Fault Code, 11-220-2, indicates that the Elevator failed to leave the home position (max down). The Stacker Elevator Down Sensor, Q1135B, failed to deactuate within the specified amount of time after the UP winding of the Elevator Motor, MOT1106B, was energized to raise the Elevator.

Use caution when working near the motor. The Stacker Elevator Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [Stacker Elevator Up] motor. Press Continue. The Stacker Elevator moves up. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP. Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18).

Stacker C Fault Code, 11-220-3, indicates that the Elevator failed to leave the home position (max down). The Stacker Elevator Down Sensor, Q1135C, failed to deactuate within the specified amount of time after the UP winding of the Elevator Motor, MOT1106C, was energized to raise the Elevator. Stacker D Fault Code, 11-220-4, indicates that the Elevator failed to leave the home position (max down). The Stacker Elevator Down Sensor, Q1135D, failed to deactuate within the specified amount of time after the UP winding of the Elevator Motor, MOT1106D, was energized to raise the Elevator.

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive belt for wear, damage, contamination, and correct tension (PL 11.18).

Press Stop. Check the following: • Lead screw or bearings for binding (PL 11.18). •

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive Belt for wear, damage, contamination, and that it is under tension (PL 11.18).

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Preliminary Working Document

Initial Actions WARNING Keep fingers/hands away from moving elevator parts. Check the following: •

Stacker Drawer is closed and latched.

•

Main Pallet is positioned correctly and the "spider" latch is latched.

•

Ensure that the containers or pallet is empty.

Procedure NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. Enter dC330, [Stacker X], [11X2]. Block the Stacker Elevator Down Sensor. The Elevator Down / Home Sensor display changes from L to H. Y N Go to Flag 1. Check the Stacker Elevator Down / Home Sensor circuit (Generic Switch RAP GP 6-1, General Procedures) (PL 11.18). Block the Stacker Empty Sensor. The Stacker Empty Sensor display changes from L to H. Y N Go to Flag 2. Check the Stacker Empty Sensor circuit (GP 6-2, General Procedures) (PL 11.18).

A Section Name

11-220

No Product Name Assigned

Figure 1 11-220 Circuit Diagram (8121)

Preliminary Working Document No Product Name Assigned

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Section Name

11-220

A

11-221 RAP

B Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18).

Stacker A Fault Code, 11-221-1, indicates that the Stacker Elevator Down Sensor, Q1135A, failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker Elevator Motor, MOT1106A, was energized to lower the Elevator.

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL 11.18).

Stacker B Fault Code, 11-221-2, indicates that the Stacker Elevator Down Sensor, Q1135B, failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker Elevator Motor, MOT1106B, was energized to lower the Elevator.

•

Lift Frame is not damaged (PL 11.17).

•

Pallet Lift Frame Parallelism Adjustment (ADJ 11-31).

Stacker C Fault Code, 11-221-3, indicates that the Stacker Elevator Down Sensor, Q1135C, failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker Elevator Motor, MOT1106C, was energized to lower the Elevator.

Press Stop. Check the following: • Lead screw or bearings for binding (PL 11.18). •

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive Belt for wear, damage, or contamination and that it is under tension (PL 11.18).

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Preliminary Working Document

Stacker D Fault Code, 11-221-4, indicates that the Stacker Elevator Down Sensor, Q1135D, failed to actuate within 413 cumulative encoder pulses after the Down winding of the Stacker Elevator Motor, MOT1106D, was energized to lower the Elevator.

Initial Actions WARNING Keep fingers/hands away from moving elevator parts. Check the following: •

Stacker Drawer is closed and latched fully.

•

Stacker Doors are closed.

•

Elevator path is not obstructed.

Procedure Enter dC330, [STACKER X], [11X2]. Block the Stacker Elevator Down Sensor. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Elevator Down / Home Sensor display changes from L to H. Y N Go to Flag 1. Check the Stacker Elevator Down / Home Sensor circuit (Generic Switch RAP GP 6-1, General Procedures) (PL 11.18).

WARNING Use caution when working near the motor. The Stacker Elevator Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [Elevator Dn]. Press Continue. The Stacker Elevator moves down. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP. A

B

Section Name

11-221

No Product Name Assigned

Figure 1 11-221 Circuit Diagram (8122)

Preliminary Working Document No Product Name Assigned

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Section Name

11-221

A

11-222 RAP

If OK, go to Flag 1. Check the Elevator Motor Encoder circuit (GP 6-2, General Procedures) (PL 11.19).

Stacker A Fault Code, 11-222-1, indicates that there were no encoder pulses received from the Stacker Elevator Encoder Sensor, Q1124A, with the Stacker Elevator Motor, MOT1106A, activated. The fault code can result when the motor is activated in either the up or down mode. Stacker B Fault Code, 11-222-2, indicates that there were no encoder pulses received from the Stacker Elevator Encoder Sensor, Q1124B, with the Stacker Elevator Motor, MOT1106B, activated. The fault code can result when the motor is activated in either the up or down mode. Stacker C Fault Code, 11-222-3, indicates that there were no encoder pulses received from the Stacker Elevator Encoder Sensor, Q1124C, with the Stacker Elevator Motor, MOT1106C, activated. The fault code can result when the motor is activated in either the up or down mode. Stacker D Fault Code, 11-222-4, indicates that there were no encoder pulses received from the Stacker Elevator Encoder Sensor, Q1124D, with the Stacker Elevator Motor, MOT1106D, activated. The fault code can result when the motor is activated in either the up or down mode.

Initial Actions WARNING Keep fingers/hands away from moving elevator parts.

Select [11X1]. The Stacker Drawer In Switch display indicates an L. Y N Go to Flag 4. Check the circuit of the Stacker Drawer In Switch, S1129 (Generic Switch RAP GP 6-1, General Procedures) (PL 11.18). Select [11X2]. Block the Stack Height Sensor. The Stack Height Sensor display changes from L to H. Y N Go to Flag 5. Check the circuit of the Stack Height Sensor, Q1122 (GP 6-2, General Procedures) (PL 11.30). Observe the position of the Elevator Lift Frame. The Lift Frame is in the home (down) position. Y N Block the Stacker Elevator Down Sensor. The Elevator Down/Home Sensor display changes from L to H. Y N Go to Flag 2. Check the circuit of the Stacker Elevator Down Sensor, Q1125 (GP 62, General Procedures) (PL 11.18).

Check the following:

WARNING •

Stacker Drawer is closed and latched fully.

•

Stacker Doors are closed.

•

Loose pins or connectors on the Stacker Door Interlock Switches.

•

Main Pallet is positioned correctly and the Pallet Latch is latched.

•

Elevator path is not obstructed.

•

Lift Frame is not damaged.

Use caution when working near the motor. The Stacker Elevator Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [Elevator Down]. Press Continue. The Stacker Elevator moves down. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.

Perform the following: •

Remove all paper from the stacker pallets

Procedure

Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18).

Enter dC330, [Stacker X], [11X2]. Manually rotate the Stacker Drive Belt. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. NOTE: If the Stacker Elevator is in the home (full down) position, access to the belt will have to be made from underneath with the High Capacity Tray open.

Encoder Flag is not loose or broken (PL 11.19).

•

Encoder Sensor and Flag alignment.

A Section Name

11-222

Pallet Lift Frame Parallelism Adjustment (ADJ 11-31)

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.18).

•

Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL 11.18).

•

Lift Frame is not damaged (PL 11.17).

Press Stop. Select [Elevator up]. Press Continue. The Stacker Elevator moves up. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.

The display for the Stacker Elevator Motor Encoder toggles between L and H as the belt is rotated. Y N Check the following: • Encoder Sensor is clean and is not obstructed (PL 11.19). •

•

Press Stop. Check the following: • Lead screw or bearings for binding (PL 11.18). B 0/0/00 ?-974

C Preliminary Working Document No Product Name Assigned

B

C •

Pallet Lift Frame Parallelism Adjustment (ADJ 11-31)

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive Belt for wear, damage, contamination, and under proper tension (PL 11.18).

•

Lift Frame is not damaged (PL 11.17).

•

Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL 11.18).

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Section Name

Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18). •

Pallet Lift Frame Parallelism Adjustment (ADJ 11-31)

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.18).

•

Elevator Drive belt for wear, damage, contamination, and under proper tension (PL 11.18).

•

Lift Frame is not damaged (PL 11.17).

Ensure that the Stacker Elevator Down Sensor is blocked by the flag on the lift frame. The Stacker Elevator Down Sensor display is H. Y N Go to Flag 4. Check the circuit of the Stacker Empty Sensor, Q1130 (GP 6-2, General Procedures) (PL 11.18). Block the Stacker Empty Sensor. The Stacker Empty Sensor display changes from L to H. Y N Go to Flag 2. Check the circuit of the Stacker Empty Sensor, Q1130 (GP 6-2, General Procedures) (PL 11.18).

WARNING Use caution when working near the motor. The Stacker Elevator Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Select [Elevator up]. Press Continue. The Stacker Elevator moves up. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP. Press Stop. Check the following: • Lead screw or bearings for binding (PL 11.18). •

Pallet Lift Frame Parallelism Adjustment (ADJ 11-31)

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.18).

•

Elevator Drive Belt for wear, damage, or contamination and that it is under tension (PL 11.18).

Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18). •

Pallet Lift Frame Parallelism Adjustment (ADJ 11-31)

•

Lift Frame for damage (PL 11.17).

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

Preliminary Working Document No Product Name Assigned

11-222

Figure 1 11-222 Circuit Diagram (8123)

Section Name

11-222

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Figure 2 11-222 Circuit Diagram (8148)

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Section Name

11-222

A

B

11-223 RAP

C Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18).

Stacker A Fault Code, 11-223-1, Stacker B Fault Code, 11-223-2, Stacker C Fault Code, 11223-3, or Stacker D Fault Code, 11-223-4, indicates either one of the following problems:

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

The Stacker Elevator failed to interrupt the Stack Height Sensor, Q1122, within 28 seconds after the Stacker Elevator Motor, MOT1106, was energized to drive the elevator up.

Elevator Drive belt for wear, damage, or contamination and that it under tension (PL 11.19).

•

Lift Frame is not damaged (PL 11.17).

Press Stop. Select [Elevator up]. Press Continue. The Stacker Elevator moves up. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP.

The Stacker Elevator failed to reach the Stacker Elevator Down Sensor, Q1135, within 18 seconds after the Stacker Elevator Motor, MOT1106, was energized to drive the elevator down.

Initial Actions WARNING

Press Stop. Check the following: • Lead screw or bearings for binding (PL 11.18).

Keep fingers/hands away from moving elevator parts. Check the following: •

Stacker Elevator is not obstructed

•

Stacker Doors close and latch correctly.

•

Lift Frame is not damaged.

Procedure NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Stack Height Sensor display changes from L to H. Y N Go to Flag 1. Check the Stack Height Sensor circuit (GP 6-2, General Procedures) (PL 11.30). Block the Stacker Elevator Down Sensor. The display changes from L to H. Y N Go to Flag 2. Check the Stacker Elevator Down Sensor circuit (Generic Switch RAP GP 6-1, General Procedures) (PL 11.18).

WARNING Use caution when working near the motor. The Stacker Elevator Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

Section Name

11-223

Elevator Drive Belt for wear, damage, or contamination and that it is under tension (PL 11.18).

•

Lift Frame is not damaged (PL 11.17).

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL 11.18).

•

Lift Frame is not damaged (PL 11.17).

Select [Elevator up]. Press Continue. The Stacker Elevator moves up. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP. Press Stop. Check the following: • Lead screw or bearings for binding (PL 11.18).

Observe the position of the Elevator Lift Frame. The Lift Frame is in the home (down) position. Y N

A

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18).

Enter dC330, [Stacker X], [11X2]. Block the Stack Height Sensor.

Select [Elevator Down]. Press Continue. The Stacker Elevator moves down. Y N The Stacker Elevator Motor comes on. Y N Press Stop. Go to the 11-703, Stacker Elevator Motor RAP. B C

•

•

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive Belt for wear, damage, or contamination and that it is under tension (PL 11.18).

Press Stop. Check the following: • Lead screw or bearing for binding (PL 11.18). •

Elevator Drive Assembly for damage, binding, or obstructions (PL 11.19).

•

Elevator Drive belt for wear, damage, or contamination and that it is under tension (PL 11.18).

•

(ADJ 11-31), Pallet Lift Frame Parallelism Adjustment

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Figure 1 11-223 Circuit Diagram (8124)

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Section Name

11-223

11-224 RAP Stacker A Fault Code, 11-224-1, indicates that the Stacker Module Top Cover was sensed open while Stacker A was in use. Stacker B Fault Code, 11-224-2, indicates that the Stacker Module Top Cover was sensed open. Stacker C Fault Code, 11-224-3, indicates that the Stacker Module Top Cover was sensed open. Stacker D Fault Code, 11-224-4, indicates that the Stacker Module Top Cover was sensed open.

Initial Actions Check the following: •

Top Cover closes correctly and is not obstructed.

•

Top Cover hinges for damage and that the pins are secure.

•

Interlock actuator aligns with switch and is not damaged,

•

Bypass Transport baffles are seated correctly.

•

Interlock mounting bracket is not damaged.

Procedure Enter dC330, [Stacker X], [11X1]. Close the Top Cover. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Top Cover Interlock SW display indicates a L. Y N Open the Top Cover. Manually actuate the Top Cover Interlock. The display changes from H to L. Y N Go to Flag 1. Check the Top Cover Interlock circuit (GP 6-2, General Procedures) (PL 4.14). Check the following: • Top Cover Interlock adjustment, (ADJ 4-3). •

Top Cover and hinges for damage (PL 4.14).

Check the Top Cover/actuator to switch alignment.

Section Name

11-224

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Figure 1 11-224 Circuit Diagram (8125)

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Section Name

11-224

A

B

11-228, 11-229 RAP Stacker A Fault Code, 11-228-1, indicates that the Stacker Left Door Interlock Switch, S1163A, deactuated with print in process to the Stacker bin.

Check the following: • (ADJ 4-5), Left Door Interlock adjustment

Stacker B Fault Code, 11-228-2, indicates that the Stacker Left Door Interlock Switch, S1163B, deactuated with print in process to the Stacker bin. Stacker C Fault Code, 11-228-3, indicates that the Stacker Left Door Interlock Switch, S1163C, deactuated with print in process to the Stacker bin. Stacker D Fault Code, 11-228-4, indicates that the Stacker Left Door Interlock Switch, S1163D, deactuated with print in process to the Stacker bin. Stacker A Fault Code, 11-229-1, indicates that the Stacker Right Door Interlock Switch, S1138A, deactuated with a print in process to the Stacker bin.

•

Go to Flag 2. Check the Stacker Right Door Interlock circuit (Generic Switch RAP GP 6-1, General Procedures), (PL 4.12). Check the following: • (ADJ 4-5), Right Door Interlock adjustment

Stacker C Fault Code, 11-229-3, indicates that the Stacker Right Door Interlock Switch, S1138C, deactuated with a print in process to the Stacker bin.

•

Front Door and hinges for damage (PL 4.12).

Check the following: • Magnets and strike plates are not missing or damaged (PL 4.12). •

Initial Actions

Front Door and hinges for damage (PL 4.12).

The Stacker RH Door INTLK SW display indicates a L. Y N Open and close the Right Door several times. The display changes from H to L. Y N Remove the Stacker Front Cover assembly. Check the interlock actuator hardware for proper actuation of the interlock switch. The switch is being actuated properly. Y N Repair or replace the defective components (PL 4.12).

Stacker B Fault Code, 11-229-2, indicates that the Stacker Right Door Interlock Switch, S1138B, deactuated with a print in process to the Stacker bin.

Stacker D Fault Code, 11-229-4, indicates that the Stacker Right Door Interlock Switch, S1138D, deactuated with a print in process to the Stacker bin.

C Go to Flag 1. Check the Stacker Left Door Interlock circuit (Generic Switch RAP GP 6-1, General Procedures, (PL 4.12).

Obstructions keeping doors from closing fully.

Check the following: •

Front Doors close correctly and are not obstructed.

•

Front Door hinges for damage and that the pins are secure.

•

Interlock mounting bracket is not damaged.

•

Interlock Switch connectors are not loose or pulled off.

•

The Stacker Door Interlocks are adjusted properly, (ADJ 4-5).

Procedure Enter dC330, [Stacker X], [11X1]. Close the Stacker Front Doors. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Stacker LH Door INTLK SW display indicates a L. Y N Open and close the Left Door several times. The display changes from H to L. Y N Remove the Stacker Front Cover assembly. Check the interlock actuator hardware for proper actuation of the interlock switch. The switch is being actuated properly. Y N Repair or replace the defective components (PL 4.12). A

B

C

Section Name

11-228, 11-229

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Figure 1 11-228/229 Circuit Diagram (8126)

Preliminary Working Document No Product Name Assigned

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Section Name

11-228, 11-229

A

11-231 RAP

•

dC131 FSN1, address location 176 value in the appropriate level Software dC 131 Table in General Procedures.

Stacker A Fault Code, 11-231-1, indicates that there were no transitions in 117 steps seen on the Disk Home Sensor, Q1121A. There were too many steps required to find the disk home position.

•

Disk shaft for binding (PL 11.30)

Stacker B Fault Code, 11-231-2, indicates that there were no transitions in 117 steps seen on the Disk Home Sensor, Q1121B. There were too many steps required to find the disk home position.

•

Stack Height Adjustment, (ADJ 11-27)

•

Stack is not binding against Disk. Check the Stacker Disk Gate Height Adjustment (ADJ 11-25)

•

Disk Gate Cam Follower binding on the Disk Shaft (PL 11.30)

•

Disk Drive Coupling (PL 11.30)

If OK, go to the 11-700, Disk Motor RAP. Stacker C Fault Code, 11-231-3, indicates that there were no transitions in 117 steps seen on the Disk Home Sensor, Q1121C. There were too many steps required to find the disk home position. Stacker D Fault Code, 11-231-4, indicates that there were no transitions in 117 steps seen on the Disk Home Sensor, Q1121D. There were too many steps required to find the disk home position.

Press Stop. Enter dC330, [Stacker X], [11X1]. Block the Disk Sheet Sensor. The Disk Sheet Sensor display changes from L to H. Y N Go to Flag 1. Check the Disk Sheet Sensor circuit (GP 6-2, General Procedures) (PL 11.30).

Initial Actions

Check the following: • Disk shaft for binding (PL 11.30)

Check the following:

•

•

Binding of the Disk shaft

•

Excessive upcurl of the stack causing the Disk to bind

•

Disk Home Sensor is clean and not obstructed

•

Disk Home Sensor actuator for damage

•

Disk Drive Coupling assembly loose or damaged

Procedure

Disk Gate Cam Follower binding on the Disk Shaft (PL 11.30)

•

Disk Home Adjustment (ADJ 11-25)

•

Disk Drive Coupling (PL 11.30)

•

Stack Height Adjustment, (ADJ 11-27)

•

Stack is not binding against Disk.

•

Disk Entrance Gate Height Adjustment, (ADJ 11-26)

•

Disk Home Sensor actuator for damage or obstructions (PL 11.30)

•

Disk Assembly for damage (PL 11.30)

A Stacker Elevator which is not indexing down can cause a 11-231 fault. If Stacker Elevator fault codes 11-221,222,or 223 are occurring, go to the respective RAP. If messages indicating problems with the stacker elevators are occurring, go to the 11-222 RAP. Enter dC330, [Stacker X], [11X1]. Rotate the disk to block the Disk Home Sensor. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The display changes from L to H. Y N Go to Flag 2. Check the Disk Home Sensor circuit (GP 6-2, General Procedures) (PL 11.30). Enter dC203. Select [Stacker Disk], [Stacker X], [7 Pitch or 3 Pitch], [Continuous Run]. Press Continue. Observe the Disk Module for several cycles. The Disk Module cycles smoothly and the measured times are consistent and fall within the expected range. Y N The Disk Motor comes on. Y N Press Stop. Go to the 11-700, Disk Motor RAP. Press Stop. Check the following: A Section Name

11-231

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Figure 1 11-231 Circuit Diagram (8127)

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Section Name

11-231

11-232, 11-233 RAP

Y

Stacker A Fault Code, 11-232-1, indicates that the Right Guide Home Sensor, Q1132A, remained blocked after 100 steps of the Right Guide Motor, MOT1105A.

N The Right Guide Motor comes on. Y N Press Stop. Go to the 11-702, Right Guide Motor RAP.

Stacker B Fault Code, 11-232-2, indicates that the Right Guide Home Sensor, Q1132B, remained blocked after 100 steps of the Right Guide Motor, MOT1105B.

Press Stop. Check the following:

Stacker C Fault Code, 11-232-3, indicates that the Right Guide Home Sensor, Q1132C, remained blocked after 100 steps of the Right Guide Motor, MOT1105C.

•

Right Guide positioning mechanism for binding.

•

Drive Belt for wear, damage, or contamination and that it is set to the correct tension.

Stacker D Fault Code, 11-232-4, indicates that the Right Guide Home Sensor, Q1132D, remained blocked after 100 steps of the Right Guide Motor, MOT1105D.

•

Lead screw for binding.

•

Drive pulley for slippage on shaft.

Stacker A Fault Code, 11-233-1, indicates that the Right Guide Home Sensor, Q1132A, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, MOT1105A. Stacker B Fault Code, 11-233-2, indicates that the Right Guide Home Sensor, Q1132B, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, MOT1105B.

NOTE: Use Parts List (PL 11.9).

•

Rails for binding.

•

Coil cord not catching.

Press Stop. Check the Right Guide mechanism for parallel to the Rear Frame. The nism is parallel. Y N Perform (ADJ 11-28), Right Guide adjustment.

mecha-

Check the following: Stacker C Fault Code, 11-233-3, indicates that the Right Guide Home Sensor, Q1132C, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, MOT1105C. Stacker D Fault Code, 11-233-4, indicates that the Right Guide Home Sensor, Q1132D, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Right Guide Motor, MOT1105D.

NOTE: Use Parts List (PL 11.9). •

Drive belt for wear, damage, contamination, and correct tension.

•

Drive pulley for slippage on shaft.

•

Rails for binding.

•

Lead Screws for binding.

Initial Actions Check the following: •

Right Guide for obstructions

•

Right Guide Home Sensor is clean and is not obstructed.

•

Flag is not damaged and is aligned to the sensor.

Procedure Enter dC330, [Stacker X], [11X2]. Block the Right Guide Home Sensor. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Right Guide Home Sensor display changes from L to H. Y N Go to Flag 1. Check the Right Guide Home Sensor circuit (GP 6-2, General Procedures) (PL 11.9). Enter dC203. Select [Edge Guides], [Stacker X], [Right Guide], [Continuous Run]. Press Continue. The Right Guide moves forward and backward. Section Name

11-232, 11-233

0/0/00 ?-986

Preliminary Working Document No Product Name Assigned

Figure 1 11-232/233 Circuit Diagram (8128)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-987

Section Name

11-232, 11-233

11-237, 11-238 RAP

Y

Stacker A Fault Code, 11-237-1, indicates that the Back Guide Home Sensor, Q1133A, remained blocked after 100 steps of the Back Guide Motor, MOT1105A.

N The Back Guide Motor comes on. Y N Press Stop. Go to the 11-701, Back Guide Motor RAP.

Stacker B Fault Code, 11-237-2, indicates that the Back Guide Home Sensor, Q1133B, remained blocked after 100 steps of the Back Guide Motor, MOT1105B.

Press Stop. Check the following: • Back Guide positioning mechanism for binding (PL 11.7).

Stacker C Fault Code, 11-237-3, indicates that the Back Guide Home Sensor, Q1133C, remained blocked after 100 steps of the Back Guide Motor, MOT1105C. Stacker D Fault Code, 11-237-4, indicates that the Back Guide Home Sensor, Q1133D, remained blocked after 100 steps of the Back Guide Motor, MOT1105D.

•

Drive Belt for wear, damage, or contamination and that it is set to the correct tension (PL 11.7).

•

Lead screw for binding (PL 11.7).

•

Drive pulley for slippage on shaft (PL 11.7).

If OK, go to the 11-701, Back Guide Motor RAP.

Stacker A Fault Code, 11-238-1, indicates that the Back Guide Home Sensor, Q1133A, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, MOT1105A.

Press Stop. Check the Back Guide mechanism for parallel to the Rear Frame. The nism is parallel. Y N Perform (ADJ 11-29), Back Guide adjustment.

Stacker B Fault Code, 11-238-2, indicates that the Back Guide Home Sensor, Q1133B, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, MOT1105B.

Check the following: • Drive belt for wear, damage, contamination, and correct tension (PL 11.7).

Stacker C Fault Code, 11-238-3, indicates that the Back Guide Home Sensor, Q1133C, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, MOT1105C.

•

Drive pulley for slippage on shaft (PL 11.7).

•

Lead screw for binding (PL 11.7).

mecha-

Stacker D Fault Code, 11-238-4, indicates that the Back Guide Home Sensor, Q1133D, remained unblocked after 2600 steps (7 pitch) or 100 steps (3 pitch) of the Back Guide Motor, MOT1105D.

Initial Actions Check the following: •

Back Guide for obstructions

•

Back Guide Home Sensor is clean and is not obstructed.

•

Flag is not damaged and is aligned to the sensor.

Procedure Enter dC330, [Stacker X], [11X2]. Block the Back Guide Home Sensor. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Back Guide Home Sensor display changes from L to H. Y N Go to Flag 1. Check the Back Guide Home Sensor circuit (GP 6-2, General Procedures) (PL 11.7). Enter dC203. Select [Edge Guides], [Stacker X], [Back Guide], [Continuous Run]. Press Continue. The Back Guide moves forward and backward. Section Name

11-237, 11-238

0/0/00 ?-988

Preliminary Working Document No Product Name Assigned

Figure 1 11-237/238 Circuit Diagram (8129)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-989

Section Name

11-237, 11-238

A

B

11-242 RAP Stacker A Fault Code, 11-242-1, indicates that there was a Front Tamper positioning failure after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper Clutch actuated without the Front Tamper Position Sensor, Q1135A, transitioning within 200ms.

C The Front Tamper motor comes on. Y N Select [Clear Outputs]. Go to the 11-704, Front Tamper Motor RAP. Select [Clear Outputs]. Check the following: • Bearing for binding (PL 11.8). •

Stacker B Fault Code, 11-242-2, indicates that there was a Front Tamper positioning failure after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper Clutch actuated without the Front Tamper Position Sensor, Q1135B, transitioning within 200ms. Stacker C Fault Code, 11-242-3, indicates that there was a Front Tamper positioning failure after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper Clutch actuated without the Front Tamper Position Sensor, Q1135C, transitioning within 200ms.

Front Tamper positioning mechanism for binding (PL 11.8).

•

Drive coupling for damage (PL 11.8).

•

Drive coupling for slippage on shaft (PL 11.8).

•

Clutch Drive Gear for damage (PL 11.8).

•

Proper Right Guide positioning. Check the Right Guide Adjustment (ADJ 1128).

The Front Tamper Position Sensor display toggles as the Tampers extend and retract. Y N Select [Clear Outputs]. Go to Flag 1. Check the Front Tamper Position Sensor circuit (GP 6-2, General Procedures) (PL 11.8).

Stacker D Fault Code, 11-242-4, indicates that there was a Front Tamper positioning failure after the second attempt to extend or retract the Front Tamper Fingers. The Front Tamper Clutch actuated without the Front Tamper Position Sensor, Q1135D, transitioning within 200ms.

Select [Clear Outputs]. Check the following: • Bearing for binding (PL 11.8).

Initial Actions

•

Front Tamper positioning mechanism for binding (PL 11.8).

Check the following:

•

Drive coupling for slippage on shaft or damage (PL 11.8).

•

Clutch Drive Gear for damage (PL 11.8).

•

Tamper Linkage Arm Short Shafts. Ensure that the shafts have not come out of position.

•

Tamper Position Sensor is clean and is not obstructed.

•

Tamper finger area for obstructions.

Press Stop. Check the following: • Front Tamper positioning mechanism for intermittent binding (PL 11.8).

•

Guides are not too tight against stack.

•

Drive coupling for slippage on shaft or damage (PL 11.8).

Gears for wear or damage.

•

Clutch Drive Gear for damage (PL 11.8).

•

Linkages for binding.

•

Proper Right Guide positioning. Check the Right Guide Adjustment (ADJ 11-28).

•

Drive Coupling is not loose.

•

Procedure Enter dC203, [Tamper Fingers], [Stacker X], [Tamper Front], [Continuous Cycle]. Press Continue. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Front Tampers extend and retract correctly within the expected times. Y N Enter dC330, [Stacker X], [11X2], [Front Tamper] motor. Press Continue. Select [Offset FWD] clutch. Press Continue. The Tamper fingers extend and retract correctly. Y N The Front Tamper Clutch energized. Y N Select [Clear Outputs]. Go to Flag 2. Check the Front Tamper Clutch circuit (Generic Clutch RAP GP 6-3, General Procedures) (PL 11.8). A

B

C

Section Name

11-242

0/0/00 ?-990

Preliminary Working Document No Product Name Assigned

Figure 1 11-242 Circuit Diagram (8130)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-991

Section Name

11-242

A

B

11-244 RAP

•

Proper positioning of Tampers against stack. Check the Back Guide Adjustment, (ADJ 11-29).

Stacker A Fault Code, 11-244-1 indicates that there was a Back Tamper positioning failure after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper Clutch actuated without the Back Tamper Position Sensor, Q1134A, transitioning within 100ms.

•

Bearing for binding (PL 11.7).

Stacker B Fault Code, 11-244-2, indicates that there was a Back Tamper positioning failure after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper Clutch actuated without the Back Tamper Position Sensor, Q1134B, transitioning within 100ms.

•

Drive pulley for slippage on shaft (PL 11.7)

•

Clutch Drive Gear for damage (PL 11.7).

•

Back Tamper positioning mechanism for binding (PL 11.7).

•

Drive Belt for wear, damage, contamination, and correct tension (PL 11.7).

The Back Tamper Position Sensor display toggles. Y N Select [Clear Outputs]. Go to Flag 1. Check the Back Tamper Position Sensor circuit (GP 6-2, General Procedures) (PL 11.7).

Stacker C Fault Code, 11-244-3 indicates that there was a Back Tamper positioning failure after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper Clutch actuated without the Back Tamper Position Sensor, Q1134C, transitioning within 100ms. Stacker D Fault Code, 11-244-4, indicates that there was a Back Tamper positioning failure after the second attempt to extend or retract the Back Tamper Fingers. The Back Tamper Clutch actuated without the Back Tamper Position Sensor, Q1134D, transitioning within 100ms.

Select [Clear Outputs]. Check the following: • Bearing for binding (PL 11.7).

Initial Actions Check the following:

•

Back Tamper positioning mechanism for binding (PL 11.7).

•

Drive Belt for wear, damage, contamination, and correct tension (PL 11.7).

•

Drive pulley for slippage on shaft (PL 11.7).

•

Clutch Drive Gear for damage (PL 11.7).

•

Tamper Linkage Arm Short Shafts. Ensure that they are positioned properly.

•

Tamper Position Sensor is clean and is not obstructed.

Press Stop. Check the following: • Back Guide Adjustment (ADJ 11-29).

•

Tamper finger area for obstructions.

•

•

Gears for wear or damage.

•

Drive Belt for wear, damage, contamination, and correct tension (PL 11.7).

•

Tamper drive belt has tension.

•

Drive pulley for slippage on shaft (PL 11.7).

•

Clutch Drive Gear for damage (PL 1.7).

Procedure

Back Tamper positioning mechanism for intermittent binding (PL 11.7).

Enter dC203, [Tamper Fingers], [Stacker X], [Back Tamper], [Continuous Run]. Press the Continue button. NOTE: The following procedure can be used for fault codes that may appear in any of the Inverter Feeder Stacker, Middle Module, or Feeder/Stacker modules. The correct module letter (A/B/C/D) must be inserted into the procedure instructions, or circuit diagrams (in place of X) in order to properly diagnose the fault codes. The Back Tampers extend and retract correctly within the expected times. Y N Press Stop. Enter dC330, [Stacker X], [11X2], [Offset Back] clutch. Press Continue. Select [Back Tamper] motor. Press Continue. The Tamper fingers extend and retract correctly. Y N The Back Tamper Clutch energized. Y N Select [Clear Outputs]. Go to Flag 2. Check the Back Tamper Clutch circuit (Generic Clutch RAP GP 6-3, General Procedures), (PL 11.7). The Back Tamper motor comes on. Y N Select [Clear Outputs]. Go to the 11-705, Back Tamper Motor RAP. Select [Clear Outputs]. Check the following: A

B

Section Name

11-244

0/0/00 ?-992

Preliminary Working Document No Product Name Assigned

Figure 1 11-244 Circuit Diagram (8131)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-993

Section Name

11-244

11-250-1 RAP Fault code, 11-250-1, indicates that +24 VDC is missing in the Inverter Feeder/Stacker (module A).

Initial Actions Perform the following: •

Check the queued faults for 1-220 or 10-216. If they are present, go to the appropriate RAP.

Procedure +24 VDC is measured between the orange and violet sides of A-TB7. Y N +24 VDC is measured between TH10 (+) and TH14 (-) on the LVPS. Y N Go to the 1-717 +24, +34, and -34 VDC RAP. Go to Flag 3 and Flag 4. Check the wires for an open circuit. +24 VDC is measured between P4093-3 (+) and P4093-1 (-). Y N Go to Flag 1 and Flag 2. Check the wires for an open circuit. Enter dC330, [11A2]. Disconnect P4069 from J6 on the FSN DIO PWB #3A. Connect a jumper wire from TS32 to TS37 on the PWB. The F/S LVPS Monitor display is L. Y N Replace the FSN DIO PWB #3A (PL 1.17). Go to Flag 5. Check the wires for an open circuit. If OK, replace the 24 LVPS Sensor, Q1162 (PL 1.16).

Section Name

11-250-1

0/0/00 ?-994

Preliminary Working Document No Product Name Assigned

Figure 1 11-250-1 Circuit Diagram (8157)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-995

Section Name

11-250-1

11-250-2 RAP Stacker B fault code, 11-250-2, indicates that a loss of +24 VDC has been detected in the Feeder/Stacker module. The Printer will enter the Power Interrupt mode when this fault occurs.

Initial Actions Perform the following: •

Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB #2 before starting the procedure. If directed to the 1-719 RAP, leave the jumper in place. Remove the jumper when the fault is corrected.

Procedure The 24V LVPS Cooling Fan, MOT108, is operating. Y N Go to the 1-719, F/S 24VDC RAP. +24 VDC is measured at P4093-3. Y N Go to Flag 5. Check the wire for an open circuit. +24 VDC is measured between P4093-3 (+) and P4093-2 (-). Y N Go to Flag 4. Check the wire for an open circuit. Enter dC330, [11B2]. Observe the F/S LVPS Monitor display. Connect a jumper wire between TS 32 and TS 37 on the FSN DIO PWB #3B. The F/S LVPS Monitor display toggles from H to L. Y N Go to Flag 3. Check the wires for a short circuit. If OK, replace the FSN DIO PWB #3B (PL 1.16). Go to Flag 3. Check the wires for an open circuit. If OK, replace the 24 VDC Sensor, Q1162 (PL 1.16).

Section Name

11-250-2

0/0/00 ?-996

Preliminary Working Document No Product Name Assigned

Figure 1 11-250 Circuit Diagram (7131)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-997

Section Name

11-250-2

11-250-3 RAP Stacker C fault code, 11-250-3, indicates that a loss of +24 VDC has been detected in the Feeder/Stacker module. The Printer will enter the Power Interrupt mode when this fault occurs.

Initial Actions Perform the following: •

Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB #2 before starting the procedure. If directed to the 1-719 RAP, leave the jumper in place. Remove the jumper when the fault is corrected.

Procedure The 24V LVPS Cooling Fan, MOT108, is operating. Y N Go to the 1-719, F/S 24VDC RAP. +24 VDC is measured at P4093-3. Y N Go to Flag 5. Check the wire for an open circuit. +24 VDC is measured between P4093-3 (+) and P4093-2 (-). Y N Go to Flag 4. Check the wire for an open circuit. Enter dC330, [Stacker C], [11C2]. Observe the F/S LVPS Monitor display. Connect a jumper wire between TS 32 and TS 37 on the FSN DIO PWB #3C. The F/S LVPS Monitor display toggles from H to L. Y N Go to Flag 3. Check the wires for a short circuit. If OK, replace the FSN DIO PWB #3C (PL 1.16). Go to Flag 3. Check the wires for an open circuit. If OK, replace the 24 VDC Sensor, Q1162 (PL 1.16).

Section Name

11-250-3

0/0/00 ?-998

Preliminary Working Document No Product Name Assigned

Figure 1 11-250 Circuit Diagram (7131)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-999

Section Name

11-250-3

11-250-4 RAP Stacker D fault code, 11-250-4, indicates that a loss of +24 VDC has been detected in the Feeder/Stacker module. The Printer will enter the Power Interrupt mode when this fault occurs.

Initial Actions Perform the following: •

Connect a jumper wire between TS53 and TS37 on the PHN DIO PWB #2 before starting the procedure. If directed to the 1-719 RAP, leave the jumper in place. Remove the jumper when the fault is corrected.

Procedure The 24V LVPS Cooling Fan, MOT108, is operating. Y N Go to the 1-719, F/S 24VDC RAP. +24 VDC is measured at P4093-3. Y N Go to Flag 5. Check the wire for an open circuit. +24 VDC is measured between P4093-3 (+) and P4093-2 (-). Y N Go to Flag 4. Check the wire for an open circuit. Enter dC330, [Stacker X], [11D2]. Observe the F/S LVPS Monitor display. Connect a jumper wire between TS 32 and TS 37 on the FSN DIO PWB #3D. The F/S LVPS Monitor display toggles from H to L. Y N Go to Flag 3. Check the wires for a short circuit. If OK, replace the FSN DIO PWB #3D (PL 1.16). Go to Flag 3. Check the wires for an open circuit. If OK, replace the 24 VDC Sensor, Q1162 (PL 1.16).

Section Name

11-250-4

0/0/00 ?-1000

Preliminary Working Document No Product Name Assigned

Figure 1 11-250 Circuit Diagram (7131)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1001

Section Name

11-250-4

11-270-2 RAP Fault Code, 11-270-2, indicates that a stray print arrived at the Purge Transport Sensor, Q1164B, unexpectedly. This fault is logged in NVM only.

Initial Actions Check the following: •

The Purge Transport Sensor is clean and is not obstructed.

•

Paper path for obstructions.

•

Jam clearance baffles for damage and that they are seated correctly.

•

Idler springs missing or idlers that are bound or contaminated.

•

Bypass Transport Gate is operating correctly and is not obstructing the paper path.

Procedure Observe the prints entering the Bypass Transport. The prints are free from damage and are not skewed. Y N Check the following: • Drive Rolls for wear, damage or contamination (PL 11.12). •

Idler Rolls and retaining springs for damage or binding (PL 11.12).

Enter dC330, [11A1]. Block the Stacker A Bypass Transport Sensor. The display changes from L to H. Y N Go to Flag 1. Check the Bypass Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.29). Select [11B2]. Block the Purge Transport Sensor. The display changes from L to H. Y N Go to Flag 2. Check the Purge Transport Sensor circuit (GP 6-2, General Procedures) (PL 11.12). Select [Bypass Gate] solenoid. Press Continue. The Bypass Gate actuated. Y N The Bypass Gate Solenoid energized. Y N Press Stop. Go to Flag 3. Check the Bypass Gate Solenoid circuit (Generic Solenoid RAP GP 6-3, General Procedures), (PL 11.12). Press Stop. Check the following: • Bypass Gate for wear or damage (PL 11.12). •

(ADJ 11-11), Bypass Gate Solenoid RAP adjustment.

Press Stop. Check the Bypass Gate Solenoid RAP circuit for an intermittent condition.

Section Name

11-270-2

0/0/00 ?-1002

Preliminary Working Document No Product Name Assigned

Figure 1 11-270 Circuit Diagram (8116)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1003

Section Name

11-270-2

11-600 Poor Stacking Quality RAP

CAUTION

Check the following:

If the Customer is senstive to offset stacking quality, perform the following step. However, note that as short report/jobs run, perform degradation may be experienced when the following step is performed.

•

Quality of the paper supply. Ensure that the paper falls within the capabilities of the Printer. Refer to the System Specifications.

6.

•

Printer to IF/S Alignment.

•

Ensure that the Right Guide Tamper Motor is working. Use dC330, [Tamper Front]. If not OK, go to the 11-704.

•

Lift Frame for damage. Ensure that it is not broken or bent and that it is keeping the pallet level.

•

Main Pallet or Container Pallet is seated properly. Ensure that the locating studs on the lift frame line up properly with the locating holes.

•

Pallet Lift Frame Parallelism adjustment, (ADJ 11-31).

Procedure 1.

Enter dC131 [EDN]. Change EDN location 494 from 000 to 001. The (Skip Pitch Mode) is now enabled.

NOTE: It may be beneficial to remove the Stacker Front Cover and view the Stacker while stacking. Bypass the Feeder/Stacker Interlocks. 2.

Match the sketch and problem descriptions shown in Figure 1 with what best describes the defects that are occurring. The table below will reference the appropriate RAP. Table 1 Problem Description

RAP

1. Sloppy set, side-to-side

Go to the 11-601 RAP

2. Sloppy set, skewed sheets

Go to the 11-602 RAP

3. Sloppy set, front-to-back

Go to the 11-603 RAP

4. Bottom sheet misregistration

Go to the 11-604 RAP

5. Clumped misregistration, top of set

Go to the 11-605 RAP

6. Shingled set/stack

Go to the 11-606 RAP

7. Sloppy set, curled prints

Go to the 11-607 RAP

8. Random misregistration

Go to the 11-608 RAP

9. Rolled or folded prints 8.5X11 or A4

Go to the 11-609 RAP

10. Rolled or folded prints 11X17 or A3

Go to the 11-610 RAP

11. Sloppy Set, all sides. Elevator too low Sloppy Offset Stacking (7 X 11 Paper) 3. 4.

5.

Go to the 11-611 RAP Go to the 11-612 RAP

To set the Printer to use 7 X 10 paper, enter dc105. Under the Features icon, select 7x10 F2. When using 7 X 10 paper, the stacking quality may be poor when: a.

Printing short report/jobs which require short offsetting time between jobs.

b.

Light weight paper is usedd, less than 20 lb. (75 g/m).

•

If stacking quality is poor, continue with Step 5.

The DP180LPS IOT software is enabled with a feature that allows the Stacker to “Skip” a pitch (Skip Pitch Mode) before the Stacker offsets to the next stack. This allows for the last sheet to settle on the stack before the next offset occurs.

Section Name

11-600

0/0/00 ?-1004

Preliminary Working Document No Product Name Assigned

Figure 1 11-600 Stacking Quality Diagram

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1005

Section Name

11-600

11-601 Sloppy Set, Side-To-Side RAP

11-602 Sloppy Set, Skewed Sheets RAP

Initial Actions

Procedure

Perform the following:

Check the following:

•

•

Preregistration baffle is closed.

Procedure

Check the quality of the paper supply.

•

Right Guide is square to the stack. Perform the Right Guide Adjustment (ADJ 11-28).

Check the following:

•

The scatter guards are positioned properly and that they are not binding.

•

The pallet is level front to back. Check the Pallet Lift Frame Parallelism Adjustment (ADJ 11-31).

•

Stack Height Adjustment, (ADJ 11-27).

•

Excessive paper curl of the prints entering the stacker. Refer to the Physical Checks, Print Paper Diagnostics (Service Call Procedures).

•

The Front and Back Tampers are positioned properly and are not damaged.

•

The Right Guide Tamper Motor is working. Use dC203 to check for proper operation. (The Right Guide Tamper Motor is energized with the Front Tamper Motor).

•

Right Guide Adjustment, (ADJ 11-28).

•

The Stack Height Sensor toggles in dC330.

•

Stack Height Adjustment, (ADJ 11-27).

Section Name

11-601, 11-602

0/0/00 ?-1006

Preliminary Working Document No Product Name Assigned

11-603 Sloppy Set, Front-To-BacK RAP

11-604 Bottom Sheet Misregistration RAP

Initial Actions

Procedure

Perform the following:

Check the following:

•

•

Possible high static condition on the pallet. Clean the Pallet.

•

Check the static eliminators in the paper path. Go to the (TBD) Procedure.

Check the quality of the paper supply.

Procedure Check the following: •

Excessive paper curl. Refer to the Physical Checks, Print Paper Diagnostics (Service Call Procedures).

•

Perform the Back Guide Adjustment (ADJ 11-29).

•

The Front and Back Tampers are working properly in dC203.

•

The scatter guards are positioned properly and not binding.

•

The prints are being registered against the registration edge on the Preregistration Transport. Check the Corrugator Rolls for wear or contamination. Check the Corrugator Rolls Adjustment, (ADJ 11-6)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1007

Section Name

11-603, 11-604

11-605 Clumped Registration, Top Of Set RAP

11-606 Shingled Set/Stack RAP

Procedure

Initial Actions

Ensure that the Edges Guides are not too tight. Check the following:

Perform the following:

•

Back Guide Adjustment (ADJ 11-29).

•

•

Right Guide Adjustment (ADJ 11-28).

Procedure

•

Tamper Finger Short Shaft is in proper position. Ensure that it has not come out of its mounting tabs.

Check the following: •

Section Name

11-605, 11-606

Ensure that the pallet is positioned properly.

Right Guide Adjustment (ADJ 11-28).

•

Back Guide Adjustment (ADJ 11-29)

•

Feeder/Stacker Leveling Adjustment (ADJ 11-27).

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Preliminary Working Document No Product Name Assigned

11-607 Sloppy Set, Curled Prints RAP

11-608 Random Misregistration RAP

Procedure

Initial Actions

Check the following:

Perform the following:

•

•

Refer to the Physical Checks, Print Paper Diagnostics (Service Call Procedures).

Check the quality of the paper supply.

Procedure NOTE: The Stacker offsets one sheet after every jam. Do not confuse this with random misregistration. Check the following:

Preliminary Working Document No Product Name Assigned

•

Back Guide Adjustment (ADJ 11-29).

•

Right Guide Adjustment (ADJ 11-28).

•

Stack Height Adjustment (ADJ 11-27).

•

Excessive curl. Go to the Physical Checks, Print Paper Diagnostics (Service Call Procedures)

0/0/00 ?-1009

Section Name

11-607, 11-608

11-609 Rolled Or Folded Prints RAP 8.5X11 OR A4

11-610 Rolled Or Folded Prints RAP 11X17 OR A3

Initial Actions

Initial Actions

Perform the following:

Perform the following:

•

•

Ensure that there are no obstruction in the paper path.

Ensure that there are no obstructions in the paper path.

Procedure

Procedure

Check the following:

Check the following:

•

Bypass Transport Gate for proper operation. Ensure that it is not binding.

•

•

Disk Gate for proper operation. Ensure that the Cam Follower is working properly.

Trail Edge Assist assembly for proper operation. Ensure that the belts are tracking properly and are not slipping. NOTE: The smooth side of the belts should ride on the drive rollers.

Section Name

11-609, 11-610

•

Bypass Transport Gate and Disk Gate for proper operation. Ensure that they are not binding.

•

Perform the Stack Height Sensor Adjustment (ADJ 11-27).

0/0/00 ?-1010

Preliminary Working Document No Product Name Assigned

11-611 Sloppy Set, Elevator Too Low RAP

11-612 Poor Stacking Quality (7X10 Paper) RAP

Procedure

The purpose of the 11-612 RAP is to improve on what the customer views as poor Offset Quality when 7 X 10 paper stock is used.

Enter dC330, [11X2]. Block the Stack Height Sensor. The Stack Height Sensor display changes from L to H. Y N Go to the 11-222. Go to Flag 5 on the Circuit Diagram and check the circuit of the Stack Height Sensor. Check the following: • Excessive Curl or bent corners. Go to the Physical Checks, Print Paper Diagnostics (Service Call Procedures). •

Image build-up. If one area of the prints has most of the image, in a large stack this area will protrude upward and possibly cause the Stack Height Sensor to overcompensate.

•

Stack Height Adjustment (ADJ 11-27).

If the problem continues only when the stack is near maximum capacity, the stack height can be limited to avoid poor stacking. See the Operators Manual for the procedure.

Initial Actions Check the following: •

Quality of the paper supply. Ensure that the paper falls within the capabilities of the Printer. Refer to the System Specifications.

•

Printer to IF/S Alignment.

•

Ensure that the Right Guide Tamper Motor is working. Use dC330, [Tamper Front]. If not OK, go to the 11-704.

•

Lift Frame for damage. Ensure that it is not broken or bent and that it is keeping the pallet level.

•

Main Pallet or Container Pallet is seated properly. Ensure that the locating studs on the lift frame line up properly with the locating holes.

•

Go to (ADJ 11-31) and perform the Pallet Lift Frame Parallelism adjustment.

Procedure NOTE: It may be beneficial to remove the Stacker Front Cover and view the Stacker while stacking. Bypass the Feeder/Stacker Interlocks. 1.

Stacking quality may be poor and especially noticeable using 7 X 10 paper when: a.

Printing short report/jobs which require short offsetting time between jobs.

b.

Light weight paper is used, less than 20 lb. (75 g/m).

2.

The DP180LPS IOT software is enabled with a feature that allows the Stackers to “Skip” a pitch (Skip Pitch Mode) before the Stacker offsets to the next stack. This allows time for the last sheet to settle on the stack before the next offset occurs.

3.

Before initiating the Skip Pitch Mode, ensure that the steps in the Initial Actions have been completed to eliminate causes for poor stacking quality. CAUTION

If the Customer is sensitive to the offset stacking quality, perform the following step. Advise the customer that performance degradation may be experienced (jobs will run and stack slower) with the Skip Pitch Mode enabled. 4.

Preliminary Working Document No Product Name Assigned

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To enable the Skip Pitch Mode, enter dC131 [EDN]. Change EDN location 494 from default 000 to 001, (7 X 10, 8Pitch Enablement).

Section Name

11-611, 11-612

11-700 Disk Motor, MOT1103 RAP

Y

The purpose of the Disk Motor RAP is to aid in the troubleshooting of Disk Motor and related control circuitry. This RAP is designed to be used for the Disk Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators order to properly diagnose the fault.

Initial Actions Check the following: •

Disk Motor for physical damage.

•

Defective bearing causing the motor shaft to sound rough or to be bound when rotated by hand.

•

Disk mechanism rotates smoothly and there are no obstructions that interfere with the rotation of the disk Module.

•

Motor to disk drive coupling hardware is OK.

(Stacker A) Go to the Wirenets (Wiring Data). Check the wire #64H for an open circuit. (Stacker B, C, D) Go to the Wirenets (Wiring Data). Check the wire #88A for an open circuit. Go to Flag 2 and Flag 3. Check the wires for a short circuit. If a short circuit is found, repair the wires and then replace the FSN Stepper PWB (PL 1.17). If no short circuit is found in the wires, replace the Disk Motor, MOT1103 (PL 11.29) and the FSN Stepper PWB (PL 1.17).

Procedure Visually inspect the component marked U13 on the FSN Stepper PWB. (It is one of the three devices mounted to a heat sink). Look for the following: • A bubble and/or cracks in the component. •

Burn marks and/or discoloration on the component legs.

The U13 component is OK. Y N There is a short circuit in the output of the FSN Stepper PWB. Do not replace the FSN Stepper PWB until the following checks are made and the short circuit is located. Enter the [Power Interrupt] mode. Disconnect P497 from J1 at the Disk Motor, MOT1103. Measure the resistance between the following points: • J1-6 and J1-5 •

J1-2 and J1-1

Enter the Power Interrupt mode. Disconnect P4073 from J2 on the FSN Stepper PWB. Measure the resistance between the following points: • P4073-1 and P4073-2 •

•

Section Name

11-700

J1-5 and J1-6

The resistance of both measurements is between 80 and 127 ohms. Y N Replace the Disk Motor, MOT1103 (PL 11.29), and if the resistance was less than 80 ohms, also replace the FSN Stepper PWB (PL 1.17).

Go to Flag 2 and Flag 3. Locate and repair the short circuit, then replace the FSN Stepper PWB (PL 1.17).

Reconnect P497 to the Disk Motor. +24 VDC is measured between TS24 (+) and TS9 on the FSN Stepper PWB (#1 or #2).

P4073-5 and P4073-6

The resistance of both measurements is between 80 and 127 ohms. Y N Reconnect P4073 to the FSN Stepper PWB. Disconnect P497 from the Disk Motor. Measure the resistance between the following points: • J1-1 and J1-2

The resistance of the above checks is between 80 and 200 ohms. Y N Replace the Disk Motor, MOT1103 (PL 11.29) and the FSN Stepper PWB (PL 1.17).

Press Stop. Enter dC330, [11X1]. Disconnect P497 from the Disk Motor, MOT1103. Rotate the Disk shaft so that the encoder disk is positioned to interrupt the Disk Home Sensor, Q1121. The Disk Home Sensor display toggles when the sensor is interrupted. Y N Go to Flag 1. Check the circuit of the Disk Home Sensor, Q1121, (GP 6-2, General Procedures) (PL 11.29).

N Switch off the Printer Power. Disconnect wire # 64H from P444-8 at the FSN Stepper PWB. Switch on the Printer power. Wait for printer to complete initialization. +24 VDC is measured between wire #64H (+) (Stacker A) or wire #88A (+) (Stacker B,C,D) and TS9 (-) on the FSN Stepper PWB. Y N (Stacker A) +24 VDC is measured between TH11 (+) and TH14 (-) on the LVPS. (Stacker B,C,D) +24 VDC is measured between J136-23 (+) and J136-5 (-). Y N (Stacker A) Go to the 1-717, +24, -34, +34VDC RAP. (Stacker B,C,D) Go to the 1-719, Feeder/Stacker #2 +24 VDC RAP.

Go to Flag 2 and Flag 3. Check the wires for an open or short circuit. If a short circuit is found, replace the FSN Stepper PWB (PL 1.17). Reconnect P4073 to the FSN Stepper PWB. Exit the Power Interrupt mode. Enter dC203, [Stepper Motor], [Stacker X], [Stacking Disk]. Press Continue. Measure the voltage between the following test stakes on the FSN Stepper PWB: • TS27 (+) and TS9 (-) •

TS26 (+) and TS9 (-)

•

TS23 (+) and TS9 (-)

•

TS22 (+) and TS9 (-)

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Preliminary Working Document No Product Name Assigned

NOTE: Voltage will be applied to the motor windings sequentially for a period of 2 seconds. Leave the meter probes on the test points for at least 10 seconds to ensure enough time for the routine to energize all windings. +24 VDC is measured between all four pairs of test stakes. Y N Press Stop. Replace the FSN Stepper PWB (PL 1.17). Press Stop. Check the following: • Binding bearings (PL 11.29). •

Wires and connectors for intermittent connections.

•

Ensure that the Encoder flag is secure and has two lobes (PL 11.29).

•

Ensure that the Disk Home Sensor is secure (PL 11.29).

•

Disk Motor mounting hardware (PL 11.29).

•

Disk Drive coupling hardware (PL 11.29).

•

Disk shaft bearing failure (PL 11.29).

•

Mechanical Interference.

If no problems can be found, replace the Disk Motor, MOT1103 (PL 11.29).

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Section Name

11-700

Figure 1 11-700 Circuit Diagram (8133)

Section Name

11-700

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Preliminary Working Document No Product Name Assigned

A

11-701 Back Guide Motor, MOT1104 RAP The purpose of the Back Guide Motor RAP is to aid in the troubleshooting of the Back Guide Motor and related circuitry. This RAP is designed to be used for the Back Guide Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators order to properly diagnose the fault.

Switch off the Printer power. Disconnect P4073 from J2 on the FSN Stepper PWB. Measure the resistance between the following points: • P4073-13 and P4073-14

•

Back Guide Motor for physical damage.

•

Loose pulley on the motor.

•

Defective bearing causing the motor shaft to sound rough or to be bound when rotated by hand.

•

Ensure that the Offset mechanism moves freely.

•

Lead screw bearing failure causing the motor to bind due to fatigue or contamination.

Procedure Visually inspect the component marked U12 on the FSN Stepper PWB. (It is one of the three devices mounted to a heat sink). Look for the following: • A bubble and/or cracks in the component. •

Burn marks and/or discoloration on the component legs.

The U12 component is OK. Y N There is a short circuit in the output of the FSN Stepper PWB. Do not replace the FSN Stepper PWB until the following checks are made and the short circuit is located. Enter the [Power Interrupt] mode. Disconnect P499 from J1 at the Back Guide Motor, MOT1104. Measure the resistance between the following points: • J1-6 and J1-5 •

Go to Flag 2 and Flag 3. Locate and repair the short circuit, then replace the FSN Stepper PWB (PL 1.16). +24 VDC is measured between TS30 (+) and TS9 on the FSN Stepper PWB (#1 or #2). Y N Switch off the Printer Power. Disconnect wire # 64K (Stacker A) or wire #90A (Stacker B,C,D) from P444-10 at the FSN Stepper PWB. Switch on the Printer power. +24 VDC is measured between wire #64H (or 90A) (+) and TS9 (-) on the FSN Stepper PWB. Y N (Stacker A) +24 VDC is measured between TH11 (+) and TH14 (-) on the LVPS. (Stacker B,C,D) +24 VDC is measured between J136-23 (+) and J136-5 (-). Y N (Stacker A) Go to the 1-717, +24, -34, +34VDC RAP. (Stacker B, C, D) Go to the 1-719, Feeder/Stacker #2 +24 VDC RAP. B

•

P4073-17 and P4073-18

The resistance of both measurements is between 50 and 100 ohms. Y N Reconnect P4073 to the FSN Stepper PWB. Go to Flag 2 and Flag 3. Check the wires for an open or short circuit. If a short circuit is found, replace the FSN Stepper PWB (PL 1.16). If the wires are OK, replace the Back Guide Motor, MOT1104 (PL 11.6), and if the resistance was less than 50 ohms, also replace the FSN Stepper PWB (PL 1.16). Reconnect P4073 to the FSN Stepper PWB. Switch on the Printer power. Enter dC203, [Stepper Test], [Back Guide], [Stacker X]. Press Continue. Measure the voltage between the following test stakes on the FSN Stepper PWB: • TS32 (+) and TS9 (-) •

TS31 (+) and TS9 (-)

•

TS29 (+) and TS9 (-)

•

TS28 (+) and TS9 (-) NOTE: Voltage will be applied to the motor windings sequentially for a period of 2 seconds. Leave the meter probes on the test points for at least 10 seconds to ensure enough time for the routine to energize all windings.

J1-2 and J1-1

The resistance of the above checks is between 80 and 200 ohms. Y N Replace the Back Guide Motor, MOT1104 (PL 11.6) and the FSN Stepper PWB (PL 1.16).

A

C (Stacker A) Go to the Wirenets (Wiring Data). Check the wire #64J for an open circuit. (Stacker B, C, D) Go to the Wirenets (Wiring Data). Check the wire #90A for an open circuit.

Go to Flag 2 and Flag 3. Check the wires for a short circuit. If a short circuit is found, repair the wires and then replace the FSN Stepper PWB (PL 1.16). If no short circuit is found in the wires, replace the Back Guide Motor, MOT1104 (PL 11.6) and the FSN Stepper PWB (PL 1.16).

Initial Actions Check the following:

B

+24 VDC is measured between all four pairs of test stakes. Y N Press Stop. Replace the FSN Stepper PWB (PL 1.16). Press Stop. Check the following: • Binding lead screws, bearings, and linkage mechanisms (PL 11.6). •

Check the wires for intermittent connections.

If no problems can be found, replace the Back Guide Motor, MOT1104 (PL 11.6).

C

Preliminary Working Document No Product Name Assigned

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Section Name

11-701

Figure 1 11-701 Circuit Diagram (8134)

Section Name

11-701

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Preliminary Working Document No Product Name Assigned

A

11-702 Right Guide Motor, MOT1105 RAP The purpose of the Right Guide Motor RAP is to aid in the troubleshooting of the Right Guide Motor and related circuitry. This RAP is designed to be used for the Right Guide Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators order to properly diagnose the fault.

Switch off the Printer power. Disconnect P4053 from J2 on the FSN Stepper PWB. Measure the resistance between the following points: • P4053-7 and P4053-8

•

Right Guide Motor for physical damage.

•

Loose pulley on the motor.

•

Defective bearing causing the motor shaft to sound rough or to be bound when rotated by hand.

•

Ensure that the Right Guide moves freely.

•

Lead screw bearing failure causing the motor to bind due to fatigue or contamination.

Procedure Visually inspect the component marked U10 on the FSN Stepper PWB. (It is one of the three devices mounted to a heat sink). Look for the following: • A bubble and/or cracks in the component. •

Burn marks and/or discoloration on the component legs.

The U10 component is OK. Y N There is a short circuit in the output of the FSN Stepper PWB. Do not replace the FSN Stepper PWB until the following checks are made and the short circuit is located. Enter the [Power Interrupt] mode. Disconnect P498 from J1 at the Right Guide Motor, MOT1105. Measure the resistance between the following points: • J1-6 and J1-5 •

Go to Flag 2 and Flag 3. Locate and repair the short circuit, then replace the FSN Stepper PWB (PL 1.16). +24 VDC is measured between TS18 (+) and TS9 on the FSN Stepper PWB. Y N Switch off the Printer Power. Disconnect wire # 64J (Stacker A) or wire #89A (Stacker B,C,D) from P444-8 at the FSN Stepper PWB. Switch on the Printer power. +24 VDC is measured between wire #64H (or 89A) (+) and TS9 (-) on the FSN Stepper PWB. Y N (Stacker A) +24 VDC is measured between TH11 (+) and TH14 (-) on the LVPS. (Stacker B, C, D) +24 VDC is measured between J136-22 (+) and J136-5 (-). Y N (Stacker A) Go to the 1-717, +24, -34, +34VDC RAP. (Stacker B,C,D) Go to the 1-719, Feeder/Stacker #2 +24 VDC RAP. B

•

P4053-11 and P4053-12

The resistance of both measurements is between 50 and 100 ohms. Y N Reconnect P4053 to the FSN Stepper PWB. Go to Flag 2 and Flag 3. Check the wires for an open or short circuit. If a short circuit is found, replace the FSN Stepper PWB (PL 1.16). If the wires are OK, replace the Right Guide Motor, MOT1105, (PL 11.9), and if the resistance was less than 50 ohms, also replace the FSN Stepper PWB (PL 1.16). Reconnect P4053 to the FSN Stepper PWB. Switch on the Printer power. Enter dC203, [Stepper Test], [Right Guide], [Stacker X]. Press Continue. Measure the voltage between the following test stakes on the FSN Stepper PWB: • TS25 (+) and TS9 (-) •

TS19 (+) and TS9 (-)

•

TS21 (+) and TS9 (-)

•

TS20 (+) and TS9 (-) NOTE: Voltage will be applied to the motor windings sequentially for a period of 2 seconds. Leave the meter probes on the test points for at least 10 seconds to ensure enough time for the routine to energize all windings.

J1-2 and J1-1

The resistance of the above checks is between 80 and 200 ohms. Y N Replace the Right Guide Motor, MOT1105, (PL 11.9) and the FSN Stepper PWB (PL 1.16).

A

C (Stacker A) Go to the Wirenets (Wiring Data). Check the wire #64J for an open circuit. (Stacker B, C, D) Go to the Wirenets (Wiring Data). Check the wire #89A for an open circuit.

Go to Flag 2 and Flag 3. Check the wires for a short circuit. If a short circuit is found, repair the wires and then replace the FSN Stepper PWB (PL 1.16). If no short circuit is found in the wires, replace the Right Guide Motor, MOT1105, (PL 11.9) and the FSN Stepper PWB (PL 1.16).

Initial Actions Check the following:

B

+24 VDC is measured between all four pairs of test stakes. Y N Press Stop. Replace the FSN Stepper PWB (PL 1.16). Press Stop. Check the following: • Binding lead screws, bearings, and linkage mechanisms, (PL 11.9). •

Check the wires for intermittent connections.

If no problems can be found, replace the Right Guide Motor, MOT1105, (PL 11.9).

C

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Section Name

11-702

Figure 1 11-702 Circuit Diagram (8135)

Section Name

11-702

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Preliminary Working Document No Product Name Assigned

A

B

C

11-703 Stacker Elevator Motor, MOT1106 RAP

Y

The purpose of the Stacker Elevator Motor RAP is to aid in the troubleshooting of the Stacker Elevator Motor and related circuitry. This RAP is designed to be used for the Stacker Elevator Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators order to properly diagnose the fault.

Go to Flag 1 and Flag 2. Check the wires and the switches for an open circuit.

N Go to the Wirenets (Wiring Data) and check the wire #63A (Stacker A) and wire #78A (Stacker B) for an open circuit.

Go to Flag 3. Check the wires for an open circuit. If OK, replace the Stacker Elevator Relay, K1109 (PL 1.16).

Initial Actions 115 VAC is measured between J1-3 and J1-11. Y N Go to Flag 9. Check the wires for an open circuit.

WARNING Use caution when working near the motor. The Stacker Elevator Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. The Stacker Elevator Lift Frame is not grounded. Whenever working in the vicinity of the elevator lift frame, be sure to maintain proper positioning of all AC wiring and avoid contact to the lift frame. Keep fingers/hands away from moving elevator parts.

Replace the FSN AC Remote PWB #1 (PL 1.16). Connect the meter leads to TS35 (+) and TS37 (-) on the FSN DIO PWB #1. Press and hold the Bin Unload button on the Stacker Control Panel. NOTE: Actuation of the Bin Unload button is necessary to prevent erroneous readings due to a feedback path through the Stacker Control Panel.

Perform the following: •

Ensure that the Stacker Left Door and Right Door are closed.

•

Stacker Tray is level. Check the Pallet Lift Frame Parallelism Adjustment, (ADJ 11-31)

•

Stacker Elevator moves freely.

+5 VDC is measured between TS35 (+) and TS37 (-) on the FSN DIO PWB #1. Y N +5 VDC is measured between PS2P2 (+) and PS2P1 (-) of the IFS LVPS. Y N Line to Neutral (60 Hz), Phase to Neutral (50 Hz) is measured between terminal L (+) and terminal N of the IFS LVPS. Y N Replace the IFS LVPS Relay (PL 1.15).

Procedure 115 VAC is measured between J1-12 and J1-3 on the FSN AC Remote PWB #1. Y N 115 VAC is measured between TB5-9 and TB4-6. Y N (60Hz-Stacker A) Go to the 1-704-1, Inverter/Stacker Standby AC Power RAP. (60Hz-Stacker B) Go to the 1-704-2, Stacker Standby AC Power RAP. (50Hz-Stacker A) Go to the 1-711-1, Inverter/Stacker Standby AC Power RAP. (50Hz-Stacker B) Go to the 1-711-2, Stacker Standby AC Power RAP.

Replace the IFS LVPS (PL 1.15). Go to the Wirenets (Wiring Data) and check wire # 61M for an open circuit.

(60Hz Printers) - Less than 10 VAC is measured between TB5-9 and Printer frame. (50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check. Enter dC330, [11X1], [Stacker Start/Run]. Press Continue. The voltage remains the same between TB5-9 and TB4-6. Y N (60Hz-Stacker A) Go to the 1-704-1, Inverter/Stacker Standby AC Power RAP. (60Hz-Stacker B) Go to the 1-704-2, Stacker Standby AC Power RAP. (50Hz-Stacker A) Go to the 1-711-1, Inverter/Stacker Standby AC Power RAP. (50Hz-Stacker B) Go to the 1-711-2, Stacker Standby AC Power RAP. 115 VAC is measured between terminal 4 and terminal 6 of the Stacker Elevator Relay, K1109. Y N +24 VDC is measured between terminals A (+) and B (-) of K1109. Y N +24 VDC is measured between TB7-B (+) and TB7-A (-). A

B

C

Preliminary Working Document No Product Name Assigned

+4.1 to 5.3 VDC is measured between TS40 (+) and TS37 (-). Y N Go to Flag 10 and Flag 6. Check the wires for an open circuit. If OK, replace the FSN AC Remote PWB #1 (PL 1.16). +4.1 to 5.3 VDC is measured between TS49 (+) and TS37 (-). Y N Go to Flag 5. Check the wires for an open circuit. If OK, replace the FSN AC Remote PWB #1 (PL 1.16). Enter dC330, [11X2], [Elevator DN]. Press Continue. The message "Output deenergized: Limit encountered" appears on the dC330 screen. Y N NOTE: The component will only stay energized for approximately 20 seconds without elevator movement. If it times out before the measurement is taken, press Continue again. 0.6 VDC (+/- 0.4 VDC) is measured between TS49 (+) and TS37 (-) on the FSN DIO PWB #1. D

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Section Name

11-703

D Y

N Press Stop. Replace the FSN DIO PWB #1 (PL 1.16).

Y

115 VAC is measured between J1-5 and J1-12 on the FSN AC Remote PWB #1. Y N Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16).

N Press Stop. Go to Flag 7. Check the wires and the Stacker Overtravel Up Switch, S1140, for an open circuit (PL 11.18).

Press Stop. Go to Flag 12. Check the wire for an open circuit. If OK, check the following: • Loose Pulley on the Stacker Elevator Drive Motor (PL 11.19)

Press Stop. Enter the Power Interrupt mode. Disconnect P413 from the FSN AC Remote PWB #1. Measure the resistance between P413-5 and P413-12. The resistance is less than 40 ohms. Y N Check for continuity between P413-5 and P424-1 at the Stacker Elevator Motor. Continuity is measured. Y N Go to Flag 8. Check the wires and the Stacker Overtravel Down Switch, S1141, for an open circuit (PL 11.18).

•

Drive belt for damage and that it is under tension

•

Idler Pulley

•

Intermittent binding in the elevator assembly

•

The lead screws are operating freely in their bearings (PL 11.18)

If OK, replace the following one at a time: • Stacker Elevator Capacitor, C1106 (PL 11.18). •

Stacker Elevator Drive Motor, MOT1106 (PL 11.19).

Go to Flag 4 and check the wires for an open circuit. If the wires are OK, the motor may still be in an overheat condition if it still feels warm. Allow the motor to cool and look for mechanical causes for the motor overheat. If the motor is not warm, replace the following components one at a time until the problem is resolved: • Stacker Elevator Run Capacitor C1105 (PL 11.18). •

Stacker Elevator Motor MOT1106 (PL 11.19).

Press Stop. Go to Flag 11. Check the wires for an open circuit. If OK, check the following: • Loose Pulley on the Stacker Elevator Drive Motor (PL 11.19) •

Drive belt for damage, ensure that it is under tension

•

Idler Pulley

•

Intermittent binding in the elevator assembly

•

The lead screws are operating freely in their bearings (PL 11.19)

If OK, replace the following one at a time: • Stacker Elevator Capacitor, C1106 (PL 11.18). •

Stacker Elevator Drive Motor, MOT1106 (PL 11.19).

Select [Elevator UP]. Press Continue. 0.6 VDC (+/- 0.4 VDC) is measured between TS40 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Press Stop. Replace the FSN DIO PWB #1 (PL 1.16). 115 VAC is measured between J1-1 and J1-12 on the FSN AC Remote PWB #1. Y N Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16). Press Stop. Enter the Power Interrupt mode. Disconnect P413 from the FSN AC Remote PWB #1. Measure the resistance between P413-1 and P413-12. The resistance is less than 40 ohms.

Section Name

11-703

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Figure 1 11-703 Circuit Diagram (8152) Continued on the next page...

Preliminary Working Document No Product Name Assigned

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Section Name

11-703

Figure 2 11-703 Circuit Diagram (8136)

Section Name

11-703

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Preliminary Working Document No Product Name Assigned

A

11-704 Front Tamper Motor, MOT1107, And Right Guide Tamper Motor, MOT1113 RAP The purpose of the Front Tamper Motor and Right Guide Tamper Motor RAP is to aid in the troubleshooting of the Front Tamper Motor, Right Guide Tamper Motor and related circuitry. This RAP is designed to be used for the Front Tamper Motor and Right Guide Tamper Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators order to properly diagnose the fault.

B The Front Tamper Motor does not comes on. Press Stop. Enter the Power Interrupt mode, disconnect P418 from the Front Tamper Motor, MOT1107. Measure the resistance between J1-1 and J1-3. The resistance is less than 200 Ohms. Y N The motor is in an overheat condition. Check the Tamper Drives for binding. The motor must cool for the thermal sensor to reset. If it does not reset after allowing the motor to cool, replace the Front Tamper Motor, MOT1107 (PL 11.5).

WARNING

Enter dC330, [11X2], [Tamper Front]. Press Start. 115 VAC is measured between P418-1 and P418-3. Y N Press Stop. Go to Flag 3 and Flag 4. Check the wires and connections for an open circuit.

Use caution when working near the motor. The Front Tamper Motor and Right Guide Tamper Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

Press Stop. Go to Flag 5. Check the wires for an open circuit. If OK, replace the following components one at a time, until the problem is resolved: • Capacitor C1106 (PL 11.5)

Perform the following:

•

Initial Actions

•

Ensure that the Stacker Doors are closed or that the Interlocks are bypassed.

•

Ensure that the Tamper Drive system moves freely. A motor bearing failure will cause the motor shaft to sound rough or be bound when rotated by hand.

•

Ensure that the coupling hardware is tight.

Procedure Enter dC330, [11X2], [Tamper Front]. Press Continue. Both the Front Tamper Motor and the Right Guide Tamper Motor DO NOT come on. Y N The Right Guide Tamper Motor comes on. Y N NOTE: It may be necessary to extend the Right Guide out using dC203 to access the connector. 115 VAC is measured between P1-1 and P1-2. Y N Press Stop. Go to Flag 7. Check the wires for an open circuit. Press Stop. With the Printer power switched off, or in the Power Interrupt mode, disconnect P1 from the Right Guide Tamper Motor, MOT1113. Measure the resistance between J1-1 and J1-2. The resistance is less than 300 Ohms. Y N The motor is in an overheat condition. Check the Tamper Drives for binding. The motor must cool for the thermal sensor to reset. If it does not reset after allowing the motor to cool, replace the Right Guide Tamper Motor, MOT1113, (PL 11.9). Go to Flag 7. Check the wires for an open circuit. If OK, replace the Right Guide Tamper Motor, MOT1113, (PL 11.9).

Front Tamper Motor MOT1107 (PL 11.5)

Press Stop. 115 VAC is measured between TB4-9 and TB5-10. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP for Stacker B. (60Hz Printers) - Less than 10 VAC is measured between TB5-10 and Printer frame. (50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check. Enter dC330, [11X2], [Tamper Front]. Press Continue. The voltage remains the same between TB4-9 and TB5-10. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP for Stacker B. 115 VAC is measured between J1-8 and J1-17 on the FSN AC Remote PWB #1 Y N Go to Flag 1. Check the wires for an open circuit. Press Continue. 115 VAC is measured between J1-10 and J1-19 on the FSN AC Remote PWB #1 Y N Press Stop. +5 VDC is measured between TS41 (+) and TS37 (-) on the FSN DIO PWB #1. Y N +5 VDC is measured between TS35 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to the Wirenets (Wiring Data) and check the wire #61M for an open circuit. Go to Flag 2. Check the wires for an open circuit.

A

B

Preliminary Working Document No Product Name Assigned

C 0/0/00 ?-1023

D Section Name

11-704

C

C

D Press Continue. Less than 1 VDC is measured between TS35 (+) and TS41 (-). Y N Press Stop. Replace the FSN DIO PWB #1 (PL 1.16). E

C

E Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16).

Press Stop. Go to Flag 6. Check the wires for an open circuit.

Figure 1 11-704 Circuit Diagram (8137) Section Name

11-704

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Preliminary Working Document No Product Name Assigned

11-705 Back Tamper Motor, MOT1108 RAP The purpose of the Back Tamper Motor RAP is to aid in the troubleshooting of the Back Tamper Motor and related circuitry. This RAP is designed to be used for the Back Tamper Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators order to properly diagnose the fault.

Initial Actions WARNING Use caution when working near the motor. The Back Tamper Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Perform the following: •

Ensure that the Stacker Doors are closed or that the Interlocks are bypassed.

•

Ensure that the Tamper Drive system moves freely. A motor bearing failure will cause the motor shaft to sound rough or be bound when rotated by hand.

•

Check for a loose pulley on the motor.

Procedure 103 to 127 VAC is measured between TB4-9 and TB5-10. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP for Stacker B.

A Deactuate the Bin Unload button. +5 VDC is measured between TS51 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to Flag 2. Check the wires for an open circuit. Enter dC330, [11X2], [Tamper Back]. Press Continue. .2 to 1 VDC is measured between TS51 (+) and TS37 (-). Y N Press Stop. Replace the FSN DIO PWB #1 (PL 1.16). Press Stop. 115 VAC is measured between TB5-10 and P413-6. Y N Go to Flag 3, Flag 4, and Flag 5, and check the wires and connections for an open circuit. Press Continue. The voltage goes LOW. Y N Press Stop. Replace the FSN AC Remote PWB #1 (PL 1.16). Press Stop. If the wires are OK, the motor may be in an overheat condition. If the motor feels warm, check the Tamper Drives for binding. The motor must cool for the thermal sensor to reset. If it does not reset after allowing the motor to cool, replace the Back Tamper Motor, MOT1108 (PL 11.6). If the motor was not still warm, replace the following components one at a time, until the problem is resolved: • Capacitor C1107 (PL 11.6) •

Back Tamper Motor MOT1108 (PL 11.6)

(60Hz Printers) - Less than 10 VAC is measured from TB5-10 to Printer frame. (50Hz Printers) - Enter dC330, [11X1], [Stacker Main Drive Start/Run]. Press Continue. The voltage between TB4-9 and TB5-10 remains between 103 to 127 VAC. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP for Stacker B. 115 VAC is measured between J1-8 and J1-17 on the FSN AC Remote PWB #1 Y N Go to Flag 1. Check the wires for an open circuit. Press Stop. Connect the meter leads to TS35 (+) and TS37 (-) on the FSN DIO PWB #1. Press and hold the Bin Unload button on the Stacker Control Panel. NOTE: Actuation of the Bin Unload button is necessary to prevent erroneous readings due to a feedback path through the Stacker Control Panel. +5 VDC is measured between TS35 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to the Wirenets (Wiring Data) and check the wire #61M for an open circuit. A Preliminary Working Document No Product Name Assigned

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Section Name

11-705

Figure 1 11-705 Circuit Diagram (8138)

Section Name

11-705

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Preliminary Working Document No Product Name Assigned

A

11-706 Stacker Main Drive Motor, MOT1110 RAP The purpose of the Stacker Main Drive Motor RAP is to aid in the troubleshooting of the Stacker Main Drive Motor and related circuitry. This RAP is designed to be used for the Stacker Main Drive Motor of any Stacker module. The correct module letter (A/B) must be inserted into the procedure instructions (in place of X) and circuit diagram component designators to properly diagnose the fault.

Initial Actions WARNING Use caution when working near the motor. The Stacker Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Perform the following: •

Ensure that the Stacker Doors are closed or that the Interlocks are bypassed.

•

Ensure that the Stacker Main Drives rotate freely.

•

Check for a loose pulley on the motor.

Procedure With the Printer power switched off, or in the Power Interrupt mode, disconnect P421 from the Stacker Main Drive Motor, MOT1110. Measure the resistance between J1-1 and J1-3. The resistance is less than 300 Ohms. Y N The motor is in an overheat condition. The motor must cool for the thermal sensor to reset. If it does not, replace the Stacker Main Drive Motor, MOT1110 (PL 11.1). When it does reset, measure the voltage between TS44 (-) and TS33 (+) on the FSN DIO PWB #1. +24 VDC is measured. Y N Check for the following causes of overheating: • Stacker Main Drives for binding •

Stacker Main Drive Start Relay, K1106, for shorted contacts (PL 1.17)

•

Flag 2 for a short circuit

Press Stop. Replace the Stacker Main Drive Start Relay, K1106 (PL 1.16). Press Stop. 115 VAC is measured between TB5-8 and TB4-7. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, for Stacker B. (60Hz Printers) - Less than 10 VAC is measured between TB5-8 and Printer frame. (50Hz Printers) - Keep the multimeter leads on the same terminals. Enter dC330, [11X1], [Stacker Start/Run]. Press Continue. The voltage remains the same between TB5-8 and TB4-7. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for Stacker B. Press Stop. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1711-2, for Stacker B. Press Stop. 115 VAC is measured between TB4-7 and terminal 1 of the Stacker Main Drive Run Relay, K1105. Y N Go to Flag 4. Check the wire for an open circuit. 115 VAC is measured between terminal 1 and 2 of K1105. Y N Disconnect P421 from the Stacker Main Drive Motor, MOT1110. 115 VAC is measured between P421-3 and TB5-8. Y N Go to Flag 11. Check the wire for an open circuit. Go to Flag 10. Check the wires for an open circuit. If OK, replace the Stacker Main Drive Motor, MOT1110 (PL 11.1).

Replace the FSN DIO PWB #1 (PL 1.17). Enter dC330, [11X1], [Stacker Start/Run]. Observe the Stacker Main Drive Start Relay, K1106. Press Continue. K1106 momentarily actuates. Y N Press Stop. +24 VDC is measured between TS33 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to the Wirenets (Wiring Data) and check wire #63J (Stacker A) or #78C (Stacker B) for an open circuit.

Press Continue. The voltage goes Low. Y N Press Stop. +5 VDC is measured between TS34 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to the Wirenets (Wiring Data) and check wire #61N for an open circuit. +5 VDC is measured between TS45 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to Flag 3. Check the wires for an open circuit. If OK, replace the Stacker Main Drive Run Relay, K1105 (PL 1.17).

+24 VDC is measured between TS44 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to Flag 1 and Flag 2. Check the wires for an open circuit. If OK, replace the Stacker Main Drive Start Relay, K1106 (PL 1.17). A

B

Preliminary Working Document No Product Name Assigned

B Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC. Y N Press Stop. Replace the FSN DIO PWB #1 (PL 1.16).

Press Continue. 0.2 to 1.0 VDC is measured between TS45 (+) and TS37 (-) on the FSN DIO PWB #1. C

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Section Name

11-706

C Y

N Press Stop. Replace the FSN DIO PWB #1 (PL 1.17).

Press Stop. Replace the Stacker Main Drive Run Relay, K1105 (PL 1.17). Press Stop. 115 VAC is measured between K1105-1 and terminal 9 of the Stacker Main Drive Start Relay, K1106. Y N 115 VAC is measured between K1105-1 and terminal A1 of the Start Capacitor, C1111. Y N Go to Flag 8 and Flag 9. Check the wires for an open circuit. Go to Flag 7. Check the wire and connections for an open circuit. 115 VAC is measured between K1105-1 and K1106-4. Y N Press Stop. Go to Flag 5 and check for an open circuit. Select Peak Hold on the multimeter. Press Continue. Greater than 50 VAC is measured between K1105-1 and K1106-6. Y N Press Stop. Go to Flag 6. Check the wire for an open circuit. If OK, replace the Stacker Main Drive Relay, K1106 (PL 1.16). Press Stop. Replace the following components one at a time until the problem is resolved: • Run Capacitor C1110 (PL 11.22) •

Start Capacitor C1111 (PL 11.22)

•

Stacker Main Drive Motor MOT1110 (PL 11.1)

Section Name

11-706

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Preliminary Working Document No Product Name Assigned

Figure 1 11-706 Circuit Diagram (8139)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1029

Section Name

11-706

11-707 Inverter Drive Motor, MOT1111 RAP The purpose of the Inverter Drive Motor RAP is to aid in the troubleshooting of the Inverter Drive Motor and related circuitry.

A 115 VAC is measured between J1-8 and J1-17 on the FSN AC Remote PWB #2. Y N Go to Flag 1. Check the wires for an open circuit. 115 VAC is measured between P403-3 and A-TB5-5. Y N Go to Flag 4. Check the wire for an open circuit.

Initial Actions WARNING Use caution when working near the motor. The Inverter Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

NOTE: Ensure that the RHHD is disconnected from the F/S when performing this voltage measurement. This is necessary due to a feedback path through the RHHD which will give incorrect readings.

Perform the following:

+5 VDC is measured between TS33 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to the Wirenets (Wiring Data) and check the wire #61D for an open circuit.

•

Check the Inverter Motor for signs of physical damage.

•

Ensure that the Stacker Doors are closed or that the Interlocks are bypassed.

•

Ensure that the Inverter Drive system moves freely. A motor bearing failure will cause the motor shaft to sound rough or be bound when rotated by hand.

•

Check for a loose pulley on the motor.

Procedure With the Printer power switched off, or in the Power Interrupt mode, disconnect P403 from the Inverter Motor, MOT1111. Measure the resistance between J1-1 and J1-3. The resistance is less than 300 Ohms. Y N The motor is in an overheat condition. Check the Inverter Drives for binding. The motor must cool for the thermal sensor to reset. If it does not reset after allowing the motor to cool, replace the Inverter Motor, MOT1111 (PL 11.24). Perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14). NOTE: The Remote Hand Held Device (RHHD) may be used to remotely operate the Printer components when taking measurements or observing component operation. For detailed Operating Instructions of the RHHD, go to (GP 1) Remote Hand Held Device (RHHD). Reconnect P403 to the Inverter Drive Motor. Switch on the Printer power. Allow time for System Download to be completed. 115 VAC is measured between A-TB4-4 and A-TB5-5. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP for Stacker B.

+4.2 to 5.2 VDC is measured between TS43 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to Flag 2. Check the wires for an open circuit. Enter dC330, [10], [Inverter FWD]. Press Continue. 0.2 to 1.0 VDC is measured between TS43 (+) and TS37 (-). Y N Press Stop. Replace the PHN DIO PWB #5 (PL 1.16). Press Stop. +4.2 to 5.2 VDC is measured between TS52 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to Flag 3. Check the wire for an open circuit. Select [Inverter REV]. Press Continue. 0.2 to 1.0 VDC is measured between TS52 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Press Stop. Replace the PHN DIO PWB #5 (PL 1.16). Press Stop. 115 VAC is measured between P402-6 and A-TB5-5. Y N Go to Flag 7. Check the wires and connections for an open circuit. Keep the meter leads on the same terminals. Press Continue. The voltage goes LOW. Y N Press Stop. Replace the FSN AC Remote PWB #2 (PL 1.16).

(60Hz Printers) - Less than 10 VAC is measured from A-TB5-5 and Printer frame. (50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check. Enter dC330, [10], [Inverter FWD]. Press Continue. The voltage remains the same between A-TB4-4 and A-TB5-5. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, RAP for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, RAP for Stacker B.

Select [Inverter FWD]. Keep the meter leads on the same terminals. Press Continue. The voltage goes LOW. Y N Press Stop. Replace the FSN AC Remote PWB #2 (PL 1.16).

A

B

Section Name

11-707

Press Stop. 115 VAC is measured between P402-10 and A-TB5-5. Y N Go to Flag 8. Check the wires and connections for an open circuit.

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Preliminary Working Document No Product Name Assigned

B Press Stop. Go to Flag 5 and Flag 6. Check the wires and connections for an open circuit. If OK, replace the following components one at a time until the problem is resolved: • Capacitor C1101 (PL 11.22).

•

Inverter Motor MOT1111 (PL 11.24). After replacing, perform the Inverter Transport Motor Belt Tension adjustment (ADJ 11-14).

Figure 1 11-707 Circuit Diagram (8140) Preliminary Working Document No Product Name Assigned

0/0/00 ?-1031

Section Name

11-707

A

11-708 Inverter Main Drive Motor, MOT1112 RAP The purpose of the Inverter Main Drive Motor RAP is to aid in the troubleshooting of the Inverter Main Drive Motor and related circuitry.

Initial Actions WARNING Use caution when working near the motor. The Inverter Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot. Perform the following: •

Ensure that the Inverter Front Door is closed or that the Interlocks are bypassed.

•

Ensure that the Inverter Main Drives rotate freely.

•

Check for a loose pulley on the motor.

Procedure With the Printer power switched off, or in the Power Interrupt mode, disconnect P404 from the Inverter Main Drive Motor, MOT1112. Measure the resistance between J1-1 and J1-3. The resistance is less than 300 Ohms. Y N The motor is in an overheat condition. The motor must cool for the thermal sensor to reset. If it does not, replace the Inverter Main Drive Motor, MOT1112 (PL 11.22). When it does reset, measure the voltage between TS40 (-) and TS35 (+) on the PHN DIO PWB #5. +24 VDC is measured. Y N Check for the following causes of overheating: • Inverter Main Drives for binding •

Inverter Main Drive Start Relay, K1108, for shorted contacts (PL 1.17)

•

Flag 2 for a short circuit

Press Stop. 115 VAC is measured between A-TB5-6 and A-TB4-11. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, for Stacker B. (60Hz Printers) - Less than 10 VAC is measured between A-TB5-6 and Printer frame. (50Hz Printers) - Keep the multimeter leads on the same terminals as the previous check. Enter dC330, [10], [Inverter Start/Run]. Press Continue. The voltage between A-TB5-6 and A-TB4-11 remains the same. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for Stacker B. Press Stop. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or the 1-711-2 for Stacker B. Press Stop. 115 VAC is measured between A-TB4-11 and terminal 1 of the Inverter Main Drive Run Relay, K1107. Y N Go to Flag 4. Check the wire for an open circuit. 115 VAC is measured between terminal 1 and 2 of K1107. Y N Disconnect P404 from the Inverter Main Drive Motor, MOT1112. 115 VAC is measured between P404-3 and A-TB5-6. Y N Go to Flag 11. Check the wire for an open circuit. Go to Flag 10. Check the wires for an open circuit. If OK, replace the Inverter Main Drive Motor, MOT1112 (PL 11.22).

Replace the PHN DIO PWB #5 (PL 1.17). Switch printer power on. Enter dC330, [10], [Inverter Start/Run]. Observe the Inverter Main Drive Start Relay, K1108. Press Continue. K1108 momentarily actuates. Y N Press Stop. +24 VDC is measured between TS35 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to the Wirenets (Wiring Data) and check wire #64D for an open circuit.

Press Continue. The voltage goes Low. Y N Press Stop. +5 VDC is measured between TS33 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to the Wirenets (Wiring Data) and check wire #61D for an open circuit. +5 VDC is measured between TS53 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to Flag 3. Check the wires for an open circuit. If OK, replace the Inverter Main Drive Run Relay, K1107 (PL 1.16).

+24 VDC is measured between TS40 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Go to Flag 1 and Flag 2. Check the wires for an open circuit. If OK, replace the Inverter Main Drive Start Relay, K1108 (PL 1.16).

Press Continue. 0.2 to 1.0 VDC is measured between TS53 (+) and TS37 (-) on the PHN DIO PWB #5. Y N Press Stop. Replace the PHN DIO PWB #5 (PL 1.16).

Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC. Y N Press Stop. Replace the PHN DIO PWB #5 (PL 1.16). A

B

Section Name

11-708

B Press Stop. Replace the Inverter Main Drive Start Relay, K1108 (PL 1.16).

Press Stop. Replace the Inverter Main Drive Run Relay, K1107 (PL 11.22). C 0/0/00 ?-1032

Preliminary Working Document No Product Name Assigned

C Press Stop. 115 VAC is measured between K1107-1 and terminal 7 of the Inverter Main Drive Start Relay, K1108. Y N 115 VAC is measured between K1107-1 and terminal 1 of the Start Capacitor, C1112. Y N Go to Flag 8 and Flag 9. Check the wires for an open circuit. Go to Flag 7. Check the wire and connections for an open circuit. 115 VAC is measured between K1107-1 and K1108-6. Y N Press Stop. Go to Flag 5 and check for an open circuit. Select Peak Hold on the multimeter. Press Continue. Greater than 50 VAC is measured between K1107-1 and K1107-4. Y N Press Stop. Go to Flag 6. Check the wire for an open circuit. If OK, replace the Inverter Main Drive Relay, K1108 (PL 1.16). Press Stop. Replace the following components one at a time until the problem is resolved: • Run Capacitor C1102 (PL 11.22) •

Start Capacitor C1112 (PL 11.22)

•

Inverter Main Drive Motor MOT1112 (PL 11.22)

Preliminary Working Document No Product Name Assigned

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Section Name

11-708

Figure 1 11-708 Circuit Diagram (8141)

Section Name

11-708

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Preliminary Working Document No Product Name Assigned

11-709 Interlock Bypass Switch RAP This RAP is for troubleshooting problems with the logic side of the Interlock Bypass Switch.

Procedure Enter dC330, [11X1]. Actuate the Interlock Bypass Switch. The Interlock Bypass SW display changes from H to L. Y N Go to Flag 1. Check the circuit of the Interlock Bypass Switch, S1152 (Generic Switch General Procedures, GP 6-1). Check the following: • Loose wires or connectors •

Switch for damage

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1035

Section Name

11-709

Figure 1 11-709 Circuit Diagram (8153)

Section Name

11-709

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Preliminary Working Document No Product Name Assigned

11-710 Container Sensing RAP

•

Container magnetic actuators missing, misaligned, or damaged.

•

Container hardware for damage or misadjustment in the area where the magnets are located.

•

Ensure that the positions of the magnets are the same as the locations shown in the chart.

The Container Sensing RAP will aid in troubleshooting problems with the container decoding.

Initial Actions Check the following: •

Paper size matches the container size.

•

Container size on the System Controller Printer Status screen matches the Container that is being used

•

Container is properly seated on the pallet.

•

Stacker Drawer is fully latched

•

Run with the container pallet only or try another container if available (any size).

•

(ADJ 11-31), Pallet Lift Frame Parallelism adjustment.

•

(ADJ 11-32), Container Size Sensor adjustment (Ensure that the top edge of the sensor is flush with the alignment block)

If OK, replace the container (PL 11.17).

Procedure CAUTION The following procedure can be used for fault codes that may appear in any of the Feeder/ Stacker modules. The correct module letter (A/B) must be inserted into the procedure directions (in place of X) and circuit diagrams in order to properly diagnose the fault codes. Enter dC330, [11X1]. Actuate the Container Size A Sensor (use a small magnet, such as the magnetic pick up tool). The location of the A, B, or C sensor is marked on the top surface of the sensor. The display changes from H to L. Y N Go to Flag 1. Check the Container Size A Sensor circuit (GP 6-2, General Procedures) (PL 11.18). Actuate the Container Size B Sensor. The display changes from H to L. Y N Go to Flag 2. Check the Container Size B Sensor circuit (GP 6-2, General Procedures) (PL 11.18). Actuate the Container Size C Sensor. The display changes from H to L. Y N Go to Flag 2. Check the Container Size C Sensor circuit (GP 6-2, General Procedures) (PL 11.18). Ensure that the Main Pallet is in the home (down) position. The Pallet Latch display indicates an L. Y N Ensure that the Pallet Latch Sensor is not blocked. The Pallet Latch should be pivoted so that the flag is not blocking the sensor in the Container mode. If OK, go to Flag 4. Check the circuit of the Pallet Latch Sensor, Q1149 (GP 6-2 Generic Sensor RAP, General Procedures). The Drawer In SW display indicates an L. Y N Go to Flag 5. Check the circuit of the Drawer In Switch (Generic Switch RAP GP 6-1, General Procedures). Check the following:

Preliminary Working Document No Product Name Assigned

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Section Name

11-710

Figure 1 11-710 Circuit Diagram (8154) Continued on the next page

Section Name

11-710

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Preliminary Working Document No Product Name Assigned

Figure 2 11-710 Circuit Diagram (8132)

Preliminary Working Document No Product Name Assigned

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Section Name

11-710

11-711 Stacker Attention Light RAP This RAP is designed to aid in troubleshooting a non-functioning Attention Light.

Procedure Enter dC330, [Attention Light]. Press Continue. The Attention Light comes on. Y N Press Stop. Connect a jumper wire between TS49 and TS37 on the PHN DIO PWB #5. The Attention Light comes on. Y N Remove the jumper wire. +24 VDC is measure at TS35 on the PHN DIO PWB #5. Y N Go to the Wirenets (WIRING DATA) and check wire #64D for an open circuit. Disconnect P4053 from J3 on the PHN DIO PWB #5. Enter dC330, [Attention Light]. Press the Continue button. +24 VDC is measured between TS35 (+) and TS49 (-). Y N Press Stop. Replace the PHN DIO PWB #5 (PL 1.17). Press Stop. Reconnect P4053 to J3. Go to Flag 1 and Flag 2. Check the wires for an open circuit. If OK, replace the Attention Light (PL 4.14). Replace the PHN DIO PWB #5 (PL 1.17). Press Stop. Check the wires and connectors for an intermittent circuit.

Section Name

11-711

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Preliminary Working Document No Product Name Assigned

Figure 1 11-711 Circuit Diagram (8155)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1041

Section Name

11-711

A

11-712 Inverter/Stacker Noise RAP

B Press Stop. Check the following on the Stacker Preregistration Transport: • Drive Belts for wear or damage

Audible noise in the Inverter/Stacker can be caused by defective bearings on shafts or idlers, drive rolls rubbing on baffles, or defective idlers. Use this procedure to isolate components that are causing noise in the Inverter/Stacker.

•

Drive Pulleys for damage or slippage on the shaft

•

Bearings

•

Idlers are free and positioned properly

Procedure

•

Baffles for interference with shafts

Enter dC330, [10], [Inverter Start/Run]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Drive Gears for wear, damage, or contamination

•

Drive Belt Idler for wear or damage

•

Drive Belts for wear or damage

•

Drive Pulleys for damage or slippage on the shaft

Press Stop. Select [11B1] [Stacker Start/Run]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following on the Purge Transport: • Drive Belts for wear or damage

•

Drive Belt idlers for wear or damage

•

Drive Pulleys for damage or slippage on the shaft

•

Idlers free and are positioned properly

•

Bearings

•

Bearings

•

Idlers are free and positioned properly

•

Inverter Main Drive Motor

•

Baffles for interference with shafts

Press Stop. Select [Inverter FWD]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Inverter Drive Belt for wear or damage •

Drive Pulleys for damage or slippage on the shaft

•

Bearings

•

Inverter Motor

Drive Pulleys for damage or slippage on the shaft

•

Bearings

•

Inverter Motor

Telescopic Drive Shaft

NOTE: This part of the procedure will work for both Stacker A and Stacker B. Use A or B in place of X in the procedure instructions. If unsure of the location of the noise, do this procedure first on Stacker A and the Stacker B. The sound levels are normal. Y N Press Stop. Check the following on the Stacker Elevator: • Lead Screws for binding

Press Stop. Select [11A1] [Stacker Start/Run]. Press Continue. The sound levels are normal. Y N Press Stop. Disconnect the Drive Belt from the Preregistration Transport Drive Pulley and the Stacker Main Drive Motor RAP. Press Continue. The sound levels are normal. Y N Press Stop. Check the following on the Bypass Transport: • Drive Belts for wear or damage

A

Stacker Main Drive Motor

•

Press Stop. Select [11X2] [Elevator Dn]. Press Continue.

Press Stop. Select [Inverter REV]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Inverter Drive Belt for wear or damage •

•

•

Drive Belts for wear or damage

•

Drive Pulleys for wear or damage

•

Bearings

•

Lift Frame for interference

•

Stacker Elevator Motor

Press Stop. Select [11X2] [Elevator Up]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Lead Screws for binding •

Drive Belts for wear or damage

•

Drive Pulleys for wear or damage

•

Drive Pulleys for damage or slippage on the shaft

•

Bearings

•

Bearings

•

Lift Frame for interference

•

Idlers are free and positioned properly

•

Stacker Elevator Motor

•

Baffles for interference with shafts

•

Stacker Main Drive Motor

•

Telescopic Drive Shaft

Press Stop. Select [11X1] [Tamper Front]. Press Continue. The sound levels are normal.

B

Section Name

11-712

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Preliminary Working Document No Product Name Assigned

Y

N Press Stop. Check the following on the Front Guide and Right Guide Tampers: • Drive Coupling for damage or slipping •

•

Select and energize clutches and solenoids that may be causing noise

•

Ensure all transports are latched properly

Gears for wear or contamination

•

Linkages for damage or binding

•

Bearings

•

Front Tamper Motor

•

Right Guide Tamper Motor

Press Stop. Select [Tamper Back]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following on the Back Guide Tampers: • Gears for wear or contamination •

Linkages for damage or binding

•

Bearings

•

Back Tamper Motor

Press Stop. Enter dC203, [Stacker Disk], [Stacker X], [7 pitch], [Continuous Run]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Disk Shaft for binding or interference •

Bearings

•

Disk Motor

Press Stop. Select [Edge Guides] [Stacker X] [Right Guide] [Continuous Run]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Lead Screws for binding •

Drive belt for wear or contamination

•

Drive belt tensioned properly

•

Interference with Right Guide

•

Bearings

•

Right Guide Motor

Press Stop. Select [Back Guide] [Stacker X] [Continuous Run]. Press Continue. The sound levels are normal. Y N Press Stop. Check the following: • Drive Belt for wear or damage •

Drive Belt for proper tension

•

Lead Screws for binding

•

Interference with Back Guide

•

Bearings

•

Back Guide Motor

Press Stop. If the noise is still present when the Stackers are running, perform the following: Preliminary Working Document No Product Name Assigned

0/0/00 ?-1043

Section Name

11-712

Figure 1 11-712 Circuit Diagram (8156)

Section Name

11-712

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Preliminary Working Document No Product Name Assigned

11-713 Stacker Control Panel RAP The Stacker Control Panel RAP will assist in diagnosing faults with the Stacker Control Panel PWB and related circuitry.

Procedure Enter dC330, [11A2]. Press the Bin Unload button. The Bin Unload SW display toggles from H to L. Y N Connect a jumper wire between TS21 and TS37 on the FSN DIO PWB #1. The Bin Unload SW display toggles from H to L when the jumper is connected. Y N Replace the FSN DIO PWB #1 (PL 1.17). Go to Flag 1. Check the wires for an open or short circuit. If OK, replace the Stacker Control Panel PWB (PL 4.12). Select [11A1] [Ready to Unload]. Press Continue. The Ready to Unload light illuminates. Y N Press Stop. Connect a jumper wire between TS46 and TS37 on the FSN DIO PWB #1. The Ready to Unload lamp illuminates. Y N Remove the jumper wire. Go to Flag 2. Check the wires for an open or short circuit. If OK, replace the Stacker Control Panel PWB (PL 4.12). Remove the jumper wire. Replace the FSN DIO PWB #1 (PL 1.17). Press Stop. Select [Stacker In Use]. Press Continue. The Stacker In Use lamp illuminates. Y N Press Stop. Connect a jumper wire between TS47 and TS37 on the FSN DIO PWB #1. The Stacker In Use lamp illuminates. Y N Remove the jumper wire. Go to Flag 3. Check the wires for an open or short circuit. If OK, replace the Stacker Control Panel PWB (PL 4.12). Remove the jumper wire. Replace the FSN DIO PWB #1 (PL 1.17). Press Stop. Select [Stacker Please Wait]. Press Continue. The Stacker Please Wait lamp illuminates. Y N Press Stop. Connect a jumper wire between TS39 and TS37 on the FSN DIO PWB #1. The Stacker Please Wait lamp illuminates. Y N Remove the jumper wire. Go to Flag 4. Check the wires for an open or short circuit. If OK, replace the Stacker Control Panel PWB (PL 4.12). Remove the jumper wire. Replace the FSN DIO PWB #1 (PL 1.17). Press Stop. The Stacker Control Panel is OK. Check the wires and connectors for an intermittent circuit.

Preliminary Working Document No Product Name Assigned

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Section Name

11-713

Figure 1 11-713 Circuit Diagram (8158)

Section Name

11-713

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Preliminary Working Document No Product Name Assigned

11-901-X Purge Tray Is Not Available RAP Fault Code, 11-901-X, indicates the presence of paper in the purge path. The Primary Fault becomes masked at this time.

Initial Actions •

Remove all Paper from the Purge Path to enable the start of a new job to any Upstream destination.

Procedure Check the Queued Faults [SCP] [Last 50]. Identify the Primary Fault prior to the 11-901-X Fault. Refer to the Primary Fault RAP to diagnose any hardware problem associated with the primary fault code.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1047

Section Name

11-901-X

Section Name

11-901-X

0/0/00 ?-1048

Preliminary Working Document No Product Name Assigned

13-131 RAP Fault Code, 13-131, indicates that the lead edge of the print, delivered from the Bypass Sensor, Q-1307, did not arrive at the Output Exit Sensor, Q1375, within 1114 milli seconds after actuating the sensor. (LE Q1307 late to LE Q1375)

A Press Stop. Select dC330, [Third Party], [Fin 2], [Output Drive Motor]. Press Continue. The Output Exit Transport Drive Rolls rotate. Y N The Output Drive Motor, MOT 1301, comes on. Y N Press Stop. Go to the 13-700, Output Drive Motor RAP, Mot 1301.

Initial Actions •

Ensure that all Transition Module Baffles are closed properly and are not damaged.

•

Ensure that all drive roll idlers are properly seated, and that the idler springs are correctly installed.

•

Ensure that the paper path is free of obstructions.

•

Ensure that the Bypass Transport Sensor and Output Exit Sensor are clean and not obstructed.

The Output Exit Drive Rolls operate correctly. Y N Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension. •

Press Stop. Check the following: • Drive and Idler Rolls for wear, damage, or contamination.

Procedure Observe the Prints entering the Transition Module. The Prints are free from damage, skew, or excessive curl. Y N Check the following: • Paper path for obstructions. •

Transition Module Height Adjustment (ADJ 13-5).

•

Idler Springs for wear or damage.

Press Stop. Select [Stacker A/B] [11X1]. Block and then unblock the Bypass Transport Sensor. The display changes from L to H. Y N Go to Flag 2. Check the circuit of the Bypass Transport Sensor, (GP 6-2, General Procedures).

•

Transition Module Inboard/Outboard Adjustment (ADJ 13-6).

•

Drive Rolls and Idlers for wear damage or contamination.

•

Idler Retaining Springs for damage missing.

•

If a problem is not found, or if the prints are damaged, skewed, or curled before entering the Transition Module, Go to the 8-705, or to the Physical Checks, Print Paper Diagnostics (Service Call Procedures).

•

Enter dC330, [Third Party], [Fin 2]. Block and then clear the Output Exit Sensor, Q1375. The display changes from L to H. Y N Go to Flag 1. Check the circuit of the Output Exit Sensor (GP 6-2, General Procedures). Enter [Stacker A/B] [11X1]. Select [Stacker Start/Run]. Press Continue. The Bypass Transport Drive Rolls rotate. Y N The Stacker Main Drive Motor comes on. Y N Press Stop. Go to the 11-706, Stacker Main Drive Motor, Mot 1110, RAP.

One way clutch, pulley or shaft for wear, binding, or slipping.

Check the following: • ADJ 13-5, Transition Module Height. Drive Shaft Bearings for binding.

•

Drive belts for wear, damage, contamination and tension.

•

Drive belt idlers for binding.

•

Static in the Descending Transport.

Stacker

The Bypass Drive Rolls operate correctly. Y N Press Stop. Check The following: • Drive belts for wear, damage, contamination, and correct tension. •

Flexible Drive Cable for damage, loose coupling, or loose setscrew.

Press Stop. Check the following: • Bypass Transport Drive and Idler Rolls for wear, damage or contamination. •

Idler Springs for wear damage or missing.

A Preliminary Working Document No Product Name Assigned

0/0/00 ?-1049

Section Name

13-131

Figure 1 13-131 Circuit Diagram (8502)

13-132 RAP

Section Name

13-131

Fault Code, 13-132, indicates that the trail edge of the print did not arrive at the Output Exit Sensor, Q1375, within the specified amount of time, after the lead edge arrived at the sensor.

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Preliminary Working Document No Product Name Assigned

Initial Actions •

Ensure that all Transition Module Baffles are closed properly and are not damaged.

•

Ensure that all Drive Roll Idlers are properly seated, and that the idler springs are correctly installed.

•

Ensure that the paper path is free of obstructions.

•

Ensure that the Bypass Transport Sensor and Output Exit Sensor are clean and not obstructed.

•

Ensure that the Transition Module static brushes do not obstruct the paper path.

Procedure Enter dC330, [Third Party], [Fin 2]. Block and then clear the Output Exit Sensor, Q1375. The display changes from L to H. Y N Go to Flag 1. Check the circuit of the Output Exit Sensor (GP 6-2, General Procedures). Select [Output Drive Motor]. Press Continue. The Output Exit Drive Rolls rotate. Y N The Output Drive Motor comes on. Y N Press Stop. Go to the 13-700, Output Drive Motor, Mot 1301, RAP. Press Stop. Check The following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.40), (PL 11.41). •

Bearings for binding (PL 11.40, (PL 11.41).

•

Drive Rolls for wear, damage, or contamination, and that they are not slipping on the shaft (PL 11.40)

•

Idler Rolls for binding, and for missing Idler Roll springs (PL 11.40)

Press Stop. Check the following: • Drive belts for wear, damage, contamination, and correct tension (PL 11.40) •

Bearings for binding (PL 11.40)

•

Drive Rolls for wear, damage or contamination, and that they are not slipping on the shaft (PL 11.40)

•

Idler Rolls for binding and for missing idler roll springs (PL 11.40)

•

Ensure that there is continuity in the harness to the third party device (PL 1.19)

•

Ensure that the third party devices are operational.

•

Ensure that the third party device is properly aligned to the Transition Module.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1051

Section Name

13-132

Figure 1 13-132 Circuit Diagram (8502)

13-201 RAP

Section Name

13-132

Fault Code, 13-201, indicates that the Transition Module Front Door Interlock Switch, S1381, opened with the Transition Module Main Drive Motor on.

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Preliminary Working Document No Product Name Assigned

Procedure Open the Transition Module Front Door. Enter dC330, [Third Party], [Fin 2]. Manually actuate the Transition Module Front Door Interlock Switch. The Transition Module Door INTLK SW display changes from H to L. Y N Go to Flag 1. Check the Transition Module Front Door Interlock circuit (Generic Switch RAP GP 6-1, General Procedures). Close and open the door several times. The Transition Module Door INTLK SW display changes from H to L as the door is closed and opened. Y N Check the following: • Transition Module Front Door Interlock is adjusted properly. •

Transition Module Front Door is not damaged or obstructed (PL 4.25).

•

Door hinges and pins are in place and intact (PL 4.25).

•

Interlock mounting bracket is not damaged (PL 4.25).

The Interlock appears to be OK. The problem may be intermittent. Check the Transition Module Front Door Interlock Switch, its associated wires, and the interlock actuator for intermittent operation.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1053

Section Name

13-201

Figure 1 13-201 Circuit Diagram (8505)

Section Name

13-201

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Preliminary Working Document No Product Name Assigned

13-203 RAP Fault Code, 13-203, indicates that a loss of +24 VDC has been detected in the TMN Module. This fault will cause the machine to go into the Power Interrupt mode and will disable the +24 VDC section of the Low Voltage Power Supply.

Initial Actions Checked the queued faults. If any of the following faults are present, 1-220, 10-216, or 11-2502, go to the appropriate RAP.

Procedure +24 VDC is measured between TB12-2 (+) and TB12-11 (-) in the TMN. Y N +24 VDC is measured between J803 pin 1 (+) and pin 2 (-). Y N +24 VDC is measured between TB7-12B (+) and TB7-12A (-) in the last Feeder Stacker Module. Y N Go to the 11-250-2 RAP. +24 VDC is available at J803-1. Y N Go to Flag 1. Check the wire 133J for an open. Go to Flag 2. Check the wires 134H for an open. +24 VDC is available at TB12-2. Y N Go to Flag 3. Check the wire 133A for an open. Go to Flag 4. Check wire 134A for an open. +24 VDC is measured between P804-3 (+) and P804-1 (-). Y N +24 VDC is available at P804-3. Y N Go to Flag 5 and check wire 133F for an open. Go to Flag 6 and check wire 134D for an open. Enter dC330, [Third Party] [Fin 1]. Disconnect P810 from J7 on the TMN DIO PWB. Connect a jumper from TS2 to TS37 on the TMN DIO PWB. The TMN +24 VDC monitor is L. Y N Replace the TMN DIO PWB (PL 1.19). Go to Flag 7. Check the wires for an open. If an open is not found, replace the 24 VDC Sensor, Q1384 (PL 1.19).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1055

Section Name

13-203

Figure 1 13-203 Circuit Diagram (8506)

Section Name

13-203

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Preliminary Working Document No Product Name Assigned

A

13-205 RAP Fault Code, 13-205, indicates that the Third Party Finisher faulted during print.

Initial Actions •

Ensure that the Third Party Interface Cable is properly connected at both ends and is not visibly damaged.

•

Ensure that the Third Party Finisher has power and is switched on.

+24 VDC is available at TS55 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19). +24 VDC is available at TS 47 on the TMN DIO PWB. Y N Go to Flag 2. Check the violet wire for an open.

Procedure Disconnect the Third Party Interface Cable from the Opto-Isolator PWB in the Transition Module. Use the +5 VDC scale and connect the meter to TS22 (+) and TS 37 (-) on the TMN DIO PWB. Place an E-Z hook from TS 22 on the TMN DIO PWB to TS24 on the Opto-Isolator PWB in the TMN. Place an E-Z hook from TS37 on the TMN DIO PWB to TS8 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C0]. Press Continue. Less than 1.2 VDC is indicated on the meter. Y N +24 VDC is available at TS35 on the TMN DIO PWB. Y N +24 VDC is available at J1-7 on the TMN DIO PWB. Y N Go to the 133D wire net and check for an open.

B +24 VDC is available at TS53 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the black, and Grey wires for an open.

Replace the TMN DIO PWB (PL 1.19). Move the E-Z hook from TS23 to TS22 on the Opto-Isolator PWB. Move the E-Z hook from TS7 to TS6 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C2]. Press Continue. Less than 1.2 VDC is indicated on the meter. Y N +24 VDC is available at TS35 on the TMN DIO PWB. Y N +24 VDC is available at J1-7 on the TMN DIO PWB. Y N Go to the 133D wire net and check for an open.

Replace the TMN DIO PWB (PL 1.19). Replace the TMN DIO PWB (PL 1.19). +24 VDC is available at TS53 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the black, and Grey wires for an open.

+24 VDC is available at TS53 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the black, and grey wires for an open.

+24 VDC is available at TS54 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+24 VDC is available at TS56 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+24 VDC is available at TS 46 on the TMN DIO PWB. Y N Go to Flag 2. Check the white wire for an open.

+24 VDC is available at TS39 on the TMN DIO PWB. Y N Go to Flag 2. Check the green wire for an open.

Replace the TMN DIO PWB (PL 1.19). Replace the TMN DIO PWB (PL 1.19). Move the E-Z hook from TS24 to TS23 on the Opto-Isolator PWB. Move the E-Z hook from TS8 to TS7 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C1]. Press Continue. Less than 1.2 VDC is indicated on the meter. Y N +24 VDC is available at TS35 on the TMN DIO PWB. Y N +24 VDC is available at J1-7 on the TMN DIO PWB. Y N Go to the 133D wire net and check for an open.

Move the E-Z hook from TS22 to TS21 on the Opto-Isolator PWB. Move the E-Z hook from TS6 to TS5 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C3]. Press Continue. Less than 1.2 VDC is indicated on the meter. Y N +24 VDC is available at TS35 on the TMN DIO PWB. Y N +24 VDC is available at J1-7 on the TMN DIO PWB. Y N Go to the 133D wire net and check for an open.

Replace the TMN DIO PWB (PL 1.19). Replace the TMN DIO PWB (PL 1.19). A

B

Preliminary Working Document No Product Name Assigned

C 0/0/00 ?-1057

D Section Name

13-205

C

D +24 VDC is available at TS53 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the black, and grey wires for an open.

E

+24 VDC is available at TS57 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+5 VDC is available at TS47 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+24 VDC is available at TS48 on the TMN DIO PWB. Y N Go to Flag 2. Check the orange wire for an open.

Go to Flag 2. Check the black wire for an open. If no open is found, replace the TMN DIO PWB (PL 1.19).

Replace the TMN DIO PWB (PL 1.19). Move the E-Z hook from TS21 to TS18 on the Opto-Isolator PWB. Move the E-Z hook from TS5 to TS2 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. Select [C3]. Press Continue. Less than 1.2 VDC is indicated on the meter. Y N +24 VDC is available at TS35 on the TMN DIO PWB. Y N +24 VDC is available at J1-7 on the TMN DIO PWB. Y N Go to the 133D wire net and check for an open.

Move the E-Z hook from TS32 to TS31 on the Opto-Isolator PWB in the TMN. Move the E-Z hook from TS16 to TS15 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S1] changes state and the counter has incremented for the S0 counter. Y N +5 VDC is available at TS28 on the TMN DIO PWB. Y N +5 VDC is available at TS38 on the TMN DIO PWB. Y N Go the 59F wirenet and check for an open. Replace the TMN DIO PWB (PL 1.19). +5 VDC is available at TS35 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the orange wire for an open.

Replace the TMN DIO PWB (PL 1.19). +24 VDC is available at TS53 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the black, and grey wires for an open.

+5 VDC is available at TS39 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+24 VDC is available at TS51 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+5 VDC is available at TS18 on the TMN DIO PWB. Y N Go to Flag 2. Check the brown wire for an open.

+24 VDC is available at TS51 on the TMN DIO PWB. Y N Go to Flag 2. Check the violet wire for an open.

Replace the TMN DIO PWB (PL 1.19).

Replace the TMN DIO PWB (PL 1.19). Ensure that all counters are cleared before beginning this procedure. Place an E-Z hook from TS23 on the TMN DIO PWB to TS32 on the Opto-Isolator PWB in the TMN. Place an E-Z hook from TS37 on the TMN DIO PWB to TS16 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S0] changes state and the counter has incremented for the S0 counter. Y N +5 VDC is available at TS17 on the TMN DIO PWB. Y N +5 VDC is available at TS38 on the TMN DIO PWB. Y N Go the 59F wirenet and check for an open.

Move the E-Z hook from TS31 to TS30 on the Opto-Isolator PWB in the TMN. Move the E-Z hook from TS15 to TS14 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S2] changes state and the counter has incremented for the S2 counter. Y N +5 VDC is available at TS21 on the TMN DIO PWB. Y N +5 VDC is available at TS38 on the TMN DIO PWB. Y N Go the 59F wirenet and check for an open. Replace the TMN DIO PWB (PL 1.19).

Replace the TMN DIO PWB (PL 1.19). E

F +5 VDC is available at TS43 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the red wire for an open.

F

Section Name

13-205

G 0/0/00 ?-1058

+5 VDC is available at TS44 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the blue wire for an open. H Preliminary Working Document No Product Name Assigned

G

H +5 VDC is available at TS48 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

I

J +5 VDC is available at TS38 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19).

+5 VDC is available at TS20 on the TMN DIO PWB. Y N Go to Flag 2. Check the yellow wire for an open.

+5 VDC is available at TS31 on the TMN DIO PWB. Y N Go to Flag 2. Check the black wire for an open.

Replace the TMN DIO PWB (PL 1.19).

Replace the TMN DIO PWB (PL 1.19).

Move the E-Z hook from TS30 to TS29 on the Opto-Isolator PWB in the TMN. Move the E-Z hook from TS14 to TS13 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S3] changes state and the counter has incremented for the S3 counter. Y N +5 VDC is available at TS24 on the TMN DIO PWB. Y N +5 VDC is available at TS38 on the TMN DIO PWB. Y N Go the 59F wirenet and check for an open.

Check the cable.

Replace the TMN DIO PWB (PL 1.19). +5 VDC is available at TS36 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the white wire for an open. +5 VDC is available at TS40 on the Opto-Isolator PWB. Y N Replace the Opto-Isolator PWB (PL 1.19). +5 VDC is available at TS30 on the TMN DIO PWB. Y N Go to Flag 2. Check the violet wire for an open. Replace the TMN DIO PWB (PL 1.19). Move the E-Z hook from TS29 to TS28 on the Opto-Isolator PWB in the TMN. Move the E-Z hook from TS13 to TS12 on the Opto-Isolator PWB. Enter dC330, [Third Party], [Fin 2]. [S3] changes state and the counter has incremented for the S3 counter. Y N +5 VDC is available at TS32 on the TMN DIO PWB. Y N +5 VDC is available at TS38 on the TMN DIO PWB. Y N Go the 59F wirenet and check for an open. Replace the TMN DIO PWB (PL 1.19). +5 VDC is available at TS34 on the Opto-Isolator PWB. Y N Go to Flag 1. Check the red wire for an open. I

J

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1059

Section Name

13-205

Figure 1 13-205 Circuit Diagram (8510)

13-206 RAP Section Name

13-205

Fault Code, 13-206, indicates that no Set delivery signal was received from the Third Party Module within the allowed time interval.

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Preliminary Working Document No Product Name Assigned

13-207 RAP

Initial Actions •

Ensure that the Third Party Interface Cable is properly connected at both ends and is not visibly damaged.

•

Ensure that the Third Party Finisher has power and is switched on.

•

Ensure that the personality profile is configured correctly for the Third Party equipment.

•

Ensure that there are no Jams in the Third Party Module.

Fault Code, 13-207, indicates that no Sheet delivery signal was received from the Third Party Module within the allowed time interval.

Initial Actions •

Ensure that the Third Party Interface Cable is properly connected at both ends and is not visibly damaged.

•

Ensure that the Third Party Finisher has power and is switched on.

•

Ensure that the personality profile is configured correctly for the Third Party equipment.

•

Ensure that there are no Jams in the Third Party Module.

Procedure Press R (Reset) on the IOT Monitor or type CLE on the ESS System Console to reset the system. If the Fault does not clear, go to 13-205 RAP.

Procedure Press R (Reset) on the IOT Monitor or type CLE on the ESS System Console to reset the system. If the Fault does not clear, go to 13-205 RAP.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-1061

Section Name

13-206, 13-207

13-208 RAP

13-700 Transition Module Main Drive Motor, MOT1301 RAP

Fault Code, 13-208, indicates that the Set delivery signal was received before the Sheet delivery signal from the Third Party Module within the allowed time interval.

The purpose of the Output Transport Main Drive Motor RAP is to aid in the troubleshooting of the Output Transport Main Drive Motor and related circuitry.

Initial Actions

Initial Actions

•

Ensure that the Third Party Interface Cable is properly connected at both ends and is not visibly damaged.

•

Ensure that the Third Party Finisher has power and is switched on.

•

Ensure that the personality profile is configured correctly for the Third Party equipment.

•

Ensure that there are no Jams in the Third Party Module.

WARNING Use caution when working near the motor. The Output Transport Main Drive Motor may run automatically. There is an internal thermal sensor that opens when the motor overheats. When the motor cools, the thermal sensor will close, allowing power to the motor. The outside surfaces of the motor could also be very hot.

Procedure

Perform the following:

Press R (Reset) on the IOT Monitor or type CLE on the ESS System Console to reset the system. If the Fault does not clear, go to 13-205 RAP.

•

Ensure that the Transition Module Door is closed or that the Interlock is bypassed.

•

Ensure that the Transition Module Main Drive rotates freely.

•

Check for a loose pulley on the motor.

Procedure With the Printer power switched off, or in the Power Interrupt mode, disconnect P801 from the Output Transport Main Drive Motor, MOT1301. Measure the resistance between J1-1 and J13. The resistance is less than 300 Ohms. Y N The motor is in an overheat condition. The motor must cool for the thermal sensor to reset. If it does not, replace the Output Transport Main Drive Motor, MOT1301 (PL 11.39). When it does reset, power on the printer and measure the voltage between TS43 (-) and TS33 (+) on the TMN DIO PWB. +24 VDC is measured. Y N Check for the following causes of overheating: • Transition Module Main Drives for binding. •

Transition Module Main Drive Start Relay, K1372, for shorted contacts (PL 1.19).

•

Flag 2, for a short circuit.

Replace the TMN DIO PWB (PL 1.19). DO NOT reconnect P801 at this time. Power on the Printer. Enter dC330, [Third Party], [Fin 2], [Output Transport Start/Run]. Observe the Transition Module Main Drive Start Relay, K1372. Press Continue. K1372 momentarily actuates. Y N Press Stop. +24 VDC is measured between TS33 (+) and TS37 (-) on the TMN DIO PWB. Y N Go to the Wirenets (Wiring Data) and check wire #133C for an open circuit. +24 VDC is measured between TS43 (+) and TS37 (-) on the TMN DIO PWB. Y N Go to Flag 1 and 2. Check the wires for an open circuit. If OK, replace the Transition Module Main Drive Start Relay, K1372 (PL 1.19). Press Continue. The voltage momentarily drops from +24 VDC to less than 1 VDC. A Section Name

13-208, 13-700

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Preliminary Working Document No Product Name Assigned

A Y

N Press Stop. Replace the TMN DIO PWB (PL 1.19).

Y

Press Stop. Replace the Transition Module Main Drive Start Relay, K1372 (PL 1.19). Press Stop. 115 VAC is measured between J800-3, and J800-15. Y N (60Hz) Go to the 1-704-1, Inverter/Stacker A Standby AC Power RAP or to 1-704-2, for Stacker B. (50Hz) Go to the 1-711-1, Inverter/Stacker A Standby AC Power RAP or to 1-711-2, for Stacker B. Ensure that the TMN front door is closed properly. 115 VAC is measured between J800-3, and Transition Module Interlock Relay, K1376-9. Y N 115 VAC is measured between J800-3, and the Transition Module Interlock Relay, K1376-6. Y N 115 VAC is measured between J800-3, and TB10-8. Y N Go to Flag 13, and check wire 40H for an open.

N 115 VAC is measured between the Transition Module Interlock Relay, K1376-4 and K1376-9. Y N Go to Flag 15, and check wire 21H for an open. Replace the Transition Module Interlock Relay, K1376, (PL 1.19)

115 VAC is measured between the Transition Module Main Drive Run Relay, K1373-1, and the Transition Module Interlock Relay, K1376-9. Y N Go to Flag 4. Check the wire for an open circuit. Reconnect P801. 115 VAC is measured between terminal 1 and 2 of K1373. Y N Disconnect P801 from the Output Transport Main Drive Motor, MOT1301. 115 measured between P801-3 and K1373-1. Y N Go to Flag 11. Check the wire for an open circuit.

VAC

is

Go to Flag 10 and 12. Check the wires for an open circuit. If OK, replace the Output Transport Main Drive Motor, MOT1301 (PL 11.39).

Go to Flag 14, and check wire 40J, for an open. The TMN Interlock Relay, K1376, is actuated. Y N +24 VDC is measured between TB12-2 (+) and TB12-11 (-). Y N Go to Flag 16 and 17, and check for an open. If an open is not found go to the wirenets (Wiring Data) and check wires 82A and 78A.

Press Continue. The voltage goes Low. Y N Press Stop. +5 VDC is measured between TS34 (+) and TS37 (-) on the TMN DIO PWB. Y N Go to the Wirenets (Wiring Data) and check wire #59H for an open circuit. +5 VDC is measured between TS54 (+) and TS37 (-) on the FSN DIO PWB #1. Y N Go to Flag 3. Check the wires for an open circuit. If OK, replace the Transition Module Main Drive Run Relay, K1373 (PL 1.19).

+24 VDC is measured between pin 2 of the TMN front door interlock switch (+) and TB12-11 (-). Y N Check the TMN Front Door Interlock Actuator for proper operation. If the actuator is operating correctly, Go to Flag 18, and check wire 133H for an open. If the wire is OK replace the TMN Front Door Interlock Switch (PL 4.25). +24 VDC is measured between pin B (+) of the TMN Interlock Relay, K1376, and TB12-11 (-). Y N Go to Flag 19, and check wire 136A for an open. If the wire is OK replace the TMN Interlock Relay, K1376 (PL 1.19). Go to Flag 20, check wire 134F for an open. Replace the Transition Module Interlock Relay (PL 1.19). 115 VAC is measured between the Transition Module Interlock Relay, K1376- 7 and K1376-9.

Press Continue. 0.2 to 1.0 VDC is measured between TS54 (+) and TS37 (-) on the TMN DIO PWB. Y N Press Stop. Replace the TMN DIO PWB (PL 1.19). Press Stop. Replace the Transition Module Main Drive Run Relay, K1373 (PL 1.19). Press Stop. 115 VAC is measured between K1373-1 and terminal 9 of the Transition Module Main Drive Start Relay, K1372. Y N 115 VAC is measured between K1373-1 and terminal A1 of the Start Capacitor, C1371. Y N Go to Flag 8 and 9. Check the wires for an open circuit. Go to Flag 7. Check the wire and connections for an open circuit. B

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Section Name

13-700

B 115 VAC is measured between K1373-1 and K1372-4. Y N Press Stop. Go to Flag 5 and check for an open circuit. Select Peak Hold on the multimeter. Press Continue. Greater than 50 VAC is measured between K1373-1 and K1372-6. Y N Press Stop. Go to Flag 6. Check the wire for an open circuit. If OK, replace the Transition Module Main Drive Relay, K1373 (PL 1.19). Press Stop. Replace the following components one at a time until the problem is resolved: • Run Capacitor C1370 (PL 1.19) •

Start Capacitor C1371 (PL 1.19)

•

Transition Module Main Drive Motor MOT1301 (PL 11.39)

Section Name

13-700

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Figure 1 13-700 Circuit Diagram (8501)

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Section Name

13-700

Section Name

13-700

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Transmittal Page Product

Title

Part Number

DocuPrint 180F

Service Manual

720P16290B

Section 3 : Print Quality Status

Date

Revision

November 2000

THIS PAGE INTENTIONALLY LEFT BLANK

3. Image Quality RAPS Image Quality Analysis RAPs PQ 9-601 Printer Image Quality Entry RAP .................................................................... PQ 9-601.1 Printer Motion Quality Procedure................................................................. PQ 9-602 Black Print RAP .............................................................................................. PQ 9-603 Blank Print RAP .............................................................................................. PQ 9-604 Prints With Agglomerates/Debris RAP ........................................................... PQ 9-606 Print Distortion RAP ........................................................................................ PQ 9-607/608 Uniform And Non-Uniform High Background RAP .................................. PQ 9-609 Low Image Darkness (Low Signal Strength, w/MICR) RAP ........................... PQ 9-610 High Image Darkness RAP ............................................................................. PQ 9-611 Dark Streaks/Scratches/Bands RAP .............................................................. PQ 9-612 Light Streaks/Bands RAP ............................................................................... PQ 9-613 Black Spots RAP ............................................................................................ PQ 9-614 Non-Uniform Image Darkness RAP ................................................................ PQ 9-615 Deletions RAP ................................................................................................ PQ 9-616 Development RAP .......................................................................................... PQ 9-617 Cleaner RAP................................................................................................... PQ 9-618 PR Ground RAP ............................................................................................. PQ 9-619 ESV RAP ........................................................................................................ PQ 9-620 DSS RAP ........................................................................................................ PQ 9-621 Patch Gen/Patch Integrity RAP ...................................................................... PQ 9-622 Transfer Assist Device RAP ........................................................................... PQ 9-623 Border Bands RAP ......................................................................................... PQ 9-624 Precharge/Pretransfer Lamps RAP ................................................................ PQ 9-625 White Spots RAP ............................................................................................ PQ 9-626 Dicorotron RAP............................................................................................... PQ 9-627 Patch Integrity RAP ........................................................................................ PQ 9-628 HVAC RAP ..................................................................................................... PQ 9-629 HVDC RAP ..................................................................................................... PQ 9-630 Toner/Charge Control RAP............................................................................. PQ 9-631 Bead Carryout RAP ........................................................................................ PQ 9-632 Dirt RAP .......................................................................................................... PQ 9-633 PR Belt Uniformity RAP .................................................................................. PQ 9-634 Residual Image RAP ...................................................................................... PQ 9-635 Smear RAP..................................................................................................... PQ 9-636 Blur RAP ......................................................................................................... PQ 9-637 Slow Scan Magnification Checkout Procedure ............................................... PQ 9-638 Scratches/Crayoning Fault Analysis ............................................................... PQ 9-639 MICR Image Quality Analysis Procedure ....................................................... PQ 9-640 MICR Checkout Procedure............................................................................. PQ 9-641 MICR Signal Strength Tester Correlation Procedure......................................

3-3 3-5 3-11 3-11 3-13 3-13 3-15 3-18 3-19 3-20 3-23 3-24 3-25 3-26 3-27 3-32 3-35 3-37 3-40 3-43 3-47 3-49 3-50 3-52 3-53 3-54 3-55 3-56 3-57 3-58 3-62 3-63 3-64 3-65 3-66 3-67 3-70 3-72 3-81 3-81

Printing Of Single Pixel Fine Lines: Printer Specification ................................................ Registration Top-to-bottom (Fast Scan): Printer Specification ........................................ ROS Image Squareness: Printer Specification ............................................................... Skew: Printer Specification.............................................................................................. Motion Quality Controller Resident Test Pattern (MMQT02)...........................................

3-101 3-102 3-104 3-105 3-107

Image Quality Defects Background, Blotchy ....................................................................................................... 3-113 Background, Halftone (Gray Page) ................................................................................. 3-115 Background, Xerographic................................................................................................ 3-117 Background, Structured................................................................................................... 3-119 Dark band, Top-To-Bottom (Fast Scan) Direction, Every Belt Revolution ...................... 3-120 Dark Band, Side-To-Side (Slow Scan) Direction............................................................. 3-122 Band Deletion, Side-To-Side (Slow Scan) Direction ....................................................... 3-125 Blotch Toner .................................................................................................................... 3-129 Fine, Dark Lines, Side-To-Side (Slow Scan) Direction Across Print, Greater Frequency At Top And Bottom (Fast Scan Direction) On Print..................................................................... 3-131 SLB/RDR Failure Defect ................................................................................................. 3-135

Image Quality Specifications Test Patterns................................................................................................................... Registration, Side-To-Side (Slow Scan): Printer Specification........................................ System Magnification Procedure .................................................................................... Printing Of High Density Solid Areas: Printer Specification ............................................

Revision DocuPrint 180F Service Manual

3-83 3-96 3-98 3-100

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Image Quality Raps

Image Quality Raps

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Revision DocuPrint 180F Service Manual

PQ 9-601 Printer Image Quality Entry RAP

a.

Obtain the customers defect samples or the samples generated in the Initial Actions of the Service Call Procedure. If the defect is identified in the list below, go to RAP indicated for repair. For additional diagnostics, go Print Quality Specifications, compare the defect to the Image Quality Defect Samples in the RAPs. If the defect cannot be identified or repaired, return to the next of this RAP.

b.

MlM IMAGE DEFECTS.

The purpose of this RAP is to isolate Print Quality defects that are caused by the IOT. Once the defect is isolated, the service action or RAP will be identified.

Procedure 1.

2.

3.

THE IMAGE DEFECT OCCURS ONLY WITH ETHERNET JOBS.

•

Bead Carryout on prints, go to the PQ 9-631, Bead Carryout RAP.

•

•

Blur, go to the PQ 9-636, Blur RAP.

•

Dark Border Bands, go to the PQ 9-623, Border Bands RAP.

THE DEFECT IS BLACK or BLANK, OR A PROBLEM IN THE MICR LINE.

•

Edge Defects, go to the PQ 9-623, Border Bands RAP.

•

•

Light Streaks or Bands, go to the PQ 9-612, Light Streaks/Bands RAP.

Go to the DP NPS System Fault Analysis Procedure or the DP IPS System Fault Analysis Procedure. Go to; PQ 9-602, Black Print RAP, PQ 9-603, Blank Print RAP or PQ 9-639, PQ 9640 MICR RAPs.

DETERMINE IF CONTROLLER OR PRINTER DEFECT.

NOTE: MIN Address 420 is the mode selection for: (48)=300 SPI or (96)=600 SPI and Lead Edge Lightening (00)=no LEL, (02)=normal, and (03)=stress. a.

b.

c.

4.

6.

Enter dC606. Select one of the resident Printer test patterns that is best suited to produce the defect. Run at least 20 prints. Ensure that the defect is not in duplex mode only. If the defect appears on at least one of the prints generated, go to 4. If the defect does not appear, continue with step 3c. Enter dC106. Select one of the resident Controller Test patterns that is best suited to produce the defect. Run at least 20 prints. If the defect does NOT appear on at least one of the prints generated, go to 4. If the defect does appear, go to 11.

Inspect the Photoreceptor Belt for damage. Repair the source of the damage. Replace the Photoreceptor Belt (PL 9.1).

THE DEFECT OCCURS ON SIDE 2 PRINT ONLY. a.

Deletions on side 2 only, go to the PQ 9-615, Deletions RAP.

b.

Wrong sign toner on side 2, go to the PQ 9-616, Development RAP.

THE DEFECT IS MISREGISTRATION OR SKEW. a.

Check/adjust the ROS Magnification (ADJ 6-1).

b.

Check/adjust the ROS Image Squareness (ADJ 6-2).

c.

Check/adjust the Pretransfer Baffles (skew) (ADJ 8-1).

NOTE: If there is gross misregistration, 4 to 5 inches, there may be a Reg Sync Signal problem, go to the 4-211, 4-213.

7.

c.

THE DEFECT IS ON EVERY SEVENTH PRINT IN STANDARD MODE OR EVERY THIRD PRINT IN OVERSIZED MODE. a.

5.

Enter dC131 [MIN]. Enter address 420. Enter the Data value shown in the appropriate level Software dC 131 Table in Section 6, General Procedures, of the Service Manual (300 SPI with normal lead edge lightening).

d.

Check/adjust the Top-to-Bottom Registration (ADJ 8-2).

e.

Check/adjust the Side-to-Side Registration (ADJ 8-3).

CATEGORIZE THE PRINTER DEFECT.

8.

Residual image, go to the PQ 9-634, Residual Image RAP.

•

Scratches, Dark Streaks, Crayon effect or Bands, go to the PQ 9-611, Black Streaks/Scratches/Bands RAP.

•

Dark horizontal marks (in the process direction only) that resemble fine lines, go to the PQ 9-638, Scratches/Crayoning Fault Analysis RAP.

•

Smear, go to the PQ 9-635, Smear RAP.

•

Solid Area Deletions or Line deletions, go to the PQ 9-615, Deletions RAP.

•

Spots or Dark marks, go to the PQ 9-613, Dark Spots RAP.

•

Background, go to the PQ 9-607/608, Uniform and Non-Uniform High Background RAP.

•

Uneven Density or Uneven Darkness, go to the PQ 9-614, Nonuniform Image Darkness RAP.

•

White Spots, go to the PQ 9-625, White Spots RAP.

FUSER RELATED DEFECTS. •

Fuser Shield/Agent on Prints, go to the 10-604, Fuser Shield/Agent on Prints RAP.

•

Glossy Print, go to the 10-602, Fuser Print Gloss RAP.

•

Lead Edge Smear, go to the 10-601, Fuser Lead Edge Smears RAP.

•

Lead Edge to Trail Edge Streaks, go to the 10-605, Fuser Lead Edge to Trail Edge Streaks (Unfused Print) RAP.

•

Type on prints unacceptable, go to the 10-607, Unable to Type on Prints RAP.

•

Perform the Printer Fuse Fix Crease/Fold Test, referenced in Step 9e of the Test Patterns procedure. If the prints fail the Crease/Fold Test, go to 10-608, Dry Ink Not Fixed RAP.

•

Unfused Prints, go to the 10-608, Dry Ink Not Fixed RAP.

•

Wrinkles, go to the 10-603, Wrinkle RAP.

THERE IS A SYSTEM MOTION QUALITY (STROBING) PROBLEM. a.

9.

•

Go to STEP 12.

STACKER RELATED DEFECTS. a.

Go to the 11-600, Poor Stacking Quality RAP.

10. UNABLE TO IDENTIFY DEFECT. a.

Perform the Xerographic Setup (ADJ 9-3). If the defect continues, return to STEP 1.

11. CONTROLLER DEFECTS.

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Section Name

PQ 9-601

a.

Enter dC106. Run prints of the Quadrille test pattern. Examine the prints. If one of the slow scan (side to side) pixel lines has multiple lines printing out and the pattern is repeating every 8 lines, go to the Test Patterns, Section 3. Troubleshoot open image data lines.

b.

Examine the Quadrille prints. If no defect is seen, check the printer Interface cable. Visually inspect the connectors at both ends. Ensure that there is no damage. Check continuity of all wires from one end to the other. If the cable is OK, reseat the SLB/ RDR PWB.

c.

Inspect the front and rear of the Controller Backplane for bent and touching pins. Reform the pins. If the problem continues, replace the SLB/RDR PWB (PL 1.11)

12. PRINTER MOTION QUALITY DIAGNOSTICS. If the problem is a Motion Quality problem, go to PQ 9-601.1, Printer Motion Quality Procedure.

Section Name

PQ 9-601

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Preliminary Working Document No Product Name Assigned

PQ 9-601.1 Printer Motion Quality Procedure This RAP is a continuation of the PQ 9-601 for Printer Motor Quality Problems. The purpose of this RAP is to isolate Printer motion quality defects.

Procedure Perform the following for a Printer Motion Quality Problem: 1.

Enter Job Exerciser, dC106. Select [Test Pattern (Halftone)], press Continue. Examine the prints. Using the 150 mm scale, measure the interval between the strobing patterns. Refer to (Figure 1).

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PQ 9-601.1

Figure 1 PQ 9-601.1 Strobing Measurement

Section Name

PQ 9-601.1

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Preliminary Working Document No Product Name Assigned

2. 3.

After the intervals have been determined, proceed to Table 1 for the appropriate service action to perform.

•

Replace the Motor Polygon Assembly (PL 6.1).

•

Replace the RCM PWB (PL 6.1).

For intervals that are greater than 150 mm, place the prints in sequential order, side by side, to determine the frequency. Be sure the prints are separated by approximately 30 mm (8.5x11 in. paper) or 36 mm (A4 paper) from each other, in order to yield an accurate measurement of the interval (interdocument zone allowance).

•

If the problem is not corrected, go to Table 1 Strobing Frequency Service Action Chart for an IOT Motion Quality problem at the same frequency.

5.

If Fault Code, 6-233, VLD Range (5% Power Fault) is declared, go to 6-233.

6.

If the strobing is within the image structure, replace the following components in the order given:

NOTE: There may be more than one strobing frequency on the prints. The strobing frequency that is most easily recognizable is the primary strobing frequency There may be secondary frequencies that are not as apparent. This secondary strobing frequency information is useful in further isolating the cause of the strobing. 4.

If strobing is present at a wobble frequency or strobing jitter is present, perform the following:

7.

•

Motor Polygon Assembly (PL 6.1).

•

VLD Collimator Assembly PL 6.1).

•

ROS Assembly (PL 6.1).

•

Photoreceptor (PL 9.1).

If the problem is still not solved, go to Table 1 Strobing Frequency Service Action Chart.

Table 1 Strobing Frequency Service Action Chart PRIMARY FREQUENCY

SECONDARY FREQUENCY

A. 161 mm

C. 78.5 mm

SERVICE ACTION Check the P/R Drive Roll for excessive runout. Replace the P/R Drive Roll Assembly (PL 9.3) if runout exceeds 0.2 mm total runout (peakpeak). Inspect the P/R Drive and P/R Drive Roll couplings for excessive wear/keyway backlash. Replace, as necessary (PL 9.3). Re-align the P/R Drive Assembly (ADJ 9-10), (PL 4.17). Inspect / re-align the Prefuser Transport Drive assembly, (PL 4.16).

B. 106.5 mm

E. 53.7 mm

Inspect the P/R Drive Tri-pulley or Bi-pulley for dirt buildup in the pulley grooves. Clean, if buildup is present (PL 4.17).

C. 78.5 mm

F. 39.3 mm

Check P/R Stripper roll assembly (top roll) for excessive runout. Replace, if greater than 0.2 mm total runout (peak to peak) (PL 9.3).

Replace the Tri-pulley or Bi-pulley (REP 4-48 ). Inspect the P/R Drive and P/R Drive Roll couplings for excessive wear/keyway backlash. Replace, as necessary (PL 9.3). Re-align the P/R drive assembly (ADJ 9-10), (PL 4.17). Inspect and re-align the PreFuser Transport drive assembly (PL 4.16). C. 106.7 mm

K. 4.0 mm

D. 60.8 mm

None

Adjust Cleaner Drive Belt Tension (ADJ 4-10), (PL 4.16). Check the Main Drive Motor pulleys (PL 4.18) for dirt buildup in the grooves or a key/pulley mechanical defect. Clean/repair as necessary. If the Main Drive Motor is okay, check the Fuser-Developer Drive Motor pulley, and repair, as required (REP 4-41), (PL 4.20). Ensure the Main Drive motor pulleys (PL 4.18) and the Fuser-Developer Drive motor pulleys (PL 4.20) are fastened securely and are positioned properly on the motor shafts. Replace the Drive Motor (REP 4-27), (PL 4.18) if the output shaft appears to be bent (shaft runout), or if there is excessive radial free-play when the shaft is biased at the free end of the shaft. Replace 32T pulley on Main Drive Motor (REP 4-28), (PL 4.18). Replace 40T pulley on Main Drive Motor (REP 4-28), (PL 4.18). Replace the pulley on the Fuser-Developer Drive Motor (REP 4-41), (PL 4.20).

D. 50.3 mm F. 37.3 mm F. 106.7 mm

N. 2.4 mm

Realign the Prefuser Transport Drive Assembly (PL 4.16).

C. 81.1 mm, A. 167.7 Check the Decurler drive and subsystem for binding, excessive load, or part failure. Repair/replace as required (REP 4-22), (PL 4.16). mm C. 96.6 mm, N. 5.1 Verify that the Cleaner subsystem has had Preventive Maintenance per the specified interval. mm

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Section Name

PQ 9-601.1

Table 1 Strobing Frequency Service Action Chart PRIMARY FREQUENCY

SECONDARY FREQUENCY

SERVICE ACTION Check the Cleaner Assembly for excessive binding at the drive shaft.

183 mm F. 40.0 mm

I. 20.0 mm

Check for clogged/foreign material in Cleaner Assembly. Check the P/R drive roll for excessive runout. Replace the P/R drive roll assembly (PL 9.3), if runout exceeds 0.2 mm total runout (peak-topeak). Inspect the P/R drive and P/R drive roll couplings for excessive wear or keyway backlash. Replace as necessary (PL 9.3). Realign the P/R drive assembly (ADJ 9-10). Inspect/re-align the Pre-fuser Transport Drive assembly (PL 4.16).

F. 167 mm

J. 8.0 mm

G. 28.2 mm

None

H. 24.5 mm, I. 20 mm

C. 78.5 mm

Adjust the tension of the Prefuser Transport drive belt (ADJ 4-19). Check CHM - Duplex Idler Roll. IF SECONDARY FREQUENCY "C" IS PRESENT: Check the P/R Drive Roll for excessive runout. Replace the P/R drive roll (PL 9.3) assembly if runout exceeds 0.2 mm total runout (peak-topeak). Ensure that the idler lock down screw of the Prefuser Transport Drive Assembly is seated fully and is torqued (PL 4.16). Inspect the P/R drive and P/R drive roll couplings (PL 9.3) for excessive wear or keyway backlash. Replace, as necessary. Re-align the P/R drive assembly (ADJ 9-10). Inspect and re-align the Prefuser Transport Drive Assembly (PL 4.16). IF SECONDARY FREQUENCY "C" IS NOT PRESENT: Ensure that the MIM Air Compressor Motor or its air fittings are not contacting the Printer frames. Ensure that the MIM Air Compressor Motor rubber isolator mounts are in satisfactory condition. Ensure that the MIM Air Compressor Motor mounting plate bolts are secure.

J. 13.1 mm

D. 60.6 mm

Ensure that the ROS Upper Mounting clamps are secure. Check the Fuser-Developer Drive Motor bracket mounting screws (6) for tightness. Replace the P/R Stripper Roll (PL 9.3).

K. 10.2 mm

None

None

L. 8 mm

None

Retension Pre-Fuser drive belt (ADJ 4-19). Clean pulley teeth.

M. 5.6 mm, N. 4.7 mm

R. 2.3 mm

None Adjust the tension of the P/R Intermediate Drive Belt (Main Drive Motor to tri-pulley / bi-pulley) (ADJ 4-15), (PL 4.17). Inspect P/R Drive Tri-pulley or Bi-pulley and the 36T pulley on the P/R Drive Assembly for dirt buildup in the pulley grooves. Clean the pulleys, if buildup is present (PL 4.17). Check the drive belt that runs from the P/R drive Tri-pulley or Bi-pulley to the P/R drive assembly (i.e., the belt that does not have a tensioning idler) for abnormal or excessive wear. Replace as necessary (PL 4.17). Verify that the Cleaner Assembly has had Preventive Maintenance per the specified interval. Check the Cleaner Assembly for excessive binding at the drive shaft. Verify that the Fuser Metering Roll Blade is not tucked and that the Fuser Rolls are in good condition. Verify that the Fuser Roll (Contact Arc) is set to specification. Reset as necessary, (ADJ 10-2). Inspect the Developer (also check for foreign material) drive assembly and their subsystems for excessive binding of bearing or other failures. Inspect the P/R dive assembly, P/R module rolls, and their subsystems for excessive binding of bearing or other failures.

Section Name

PQ 9-601.1

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Preliminary Working Document No Product Name Assigned

Table 1 Strobing Frequency Service Action Chart PRIMARY FREQUENCY

SECONDARY FREQUENCY

SERVICE ACTION Inspect all other driven elements in the MIM and their subsystems for excessive binding of bearing or other failures. Inspect all other driven elements in the PHM and their subsystems for excessive binding or bearing or other failures. NOTE: Evidence of excessive fretting (rust colored) or drive belt (black) deposits may be a sign of the problem cause. Adjust the tension of the Fuser-Developer Drive Belt (ADJ 4-21).

N. 4.7 mm

C. 78.5 mm

O. 4.4 mm

None

Ensure that the P/R drawer is latched securely and that the Pretransfer Lead-in Baffle is cammed into the operating position. If this action does not resolve the problem, proceed to other service actions associated with strobing interval "N." Check the Bi-pulley, Tri-pulley, and 36T P/R Drive pulley for contamination in the grooves. Verify that the Bi-pulley and Tri-pulley to P/R Drive belt are in good condition. Reset the tension in the belt that connects the Main Drive Motor to the Bi-/Tri-pulley (ADJ 4-16). Ensure that there is no binding within the P/R Module rolls or P/R Drive assembly.

P. 3.9 mm and for 4.0 mm

None

Verify that the Cleaner Assembly has had Preventive Maintenance per the specified interval. Check the Cleaner Assembly for excessive binding at the drive shaft. Check the Cleaner De-toning Roll Drive Gears for abnormal or excessive wear. Replace as required (PL 4.16).

Q. 3 mm

None

Check the Developer subsystem gear teeth for abnormal wear (all gears). Repair/replace as necessary (PL 4.17).

R. 2.5 mm

None

Motor gear mesh frequency.

S. 1.7 mm

None

Ensure that the upper ROS mounts are secure.

Check the Developer subsystem sump and rolls for foreign objects Repair/replace as required (PL 4.17).

Ensure that the lower inboard ROS Mounting Spring is restraining the ROS Guide Pin against the ROS Guide Rail. Reset (bias it counter-clockwise) and replace the spring PL 6.1, as necessary. Verify that the Fuser Metering Roll Blade is not tucked, and that the Fuser Rolls are in good condition. Check/adjust the tension of the Fuser-Developer Drive Belt (ADJ 4-21). Adjust Fuser-Developer Intermediate Drive Belt (ADJ 4-23). Check/adjust Pressure Roll contact arc (ADJ 10-2). Replace the Fuser-Developer Drive Motor (REP 4-41), (PL 4.20). T. 1.5 mm

U 1.4 mm (may be present)

Ensure that the ROS is seated securely in the upper mounting blocks and its inboard guide pin is seated within the guide rail, held by the bias spring. Ensure that the P/R Module and drawer assemblies are latched securely. Replace the ROS Polygon Motor Assembly. Go to (PL 6.1). If the problem persists, and secondary frequency U. is present, go to REP 4-27 and replace the Fuser-Developer Drive Motor.

U. 1.4 mm

None

50 Hz. Machine Ensure that the upper ROS Mounts are secure. Ensure that the lower inboard ROS Mounting Spring is restraining the ROS Guide Pin against the ROS Guide Rail. Reset (bias it counter-clockwise) and replace the spring, as necessary. Verify that the Fuser Metering Roll Blade is not tucked and that the Fuser Rolls are in good condition. Replace ROS Polygon Motor Assembly (PL 6.1). 60 Hz Machine Ensure that the upper ROS Mounts are secure. Ensure that the lower inboard ROS Mounting Spring is restraining the ROS Guide Pin against the ROS Guide Rail. Reset (bias it counter-clockwise) are replace the spring, as necessary. Verify that the Fuser Metering Roll Blade is not tucked and that the Fuser Rolls are in good condition. Check/adjust the tension of the Fuser-Developer Drive Belt (ADJ 4-21). Adjust Fuser-Developer Intermediate Drive Belt (ADJ 4-23).

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-601.1

Table 1 Strobing Frequency Service Action Chart PRIMARY FREQUENCY

SECONDARY FREQUENCY

SERVICE ACTION Check/adjust Pressure Roll contact arc (ADJ 10-2). Replace the Fuser-Developer Drive Motor (REP 4-41), (PL 4.20). Replace the ROS Polygon Motor Assembly (PL 6.1).

V. 1.3 mm

None

None

W. 247.0 mm

None

Realign the Paper Tray 1 and/or 2 Drive assemblies (ADJ 4-20), or replace the Paper Tray 1 and/or 2 Drive assemblies (REP 4-36).

X. 6.3 mm

None

Replace Main Drive Motor (REP 4-27), (PL 4.18) or replace Aux Drive Motor

Section Name

PQ 9-601.1

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Preliminary Working Document No Product Name Assigned

PQ 9-602 Black Print RAP

PQ 9-603 Blank Print RAP

A Black print has a black image covering the entire print. Because no area of the Photoreceptor was discharged.

A Blank print has no image on the print. This can be caused by the PR being totally discharged or transfer not occurring.

Procedure

Initial Actions

Enter dC131 [MIN]. Check MIN NVM Address 125 in the appropriate level Software dC 131 Table (Section 6, General Procedures of the Service Manual).

Enter dC131 [MIN]. Enter Address 210. Enter Data 112 (Transfer current normal).

NOTE: If MIN Address 125 is at the Initial default value, RDR Fault (ROS Diagnostic Recovery) is enabled. The machine will not produce black prints as a result of a ROS related defect. There will be a fault declared and no prints will run. If address 125 is at (the Initial default value +1), the Printer Internal Test Pattern is enabled. The machine will only print what appears to be Black Prints or possibly Quadrille prints. The Data value is at the Initial default value. Y N Enter the Initial default value. Enter dC606. Program any job to check Print Quality. The Print is Ok. Y N A fault code is displayed. Y N Go to the PQ 9-618, PR Ground RAP.

Procedure WARNING Laser Radiation. Avoid direct exposure to beam. CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Cheat the Printer Interlock Bypass Switch. Remove the ROS Lower Inner Panel. Enter dC330 [6]. Select [Laser Write]. Press Continue. NOTE: [Polygon Drive] and [Laser Enable] are energized when dC330 [6] is entered. The reflection of the laser light can be seen on the Photoreceptor belt. Y N Go to the 6-250/251 RAP.

Go to the RAP for the fault displayed. Problem is resolved. Go to the PQ 9-618, PR Ground RAP. If the problem is not solved, go to the PQ 9-601, Printer Image Quality Entry RAP.

With [Laser Write] energized, select [Patch Enable]. Observe the reflection of the laser light on the Photoreceptor, specifically noting the patch area. There is a break in the reflected laser light where the patch area is located, approximately the center of the Photoreceptor belt. Y N Go to the 6-701, Patch Enable RAP. Leave all outputs energized. Select [1-4] [Page Sync]. Press Continue. NOTE: The ROS is on for only a brief period. Use the Remote Hand Held Device (RHHD) to make ROS observations. For detailed Operating Instructions of the RHHD, go to (GP 1) Remote Hand Held Device (RHHD). The ROS illuminates the Patch area. Y N Check the following: • The video cables are both connected to the ROS module at J203 and J204 of the Image RCM PWB (Figure 1). •

The video cables are both connected to the Printer Backplane at J103 and J104.

•

Check P101/J101 connector on the Printer backplane. If the Return Byte Clock (+ and -) signals at pins 40 and 41 of this connector are missing, blank prints can be made without a fault code being declared during normal run.

Enter dC131 [MIN]. Enter Address 125. The Data value is at the Initial default value listed in the appropriate level Software dC 131 Table in Section 6, General Procedures, of the Service Manual. Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-602, PQ 9-603

A Y

N Change value to the Initial default value. Enter dC606. Run any job. A fault is declared. Y N Enter dC909. Observe the Control Value display for Charge 1 ua. Press Continue. The Charge 1 ua value is greater than 150. Y N Go to the PQ 9-630, Toner/Charge Control RAP.

B Go to the RAP for the fault code displayed.

Enter dC909. Observe the Control Value display for Charge 1 ua. Press Continue. The Charge 1 ua value is greater than 150. Y N Go to the PQ 9-630, Toner/Charge Control RAP. Go to the PQ 9-616, Development RAP.

Go to the PQ 9-616, Development RAP. A

B

Figure 1 PQ 9-603 Component Diagram (8310B)

Section Name

PQ 9-603

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Preliminary Working Document No Product Name Assigned

PQ 9-604 Prints With Agglomerates/Debris RAP

PQ 9-606 Print Distortion RAP

Agglomerates: Agglomerates are toner particles that are partially fused together forming larger masses. Partial fusing is caused by the pressure and heated surfaces areas found in the Cleaner, Developer Housing, Toner Dispenser, Waste and Transport systems, and the Photoreceptor module.

A printed image appears to be stretched in either (or both) the slow scan or the fast scan direction. Distortion can be categorized as follows: •

Slow scan distortion problems (motion quality problems relating to the PR speed or paper transportation speed) appear on the print as a defect in the fast scan direction.

DCDs: Agglomerates can cause deletions in solid areas. These are called Debris Centered Deletions (DCDs). The major causes of DCDs are agglomerates and paper debris. The generation of these is caused by incorrect Xerographic Setups.

•

Fast scan distortion problems (Polygon Motor speed fluctuations) appear on the print as defects in the slow scan direction.

Procedure

Observe the output prints. If wrinkles or folds are observed, go to the 10-604 Fuser Wrinkle RAP.

Check the following: 1.

2.

Procedure

Developer Housing Contaminants and their source. •

Check the cleaner for agglomerates. Refer to PQ 9-617, Cleaner RAP.

•

Ensure that the Dicorotrons or other hardware is not contacting the Photoreceptor belt.

•

Check for obstructions and agglomerates in the Developer Housing. Refer to PQ 9616, Development RAP.

Toner Dispense System. Remove the Toner Bottle. Dump a small amount of toner onto a sheet of paper. If agglomerates are present in the toner, replace the toner. Perform the Developer Dump and Thump (REP 9-6).

3.

Initial Actions

Check/Verify the following: •

The Cleaner Zone Roll is fully engaged (PL 9.2)

•

The Developer Housing, Xerographic Drawer, and Photoreceptor module are properly locked into their operating positions.

•

Enter dC131 [MIN]. Ensure that Address 202=125 (Dtac Current ref) and Address 210=112 (Tran Shld current).

•

Enter dC314. Select [DC PWB (10-18)]. Ensure that the calibration values entered for DTAC$$SI (Detack Current Control) and TRAN$$SI (Transfer Current Control) equal the values on the HVDC PWB calibration card.

•

DCDs are dependent on process control setup. Low TC, for example increases DCDs. Perform the Xerographic Setup (ADJ 9-3).

•

Certain papers generate more debris than others. If paper debris is suspected try different paper stock.

•

If agglomerates or debris remain a problem, replace the Toner Dispenser Assembly (PL 9.19)

Enter dC131 [MIN]. Ensure that Address 420 is at the Data value shown in the appropriate level Software dC 131 Table in Section 6, General Procedures, of the Service Manual. NOTE: MIN Address 420 is the mode selection for: (48)=300 PSI or (96)=600 PSI and Lead Edge Lightning (00)=no LEL, (02)=normal, and (03)=stress. Check the sequential prints for a repeatable pattern of print distortion. Enter dC106. Select [Test Patterns and PQ] [Halftone]. Program a 50 print job. Press Continue. Number the prints as they exit the machine. Examine the prints for distortion. Determine if distortion is observed in a pattern. Y N The distortion occurs on every seventh print (A4 mode) or every third print (A3 mode). Y N CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. The distortion occurs on every print. Y N The distortion occurs randomly. Check the following: • Broken Light Shield (PL 9.2)

A Preliminary Working Document No Product Name Assigned

0/0/00 ?-13

B

•

Any damaged Photoreceptor Module components that support the PR Belt from the back.Foreign objects under the PR Belt. Fold, curl, or damage to the PR Belt. Repair/replace as required.

•

Photoreceptor Belt Tension Roll and the Cleaner Zone Roll are properly engaged. Check the Photoreceptor Tension (ADJ 9-11).

•

Ensure that the wires going to the Photoreceptor Module, P212 connector, are not rubbing against the PR Belt. Redress as required. If damaged, replace the Photoreceptor Belt (PL 9.1)

•

Xerographic Drawer properly mounted. Ensure that the drawer is aligned and securely engages into the closed position. Check the PR Module Alignment (ADJ 9-10).

•

Check the Photoreceptor Drives

C Section Name

PQ 9-604, PQ 9-606

A

B

C

A •

Continued problems, go to the Printer Electrical Noise Procedure RAP.

The defect appears on the print as a line in the slow scan direction. Y N If the defect appears as a deletion, go to the PQ 9-615 Deletions RAP. If the defect appears as a smear, go to the PQ 9-635 Smear RAP. CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Check the following: • Dirt/Contamination on the ROS exiting window. Clean as required. •

Scratches on the Photoreceptor Belt. Replace the Photoreceptor (PL 9.1). Perform a Xerographic Setup (ADJ 9-3).

•

Scratches/Build-up on the Fuser (PL 10.6)

•

Build-up on the paper transport rolls. Go to the 8-705 Print Damage RAP. Determine the problem area. Repair as required.

•

Continued problems, go to the Printer Electrical Noise Procedure RAP. Figure 1 PQ 9-606 Component Diagram (8311A).

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Check for the following: • Any damaged Photoreceptor Module components that support the Photoreceptor Belt from the back.Foreign objects under the Photoreceptor Belt. Fold, curl, or damage to the Photoreceptor Belt. Repair/replace as required. •

Photoreceptor Belt Tension Roll and the Cleaner Zone Roll are properly engaged. Check the Photoreceptor Tension (ADJ 9-11).

•

Ensure that the wires going to the Photoreceptor Module, P212 connector, are not rubbing against the Photoreceptor Belt. Redress as required. If damaged, replace the Photoreceptor Belt (PL 9.1)

•

Xerographic Drawer properly mounted. Ensure that the drawer is aligned and securely engages into the closed position. Check the PR Module Alignment (ADJ 910).

•

Check the Photoreceptor Drives

•

Continued problems, go to Printer Electrical Noise Procedure RAP.

A Section Name

PQ 9-606

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Preliminary Working Document No Product Name Assigned

A

PQ 9-607/608 Uniform And Non-Uniform High Background RAP

Procedure

Uniform background - a noticeable darkness or dirtiness in all areas of a print where no image appears.

Enter dC131 [MIN]. Check the following NVM addresses and enter the data values as listed in the appropriate level Software dC 131 Table, Section 6, General Procedures, in the Service Manual. Table 1 MIN NVM

Nonuniform background - a noticeable darkness or dirtiness discernible in localized areas of a print where no image appears.

Address

Address

Address

Address

187

205

243

347

Structured background - a background defect that appears as fast or slow scan black lines on the non-image areas of a print, which may have a woodgrain or plywood appearance, and can appear on the entire print or in localized areas.

189

206

244

348

192

207

245

349

194

208

247

350

Initial Actions

199

210

251

351

200

217

300

352

203

218

302

204

220

305

•

Check for Reverse Developer Flow (Figure 1). Inspect the Developer Material flow across Developer Roll #1. Reverse Developer Flow exists when Developer Material accumulates between rolls 1 and 2 and appears to flow in the reverse from normal direction. It can occur at one or at both ends of Developer Roll #1. If Reverse Developer Flow is in evidence, go to the PQ 9-631, Bead Carryout RAP, Check for Reverse Developer Flow section at the end of the RAP.

•

Enter dC107 [Xero]. Replace the Developer Material (REP 9-4) as required.

•

Replace the Photoreceptor (PL 9.2).

•

Check/clean the exterior of the Developer Housing and all Dicorotron Shields. Inspect all dicorotron shields and wires for contamination. Replace them as required. Reset the HFSI counters.

•

Examine the shoulder washer located on the back of the PR Module Drive Roll for wear or damage (PL 9.3).

•

Examine the rear edge of the Photoreceptor for damage. If damage is apparent, examine the rear of the Edge Guide (PL 9.5) for fused toner. If fused toner is found, replace the Edge Guide (REP 9-45).

•

Enter dC909. Run 200 prints. The difference between Roll 1 and Roll 2 Bias and ESV Zone 2 is approximately 120 volts. If it is not, run dC951, Xerographic Setup. During the dC909 Print Run, the DSS readings in ID Zone 2, 4, 6 are between 90 and 100. If they are not, perform DSS Saturation (ADJ 9-13), DSS Timing (ADJ 9-14) and PGen Timing (ADJ 9-5). Immediately run dC951, Complete Setup.

•

Enter dC951 [Automatic Xerographic Setup]. Ensure that the ROS Calibration display value is equal to the value on the ROS Calibration tag on the front of the ROS assembly. Perform the ROS Low Correction Factor adjustment (ADJ 6-3). Perform the Xerographic Setup (ADJ 9-3).

•

Ensure that the Transfer Assist Device is in place.

•

Go to the PQ 9-616, Development RAP. Return to this RAP upon completion.

•

Go to the PQ 9-617, Cleaner RAP. Return to this RAP upon completion.

•

Go to the PQ 9-620, DSS RAP. Return to this RAP upon completion.

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. All printer MIN NVM Data values were equal to the values listed in the appropriate level Software Table. Y N Inspect the Photoreceptor Belt for surface wear. Replace if it has a buffed or streaked appearance (PL 9.1) Change data values as required. Perform Xeroxgraphic Setup, (ADJ 9-3). Open the Printer Front Doors. Pull out the Xerographic Drawer. Raise the Photoreceptor Module. Verify the operation of the discharge lamps. Press the Red test button on the Photoreceptor Module. All segments of the Precharge and the Pretransfer Lamps are lit. Y N Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP. Examine the background on the sample prints. The background is uniform on the prints. Y N (Nonuniform Background). Perform the following checks: • Enter dC314. Select [DC PWB #2]. Ensure that the calibration values entered for DETAC$$SI (Detac current control) and TRAN$$SI (Transfer current control) equal the values on the HVDC calibration card. •

Inspect the Photoreceptor Belt for surface wear. Replace the belt if it has a buffed or streaked appearance (PL 9.1).

•

Check for any kinked or damaged Ozone Ducts (PL 9.8).

•

Go to the PQ 9-616, Development RAP.

(Uniform Background). Enter dC909. Press Continue. Observe the Control Values, Charge 2V and ESV #2 (Patch reading #2 under Image Frame). Charge 2V is LESS THAN 750 VDC, or ESV #2 is less than 200 VDC. Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-607/608

Y

N Verify the DSS Saturation (ADJ 9-13). Perform the Xerographic Setup (ADJ 9-3). If background problem continues, return to this RAP; go to the Y response to the previous statement.

Select [ESV-DSS Test]. Record the DSS reading. Carefully wipe off the Photoreceptor Belt directly over the DSS with a clean piece of cotton. Recheck the DSS reading for the clean Photoreceptor Belt. The difference between the two DSS readings is less than 5 units. Y N (The difference between the two DSS readings is greater than 5 units). This indicates that a DSS calibration was done with toner on the Photoreceptor Belt. Enter dC951 [TC/ PGen]. Press the Continue button. When the program is completed, check the DSS Saturation (ADJ 9-13), and perform a Xerographic Setup (ADJ 9-3). Look for background on the last prints. If background is still present, go to Flag 1. Check the Developer Bias 1 and 2 wires. If the problem continues, perform the following actions until the problem is fixed: • Perform PQ 9-621, Patch Gen/Patch Integrity RAP. •

Perform PQ 9-619, ESV RAP.

If the problem continues, perform the following actions. • Go to Flag 2. Check for a short circuit or an open circuit. •

Check the DSS Saturation (ADJ 9-13)

•

Perform PQ 9-621, Patch Gen/Patch Integrity RAP.

•

Perform PQ 9-619, ESV RAP.

•

Perform the Automatic Low ROS Correction Factor procedure in dC951 Xerographic Setup (ADJ 9-3).

•

Verify that the DSS Read Timing is correct.

Section Name

PQ 9-607/608

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Preliminary Working Document No Product Name Assigned

Figure 1 PQ 9-607/608 Circuit Diagram (703007).

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-607/608

A (The deletion areas are seen on the 1 Pixel Black Line prints.) Enter dC106. Select [Test Patterns and PQ] [Xerographic]. Program a 20 print job. Press Continue. Look for density variation in the solid area density blocks of the output prints. The density is uniform without variation. Y N Go to the PQ 9-614, Nonuniform Image Darkness RAP.

PQ 9-609 Low Image Darkness (Low Signal Strength, w/ MICR) RAP The overall image density on the prints is light (undertoned).

Initial Actions •

Ensure that the Patch Generator and the DSS are operating. Go to the PQ 9-621, Patch Gen/Patch Integrity RAP and the PQ 9-620, DSS RAP. When complete, return to this procedure.

•

Ensure that a Digital Patch Generator was installed and that the Digital Patch Generator is enabled in dC105.

•

Perform the following:

Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. Table 1 MIN NVM MIN Address

1.

Power off the Printer.

2.

Saturate a clean, lint free cloth with Xerox Anti-static Fluid (8R90275).

3.

Wipe the DSS with the saturated cloth so that the fluid beads on the DSS.

4.

After a few seconds, wipe with a clean, dry, lint free cloth.

5.

Perform the DSS Saturation adjustment (ADJ 9-13).

WARNING Put on Safety glasses before inspecting the Dicorotron coronodes. Eye injury could result if the glass coronode breaks. •

Clean all dicorotron shields. Inspect all dicorotrons. If the shields or wires are contaminated, replace as necessary, and recheck the image darkness.

•

Check the OZAC system for air leaks and/or cracks in the OZAC Ducts. Repair/replace the ducts as required (PL 9.8)

•

Remove the toner bottle. Ensure that there is toner in the hopper and in the bottle. Ensure that toner is not caked in the hopper. If toner is caked, perform the Developer Dump and Thump Procedure (REP 9-6), replace the developer material (REP 9-4) and add new toner.

•

Ensure that the proper PQ Basic and Special Controls are being used for the job. Advise the operator if required.

•

Enter dC107 [Xerographic Counters]. Replace developer material (REP 9-4) as required. Perform the Xerographic Setup (ADJ 9-3).

NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These deletion bands are 1/8 to 1/2 of an inch in width, and usually more than one band appears on the print. The deletion areas are seen on the 1 Pixel Black Line prints. Y N Ensure that the Developer Bias P204 connector at the back of the Developer Housing is connected securely. (Possible ROS flare light induced defect). Replace the ROS. Perform the Xerographic Setup (ADJ 9-3). Go to 6-233 and go to 6-233, and perform the procedures. A Section Name

PQ 9-609

MIN Address

210

220

215

221

Current Value

The data values at the addresses were equal to the values listed in the appropriate level Software Table. Y N Enter the correct data values. Perform the Xerographic Setup (ADJ 9-3). Enter dC909 [ESV-DSS Test] [DSS Recalibrate]. Record the DSS value. The DSS value is greater than 232 +/- 14. Y N CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. Clean the DSS, ESV and Patch Generator. Enter dC106. Select [Printer Options] [Test Patterns and PQ] [Halftone]. Program a 150 print job. Press Continue. Examine the image darkness of the last few prints. Select [Xerographic]. Press Continue. A 9-215 fault code may occur if the machine attempts a tone up cycle. Clear the fault and continue. When the job has completed, go to the Yes response to the previous statement, and continue with this RAP.

Procedure Enter dC606. Select Black Lines [1-Pixel Lines] Image Size [8.5 by 14 inch]. Select [Printer Options]. Select a tray with 14 inch paper. Select [Test Patterns and PQ] [Darker 2]. Press Continue. Examine the prints.

Current Value

Enter dC140 [DC Bias Values]. Press Continue. Measure the Dev Roll 1 & 2 Bias voltage. Measure at the Developer Housing left side extrusion (located under the Developer Catch Tray), and the machine frame. Observe the Dev Rolls 1&2 Bias displays. The measured voltage is 180 to 320 VDC. Y N Press Stop. Switch Off the printer power. Check for continuity from P256-5 (the connector at the rear of the Toner Dispenser) to the drive shaft of Rolls 1 and 2. There is continuity. Y N Repair as required.

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C Preliminary Working Document No Product Name Assigned

B

C Go to the 9-320 RAP. To diagnose the problem (assuming there is no fault code present), follow the first No response of the 9-320 RAP.

PQ 9-610 High Image Darkness RAP The overall image density on the prints is dark (overtoned).

Press Stop. Measure the Dev Roll 3 Bias. Measure the voltage between the Developer Housing extrusion under the Developer Air Manifold and machine frame. Observe the Dev Roll 3 Bias displays. Press Continue. The measured voltage is within 20 VDC of the required display value. Y N Press Stop. Switch Off the printer power. Check for continuity from P256-8 (the connector at the rear of the toner dispenser) to the right-hand surface of the Developer Housing extrusion. There is continuity. Y N Repair as required.

Initial Actions •

Observe the solid area blocks on the prints.

•

The density of block 3 is equal to the STD:Restore density block. If not, check the Print Darkness level set by the Operator in the Print Management Screen. For Normal Print Darkness, set Darkness Level to 4.

Procedure If the Xerographic Setup has not been completed this call, go to Xerographic Setup (ADJ 9-3). Enter dC131 [MIN]. Record the Data values at the following Addresses.

Go to the 9-321 RAP. To diagnose the problem (assuming there is no fault code present), follow the first No response of the 9-321 RAP.

Table 1 MIN NVM MIN Address

If not already completed, perform the following actions until the problem is repaired. • ESV checkout: go to the PQ 9-619, ESV RAP.

220

•

Patch Generator checkout: go to the PQ 9-621, Patch Generator/Patch Integrity RAP.

251

•

DSS checkout: go to the PQ 9-620, DSS RAP.

300

•

Replace the developer material (REP 9-4). Perform the Xerographic Setup (ADJ 9-3).

302

•

Advise the customer to use modified PQ settings. Store the modified settings in the Programmed Job icon.

•

Ensure the dC131 NVM values at the following locations compare them to the values listed in the appropriate level Software dC 131 Table in Section 6, General Procedures

Current Value

222

Enter dC909. Run a 200 print job. Observe the DSS Readings in the ID Zone 2, 4, 6. Values over deadcycle setpoint (100). The Machine is deadcycling (Adjusting Print Quality. Y N Perform the DSS Saturation (ADJ 9-13). Go below to STEP A.

Table 2 MIN NVM MIN Address

•

Current Value

MIN Address

243

251

244

300

245

302

Continued problems, go to the 9-215 RAP.

Current Value

Perform the following: • DSS Timing (ADJ 9-14). •

DSS Saturation (ADJ 9-13).

(STEP A) Compare the values listed in the Table 1 to the appropriate level Software dC 131 Table in Section 6, General Procedures. The data values at the MIN NVM addresses in Table 1 were equal to the values listed in the appropriate level Software Table. Y N Enter the correct data values, perform the Xerographic Setup (ADJ 9-3). Enter dC106. Select [Test Patterns and PQ] [Xerographic]. Program a 75 print job. Press Continue. Compare the prints to the Standard Image Reference test pattern (82E4161). The background on the prints is less than the All:BKGD block. Y N (Background is high). Go to PQ 9-607/608, Uniform and Non-uniform High Background RAP. Look for density variations across the prints. Check the top and bottom density blocks on the prints. The density is uniform without variation. Y N Density variations observed, go to PQ 9-614, the Non-uniform Image Darkness RAP. A

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-609, PQ 9-610

A Observe the solid area blocks on the prints. The density of block 3 is less than or equal to the STD:Restore density block. Y N (The density is too dark). Enter dC131 [MIN]. Enter Address 250 (Patch Generator Intercept Value) and record the value. Decrease the current Data value by 3. Select [Enter]. Enter dC606. Program a 500 print job. Press Continue. After the 200 prints are complete, check the block 3 density. Repeat the decreasing of Address 250, 3 bits at a time, up to 5 times (maximum 15 bits). If the density of block 3 is not less than or equal to the STD:Restore, enter the original Data value in Address 250. Go to PQ 9-621, the Patch Gen/Patch Integrity RAP, and PQ 9-620, the DSS RAP. Normal Mode density is OK. Instruct the customer to use the Print Quality darkness controls to optimize Print Quality.

PQ 9-611 Dark Streaks/Scratches/Bands RAP Dark streaks and bands are toner deposits (marks on copy) in any direction. Streaks and scratches are narrow widths, such as the width of a line, that is up to one millimeter across. Bands are wider widths greater than one millimeter across.

Initial Actions Observe the MIN cooling fan. If the fan is not functioning properly, go to the 9-705, MIN Cooling Fan RAP. If the PQ defect is a fast scan band running the entire length of the print, go to the PQ 9-618, PR Ground RAP. Return to this RAP if the problem continues.

WARNING Put on Safety glasses before inspecting dicorotron coronodes. Eye injury could result if the glass coronode breaks. Clean the dicorotron shields and ensure that the dicorotrons are seated properly. Check the wires for hot spots, cracked glass. Replace components as required (PL 9.10) If the defect occurs only in the 11 to 14 inch area of the prints, replace the Metering Blade and Wick (PL 10.7)

Procedure Classify the symptom. Enter dC606. Select [Light Dusting]. Run 14 prints using the longest print paper stock available. Determine which of the following categories the prints fall into: Scratches/Streaks/Bands. •

Slow Scan Direction (parallel to the Process Direction), go to STEP 1.

•

Fast Scan Direction (perpendicular to Process Direction), go to STEP 2.

1.

SLOW SCAN DEFECTS (parallel to process direction) a.

Slow Scan Bands. Go to the Print Quality Defect section if the bands are as follows: •

Dark Bands, (1 scan line) 0.042mm wide every 0.25mm or 0.35mm in the fast scan direction.

NOTE: Do not assume that new Developer or new Toner is defect free. Always compare the batch numbers to past bulletins and purge notices to determine if the consumable has been previously identified as being defective.

Section Name

PQ 9-610, PQ 9-611

0/0/00 ?-20

b.

Consumable Check. Determine if the Toner and/or the Developer Material are defective. Check the batch numbers against any past bulletins or purge notices.

c.

Toner batch number identified as defective. Remove the Toner Bottle. Empty the Toner out of the hopper. Tap the sides of the Hopper with the handle of a screwdriver as you vacuum it out. Perform the Developer Dump and Thump (REP 9-6). Install new Developer Material (REP 9-4). Go to STEP 3 in this RAP.

d.

Developer material batch number identified as defective. Perform the Developer Dump and Thump (REP 9-6). Install new Developer Material (REP 9-4). Go to STEP 3 in this RAP.

Preliminary Working Document No Product Name Assigned

CAUTION

NOTE: The spots blade must be adjusted after a cleaner replacement.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. e.

Check/clean toner debris/deposits from the Cleaner Housing right side (Entrance Baffle). Check that the Spots Blade (brown) contact area is 0.5mm to 3mm and adjust if required (ADJ 9-16).

•

If the Photoreceptor has numerous scratches with a brushed appearance, vacuum the Cleaner Module. Replace the Cleaner Brush (PL 9.24) and the Flicker Bar (PL 9.24). Go to STEP 3 in this RAP.

Photoreceptor. If the marks or lines on the prints repeat every seventh print (A4 mode), inspect the Photoreceptor Belt for scratches or Crayoning. •

Scratches; There may be a PR Tension (ADJ 9-11) or a PR Module Alignment (ADJ 9-10) problem. If the adjustments are OK, complete this procedure to identify the cause.

•

Crayoning is piled up toner areas on the PR Belt. If crayoning (Toner buildup) is observed on the Photoreceptor, perform the Developer Dump and Thump Procedure (REP 9-6). Replace the Developer Material (REP 9-4). Replace the Toner Bottle (REP 9-0). Clean the Mixing Auger (REP 9-13). Go to STEP 3 in this RAP.

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. g.

NOTE: Always replace the Spots Blade (PL 9.26) whenever the PR Belt is replaced for Long scratch problems. The blade has probably suffered edge damage. Do not immediately install a new Spots Blade with a new PR Belt. Run dC951 first with no blade. Wipe the new blade with toner before installing to eliminate tuckunder that stresses the blade. f.

•

Long Slow Scan Scratches - scratches on the Photoreceptor greater than 18mm long. Before replacing the Photoreceptor Belt (PL 9.1), note the position of the scratches. Determine if they line up with any of the components of each subsystem around the PR Belt. Some causes of scratches and their corrective actions are: •

Broken/loose components around the Photoreceptor Module, repair/replace components as required.

•

Inspect the Developer Housing and the Cleaner Housing for contaminants or binding. Go to the appropriate RAP, PQ 9-616, Development RAP or the PQ 9617, Cleaner RAP if a problem is suspected.

•

2.

Ensure that the Developer housing, Xerographic Drawer, and Photoreceptor Belt Module are positioned properly and locked into the operating position.

•

Ensure that the Charge Dicorotrons are not contacting the Photoreceptor Belt. Perform the Charge Dicorotron Balance (ADJ 9-6) and Height (ADJ 9-7) adjustments.

•

Ensure that the ESV is not contacting the Photoreceptor Belt. Perform the ESV Height Adjustment (ADJ 9-12).

•

Place white paper under the Cleaner. Remove the Cleaner Brush. Tap the Cleaner Module with the handle of a screwdriver. Check the debris on the white paper for contaminants. If large contaminants are found, a binding auger problems exists, or if toner buildup on the detoning rolls is present, go to the PQ 9617, Cleaner RAP.

Preliminary Working Document No Product Name Assigned

•

If the Photoreceptor is damaged at the inboard edge, replace the Photoreceptor Belt (PL 9.1)

•

Inspect the Developer Catch Tray and the developer material for contaminants. If contaminants are found, check for binding, interference and /or bearing failure of the Developer Rolls (REP 9-9), BRD Roll (REP 9-8), Trimmer Bar (REP 9-11), Mixing Auger (REP 9-13), and Paddle Wheel (REP 9-12). Go to the PQ 9-616, Development RAP. Return to this RAP and perform STEP 3 in this RAP.

•

Unlatch and raise the Photoreceptor Module. Ensure that the Developer Housing is securely installed in the machine. Check the front and rear contact points. If either of the front two contact points are damaged or worn, replace the Front Bearing Clamp (PL 9.15)

FAST SCAN DEFECTS (Perpendicular to process direction). The defect only appears on the last print of any print run.

Transfer Assist Blade touching the Photoreceptor. Ensure that the Mylar blade is not touching the Photoreceptor in standby. If it is, check for blade damage and also that the blade is indexed to the proper position for the short paper being used by the customer. For additional information, see Transfer Blade Repair (REP 9-48).

•

Short Slow Scan Scratches - less than 18mm long. Inspect the Photoreceptor Belt.

3.

0/0/00 ?-21

a.

There may be an intermittent connection in the Preclean Dicorotron shield circuit. Clean and reseat the Preclean Dicorotron shield. If the problem continues, inspect the dicorotron shield connector, dicorotron shield lead, and the HVDC PWB shield connector.

b.

There is an intermittent connection in the circuit of the Charge 1 or the Charge 2 dicorotron shield. Clean and reset the Charge 1 and the Charge 2 dicorotron shield.

c.

The defect may be caused because of a failed Precharge or Pretransfer Discharge Lamp. Open the front covers and the Xerographic Drawer. Pull out the Photoreceptor Module to its maximum position. Press the R (Red) lamps test switch on the Photoreceptor Module. If a lamp does not light, go to the PQ 9-624, Precharge/ Pretransfer Lamps RAP.

d.

The defect may be caused by the Cleaning system. Go to the PQ 9-617, Cleaner RAP. If the problem continues, go to the PQ 9-616, Development RAP. Return to this RAP and perform 3 in this RAP.

e.

Black, fast scan line on the lead edge of the prints. If the defect is a black line or a smear on the lead edge of the prints in the direction of the fast scan, enter dC131 [PHN]. Ensure that Address 251=0. Check the Transfer Assist Blade Timing (ADJ 99). If the problem continues, replace the Transfer Blade (PL 9.11)

FINAL ACTION.

Section Name

PQ 9-611

•

Ensure that all sources of contamination have been purged from the System to prevent a callback for the spots problem. If the above or no other cause of Photoreceptor scratches are found, replace the Cleaner Brush (PL 9.24).

Possible Sources of Contamination Ensure all sources of contamination have been purged from the System to prevent callback for the spots problem. Perform the following actions unless already done while troubleshooting. Paper Dust •

Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper Trays and the paper path areas. Wipe areas as required.

CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. •

Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Precharge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum the Photoreceptor Ground Brush.

•

Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays and the paper path area. Ensure that no developer material has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform the Xerographic Setup (ADJ 9-3).

Paper Stock •

Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of paper added to the Trays.

•

Pre-drilled paper: suggest that paper be drilled after printing if possible.

•

Label stock: adhesives from the labels can cause spots.

•

Carbonless paper is not recommended for use on this system.

•

Paper stock: certain brands are known spot generators.

•

Spray adhesives: any sprays used near the system can enter the machine air system and can cause spots and damage the Photoreceptor.

Fuser Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not contaminating the developer assembly. If any oil is identified in the Developer Assembly, replace the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the Xerographic Setup (ADJ 9-3).

Tray 1 / Tray 2 Feed Components Oil leaking from the sides of bearings or debris from the following: •

Takeaway Roll (PL 7.13)

•

Feed Belt Idler (PL 7.12)

•

Feed Belt Pulley (PL 7.12)

•

Feed Belt Spool (PL 7.12)

•

Idler and Retard Brake (PL 7.13)

Belts wearing: •

Takeaway Drive Belt (PL 7.10)

•

Feed Clutch Belt (PL 7.10)

•

Top Transport Belts (4) (PL 7.10)

Dirt Shield, clean or replace as required (PL 7.10)

Xerographic CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4).

Section Name

PQ 9-611

0/0/00 ?-22

Preliminary Working Document No Product Name Assigned

A

PQ 9-612 Light Streaks/Bands RAP

B Y

The appearance of light streaks and/or light bands is an indication that there is not enough or an absence of toner in the required areas. Streaks are narrow widths, such as the width of a line, that are a maximum of 1mm across. Bands are widths greater than 1mm across.

Rotate the Developer Rolls two revolutions counterclockwise with the Belt Module opened to its maximum position. Observe the developer material on the rolls. The developer material is smooth and even. Y N Check the Developer. Remove the obstruction from the Trimmer Bar area. Perform the Developer Dump and Thump (REP 9-6). Perform the Xerographic Setup (ADJ 9-3).

Initial Actions WARNING Put on safety glasses before inspecting dicorotron coronodes. Eye injury could result if the glass coronode breaks. •

Clean the dicorotron shields, and inspect the dicorotrons. If the shields or wires are contaminated, replace them as necessary, and recheck the image darkness.

•

Check the OZAC system for air leaks and/or cracks in the OZAC ducts. Repair/replace the ducts as required (PL 9.8).

•

If the defect repeats on every seventh print, replace the Photoreceptor Belt (PL 9.1).

N Look for dirt or obstructions in the transfer area and in the stripper finger area.

Look for a large amount of developer material on the top of the Developer Housing or on the Bead Removal Device (BRD Roll). Material is present and is high enough to touch the Photoreceptor Belt. Y N If this fault is random, it may be caused by undetected, intermittent dicorotron faults. Remove all dicorotrons, and inspect the HVAC contacts for signs of arcing or corrosion. Replace the dicorotron as required (PL 9.10)

Procedure Enter dC606. Select Black Lines [1-Pixel Lines]. Select [Printer Options] [Tests Patterns and PQ] [Darker 2]. Press Continue. Examine the prints.

Use the vacuum cleaner to clean the top of the Developer Housing and the BRD. Change the Developer Material (REP 9-4). Perform Xerographic Setup (ADJ 9-3).

NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These deletion bands are 1/8 to 1/2 of an inch in width, and usually more than one band appears on the print.

Go to the PQ 9-621, Patch Gen/Patch Integrity RAP. CAUTION

The deletion areas are seen on the 1 Pixel Black Line prints. Y N (ROS flare light induced defect). Replace the ROS (PL 6.1). The defect is in the fast scan direction. Y N The defect is a deletion band that is approximately 20 millimeters wide in a vertical direction and is 180 millimeters from the top edge of the copy. Y N Enter dC106. Select [Test Patterns and PQ] [Xerographic]. Program a 20 print job. Press Continue. After approximately 10 prints have been made, open the Printer Right Front Door. Carefully remove the print from the prefuser area. The defect is on the unfused print. Y N Look for obstructions in the fuser area. Ensure that the Fuser Wick is positioned correctly.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Open the Photoreceptor Module. Press the (Red) lamps test switch on the front of the module. The Pretransfer and Precharge Lamps are lit. Y N Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP. The Developer Rolls rotate with a smooth motion. Y N Repair the cause of the defective developer drive. Look for light l leaks in the imaging areas.

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Open the Xerographic Drawer, and lift the Belt Module to its maximum position. Inspect the developed image area on the photoreceptor. Determine if the defect is present. The defect is on the developed image. A

B

Preliminary Working Document No Product Name Assigned

0/0/00 ?-23

Section Name

PQ 9-612

PQ 9-613 Black Spots RAP Black spots are areas of unwanted marks or deposits of toner within a print. Excessive image darkness on copies will tend to aggravate the dark spots problem.

NOTE: If the spots are clustered together but are in an ordered pattern they may be the result of a damaged PR belt. If the PR Module is lowered incorrectly, the result can be spots that appear in a fast scan direction. NOTE: In early software versions the dC107 counter had the units incorrectly labeled as pitches, the counter actually indicates P/R Belt revolutions.

Initial Actions •

Ensure that the Photoreceptor Module and the Xerographic Drawer are locked into their operating positions.

a.

Ensure that the Spots Blade is properly installed. Check the Spots Blade Contact (ADJ 9-16).

•

If toner is falling out of the Cleaner causing toner blotches, go to the PQ 9-617, Cleaner RAP.

b.

•

If the spots are only on the backside of the print and occur randomly, inspect/clean the Transfer Assist Blade. Check/adjust the Transfer Blade Timing (ADJ 9-9).

Examine the Photoreceptor Belt for fuser agent or other contaminants. Use the Photoreceptor Spots Cleaning procedure (REP 9-55), or replace the Photoreceptor (PL 9.1).

c.

•

Check the customers PQ settings. Black spots will increase if print darkness is set too high.

Enter dC107, [Xero]. Replace the Photoreceptor if greater than 100K revolutions (PL 9.1).

d.

•

Check for fuser agent leaking into the xerographic area.

Inform the customer that certain items can increase the potential for spots. Refer to last check of this RAP, Possible sources of contamination.

6.

Procedure 1.

Check sequential prints for a repeatable pattern of black spots. Enter dC606. Select [Light Dusting]. Program 250 prints. Press Continue. Examine the prints for dark spots.

2.

a.

Dark Spots pattern repeats on every print. Go to the PQ 9-601, Printer Image Quality Entry RAP.

b.

Dark Spots no repeat pattern. Go to STEP 6.

4.

a.

The background on the print is greater than the ALL:BKGD block, go to the PQ 9607/608, Uniform and Non-uniform High Background RAP.

b.

Block 3 on the print is greater than the STD:Restore block, go to the PQ 9-610, High Image Darkness RAP.

Enter SCP [HFSI] [Dicorotrons]. Check 09-822 Preclean Dicorotron, replace if near or over threshold (PL 9.10)

c.

Check for excessive toner/developer build up around the Developer Housing. If the developer material is contaminated and it has been in the machine for less than 500K copies, check the machine for sources of contamination. Correct the contamination problem. Replace the Developer Material (REP 9-4). Go to the PQ 9-616, Development RAP.

7.

Determine if the dark spots are present past the Cleaner. a.

Run 20 prints of the light dusting. Enter dC106. Select [Test Patterns and PQ] [Halftone]. Press Continue.

b.

After 10 prints have been made, open the Printer Front Doors. Observe the Cleaner Assembly. If excessive toner is in the cleaner or black spots are present on the Photoreceptor Belt past the Cleaner, go to the PQ 9-617, Cleaner RAP.

Black spots repeat on almost every copy, but tend to move across the page at the rate of six to 10mm print to print.

8.

If considerable levels of dirt are found in the belt module area, correct the dirt problem. Go to the PQ 9-632, Dirt RAP.

Check for offset toner images on the fuser roll. Go to the 10-606, Dry Ink Spots on Prints/ Spots Deletions RAP.

9.

Clean sources of contamination from the System to prevent callback. Perform the following actions unless already done while troubleshooting:

Black spots repeat on almost every copy, but occur in a Slow Scan direction that aligns with the front or rear edge of Tray 1 or Tray 2 Feed Heads.

Possible Sources of Contamination

a.

b. 5.

Ensure that the Toner Filter Assembly Cover is closed and latched correctly.

b.

Dark Spots on prints whose image darkness is excessive. Select dC106 [Test Patterns and PQ] [Xerographic]. Press Continue. Check the print specifications:

3.

Black spots appear randomly on the prints. a.

Remove the following parts from the feed heads and wipe off any excess grease with a dry towel: •

Take Away Drive Roll

•

Feed Belt Idler

•

Feed Belt Pulley

Paper Dust •

Replace the Photoreceptor Belt (PL 9.1). Perform the Xerographic Setup (ADJ 9-3).

Black spots repeat every seventh print and are judged unacceptable.

Section Name

PQ 9-613

Ensure all sources of contamination have been purged from the System to prevent callback for the spots problem. Perform the following actions unless already done while troubleshooting.

Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper Trays and the paper path areas. Wipe areas as required.

Paper Stock •

Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of paper added to the Trays.

•

Pre-drilled paper: suggest that paper be drilled after printing if possible.

0/0/00 ?-24

Preliminary Working Document No Product Name Assigned

PQ 9-614 Non-Uniform Image Darkness RAP

•

Label stock: adhesives from the labels can cause spots.

•

Carbonless paper is not recommended for use on this system.

•

Paper stock: certain brands are known spot generators.

•

Spray adhesives: any sprays used near the system can enter the machine air system and can cause spots and damage the Photoreceptor.

Tray 1 / Tray 2 Feed Components

There is a noticeable difference in image density on the same print. Variations in the fast scan or slow scan direction.

Initial Actions •

Check for and repair light leaks around the machine, ensure there is no ambient light getting into the Printer around the covers.

•

Check the OZAC system for air leaks, cracks in the OZAC Ducts. Repair/replace components as required (PL 9.8).

Oil leaking from the sides of bearings or debris from the following: •

Takeaway Roll (PL 7.13)

•

Feed Belt Idler (PL 7.12)

•

Feed Belt Pulley (PL 7.12)

•

Feed Belt Spool (PL 7.12)

•

Idler and Retard Brake (PL 7.13)

WARNING Put on safety glasses before inspecting dicorotron coronodes. Eye injury could result if the glass coronode breaks. Clean all dicorotron shields. Inspect the dicorotrons for contamination. Replace dicorotrons as necessary (PL 9.10).

Belts wearing: •

Takeaway Drive Belt (PL 7.10)

•

Feed Clutch Belt (PL 7.10)

•

Top Transport Belts (4) (PL 7.10)

Check the Charge Dicorotron Balance (ADJ 9-6).

Procedure Enter dC606. Select Black Lines [1-Pixel Lines] Select [Printer Options] [Tests Patterns and PQ] [Darker 2]. Press Continue. Examine the prints.

Dirt Shield, clean or replace as required (PL 7.10)

Xerographic CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4). CAUTION

Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. •

Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Precharge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum the Photoreceptor Ground Brush.

•

Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays and the paper path area. Ensure that no developer material has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform the Xerographic Setup (ADJ 9-3).

NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These type of deletion bands are 1/8th to 1/2 of an inch in width and usually more than one band appears on the print. The deletion areas are seen on the 1 Pixel Black Line prints. Y N (ROS flare light induced defect). Replace the ROS, and Perform the Xerographic Setup (ADJ 9-3). If the deletion areas are seen on the 1 Pixel Black Line prints, return to the Yes response to the previous statement. Perform the following items in the order given until the problem is resolved. • PQ 9-626, Dicorotron RAP. •

PQ 9-616, Development RAP.

•

PQ 9-624, Precharge/Pretransfer Lamps RAP.

If the problem continues, the Photoreceptor Belt may be suffering from light shock. Check all the panels for light leaks. If the problem continues, replace the Photoreceptor Belt (PL 9.1). If the problem continues after the Xerographic Setup. Enter dC106 [Test Pattern and PQ] [Xerographic]. Program a 15 print job. Press Continue. Determine if the nonuniformity of the image darkness is a problem in the solid areas or in the fine line areas of the prints run. If the solid areas appear to be uniform but the fine lines are not uniform in darkness, replace the ROS Assembly (PL 6.1).

Fuser Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not contaminating the developer assembly. If any oil is identified in the Developer Assembly, replace the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the Xerographic Setup (ADJ 9-3). Preliminary Working Document No Product Name Assigned

0/0/00 ?-25

Section Name

PQ 9-613, PQ 9-614

PQ 9-615 Deletions RAP

NOTE: It may be necessary to run 50 prints of a line/text image that extends to all edges of the print to evaluate deletions (HALFTONE).

Deletions are the localized loss of image or light images which can be taken as a deletion on the print. The most effective stress test for line print deletions is to make prints of the E Form on lightweight (16 pound) paper.

1.

Bead Carryout. (Deletions occur at random locations). These deletions are mainly circular, occurring predominantly and more severely in the initial prints generated. In severe cases some of the circular deletions are joined together. Look for developer beads on the print in the deletion areas. Inspect the printer following areas for developer beads: Developer Housing manifold, Xerographic Drawer area, DSS area, Pretransfer Baffle, and the Transfer and Detack Dicorotrons. If beads are found carryout problem is indicated, go to the PQ 9-631 Bead Carryout RAP.

NOTE: Deletions within the outer 6mm of all four edges of the prints are within specification. Adjustment of the Transfer Assist Device will not eliminate deletions along the edges.

Initial Actions •

Check SCP Range Faults for 08-225 Faults. If the deletion is occurring along the Top Edge (50 mm) of the prints, ensure that the Registration Transport Cross Roll solenoids are operating properly. If the fault is logged, go to the 8-225, return to this RAP if the deletion problem continues.

2.

Observe the Transfer Assist Device during operation. Ensure that all four solenoids energize with 14 inch paper. Ensure that the entire Actuator Lever moves without binding. If binding or other Transfer Assist Device problems are suspected, go to the PQ 9-622 Transfer Assist Device RAP.

•

Check SCP Range Faults for 08-226 or 8-227 Faults. If either fault is logged, go to the 8226, 8-227 RAP, return to this RAP if the deletion problem continues.

3.

The deletion occurs at a specific location and repeats every seventh print (7 pitch mode) or every third print (3 pitch mode). Replace the Photoreceptor Belt (PL 9.1).

Check [SCP] [HFSI] [Dicorotrons] for the Transfer and Detack Dicorotrons. Ensure that the dicorotrons electrical connectors are secure. Ensure that the connectors are not reversed. Check the Transfer and Detack Dicorotron wires for contaminants.

4.

The deletion appears on most prints and moves approximately six to 10 millimeters from print to print and there are unfused areas near the deletions. Go to the 10-606 Dry Ink Spots on Prints/Spot Deletions RAP.

•

Check [SCP] [HFSI] [Belt Module]. Clean/replace the Transfer Assist Blade (PL 9.11).

5.

The deletion repeats at a specific location. Go to the 8-705, Print Damage RAP.

•

Ensure that the Xerographic Drawer and Belt Module are latched into the operating positions. Ensure that the Cleaner Backup Roll is fully engaged. Ensure that the Pretransfer Baffle is latched left, in the operating position. Check for light leaks in the belt module image area that corresponds to the area where the deletions are occurring. Ensure that Fuser Agent is not contaminating the PR Belt.

6.

The deletion occurs on side 2 of the prints and/or the deletions are accompanied with dirt on the back of the print or dirt on the lead edge of the print.

•

Ensure dC131 [PHN]. Ensure Address 251=0, (4 Transfer Solenoids). If the Data value required change, power the printer off and power on to set NVM. Enter dC606 and run prints to see if the problem is resolved.

•

Enter dC131 [MIN]. Address 210=112, (Transfer Shield Current Normal) and Address 220=(77 w/o MICR), or (51 w/MICR), (Developer rolls 1 & 2, Reference for toner setup). If the Data values require change, perform the Xerographic Setup (ADJ 9-3).

Procedure

Determine if the sheets entering the Duplex Inverter are hitting the LE of the sheets exiting the inverter. If this is occurring, check/adjust Duplex Registration Timing, dC702.

b.

If the deletions are occurring only in 3 pitch mode, check the Registration assembly for proper operation. Go to the 8-706 PHM Misregistration and Skew RAP.

c.

Go to the PQ 9-622 Transfer Assist Device RAP

7.

Predominantly in the solid areas. If the defect resembles debris centered deletions, solids that contain debris in the center (longer than developer beads), go to the PQ 9-604 Prints with Agglomerates/Debris RAP.

8.

Predominantly in the fast scan direction. Deletions can be caused by undetected, intermittent dicorotron faults. Remove all dicorotrons and inspect the HVAC contacts for signs of arcing or corrosion. Replace as required. If the problem persists, check the HVAC contacts in the OZAC components for signs of arcing or corrosion. Replace as required. If the problem persists, go to the PQ 9-628 HVAC RAP.

9.

Deletion band(s) in the Slow scan (process direction).

Determine which paper trays were being used when the deletions occurred. If a specific tray or trays are identified, use those trays to generate prints for diagnostic analysis. If the deletion problem occurs from all three paper trays, first use the tray having the highest frequency of deletions, then repeat the process with the other trays as required. Load the paper tray with a fresh ream of 14 inch/16 lb. paper. If 16 lb. paper is not available, use the lightest weight paper available. Cheat the Printer Interlock Bypass Switch. Enter dC106. Select [Duplex]. Select the longest paper available. Select [Test Patterns and PQ] [E Form]. Program a 50 print job. Press the Continue button.

a.

a.

Check the positioning of the Pretransfer Assembly (REP 8-5).

b.

Check the OZAC System for air leaks, cracks in the OZAC Duct. Use the manometer to measure -51mm vacuum at the air nipple of the Ozone Duct. Repair/replace Ozac System as required (PL 9.8).

NOTE: ROS Flare Light slow scan deletion bands may appear as Low Image Darkness. These type of deletion bands are 1/8th to 1/2 of an inch in width and usually more than one band appears on the print. c.

Section Name

PQ 9-615

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Enter dC606. Select Black Lines [1-Pixel Lines] Image Size [8.5 by 14 inch]. Select [Printer Options] [Tests Patterns and PQ] [Darker 2]. Press Continue. Examine the prints. If the deletion areas are seen on the 1 Pixel Black Line prints. (ROS flare light induced defect). Replace the ROS (PL 6.1).

Preliminary Working Document No Product Name Assigned

10. The deletion occurs on tab stock. a.

Ensure the customer stock is not curled or damaged.

b.

Perform the Transfer Blade Timing (ADJ 9-9).

c.

Perform the PR Module Alignment (ADJ 9-10).

PQ 9-616 Development RAP The purpose of this RAP is to diagnose development related problems.

Initial Actions Check/Repair the Developer Housing (REP 9-5). Enter [SCP] [HFSI]. Ensure that all Xerographic (09) HFSI due items that are listed in the HFSI TABLES have been performed. Reset the counters as required. Enter dC131 [MIN]. Check the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. Table 1 MIN NVM Address

Current Value

Address

203

220

215

221

Current Value

217 218 If any of the MIN NVM values required change, perform the Xerographic Setup (ADJ 9-3).

Procedure Inspect the Zone Roll Support Pads on the Developer Housing. If the front pads are broken or missing, replace the Front Bearing Clamp (PL 9.15) Check the Developer Zone Roll position (ADJ 9-1). Ensure that the Zone Roll aligns with the Support Pads on the housing. Ensure that the Photoreceptor Module latches properly. Ensure that the Developer Housing is securely installed in the machine. The Photoreceptor Module to Developer Housing interface is OK. Y N CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Check the following: • Damage to the Xerographic Drawer to Photoreceptor Module hinge Bracket and Shaft (PL 9.6). •

Photoreceptor Module Frame for warping (PL 9.1).

•

Check the PR Module Alignment (ADJ 9-10).

Inspect the Developer Housing area. Check for contaminated developer or developer leakage around and under the housing. Check for bead carryout. There is a normal level of developer material under the housing (no leakage). Y N (There is a leakage problem). Check/repair the following: A Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-615, PQ 9-616

A

B •

The Developer Seals (PL 9.15).

•

The Dump Door, the Latch Mechanism, Seal, and the Developer Plates for cracks or breaks (PL 9.17).

•

Continued bead carryout problems, go to the PQ 9-631, Bead Carryout RAP.

Y

NOTE: If this is a MICR Developer Housing, DO NOT handcrank the Developer Housing slowly, there may be lumping of the developer material. If lumping occurs, the lumps should be loosened by hand. Handcrank the developer assembly in a Clockwise direction ONLY. (Developer Roll 1 should rotate counterclockwise). All three rolls rotate. Y N Check all developer drive gears. Ensure that the gear teeth are not broken or worn. Ensure that the gears properly mesh. The developer roll drive gears are OK. Y N Remove the drive gears. Individually rotate the Developer Rolls, the Mixing Auger, and the Paddle Wheel. Check for bearing failures. Repair as necessary (PL 9.15).

N Low vacuum or a loss of vacuum will result in dirt across the entire width of the manifold. Enter dC330 [1-4] [Main Drive/Start]. Press Continue. The vacuum measurement at the outboard end of the manifold should be a minimum of 8mm of vacuum. There is greater than 8mm of vacuum measured. Y N Check for a clogged filter or a kinked or a plugged hose in the rear of the machine. Replace components as required (PL 9.14) Attach the vacuum cleaner to the manifold. Tap the bottom of the manifold with the blunt end of a screwdriver while vacuuming the manifold. After cleaning the manifold, go to the Y response two statements earlier, "Inspect the PR Belt for scratches", and continue this RAP. CAUTION

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

Remove the Paddle Wheel Gear (REP 9-12). Rotate each roll. Check for packed developer, defective bearings, and debris. The rolls rotate. Y N Clean or replace as necessary (PL 9.15).

Inspect the PR Belt for scratches that appear on the prints. Check the Developer material for contaminants. The rolls are free of contaminants (metal chips, toner agglomerates, foreign materials, etc.). Y N (There are contaminants in/on the developer rolls.) Check/replace the following: • Paddlewheel bearing (PL 9.17).

Rotate the Mixing Auger. Check for binding. The Mixing Auger rotates. Y N Replace the Auger Bearings (PL 9.16).

•

Rotate the Paddle Wheel. Check for binding. The Paddle Wheel rotates freely. Y N Replace the Paddle Wheel and/or the Paddle Wheel Shaft (PL 9.18).

Prepare the printer for operation. Cheat the Printer Interlock Bypass Switch. Enter dC330 [1-4]. Select [Main Drive Start/Run]. Press Continue. Observe the drive gears and the developer rolls. The Developer Rolls rotate. Y N Inspect the Developer Drive Coupling at the rear of the Xerographic Drawer. The Drive Couplings are worn or broken. Y N Remove the Dry Ink bottle. There is dry ink in the hopper. Y N Go to the 9-702, Low/Out of Dry Ink Message RAP.

Check the Paddle Wheel Shaft Roll Pin. Replace the Paddle Wheel Shaft as required (PL 9.18). Check the BRD for dirt, developer beads, and toner. Developer build up on the BRD Roll may cause deleted or poorly developed patches. Check the developer for binding. Clean as required. Handcrank the developer assembly in a Clockwise direction ONLY, to ensure that the BRD rotates. The BRD rotates. Y N Repair/replace the Clutch Assembly and/or BRD roll (PL 9.15) Check for continuity between Roll 3 and the BRD roll. There is continuity. Y N Repair/replace the spring wire from the BRD drive shaft to the Developer Housing Extrusion Bushing (PL 9.14).

Close the Xerographic Drawer. Select dC330 [9] [Toner Dispenser]. Observe the Bell Crank Mechanism through the front window hole (to the right of the Toner Bottle Latch Handle). Press Continue. The Toner Dispenser Motor rotates. Y N Go to the 9-215 RAP.

NOTE: When the manifold is operating normally, there will be an accumulation of toner to the left of the manifold air holes (front view of housing) and there will be a clean curved area between the air holes. A small amount of toner to the right of the manifold holes is also normal.

The Stirrer is rotating. Y N Replace the Toner Dispenser (PL 9.19)

The Manifold is free of excess toner. B Section Name

PQ 9-616

Find and repair the cause of the contamination. Refer to Possible Sources of Contamination at the end of this procedure. Replace the Developer Material (REP 9-4).

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C

D

E Preliminary Working Document No Product Name Assigned

B

C

D

E Go to the 9-215 RAP.

B

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

Replace the Developer Drive Couplings (PL 9.14) Remove the developer roll 2 drive gear and reinstall the screw. Enter dC140. Select [dC Bias Values]. Press Continue. Using Peak Hold (-) measure the voltage between the Developer Housing Left Side Extrusion (a test point is located under the Developer Catch tray) and machine frame. Record the measured value for use later. The roll 1 & 2 bias is within +/- 20 VDC of the displayed value on the dC140 screen AND the bar graph on the DMM is steady. Y N Press Stop. Check for continuity from P256-5 (the connector at the rear of the toner housing) to the bias strap at the rear of the developer housing. The continuity check is good. Y N Repair as required.

Press Stop. Reinstall the developer Roll 2 drive gear. If the machine does not have Processor Tag 80, go to the next Yes statement. Pull the xerographic drawer out, raise the Photoreceptor module and check for continuity between surface of Roll 3 and the BRD roll. There is continuity between the Roll 3 and the BRD Roll. Y N Repair or replace the spring wire from the BRD drive shaft to the Developer housing extrusion brush (PL 9.14). If there is still no continuity between roll 3 and the BDR roll, replace the developer roll 3 (PL 9.14). If continuity is OK, and the Developer Bias checks out OK, return the subsystem and the Xerographic Drawer to the operate position. Otherwise, open the Xerographic Drawer. Raise the Photoreceptor module. Observe the developer material. Open the Xerographic Drawer. Raise the Photoreceptor module. Observe the developer material.

Go to the 9-320 RAP. Assuming there is no other fault present, the first No leg of the 9-320 RAP should be followed. While still measuring the Developer housing Left Side Extrusion and machine frame switch from Peak Hold (-) to Peak Hold (+) and monitor the DMM for 30 seconds. The voltage is within +/- 20 VDC of the recorded value of the left side extrusion. Y N Replace the developer drive coupling (PL 9.14) and continue with the next Yes statement.

NOTE: Hand cranking the Developer Assembly can produce bare spots. Do not hand crank the developer at this time. There is an even coating of developer on all three rolls. Y N Reverse developer flow, an uneven coating, and/or bare spots may indicate that there is too much or not enough developer material in the housing. Determine and repair the cause of the leak, replace the Developer Material (REP 9-4). If Bead Carryout is observed, go to the PQ 9-631, Bead Carryout RAP.

Ensure that the wire is connected at the inboard end of the Developer Housing. Using Peak Hold (+) measure the voltage between the screw head on the outboard end of rolls 1 and 2 and machine frame. Repeat the procedure using Peak Hold (-). The voltage reading are within +/- 10 VDC of the recorded values of the left side extrusion. Y N Replace the developer roll that did not meet specification (PL 9.15) and continue with the next Yes statement. Measure the voltage between the Developer Housing Right Side Extrusion (under the Developer Manifold) and machine frame. The reading is within +/- 20 VDC of the Roll 3 Bias on the dC140 display. Y N Press Stop. Check the continuity between P256-8 (at the connector at the rear of the toner dispenser) and the Developer Housing Right Side. The continuity is OK. Y N Repair as required. Go to the wirenets and check wire 176/176A for an open.

F

Press Stop. The Development subsystem is OK.

POSSIBLE SOURCES OF CONTAMINATION Ensure all sources of contamination have been purged from the System to prevent callback for the problem. Perform the following actions unless already done while troubleshooting. Paper Dust Check the paper trays and paper path areas for excessive paper dust. Vacuum these areas. Clean all areas as required. Paper Stock Adhesives from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of paper added to the Trays. Predrilled paper: suggest that paper be drilled after printing if possible.

B

F

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Section Name

PQ 9-616

Label stock: label adhesive can cause spots.

Ensure that fuser Shield or oil leaking from the Fuser/Developer Drive Motor is not contaminating the developer assembly. If oil is identified in the Developer Assembly, replace the Developer Assembly (PL 9.13).

Carbonless paper is not recommended for use on this system. Paper stock: certain brands are known to cause spots. Spray adhesives: any sprays used near the system can enter the machine air system and can cause spots and damage the Photoreceptor Belt. Tray 1 / Tray 2 Feed Components Oil leaking from the sides of bearings or debris from the following: •

Takeaway Roll (PL 7.13)

•

Feed Belt Idler (PL 7.12)

•

Feed Belt Pulley (PL 7.12)

•

Feed Belt Spool (PL 7.12)

•

Idler and Retard Brake (PL 7.13)

Belts wearing: •

Takeaway Drive Belt (PL 7.10)

•

Feed Clutch Belt (PL 7.10)

•

Top Transport Belts (4) (PL 7.10)

Dirt Shield, clean or replace as required (PL 7.10) CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Xerographic CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Precharge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum the Photoreceptor Ground Brush. Vacuum the top of the Developer Housing including the seals. Ensure that no developer material has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt. Perform the Xerographic Setup (ADJ 9-3). Fuser

Section Name

PQ 9-616

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Figure 1 PQ 9-616 Circuit Diagram (713006)

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Section Name

PQ 9-616

A

PQ 9-617 Cleaner RAP The purpose of this RAP is to ensure that the cleaning system is working properly. Poor cleaning can contribute to many image quality defects.

Initial Actions •

Ensure that the Cleaner Zone Rolls are engaged when the Xerographic Drawer is latched.

•

Ensure that the P290 connector is secured at the Cleaner chassis.

•

Vacuum any toner from the Waste Toner Duct assembly, the Auger Drive Pulley, the Compactor Drive Motor Pulley, and the Drive Belt.

B Check/replace any broken gears. After the repair is complete, return to (Step 1) of this RAP.

Press Stop. Enter dC140 [DC Bias Values]. Press Continue. Measure the Cleaner Brush Bias voltage at the shaft. The Cleaner Brush Bias voltage is -250 +/- 10 VDC to ground. Y N Press Stop. Measure between P290-1 (+) and P290-4 (-). Press Continue. The voltage is -250 +/- 10 VDC. Y N Replace the HVAC PWB (PL 1.7). Go to Flag 3. Check the Cleaner Assembly for an open circuit.

Procedure Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. Table 1 MIN NVM MIN Address

Current Value

MIN Address

199

206

200

207

205

208

Current Value Go to Flag 3. Check the Cleaner Assembly for an open circuit.

All the MIN NVM addresses have the data values listed in the appropriate level Software Table. Y N Change the data values as required. Perform the Xerographic Setup (ADJ 9-3). Check the Waste Bottle Full Sensor, Q906, for proper mounting. Enter dC330 [9] [Waste Bottle Full]. Place a piece of paper between the sensor and the Waste Bottle. The display changes from H to L. Y N Go to Flag 2. Check the circuit of the Waste Toner Full Sensor, Q906. Go to GP 6-2, Generic Sensor RAP and GP 6-3 Generic Solenoid RAP in General Procedures section. Remove the Waste Bottle. Place a sheet of paper under the Compactor Auger. Cheat the Printer Interlock Bypass Switch. Enter dC330, [1-4], [Main Drive Run] Motor. Press Continue. Verify that the Compactor Auger is rotating. The Compactor Auger rotates. Y N Check the Waste Compactor Drive Belt (REP 9-18), the Auger Drive Pulley and the Auger (PL 9.23). (Step 1) Press Stop. Install the Toner Waste bottle. With the drives still on, ensure that the upper and lower Cleaner Detoning Roll shafts are rotating. The Cleaner Detoning Roll shafts rotate. Y N Remove the Auger Gear Box. The shafts can be turned within the gear backlash. Y N (Indicates a bound Cleaner). Replace the Cleaner Module (PL 9.24). A

The Upper Detoning Roll Bias (UDTR) voltage is -200 +/- 20 VDC to the Cleaner Brush. Y N Press Stop. Measure between P290-3 (+) and P290-1 (-). Press Continue. The voltage is -200+/- 20 VDC. Y N Replace the HVAC PWB (PL 1.7)

The Lower Detoning Roll Bias (LDTR) voltage is +170 +/- 10 VDC to the Upper Detoning Roll. Y N Press Stop. Measure between P290-2 (+) and P290-3 (-). Press Continue. The voltage is +170 +/- 20 VDC. Y N Replace the HVAC PWB (PL 1.7) Go to Flag 3. Check the Cleaner Assembly for an open circuit.

WARNING Use the convenience outlet on the machine for vacuum cleaner power. If a wall outlet is used, verify that the wall outlet is grounded before using it. Switch off Printer power. Vacuum the Cleaner Housing, the Brush, and the Flicker Bar. Remove any impacted toner from the Flicker Bar. Replace the Filter Bag (REP 9-22) if it is more than half full. Use a flashlight to observe both cleaner augers through the waste toner duct at the rear of the machine. Handcrank the machine (rotate the drive shaft clockwise, ONLY) from the rear while observing that both augers rotate. The Augers rotate. Y N Replace the Auger or drives as necessary (PL 9.25). Use a screwdriver in the slot of the Main Drive Motor Shaft. Rotate the shaft one complete revolution (turn the shaft clockwise, front of machine view) while observing the cleaner detoning rolls with a flashlight. Examine both rolls for toner banding. The Cleaner is free of toner banding.

B

Section Name

PQ 9-617

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Y

N Replace the appropriate Cleaner Blade (PL 9.22). Enter dC330. Select [Main Drive Run]. Press Continue. Operate the drives for 10 seconds. Switch off the Printer power. Check the Detoning Rolls for banding. Switch on the Printer power. Run test prints to ensure that the banding disappears. The toner banding continues. Y N Continue this procedure below at (Step 2). The Yes response to the previous statement.

WARNING Start the following step with the blade pulled out about 2 inches. Keep body parts and clothing away from the moving machine parts. Pull the appropriate blade out about 2 inches. Enter dC330. Select [Main Drive Run]. Press Continue. While the drives are running, reinsert the blade and pull it back out about 2 inches, repeat this sawing action 3 or 4 times. Press the Stop button. Check for toner banding. Repeat the procedure as necessary to remove any toner banding. If banding remains, use Formula A to clean the band. Continue this procedure below at (Step 2). (Step 2) Ensure that the Cleaner Backup Roll, when cammed up, is against the bottom of the cleaner, both in front and rear. Enter dC330, [9]. Select [Precharge/Prexfer]. The Lamps operate properly. Y N Go to the PQ 9-624, PreCharge/Pretransfer Lamps RAP. After the repair are complete, continue this RAP, return to the Yes leg of the previous statement. Check for toner past the Cleaner. Enter dC606. Select [Printer Options] [Pages Per Set (30)]. Select [Printer Options], [Black Lines], [12-Pixel Lines]. Program a 30 print job and select a Tray with 14inch paper. Press Continue. After 15 print have been run, open the front door. Inspect the Photoreceptor Belt for toner past the cleaner. There is toner past the cleaner. Y N Vacuum the manifold, the blower hose. Ensure that the hoses are OK. Repair/replace as required. Replace the filter bag if it is more than half full. Replace the Cleaner Brush (PL 9.24). Use the manometer to check for more than 51 mm of water at the pressure tap on the elbow of the Cleaner Blower Hose. The pressure is greater than 51mm. Y N Go to the 9-704, Toner Filter Blower RAP. Vacuum any spilled toner in the entire Photoreceptor Module area. If the machine is extremely dirty, go to the PQ 9-632, Dirt RAP. Perform the Xerographic Setup (ADJ 9-3).

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Section Name

PQ 9-617

Figure 1 PQ 9-617 Circuit Diagram (713001)

Section Name

PQ 9-617

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A

PQ 9-618 PR Ground RAP

•

The purpose of this RAP is to ensure that the Photoreceptor is grounded properly. Without a good pathway to ground, the Photoreceptor will not discharge properly and xerographics cannot be setup or maintained correctly.

Lower and latch the Photoreceptor Module. Ensure that the Ground Brush contacts the Photoreceptor ground strip with enough force to depress the Ground Brush. Replace the Ground Brush if necessary (PL 9.7).

The Photoreceptor ground is OK.

Initial Actions CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Inspect the Photoreceptor Belt surface for a ground plane break. If present, the break will appear as a sharply defined line all the way around the Photoreceptor Belt.

•

Pull out the Xerographic Drawer. Raise the Photoreceptor Module. Pinch the Ground Brush, pulling on the fibers. If any fibers dislodge, replace the Ground Brush (PL 9.7)

NOTE: Do not use the Printer frame as a PR ground during diagnostics, electrical noise and the related faults will be generated. Only ground the PR through the PR Ground Brush circuit.

Procedure Ensure that the two green ground wires are securely attached to the Ground Brush. The wires must be attached to an internal star washer type of connector that penetrates the special conductive plastic of the Ground Brush. The Ground Brush and electrical connections are OK. Y N Repair any poor connections. • Replace the Ground Brush if is worn or damaged (PL 9.7). •

Inspect the Photoreceptor ground strip for damage. Replace the Photoreceptor belt if necessary (PL 9.1).

Lower the Photoreceptor Module. Measure the resistance from the Photoreceptor ground strip to machine ground (the unpainted metal bracket that holds the detack dicor is a good one). The resistance is less than 50K ohms. Y N Raise the Photoreceptor Module. Measure the resistance from the Ground Brush to machine ground. The resistance is less than 1K ohms. Y N Measure the resistance from the Ground Brush to the ground wires attached to the Ground Brush. The resistance is less than 1K ohms. Y N Replace the Ground Brush (PL 9.7) Go to Flag 1. Check for an open circuit between the ground wires on the Ground Brush and J298-17 of the Low Voltage Power Supply. Inspect the Photoreceptor ground strip for breaks or wear, replace the Photoreceptor Belt if necessary (PL 9.1) • Measure the resistance between the Ground Brush and the ground wires attached to the Ground Brush. If the resistance is not less than 1K ohms, replace the Ground Brush (PL 9.7) A Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-618

Figure 1 PQ 9-618 P/R Ground Circuit Diagram (713002A).

Section Name

PQ 9-618

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A

B

PQ 9-619 ESV RAP

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

The purpose of this RAP is to ensure that the ESV is working properly. If the ESV is not working properly, it can give erroneous readings, and the Xerographic setup will be incorrect.

Initial Actions CAUTION

If the Photoreceptor Ground Brush fibers are contacting the AMAT portion of the PR Belt, the ESV Monitor reading may be as low as 20 and as high as 38. Each time the Initialize is run, the values may be different. Enter dC909. Select [ESV-DSS Test]. Observe the ESV Monitor voltage. Normal voltage should be between 1.0 VDC +0.4VDC/-0.2 VDC. If the ground brush fibers are contacting the AMAT portion of the PR Belt, the voltage will fluctuate from +0.7 VDC to +3.5 VDC. Replace the Ground Brush (PL 9.7)

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Locate the Photoreceptor black plastic bag. Ensure that the bag is clean it will be used to make ESV checks.

WARNING Do not touch the ESV probe. The probe can have a high voltage on it, about 1KV, whenever the power is on. Although the 1KV is a low energy source, personal injury can occur responding to the shock. CAUTION The ESV should be cleaned with a clean, dry lint free cloth. Switch off the Printer power before cleaning the ESV. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements are performed with the component clean. Pull out the Xerographic Drawer. Clean the ESV probe. Check for toner on the PR Belt. If toner is observed, go to the PQ 9-617, Cleaner RAP. Ensure that the ESV is not skewed in relationship to the Photoreceptor. Check the ESV Height (ADJ 9-12). Close the drawer. Switch off the Printer power. Wait 10 seconds. Switch On the Printer power. Enter dC106. Run 10 prints to force the machine through its power-up checks.

(Step 2) Enter dC909. Select [ESV-DSS Test]. The value of the ESV reading is equal to or less than 24 VDC. Y N Go to Flag 1. Measure the ESV Peak Monitor Output signal at TS21 (+) and TS22 (-) of the MIN ADA PWB #1. The ESV Peak Monitor Output signal is +1 VDC+/- 0.2 VDC. Y N Connect the DMM to TS12 (+) of the MIB and frame ground (-). Set the DMM to (+) Peak Hold. The DMM reads +15 +/- 1.5 VDC. Y N Switch Off Printer power. Go to Flag 2. Check the wire between the MIB PWB and the ESV Power Supply for an open or a short circuit to ground. Repair/ replace as required. If the wire is OK, switch On the Printer power. Ensure that the J2 connector securely attached to the ESV Power Supply. 24 +/- 1.2 VDC measured between J2-7 (+) and J2-6 of the ESV Power Supply. Y N Go to Flag 4. Check the +24 VDC wiring. After repair, go back to the beginning of (Step 2) in this RAP. If the 24 VDC is OK, replace the ESV Assembly (PL 1.7).

Enter dC131 [MIN]. Ensure that Address 225 is at the value shown in the appropriate level Software dC 131 Table in Section 6, General Procedures, of the Service Manual (ESV calibration factor relating the ESV reading and the dark decay to the ddp setpoint). If the data value requires a change, perform the Xerographic Setup (ADJ 9-3).

Measure the ESV Reset (L) + 15 VDC signal at TS12 (+) of the MIB PWB and the frame ground (-). Approximately once each second, the DMM reads a low voltage of about +0.6 VDC. Y N Go to Flag 3. Measure the ESV Reset (L) +5 VDC signal at TS7 (+) of the MIB PWB and the chassis ground (-). Perform the following: • If approximately once each second, the DMM reads a voltage change from +5 VDC down to about +0.6 VDC, switch off the Printer power. Go to Flag 2. Check the J2-13 wire for a short to ground. If the wire is OK, replace the MIB PWB (PL 1.7).

Procedure (Step 1) Enter dC951. Select [Initialize]. Press Continue. Observe the ESV Monitor value. The normal value should be between 22-35. The ESV monitor values are between 22 and 35 Y N (HVDC PWB leakage check.) Enter dC140 [Dicorotron Values]. Press Start. After 10 seconds all the dicorotron values should be stable. Open the Printer Right Front Door to interrupt operation. Observe the Dicorotron Monitor Voltages for 30 seconds. The Monitor values cycle down to less than 0.3 after 30 seconds. Y N HVDC PWB leakage problem, replace the HVDC PWB (PL 1.7) A

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D

•

If the ESV signal in not present at TS7, go to Flag 3. Check for the signal at TS43 (+) and TS37 (-) of the MIN DIO PWB. If the signal is present, switch off Printer power. Check the wire between the MIN DIO PWB and the MIB PWB. Go back up to (Step 2) of this RAP after the repair.

•

If the signal is not present at TS43 (+) and TS37 (-), replace the MIN DIO PWB (PL 1.8).

E Section Name

PQ 9-619

C

D

E Perform the following: • Switch Off the Printer power. Go to Flag 2. Check the wire between the MIB PWB and the ESV Power Supply. If the wire is OK, ensure that the ESV probe connector is attached securely to J1 of the ESV Power Supply. Ensure that +24 VDC +/- 1.2 VDC is present between J2-7 (+) and J2-6 (-) of the ESV Power Supply. •

F

G •

Switch Off the Printer power. Go to Flag 2. Check the wire between the MIB PWB and the ESV Power Supply. If the wire is OK, ensure that the ESV probe connector is attached securely to J1 of the ESV Power Supply. Ensure that +24 VDC ± 1.2 VDC is present between J2-7 (+) and J2-6 (-) of the ESV Power Supply.

•

If the above checks are OK, replace the ESV Assembly (PL 1.7)

If the above checks are OK, replace the ESV Assembly (PL 1.7). Replace the MIN ADA PWB #1 (PL 1.8)

Replace the MIN ADA PWB #1 (PL 1.7). The ESV is OK. Observe the dC909, [ESV-DSS Test], ESV Monitor reading. The ESV Monitor Reading is 1.0 VDC ±0.2. Y N Go to Flag 1. Measure the ESV Peak Monitor Output signal at TS21 (+) and TS22 (-) of the MIN ADA PWB #1. The ESV Peak Monitor Output signal is +1 VDC ± 0.2 VDC. Y N Connect the DMM to the MIB PWB TS12 (+) and frame ground. Set the DMM to (+) Peak Hold. The DMM reads 15 ± 1.5 VDC. Y N Switch Off Printer power. Go to Flag 2. Check the wire between the MIB PWB and the ESV Power Supply for an open or a short circuit to ground. Repair/ replace as required. If the wire is OK, switch On the Printer power. Ensure that the J2 connector securely attached to the ESV Power Supply. 24 ± 1.2 VDC measured between J2-7 (+) and J2-6 of the ESV Power Supply. Y N Go to Flag 4. Check the +24 VDC wiring. After repair, go back to the beginning of (Step 2) in this RAP. If the 24 VDC is OK, replace the ESV Assembly (PL 1.7). Measure the ESV Reset (L) + 15 VDC signal at TS12 (+) of the MIB PWB and the frame ground (-). Approximately once each second, the DMM reads a low voltage of about +0.6 VDC. Y N Go to Flag 3. Measure the ESV Reset (L) +5 VDC signal at TS7 (+) of the MIB PWB and the chassis ground (-). Perform the following: • If approximately once each second, the DMM reads a voltage change from +5 VDC down to about 0.6 VDC, switch off the Printer power. Go to Flag 2. Check the J2-13 wire for a short to ground. If the wire is OK, replace the MIB PWB (PL 1.8). •

If the ESV signal in not present at TS7, go to Flag 3. Check for the signal at TS43 (+) and TS37 (-) of the MIN DIO PWB. If the signal is present, switch off Printer power. Check the wire between the MIN DIO PWB and the MIB PWB. Go to back to (Step 2) of this RAP after the repair.

•

If the signal is not present at TS43 (+) and TS37 (-), replace the MIN DIO PWB (PL 1.8).

Perform the following:

F

G

Section Name

PQ 9-619

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Figure 1 PQ 9-619 Circuit Diagram (713003)

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Section Name

PQ 9-619

PQ 9-620 DSS RAP

Y

The purpose of this RAP is to ensure that the Density Sample Sensor (DSS) is operating correctly and determine / correct the cause if it is not. If the DSS is not working properly it can give erroneous readings and the xerographic setups will be incorrect.

Initial Actions CAUTION

Go to Flag 5. Check the violet wire for an open circuit.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

Measure the voltage between TS24 (+) and TS37 (-) of the MIN DIO PWB. Greater than +3 VDC is measured. Y N Go to Flag 6. Check for an open or short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8).

CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. Switch off the Printer power before cleaning the DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the DSS calibrations are performed with the component clean. •

Pull out the Xerographic drawer and clean the DSS with a clean, soft, lint free cloth.

•

Ensure that the Photoreceptor Belt over the DSS is clean. Return the Photoreceptor Module to the lowered position.

Exit the ESV-DSS Test. Measure the voltage between TS10 (+) and TS56 (-) at the MIN DIO PWB. +15 VDC +/- .75 VDC is measured. Y N Go to Flag 3. Check for an open or short circuit. If the line is OK, replace the DSS (PL 9.7). Select [ESV-DSS Test]. Check for a negative going pulse at the between TS10 (+) and TS56 (-) MIN ADA PWB #1. The meter indicates a negative going pulse approximately every 2 seconds. Y N Replace the MIN ADA PWB #1 (PL 1.8).

Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. If any of the NVM values require change, perform the Xerographic Setup (ADJ 9-3). Table 1 MIN NVM MIN Address

Current Value

MIN Address

199

245

200

246

205

247

206

248

207

249

208

251

243

253

244

254

N Measure the input voltage to the DSS between IRD-5 and IRD-2. +15 VDC +/- .75 VDC is measured. Y N Move the meter lead from IRD-2 to frame. +15 VDC +/- .75 VDC is measured. Y N Go to Flag 4. Check for an open circuit in the +15 VDC line.

Exit ESV-DSS. Measure the voltage between TS8 (+) and TS56 (-) at the MIN ADA PWB #1. +15 VDC +/- .75 VDC is measured. Y N Go to Flag 2. Check for an open or short circuit. If the circuit is OK, replace the DSS (PL 9.7).

Current Value

Press the [DSS Recalibrate] button. Check for a negative going pulse between TS8 and TS56. The meter indicates a negative pulse every time the DSS Recalibrate button is pressed. Y N Replace the MIN ADA PWB #1 (PL 1.8). Replace the DSS (PL 9.7).

Procedure CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Enter dC909. Select [ESV-DSS Test]. Observe the DSS monitor. Select [DSS Recalibrate] five times. The DSS Monitor reading is 232 +/- 12 after each recalibration and the variation between any of the readings does not exceed 6.

Raise the Photoreceptor module at least 30 degrees from the horizontal and leave it there. The DSS Monitor reading is less than 50. Y N Replace the DSS (PL 9.7). Select [DSS Recalibrate]. A 9-212 fault is declared. Y N Exit ESV-DSS Test. Measure the voltage between TS8 (+) and TS56 (-) at the MIN ADA PWB #1. The voltage measures +15 VDC +/- 0.75VDC. A

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PQ 9-620

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A Y

N Go to Flag 2. Check for an open or short circuit. If the circuit is OK, replace the DSS (PL 9.7).

Leave the meter connected. Press the [DSS Recalibrate] button. Check for a negative going pulse between TS8 and TS56. The meter indicates a negative pulse every time the DSS Recalibrate button is pressed. Y N Replace the MIN ADA PWB #1 (PL 1.8). Replace the DSS (PL 9.7) Lower the Photoreceptor Module. Close the Xerographic drawer. Clear the 9-212 fault. Press [DSS Recalibrate]. Run any job to force a Cycle up convergence. Enter dC606. Press Continue. The DSS operation is OK. Perform the DSS Timing (ADJ 9-14).

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Section Name

PQ 9-620

Figure 1 PQ 9-620 DSS RAP Circuit Diagram (8304)

Section Name

PQ 9-620

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Preliminary Working Document No Product Name Assigned

A

PQ 9-621 Patch Gen/Patch Integrity RAP The purpose of this RAP is to ensure that the patch has been correctly created and developed to ensure proper toner concentration control setups.

B

C Go to Flag 1. Check for an open circuit. If the wires are OK, replace the MIN DIO PWB (PL 1.8)

Enter dC330 [9]. Select [Patch Gen High]. Press Continue. NOTE: When [Patch Gen High] is energized in dC330 [9]. The signal is pulsed as a square wave. Use negative Peak Hold (-) to measure the low pulse as required.

Initial Actions CAUTION

NOTE: The DMM Peak Hold Procedure is located at the end of this RAP.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes. Also, do not leave the Patch Generator energized in dC330 for longer than two (2) minutes. Severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Open the Xerographic Drawer and clean the Patch Generator by wiping the window with a clean, dry cloth. Leave the drawer open.

•

Enter dC131 [MIN]. Record the Data values at the following Addresses and ensure they compare to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. If any of the NVM values require change, perform the Xerographic Setup (ADJ 9-3).

The voltage pulses between 5 VDC and 0 VDC. Y N Go to Flag 1. Check for a short circuit. If the circuit is OK, replace the MIN DIO PWB (PL 1.8) +2.5 VDC is measured between TS13 (+) and TS20 (-) of the MIB PWB. Y N Disconnect P211 (J2) at the MIB PWB. +2.5 VDC is measured between P211-15 (+) and TS20 (-) of the MIB PWB. Y N Go to Flag 2. Check for a short or an open circuit. If the wires are OK, replace the Patch Generator (PL 9.10)

Table 1 MIN NVM MIN Address

Current Value

MIN Address

249

254

251

285

Current Value

Replace the MIB PWB (PL 1.8) Press Continue.

253 •

NOTE: When [Patch Gen High] is energized in dC330 [9]. The signal is pulsed as a square wave. Use negative Peak Hold (-) to measure the low pulse as required.

Enter dC105 [Features]. Digital Patch Generator enabled. Check the Patch Generator Timing (ADJ 9-5).

NOTE: The DMM Peak Hold Procedure is located at the end of this RAP. The voltage pulses between 2.5 VDC and 0 VDC. Y N Replace the MIB PWB (PL 1.8)

Procedure CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes. Also, do not leave the Patch Generator energized in dC330 for longer than two (2) minutes. Severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Observe the Patch Generator while the printer is idle. The Patch Generator LED's are off when the printer is in standby. Y N +5 VDC is measured between TS43 (+) and TS37 (-) at the MIN DIO PWB. Y N +5 VDC is measured between TS8 (+) and TS20 (-) at the MIB PWB. Y N Disconnect the P211 (J2) connector at the MIB PWB. +5 VDC is measured between TS8 (+) and TS20 (-) at the MIB PWB. Y N Replace the MIB PWB (PL 1.8)

Go to Flag 2. Check for an open circuit. If the circuit is OK, replace the Patch Generator (PL 9.10) Open the Xerographic Drawer. Clean the Patch Generator by wiping the window with a clean dry cloth. Leave the drawer open. Enter dC330 [9]. Select [Patch Gen High]. Press Continue. The Patch Generator should cycle on and off. NOTE: Use the inspection mirror to observe the four LEDs inside the Patch Generator window. Because of the viewing angle there may appear to be more than four LEDs, look for a dark spot between any two lit LEDs, if you see a dark spot, one or more of the LEDs are out. All four LEDs are lit. Y N At least one LED is lit. Y N No LEDs are lit, go to the 9-355 RAP.

Go to Flag 1. Check for a short circuit. If the wires are OK, replace the MIN DIO PWB (PL 1.8) A

B

C

Preliminary Working Document No Product Name Assigned

Replace the Patch Generator (PL 9.10). D

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Section Name

PQ 9-621

D +5 VDC is measured between TS52 (+) and TS37 (-) at the MIN DIO PWB. Y N Disconnect the P233/J2 connector at the MIN DIO PWB. +5 VDC is measured between P233-9 (+) and TS37 (-) of the MIN DIO PWB. Y N Go to Flag 3. Check for and Open circuit. If OK, replace the Patch Generator (PL 9.10). Select [Enable]. The voltage between TS52 (+) and TS37 (-) at the MIN DIO PWB changes from 0.5 VDC to 0 VDC. Y N Replace the MIN DIO PWB (PL 1.8)

E The measured Patch height is from 20 to 25 mm. Y N Ensure that the Cleaner Zone Roll is correctly positioned against the Photoreceptor belt and held securely in the Photoreceptor Module frame. Go to the PQ 9-616, Development RAP. The Patch width, including lead/trail edge dark bands, is from 16 to 19 mm. Y N Check/adjust the following items in the order given: • Enter dC604 Registration Setup. Press Continue. Check and adjust registration if required.

Replace the Patch Generator (PL 9.10). Select [Enable]. The voltage between TS52 (+) and TS37 (-) at the MIN DIO PWB changes from +5 VDC to 0 VDC. Y N Replace the MIN DIO PWB (PL 1.8) NOTE: For information on the physical characteristics of the patch, refer the Patch Generator Timing/Patch properties check at the end of this RAP.

•

Enter dC909 [PGen Timing]. Adjust the Patch Generator Timing.

•

Ensure that the Cleaner Zone Roll is correctly positioned against the Photoreceptor belt and held securely in the Photoreceptor Module.

•

Replace the PPMD PWB (PL 1.11).

•

Go to the PQ 9-616, Development RAP.

All ID zones are free of toner (except those with the patches printed). Y N Go to the PQ 9-617, Cleaner RAP. Check the ID zone for uncleaned patches. Enter dC909 [PGen Timing]. Adjust the Patch Generator Timing (ADJ 9-5).

Exit dC330. Enter [dC909]. Select [Patch Print] (Yes), [Charge Control] (Open). Program a 50 print job. Press Continue. The developed patches have uniform density. Y N Check Developer Roll 1, 2, and Roll 3 Bias at the Developer Housing. Refer to the circuit diagram for test points. The bias's are OK. Y N Go to the PQ 9-616, Development RAP. Observe the generated patches. The patch is free of dark, LE or TE fast scan direction bands. Y N Dark bands of 2mm or less at the LE or TE are OK. If the dark bands are greater than 2mm, check/adjust the following items in the order given: • Enter dC604 Registration Setup. Press Continue. Check and adjust Top To Bottom Registration (ADJ 8-2) and Side To Side Registration (ADJ 8-3). •

Enter dC909 [PGen Timing]. Adjust the Patch Generator Timing (ADJ 9-5).

If the patches have light streaks or bands, go to the PQ 9-612, Light Streaks/Light Bands RAP. • If the patches have dark streaks or bands, go to the PQ 9-611, Dark Streaks/ Scratches/Bands RAP. •

DMM Peak Hold Procedure •

Select V or mA as required.

•

Select AC or DC and range as required.

•

Place Meter Probes in the Volt-Ohm (+) and the COM (-) Jacks

•

Press (+) or (-) polarity.

•

To make a new measurement, release the Peak Hold button to clear previous reading and repeat procedure. NOTE: To measure for negative peaks on a positive voltage, first select (+) peak polarity, press the Peak Hold button then switch polarity to (-) peak polarity. For further information, go to the DMM operators Manual.

Patch Generator Timing/Patch Properties The diagram below gives the correct patch dimensions as well as an example of the banding due to a Patch Generator timing error. Dark Bands at the lead and trail edge of the patch will result, if there is an error in the dC909 [PGEN Timing] setup. These bands effect DSS reading of patch density and the calculation of Process Controls. The bands are sometimes hard to identify. Use Print Darker 2, if required, to observe the bands in the patch area during the PGen timing setup. Ensure that the Patch Generator exposure of the latent patch is uniform throughout the patch area.

If the patches have white spots, go to the PQ 9-625, White Spots RAP.

•

If the patches have deletions, go to the PQ 9-615, Deletions RAP.

•

If the patches have streaks/scratches or bands, go to the PQ 9-611, Dark Streaks/ Scratches/Bands RAP.

•

If the patches have dark spots or marks, go to the PQ 9-613, Dark Spots RAP.

•

If the patches have uneven density or darkness, go to the PQ 9-614, Nonuniform Image Darkness RAP.

E Section Name

PQ 9-621

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Preliminary Working Document No Product Name Assigned

NOTE: With the Digital Patch Generator installed and enabled in dC105, no timing variations are expected.

Figure 1 Patch Properties (8314A)

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Section Name

PQ 9-621

Figure 2 PQ 9-621 Circuit Diagram (703006)

Section Name

PQ 9-621

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PQ 9-622 Transfer Assist Device RAP

4.

This RAP is used to diagnose failure of the Transfer Assist Device. Generally Transfer Assist problems are seen as deletions 25 mm from the lead edge and/or the trail edge of the prints. Complete the following procedure prior to adjusting the Transfer Blade Timing (ADJ 9-9).

Select [Xfr Sol 2]. Observe Transfer Solenoid 2. Press Continue. If Transfer Solenoid 2 does not energize, press the Stop button. Go to Flag 3. Check the circuit of the Transfer Solenoid 2, SOL905 (Generic Solenoid RAP, GP 6-3, General Procedures).

5.

Select [Xfr Sol 3]. Observe Transfer Solenoid 3. Press Continue. If Transfer Solenoid 3 does not energize, press the Stop button. Go to Flag 4. Check the circuit of the Transfer Solenoid 3, SOL906 (Generic Solenoid RAP, GP 6-3, General Procedures).

6.

Select [Xfr Sol 4]. Observe Transfer Solenoid 4. Press Continue. If Transfer Solenoid 4 does not energize, press the Stop button. Go to Flag 5. Check the circuit of the Transfer Solenoid 4, SOL904 (Generic Solenoid RAP, GP 6-3, General Procedures).

7.

Perform Transfer Blade Timing (ADJ 9-9). During the Transfer Assist Blade Timing Procedure, adjust the lead edge to 4.00 mm and the trail edge to 8.00 mm. This will increase the range of the pull-in time of the Transfer Solenoid. If the problem continues, replace the Transfer Assist Device (PL 9.11)

8.

Program a sustained job (1000 prints) with the longest paper available. Observe the Transfer Assist Device during operation to determine if there is a thermal breakdown (overheat) of one or more of the Transfer Assist Solenoids. If sluggish operation or excessive heat is indicated, replace solenoids as required (PL 9.12).

9.

Explanation of the Pulsed DC Voltage between TH4 (+) and TH3 (-) on the TAD PWB output to Solenoid 1.

INITIAL ACTION •

Ensure that the Transfer Blade and the Transfer Dicorotron are completely installed. The transfer Blade can vibrate out of position. Inboard deletions can occur.

•

Check SCP Range Faults for 8-226 or 8-227 Faults. If either of these faults are logged, go to the 8-226, 8-227 RAP RAP, return to this RAP if the problem continues.

NOTE: When using transparencies, the Transfer Assist Device does not function. This is normal operation. Enter dC131 [PHN]. Ensure that Address 251=0 (4 Transfer Solenoids). If the Data value required change, power the printer off then on to set NVM. Enter dC606 and run prints to see if the problem is resolved.

Procedure WARNING Use caution when observing/checking the Transfer Assist Device as the Transfer Assist Blade has high voltage on it (in print). Ensure that clothing and body parts do not come in contact with moving machine parts. The Main Drive motor can get very warm, be careful when performing the standby checks.

a.

TS45 on the PHN DIO PWB #2 (J2/P397-3) is the normal +5 VDC signal. It toggles low to actuate the TAD PWB (J1/P399-1).

b.

When PHN DIO PWB #2, the TAD PWB supplies +24 VDC to Solenoid 1 for approximately 16 ms (between TH4 (+) and TH3 (-) on the TAD PWB).

c.

After that time, the +24 VDC is removed, and the +5 VDC is applied for the remainder of the Duty Cycle (approximately 220 ms) in dC330.

Check [SCP] [HFSI] [Belt Module]. Clean/replace the Transfer Assist Blade (PL 9.11) 1.

2.

3.

Open the Processor Right Front Door. Observe the Transfer Assist Solenoids while actuating/deactuating the Printer Right Front Door Interlock. If one or more of the solenoids energized when the interlock switch is actuated, there is a short in the solenoid circuit. Refer to the Circuit Diagram to troubleshoot the solenoid or solenoids. Diagnose the highest # solenoid first. (If three solenoids actuate with the interlock switch, go to sol #3 circuit first).

NOTE: Due to the short duration of the 16 ms that the +24 VDC is on, it will not be possible to read the +24 VDC output voltage between TH4 and TH3 on the TAD PWB.

In standby, manually actuate each solenoid. Check for binding. Observe each segment of the Transfer Assist Actuator Lever and Blade. Ensure that the blade does not touch the PR belt when the solenoid is actuated. Ensure that the plastic clips that allow the blade segments to pivot and the plastic solenoid blocks are engaged properly. Ensure that the actuator assembly does not interfere with the blade when the solenoids are actuated. If the actuator interferes, replace the Actuator Lever (PL 9.12). Cheat the Processor Right Front Door Interlock. Enter dC330 [9]. Select [Xfr Sol 1]. Observe Transfer Solenoid 1. Press Continue. If Transfer Solenoid 1 does not energize, press the Stop button.

Digital Multimeter Tips: If using a Fluke DMM, continue with Step d below. If using a Simpson DMM, go to Step e. d.

e.

FLUKE Meter: i.

Set the DMM to the 40 VDC Range.

ii.

Select Min/Max, then select Peak Min/Max.

iii.

The DMM will have a record time of 1 ms, and will display approx. 22 volts (peak + voltage).

SIMPSON Meter: i.

Set the DMM to the 20 VDC Range.

ii.

The voltage displayed should be about +4 VDC between TH4 (+) and TH3 (-).

Verify that the following test holes on the TAD PWB have the correct voltages: •

TH1 is +5 VDC at the input of the TAD PWB

•

TH2 is +24 VDC at the input of the TAD PWB

•

TH3 is DC COM output to Solenoid 1

•

TH4 is a Pulsed DC Voltage output to Solenoid 1 (+24 VDC is on for 16 milliseconds, the +5 VDC remains on). See the explanation of this voltage in 9 at the end of this RAP.

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Section Name

PQ 9-622

Figure 1 PQ 9-622 Circuit Diagram (708102)

Section Name

PQ 9-622

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Preliminary Working Document No Product Name Assigned

A

PQ 9-623 Border Bands RAP

•

Check the Photoreceptor Belt for inboard and outboard scratches. Replace the Photoreceptor Belt (PL 9.1).

Border bands are dark areas along the perimeter of the print. Check the following: • Photoreceptor Belt ground, go to the PQ 9-618, PR Ground RAP.

Initial Actions Observe the Transfer Assist Device during operation. If a problem is observed or suspected with the transfer assist, go to the PQ 9-622, Transfer Assist Device RAP.

Procedure CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Access the Xerographic Drawer. Press the (Red) Lamps test button on the Photoreceptor Module. Observe the discharge lamps. The Precharge and Pretransfer lamps light. Y N Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP. NOTE: If there are border bands in more than one area on the print (example: top edge and bottom edge), correct the problem in one area and then go to the next area. Border bands are located at the top edge (outboard edge) of the prints. Y N Border bands are located at the bottom edge (inboard edge) of the prints. Y N Border bands are located at the lead edge and/or trail edge of prints. Y N There is no border band problem. Perform the following: • Enter dC604 [Registration Setup]. Check and adjust registration if required. •

Check for dirt on the edges of the prints. This may be caused by the Transfer Assist Blade timing problems. Check/Adjust the Transfer Assist Blade Timing (ADJ 9-9). CAUTION

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Check the Photoreceptor Belt for inboard and outboard scratches. Determine and repair the cause of the scratches. Replace the Photoreceptor Belt (PL 9.1).

•

The bands may be dark bands that are coincident with the borders (and are really not border bands), go to the PQ 9-611, Dark Streaks/Bands RAP, PQ 9612, Light Streaks/Bands, or PQ 9-615, Deletions RAP.

Perform the following: • Enter dC604 Registration Setup. Check and adjust registration if required. A Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-623

PQ 9-624 Precharge/Pretransfer Lamps RAP

Y

N Replace the Precharge Lamp (PL 9.4).

This RAP is used for diagnosing the Precharge and the Pretransfer Lamps (Discharge Lamps). Closely examine the Pretransfer Lamp when it is on. All lamp segments light. Y N Replace the Pretransfer Lamp (PL 9.3).

Procedure CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Cheat the Printer Interlock Bypass Switch. Pull the Xerographic Drawer out to the latched position. Raise the Photoreceptor Module to observe the Lamps. Both lamps should be off. Both lamps are off. Y N (A lamp is on all the time). Go to Flag 4. Check for a short circuit. If the wires are OK, replace the MIN ADA PWB #2 (PL 1.8)

Press Stop. Press the Red Lamps Test Switch, S901, on the Photoreceptor Module. Both Lamps energize (light). Y N There is a problem with the Test Switch, S901. Go to Flag 1. Check for continuity across the Test Switch S901, when it is pressed. Check the wires from the Test Switch, S901, to the PWB. Replace the Test Switch (PL 9.3). The Precharge/Pretransfer Lamps are OK.

Enter dC330 [9] [Precharge/Prexfr Lamps]. Press Continue. If at least one segment of both lamps light, answer Yes to the following statement. NOTE: The Red Test button on the Photoreceptor Module does not check the entire circuit. Use dC330 [9] to energize the lamps during diagnostics. Both Lamps energize. Y N One or both of the lamps energizes (lights). Y N Press Stop. Press the Red Lamps Test Switch, S901, on the Photoreceptor Module. One or both Lamps energize (light). Y N There is +24 VDC between J1-10 (+) and J1-8 (-) at the Discharge Lamps Power Supply. Y N There is +24 VDC between TB4-12A (+) and TB4-8B (-). Y N Go to the 1-717, +24, +34, -34 VDC RAP. Go to Flag 2. Check the +24 VDC wiring from TB4-12A and TB4-4A to the PWB for an open circuit. If the +24 wiring is ok, go to Flag 3 and check the DC Com wiring from TB4-8B and TB4-12B to the PWB for an open circuit. Go to Flag 3. Check the DC Com wiring from TB4-8B and TB4-12B to the PWB for an open circuit. Go to Flag 4. Ensure that there is not an open circuit between TS17 of MIN ADA #2 and J1-5 of the Discharge Lamps Power Supply. Repair the circuit as required. If the wires are OK, replace the Discharge Lamps Power Supply PWB (PL 9.4)

Figure 1 PQ9-624 Discharge Lamp Components (8315A).

Go to Flag 5. Check the wiring for the particular Lamp that does not light. If the wiring is OK, replace the lamp (PL 9.3) Closely examine the Precharge Lamp when it is on. All lamp segments light. Section Name

PQ 9-624

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Preliminary Working Document No Product Name Assigned

Figure 2 PQ 9-624 Precharge/PreTransfer Lamps Circuit Diagram (8305).

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-624

PQ 9-625 White Spots RAP

•

White spots are deletions (absence or lack of toner) in a solid area. Halftone or continuous tone images that are circular in appearance with sharply defined edges. Deletions caused by agglomerates do not have sharply defined edges.

Paper Stock

Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper Trays and the paper path areas. Wipe areas as required.

•

Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of paper added to the Trays.

Examine the white spots with an eye loupe. If the white spots do not have sharply defined edges, go to the PQ 9-604, Prints with Agglomerates/Debris RAP. If there are sharply defined edges, continue with this RAP.

•

Pre-drilled paper: suggest that paper be drilled after printing if possible.

•

Label stock: adhesives from the labels can cause spots.

•

Carbonless paper is not recommended for use on this system.

Enter SCP [HSFI]. Ensure that all Xerographic (09) HFSI listed in the HFSI TABLES are completed.

•

Paper stock: certain brands are known spot generators.

•

Spray adhesives: any sprays used near the system can enter the machine air system and can cause spots and damage the Photoreceptor.

Procedure

Tray 1 / Tray 2 Feed Components

Initial Actions

1.

Check sequential prints for a repeatable pattern of white spots. a.

b.

Enter dC606. Select [Dark Dusting]. Select a Tray with 14 inch paper and program a 14 print job. Press Continue. Number the prints as they come out of the machine from 1 to 14. Check the prints for white spots. If the defect repeats on every seventh print, go to 4. If the defect repeats on every print in the same exact location, go to the PQ 9-601, System Image Quality Entry RAP.

Oil leaking from the sides of bearings or debris from the following: •

Takeaway Roll (PL 7.13)

•

Feed Belt Idler (PL 7.12)

•

Feed Belt Pulley (PL 7.12)

•

Feed Belt Spool (PL 7.12)

•

Idler and Retard Brake (PL 7.13)

Belts wearing: NOTE: Light image darkness on prints will tend to aggravate the white spots problem. 2.

•

White spots occur on prints whose image darkness is light. Enter dC106. Select [Test Pattern and PQ] [Xerographic]. Program a 14 print job. Press Continue. Compare the prints to the 82E4161 test pattern. Observe blocks "A" and "3" on the prints. The blocks are equal to or darker than the "STD:LT/UM" block on the test pattern.

Top Transport Belts (4) (PL 7.10)

Dirt Shield, clean or replace as required (PL 7.10)

If the prints are less than the test pattern, go to the PQ 9-609, Low Image Darkness RAP.

CAUTION

White spots repeat on almost every print, but tend to move across the page at the rate of six to ten millimeters print to print.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

Go to the 10-606, Dry Ink Spots on Prints/Spot Deletions RAP. 4.

Feed Clutch Belt (PL 7.10)

•

Xerographic

If the prints are equal to or darker than the test pattern, go to STEP 5. 3.

Takeaway Drive Belt (PL 7.10)

•

White spots repeat every seventh print and are judged unacceptable. Replace the Photoreceptor Belt (REP 9-35), (PL 9.1). Perform the Xerographic Setup (ADJ 9-3).

5.

Replace the Developer Material (PL 9.4).

6.

Considerable levels of dirt are found in the belt module area. Go to the PQ 9-632, Dirt RAP.

Possible Sources of Contamination Ensure all sources of contamination have been purged from the System to prevent callback for the spots problem. Perform the following actions unless already done while troubleshooting.

•

CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. •

Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Precharge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum the Photoreceptor Ground Brush.

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Preliminary Working Document

Paper Dust

Section Name

PQ 9-625

Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4).

No Product Name Assigned

•

Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays and the paper path area. Ensure that no developer material has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform the Xerographic Setup (ADJ 9-3).

Fuser Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not contaminating the developer assembly. If any oil is identified in the Developer Assembly, replace the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the Xerographic Setup (ADJ 9-3).

PQ 9-626 Dicorotron RAP Initial Actions Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures, in the Service Manual. If any NVM values require change, perform the Xerographic Setup (ADJ 9-3). Table 1 MIN NVM MIN Address

Current Value

MIN Address

202

216

204

223

Current Value

210

Procedure Enter dC131 [MIN]. Select Address 223 (Dicorotron AC Target). Ensure that the Data value is 95. Enter dC951. Press Continue. The Charge Ratio is between 92 and 98. Y N The Charge Ratio is greater than 98. Y N (The ratio is less than 92). Check/adjust the Charge Dicorotron Height Adjustment (ADJ 9-7), it could be too far. If adjustment is OK, check the Charge 1 Dicorotron shield for dirt, oxidation or a poor electrical connection. Repair/replace the shield as required (PL 9.10). (The ratio is greater than 98). Check/adjust the Charge Dicorotron Height adjustment (ADJ 9-7). It could be too close. If the adjustment is OK, replace the Charge 1 Dicorotron with a known good one and recheck the ratio. Leakage is suspected between the shield and ground. If the problem still exists, check the Charge 1 circuit. If the problem still exists and the machine is in a high altitude location (6000 feet or more), enter dC105 and ensure that the machine is set for high altitude operation.

WARNING Put on safety glasses before inspecting the coronodes. Eye injury could result if the glass coronode breaks. Cheat the Printer Interlock Bypass Switch. Remove the inner covers. Pull all 5 dicorotrons so that each is disconnected from the high voltage connection. Enter dC140. Press Continue. Allow the printer approximately 60 seconds to warm up. The Coronode ACV Monitor display is within +/- 0.7 of the Coronode ACV Control display. Y N Press Stop. Disconnect the HVAC Output Remote signal line connector. Press Continue. The Coronode ACV Monitor display is within +/- 0.7 of the Coronode ACV Control display. Y N Go to the PQ 9-628, HVAC RAP.

Check for the following: A Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-625, PQ 9-626

A •

HVAC cable routing. HVAC cables should not touch other HVAC wires or cables. No HVAC cable should touch low voltage DC wires or DC ground wires.

PQ 9-627 Patch Integrity RAP

•

The HVAC connectors for evidence of arcing or corrosion.

•

The HVAC cables for signs of arcing or deterioration.

The purpose of this RAP is to ensure that the patch has been created and developed correctly to ensure proper toner concentration control setups.

•

Repair or replace cables and/or connectors (PL 9.8)

•

If problem continues, replace the HVAC Output Module (PL 1.7)

Initial Actions •

Press Stop. Push in all the dicorotrons and shields. Press Continue. Observe the dicorotrons. All 5 dicorotrons are glowing. Y N Exchange the dicorotrons between the 5 dicorotron positions. Determine if the problem is dicorotron or position related. Ensure that all 5 dicorotron positions are filled with dicorotrons. • If the problem is related to a certain dicorotron, replace that dicorotron (PL 9.10), •

If the problem is position related, check the coronode sockets for damage, pitting, arcing, corrosion or foreign substances.

•

If the socket is good, replace the HVAC Output Module (PL 1.7),

•

If the above checks do not solve the problem, go to the PQ 9-628 HVAC RAP.

Each dicorotron glows evenly, without "hot" spots. Y N Replace the defective Dicorotron (PL 9.10), Press Stop. Enter dC910 [High Stress]. Rotate each of the dicorotrons in sequence into the Transfer Dicorotron position. Ensure that all 5 dicorotron positions are always occupied during this procedure. Press Continue. "Hot spots" and/or arcing is present on the dicorotron. Y N The dicorotrons are OK.

Clean the Patch Generator with a dry, soft cloth.

•

Clean the ROS exiting window with a lint-free cloth.

•

Enter dC105 [Features]. Ensure that the Precision Patch is enabled.

Procedure Enter dC909. Select [Printer Options], [Pages Per Set (50)], [Test Pattern (Xerographics)]. Reselect [Printer Options]. Select [Patch Print (Yes)], [Charge Control (Open)], [Start]. The developed patches have uniform density. Y N Check Developer Roll 1 and 2 Bias by measuring between the Developer Housing Left Side Extrusion (located under the Developer Catch Tray), and the Machine Frame. Check the Developer Roll 3 Bias by measuring between the Developer Housing Right Side Extrusion and the Machine Frame. If OK, continue on here, if not, go to PQ 9-616. The patch is free of dark, Le or TE bands in the fast scan direction. Y N Dark bands of 2 mm or less at the lead or trail edge is OK. If the dark bands are greater than 2 mm, check/adjust the registration if required. Enter Printer dC604 and select [Registration Adjustment], [Start]. Enter dC911, and perform Patch Generator Timing (ADJ 9-5). Enter dC131 [MIN]. Check the following NVM addresses and enter the data values as listed in the appropriate level Software dC 131 Table, Section 6, General Procedures, in the Service Manual. • Location 249

Replace the dicorotron with the "hot spots" or the arcing dicorotron (PL 9.10),

•

Location 253

•

Location 254

•

Location 285

•

Location 420

If any of the above NVM values are changed, perform Xerographic Setup (ADJ 9-3). Check/perform the following: • If the patches have light streaks or bands, go to PQ 9-612. •

If the patches have white spots, go to PQ 9-625 White Spots RAP.

•

If the patches have deletions, go to PQ 9-615 Deletions RAP.

•

If the patches have dark streaks or bands which are horizontal, check that the Patch Generator LEDs come on. Enter dC330, and select [9], [Patch Generator High Output], [Start]. If the Patch Generator is OK, go to PQ 9-611 Dark Streaks/Bands RAP.

•

If the patches have dark spots or marks, go to PQ 9-613 Dark Spots RAP.

•

If the patches have uneven density or darkness, go to PQ 9-614 Non-uniform Image Darkness RAP.

The measured patch height is from 20 to 25 mm.

Section Name

PQ 9-626, PQ 9-627

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Preliminary Working Document No Product Name Assigned

Y

N Ensure that the cleaner and charge zone rolls are positioned correctly against the PR Belt and held securely in the PR module frame (PL 9.2). Go to PQ 9-616.

PQ 9-628 HVAC RAP The purpose of this RAP is to ensure that the HVAC PWB is working correctly.

Procedure NOTE: With the Precision Patch, the patch width should be exactly the same size for every patch. Patch width, including load/trail edge dark bands, is from 17.5 mm. Y N Enter Printer dC604. Select [Registration Adjustment], [Start]. Go to ADJ 8-2 and check and adjust registration as required. Enter Printer dC911, and perform the Patch Generator Timing (ADJ 9-5). Check that both Cleaner and Charge Zone Rolls are correctly positioned against the Photoreceptor and held securely in the Photoreceptor Module frame (PL 9.2). Go to PQ 9-616. All ID zones are free of background (except those with the printed patches). Y N Go to PQ 9-607/608 RAP. If the PQ 9-607-608 RAP does not solve the problem, go to PQ 9-617 Cleaner RAP.

The following steps list some general areas to be checked and references the fault code raps that can be used to troubleshoot suspected problems with the HVAC PWB. 1.

2.

AC Coronode Voltage a.

Check for secure connections between the HVAC PWB, the Twist Lock Connector to the HVAC Output Module, and the MIN ADA PWB #1, repair/replace as required (PL 9.8).

b.

Check the condition and connection of the ribbon cable between the HVAC and HVDC PWBs, repair/replace as required.

c.

Check the operation of the MIN ADA PWB #1 and HVAC PWB. Go to the 9-329.

Cleaner Biases a.

Check for secure connections between the HVAC PWB, the Cleaner and the MIN ADA PWB #1, repair/replace as required.

b.

Check for proper operation of the control circuits and the correct voltages between the MIN ADA PWB #1, the HVAC PWB and the Cleaner. To perform these checks, refer to the 9-322 (cleaner voltage out of range), 9-323 (upper detoning roll bias out of range), or 9-324 (lower detoning roll out of range) as required.

The Patch integrity is OK. 3.

Control Circuit Operation for Transfer, Detack and Preclean Shield Currents a.

4.

a.

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To evaluate these circuits, refer to RAPs 9-326, 9-327 and 9-328.

ARC Detection Go to RAP 9-201.

Section Name

PQ 9-627, PQ 9-628

PQ 9-629 HVDC RAP The purpose of this RAP is to ensure that the HVDC PWB is working correctly.

Procedure The following steps list some general areas to be checked and references to the RAP's to be used to troubleshoot suspected problems with the HVDC PWB. 1.

2.

Developer Bias #1 and #2 Voltage a.

Check for secure connections between the HVDC PWB, the Developer Bias Rolls and the MIN ADA PWB #2. Repair/replace as required (PL 9.8).

b.

Ensure that the developer biases are isolated from machine ground and Photoreceptor Belt ground, that is, the biases are not shorted to ground. Ensure that there is a 50 +/- 4 VDC difference between Developer Bias 1 and 2. If not, go to 9-320.

c.

Check for the correct operation of the MIN ADA PWB #2 and HVDC PWB. Go to 9320 to diagnose MIN and 9-321 to diagnose HVDC as appropriate.

Charge 1 and 2 Dicorotron Voltage

NOTE: Because Charge 1 is controlled by Charge 2 feedback, only Charge 2 Dicorotron is checked.

3.

a.

Check for secure connections between the HVDC PWB, the Charge 2 Dicorotron and the MIN ADA PWB #2. Repair/replace as required, go to step b.

b.

Check for proper operation of the control circuits and the correct voltages between the MIN ADA PWB #2, the HVDC PWB and the Charge #2 Dicorotron. Go to the 9325 RAP, to perform these checks.

Control Circuit Operation for Transfer, Detack, and Preclean Dicorotrons 0 and interaction between HVDC and HVAC circuits a.

4.

To evaluate these circuits, go to RAPs 9-326, 9-327, and 9-328.

ARC Detection a.

Go to RAP 9-201.

Figure 1 PQ 9-628 Component Diagram (713007)

Section Name

PQ 9-628, PQ 9-629

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Preliminary Working Document No Product Name Assigned

A

PQ 9-630 Toner/Charge Control RAP

Recheck the ESV ID zone values by entering dC909. Program a 250 print job. Press Continue. Observe the ESV and DSS ID zones 2, 4, 6 readings during the first ten updates. The range for the ESV ID 2, 4, 6 updates is now less than 50 volts. Y N Check the ESV Height Adjustment (ADJ 9-12). Go to the PQ 9-619, ESV RAP. If the problem continues, go to Printer Electrical Noise Procedure RAP.

The purpose of this RAP is to ensure that the toner and charge control system components are working correctly.

Initial Actions Check SCP [Faults]. If 9-215 faults are indicated, go to the 9-215. If the problem continues return to this RAP.

The range for the DSS ID 2, 4, 6 is between 75-100 units. Y N Select [ESV-DSS Test], [DSS Recalibrate]. This will cause a power up convergence at the next print cycle. Program a 200 print job. Press Continue. Observe the DSS ID 2, 4, 6 readings during the first ten updates. If the range for the DSS updates is still not between 75-100 units, go to the PQ 9-620, DSS RAP. If the problem continues, go to the PQ 9-621, Patch Gen/Patch Integrity RAP.

Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. Table 1 MIN NVM Address

•

Current Value

Address

179

251

220

260

243

275

244

289

245

295

246

296

247

420

B

Current Value ESV is OK. DSS is OK. The range for the DSS ID 2, 4, 6 updates is between 75-100 units. Y N Select [ESV-DSS Test] [DSS Recalibrate]. This will cause a power up convergence at the next print cycle. Program a 200 print job. Press Continue. Observe the DSS ID 2, 4, 6 readings during the first ten updates. If the range for the DSS ID 2, 4, 6 is still not between 75-100 units, go to the PQ 9-620, DSS RAP. If the problem continues, go to the PQ 9-621, Patch Gen/Patch Integrity RAP.

If any of the MIN NVM values required change, perform Xerographic Setup (ADJ 9-3).

Procedure Enter dC912. Press Continue. Check the All Panels Range display. The All Panels Range display reading is less than 50 volts Y N Go to the PQ 9-633, PR Belt Uniformity RAP.

Toner/Charge Control is OK.

Enter dC909. Program a 250 print job. Press Continue. Observe the ESV and DSS ID 2, 4, 6 readings during the first ten updates. The range for the ESV ID 2, 4, 6 updates is less than 50 volts. Y N Select [ESV-DSS Test] [DSS Recalibrate]. This will cause a power up convergence at the next print cycle. Program a 200 print job. Press Continue. Observe the ESV and DSS ID 2,4,6 readings during the first ten updates. The range for the ESV ID 2,4,6 is less than 50 volts. Y N Enter dC131 [MIN]. Enter Address 126 (Vddp Setpoint Minimum). Record the data value. Enter Data value 32. Enter dC912. Press Continue. Record the Dark Decay Volts. Calculate the Dark Decay Offset by dividing the Dark Decay Volts by 5.88. Enter dC131 [MIN]. Enter Address 158 (Minimum Dark Decay for a Photoreceptor). Enter the calculated dark decay offset value rounded off, into address 158. Enter Address 126. Enter the initial Data value recorded above.

A

B

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Section Name

PQ 9-630

PQ 9-631 Bead Carryout RAP Bead Carryout is excessive amounts of Developer beads located on the Developer Manifold and outside of the Developer Housing Area. The primary causes of Bead carryout are: Incorrect toner concentration, incorrect or missing developer bias, or a mechanical problem with the Developer Housing. It is impossible to completely eliminate all BC from a correctly operating system. A small residual amount of BC which does not cause deletions or excessive machine contamination is acceptable. NOTE: DO NOT perform the DSS Saturation or dC951 Xerographic Setup until instructed to do so in this procedure. This prevents the setup procedure from being unnecessarily repeated several times.

Initial Actions Make a copy of Figure 2 (refer to hardcopy graphic), for later use in this procedure to record the dC909 values. Check/adjust the following. If the Bead Carryout Problem continues after completing this Initial Action, continue with the RAP Procedure. •

Developer Zone Roll (ADJ 9-1)

•

Photoreceptor Tension (ADJ 9-11)

•

PR Module Alignment (ADJ 9-10)

•

DSS Saturation (ADJ 9-13)

•

Xerographic Setup (ADJ 9-3)

Procedure (Developer Bias Checks) Enter dC140. Select [DC Bias Values], [Start]. Measure the DC Bias from the Developer Roll 1 drive gear (+) to the frame ground (-). Compare the values measured with the DMM to the values displayed on the dC140 screen for the corresponding Dev Roll Biases. The measured voltage is within +/- 10 VDC Actual display. Y N Enter dC902. Check and adjust the AC PWB and DC PWB Calibration Values per the Calibration Tags (found in the Machine Log Book). Enter Printer dC140. Enter [DC Bias Values]. Measure between the left side extrusion of the Developer Housing (located under the Developer Catch Tray) (+) and the Machine Frame (-). Select [Start]. NOTE: An intermittent short will not drop the voltage of 0 VDC. If there is a short, the SCP Printer Fault History should have Fault Codes 9-320 and 9-321 logged. The measured voltage is steady within +/- 2 VDC. Y N Select [Stop]. Perform the following checks for possible causes for a short: • Refer to the CD. Go to Flag 1 and Flag 2, and check the Developer Rolls 1 and 2 Bias circuitry for a short. •

Check the Developer Zone Roll Support Pads. If either of the Outboard Support Pads are damaged or broken, replace the Front Bearing Clamp Assembly (PL 9.15).

•

If the above checks are OK, replace the Developer Drive (PL 4.17).

Section Name

PQ 9-631

In dC140 [DC Bias Values], measure between the right side extrusion of the Developer Housing (+) and the Machine Frame (-). The measured voltage is within +/- 10 VDC of [Dev Roll 3] Bias Required Display, Y N select [Stop] and check the following: • Refer to the CD. Go to Flag 3 and Flag 4. Check for an open circuit. If the circuit is OK, replace the HVDC PWB (PL 1.7). Check the Developer Zone Roll Support Pads. If either of the two Outboard Support Pads are damaged or missing, replace the Front Bearing Clamp Assembly (PL 9.15). Ensure that the Hydraulic Dump Actuator is properly adjusted to relieve pressure from the cylinder when the PR Module is closed. Adjust the actuator or replace the Hydraulic Lift with the Mechanical Lift Assembly P-192 (600K25820). Ensure that the Developer Zone Roll is properly aligned on the Support Pads (ADJ 9-1). NOTE: The PR Tension Springs and Developer Seals Kit should NOT be installed except as a part of a complete Bead Carry Out procedure. The 12 lb. PR Tension Springs alone may not reduce Bead Carry Out.

Cheat the Processor Interlock Bypass Switch.

A

A Select [Start] to measure between the left side extrusion of the Developer Housing (located under the Developer Catch Tray) (+) and the Machine Frame (-). The measured voltage is within +/- 10 VDC of [Dev Rolls 1 & 2] Bias Required Display. Y N Select [Stop] and check the following: • Refer to the Figure 1. Go to Flag 1 and Flag 2 and check the Developer Rolls 1 and 2 Bias circuitry for an open. If the circuits check out OK, replace the HVDC PWB (PL 1.7).

Check for Tags P-228 and P-216. For machines with out TAG P-228, order and install the PR Tension Springs (P-228) and Developer Seals (P-216) Kit (600K32850). Developer Seal sets can be ordered individually (outboard set - 35K4130, inboard set 35K4120). Clean the entire PR Module (inside & outside), Dicorotrons & Shields, Developer Housing and Seals, Cleaner Housing (inside, outside, brush, augers & channels), Registration Transport, Top Transport, transfer zone, Transfer Assist Blade, and entire paper path (including duplex path and inverter) with the vacuum cleaner. Inspect the PR Belt for seam damage or edge damage. If the PR Belt has any edge damage or upward curl, ensure that the PR Edge Guides are not damaged and are free of fused toner buildup. Replace the Edge Guides if they are damaged or contaminated with fused toner. Clean the Edge Guides at every PR change. Replace a damaged PR Belt. If the Developer Material has been in the machine for more than 500K prints, perform the Developer Dump and Thump (REP 9-6). Ensure that the power supply calibrations are correct. Perform the DSS Saturation (ADJ 9-13). NOTE: A small amount of reverse developer flow may remain, and not significantly contribute to BCO. Check for Reverse Developer Flow: Refer to (Figure 1) for an illustration of Reverse Developer Flow. Inspect the Developer Material flow across Developer Roll #1. Reverse Developer Flow exists when Developer Material accumulates and appears to flow in the reverse from normal direction. It can occur at one or at both ends of Developer Roll #1. There is normal developer flow. Y N Reverse Developer Flow is present, perform the following: B

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Preliminary Working Document No Product Name Assigned

B •

Check the Developer Housing Support Pads for the Developer Zone Roll. If either of the two Outboard Support Pads are damaged or broken, replace the Front Bearing Clamp Assembly (PL 9.15).

•

Inspect the Developer Rolls. Replace the rolls if they are damaged or show wear-out (roll surfaces worn smooth), (REP 9-9) or (REP 9-10).

•

Inspect / clean the Trimmer Bar. Replace the Trimmer Bar if damaged (REP 9-11), (PL 9.16).

•

Inspect and adjust the Trimmer Bar toward the Developer Roll 2. If reverse developer flow still exists, install Tag P-488, the Developer Rollback Solution Kit.

Perform the following tasks: • Inspect the Developer Rolls. Replace the rolls if they are damaged or wear-out (roll surfaces worn smooth), (REP 9-9) or (REP 9-10). •

Print ten halftone images from Tray 1 and Tray 2 and examine the prints for deletions.

•

If there is still unacceptable BCO and the Developer was free of reverse developer flow, replace the Photoreceptor Module (PL 9.1).

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Section Name

PQ 9-631

Figure 1 PQ 9-631 Circuit Diagram (713004)

Section Name

PQ 9-631

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Preliminary Working Document No Product Name Assigned

Figure 2 dC909 Values

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-631

A

PQ 9-632 Dirt RAP

B •

Go to the PQ 9-624, Pretransfer/Precharge Lamps RAP.

•

Examine the Cleaner. Go to the PQ 9-617, Cleaner RAP.

The purpose of this RAP is to determine the cause of the dirt/contamination. Determine the source. Repair as required. Clean up all filings.

Initial Actions If the dirt is toner on the back of the prints or on the lead edge of the prints, go to the PQ 9-622, Transfer Assist Device RAP. Return to this RAP if the problem continues.

Perform the following: • Ensure that the Photoreceptor Module is latched properly. Ensure that the Developer Housing is properly installed in the machine and is secured.

Clean any dirt and contamination that are the result of adding consumables to the machine.

CAUTION

Follow the cleaning procedures in the Service Data (Section 4) for the following items: •

The light shields on the Screening Device, Precharge/Pretransfer Lamps, Belt Hole Sensor.

•

The Patch Generator (REP 9-36), the ESV (REP 9-37) and the DSS (REP 9-38)

•

The Dicorotron Shields (REP 9-39)

• • •

•

Pull out the Photoreceptor Drawer. Lift the Photoreceptor Module to the full open position. Inspect the Developer Housing seals for dirt and damage. Repair/replace components as required (PL 9.15).

The Photoreceptor Ground Strip

•

Replace the Dicorotron electrical connectors if they are dirty, contaminated or broken (REP 9-40).

Check the Bead Rollout Device for dirt. Ensure that the DRD rotates freely. Clean/repair components as required (PL 9.15).

•

The Developer Housing and Photoreceptor Module. Check/replace the Developer Seals if damaged or missing, (PL 9.15)

Check for developer leaks from the Dump Door, repair/replace components as required (PL 9.17).

Possible Sources of Contamination

Hints about the Developer Manifold. •

•

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

Ensure all sources of contamination have been purged from the System to prevent callback for the spots problem. Perform the following actions unless already done while troubleshooting.

When the manifold is operating normally, there will be an accumulation of toner between the Developer Housing and the air holes, and there will be a clean curved area between the air holes. A small amount of toner to the right (front view of housing) of the manifold holes is normal. A loss of vacuum or low vacuum will result in dirt across the entire width of the manifold. Clean the Developer Manifold. Remove the air hose. Tap the bottom of the manifold with the handle of a screwdriver while cleaning the manifold with the vacuum cleaner. With the Main Drive running, the vacuum measurement at the test hole at the outboard end of the manifold should be a minimum of 8mm of vacuum (-). If 8mm of vacuum is not measured, check for a clogged filter, or kinked/plugged hoses in the rear of the machine.

Procedure

Paper Dust •

Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper Trays and the paper path areas. Wipe areas as required.

Paper Stock •

Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of paper added to the Trays.

•

Pre-drilled paper: suggest that paper be drilled after printing if possible.

CAUTION

•

Label stock: adhesives from the labels can cause spots.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module.

•

Carbonless paper is not recommended for use on this system.

Inspect the Xerographic area for dirt. Examine the dirt. Most of the dirt is developer beads. Y N Most of the dirt is metal or plastic filings. Y N Check for a broken machine part or a part that is out of position. Look for a sheet of paper or a foreign object in the Cleaner or Developer Housing. If any of the above items are found, repair as required. If the previous checks are negative, the dirt problem is most likely the result of the interaction between the cleaning, the transfer, and the process controls. Perform the following: A B Section Name

PQ 9-632

•

Paper stock: certain brands are known spot generators.

•

Spray adhesives: any sprays used near the system can enter the machine air system and can cause spots and damage the Photoreceptor.

Tray 1 / Tray 2 Feed Components Oil leaking from the sides of bearings or debris from the following: •

Takeaway Roll (PL 7.13)

•

Feed Belt Idler (PL 7.12)

•

Feed Belt Pulley (PL 7.12)

•

Feed Belt Spool (PL 7.12)

•

Idler and Retard Brake (PL 7.13)

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Preliminary Working Document No Product Name Assigned

Belts wearing:

PQ 9-633 PR Belt Uniformity RAP

•

Takeaway Drive Belt (PL 7.10)

The purpose of this RAP is to determine if the Photoreceptor Belt is being charged uniformly.

•

Feed Clutch Belt (PL 7.10)

•

Top Transport Belts (4) (PL 7.10)

Procedure CAUTION

Dirt Shield, clean or replace as required (PL 7.10)

Xerographic CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4). CAUTION

Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. •

Remove the Photoreceptor. Clean the Pretransfer and Precharge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Clean the DSS, ESV and the Patch Generator with a soft, lint free cloth. Clean the ESV Vacuum the Photoreceptor Ground Brush.

•

Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays and the paper path area. Ensure that no developer material has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform the Xerographic Setup (ADJ 9-3).

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Clean the Photoreceptor Belt ground block, brush, and the ground strip. Enter dC912. Press Continue. The All Panels Range is less than 70 volts. Y N Note the image zone(s) with the maximum and minimum voltage readings. Repeat dC912. Press Continue. Again, note the image zone(s) with the maximum and minimum voltage readings. Determine if the voltage extremes are related to a specific image zones or panels on the Photoreceptor Belt. The maximum and minimum readings are on the same image zones each time. Y N Go to the PQ 9-618, PR Ground RAP. After completing that procedure, return to this RAP. Enter dC912. Press Continue. The All Panels Range is less than 70 volts. Y N Enter dC106. Select [Test Patterns and PQ] [Halftone]. Program 20 prints. Choose a Tray with 14 inch paper. Press Continue. The prints have random fast scan direction deletions (or light fast scan direction strobes) about one half inch in width. Y N Go to the Printer Electrical Noise Procedure RAP. Repeat dC912 after repair. The prints have fast scan direction white bands. Y N Remove the rear covers. Check the Photoreceptor Drives: • Examine the drives for loose, jumping belts and /or pulleys (PL 4.17).

Fuser Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not contaminating the developer assembly. If any oil is identified in the Developer Assembly, replace the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the Xerographic Setup (ADJ 9-3).

•

Check for Broken/missing idler springs (PL 4.17).

•

Check for Shaft and bearing wear signs (noise/wobble). Repair or replace as required (PL 4.17).

Go to the PQ 9-612, Light Streaks/Bands RAP. The Photoreceptor Uniformity is OK. If the Xerographic Drawer area is extremely dirty, go to the PQ 9-632, Dirt RAP. Go to the PQ 9-618, PR Ground RAP. After completing the procedure return to this RAP. Enter dC912. Press Continue. The All Panels Range is less than 70 volts. Y N Go to the PQ 9-619, ESV RAP. After completing the procedure return to this RAP. Enter dC912. Press Continue. Check the All Panels Range value. If the range is still 70 volts, replace the Photoreceptor Belt (PL 9.1). A Preliminary Working Document No Product Name Assigned

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B Section Name

PQ 9-632, PQ 9-633

A

B The Photoreceptor Uniformity is OK. If the Xerographic Drawer area is extremely dirty, go to the PQ 9-632, Dirt RAP.

The Photoreceptor Uniformity is OK. If the xerographic drawer area is extremely dirty, go to the PQ 9-632, Dirt RAP.

PQ 9-634 Residual Image RAP Residual image is a secondary or partial image that appears with the primary or desired image. Residual image is caused by Photoreceptor Belt cleaning problems or fusing problems.

Initial Actions If the residual image appears only after fuser mis-trips and disappears after several prints, go to the 10-102 RAP. If the residual image appears only in the first 30 prints from a cold start, go to the 10-608 RAP. NOTE: When duplex prints are being run, a double image can occur due to improperly loaded first side prints in the paper trays. Examine the defective prints and inform the operator. Paper Tray 1 and 2 should be loaded with the first side image down, top of the print to the outboard side. In Tray 3 the first side image should be loaded face up, with the top of the print to the outboard side.

Procedure Enter dC106. Select [Test Patterns and PQ] [Dimensional]. Program a 30 print job. Choose a Tray with 14 inch paper. Press Continue. After approximately 10 prints, open the Printer Front Doors to hard stop the printer. Inspect the PR Belt surface for toner past the Cleaner. There is toner past the Cleaner. Y N Carefully remove the prints from the Fuser and the Decurler area. Examine the prints for residual image. If present, check the Fuser Roll Temperature (ADJ 10-6) and then go to the 10-708, Fuser Agent Dispense RAP. Clear the fault. Check/perform the following in the order specified: • Go to the PQ 9-617, Cleaner RAP. Clean/vacuum any spilled Dry Ink. Vacuum the Photoreceptor module and area. Closely inspect and clean any dry ink accumulation from the PR Edge guides (the guides are located on the inboard and outboard ends of the rubber rolls). Dry ink accumulation and build up on the guides can damage the edge of the PR Belt. If excessive dirt is observed, go to the PQ 9-632, Dirt RAP. Return to this procedure after completing the PQ 9-632, Dirt RAP. •

Check the operation of the Precharge and Pretransfer Lamps. Go to the PQ 9-624, Precharge/Pretransfer Lamps RAP to repair.

•

Clean all dicorotron shields. Ensure that the Transfer and Preclean dicorotrons glow in operation. Repair/replace components as required (PL 9.10)

Enter dC131 [MIN]. Record the Data values at the following Addresses and compare them to the values listed in the appropriate level Software dC 131 Table, Section 6, General Procedures. If any of the NVM values require change, perform the Xerographic Setup (ADJ 9-3). Table 1 MIN NVM MIN Address

Section Name

PQ 9-633, PQ 9-634

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Current Value

MIN Address

199

206

200

207

204

208

205

239

Current Value

Preliminary Working Document No Product Name Assigned

PQ 9-635 Smear RAP Smear is the spread of toner on a print from an image area to adjacent non-imaged areas and possibly overlapping other images.

Initial Actions If the smeared image appears only in the first 30 prints after a cold start, go to the 10-608, Dry Ink Not Fixed RAP. Check the Spots Blade Installation (REP 9-57).

Procedure Enter dC106. Select [Test Patterns and PQ] [Halftone]. Program a 50 print job. Choose a Tray with 14 inch paper. Press Continue. After approximately 10 copies have been made, open the printer front door to hardstop the printer. Observe the post Transfer prints. The Smearing originates before the fuser roll. Y N Smearing occurs in the Fuser or post Fuser areas. • Check the Fuser Subsystem: Go to the 10-608 Dry Ink Not Fixed RAP and then the 10-708, Fuser Agent Dispense RAP. •

If the smeared images only appear on prints delivered to the Top Tray are not smeared, go to the 8-705, Print Damage RAP.

Smearing occurs before the Fuser Roll. Perform the following checks: • Load fresh paper and run the machine. If the smear is no longer present advise the Key Operator about the storage and use of paper. •

Ensure that the paper is loaded correctly and that curl is not excessive.

•

Remove the Prefuser Transport (REP 10-12). Clean the Prefuser Transport vent holes and the transport.

•

Check the condition of the Fuser Entrance Baffle. CAUTION

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. Pull out the Xerographic Drawer. Lift the Photoreceptor Belt module and examine the developed images on the Photoreceptor Belt. The images on the Belt are smeared. Y N Check the Transfer Dicorotron, Detack Dicorotron, POP Sensor, Precharge/Prexfer Lamp Reflectors, and Prefuser Transport areas for potential causes.

Figure 1 PQ 9-635 Component Diagram (713008)

Determine where the smear first occurs and look for the cause at that point. Also check/correct as required the following: • Check the Transfer Assist Blade for toner contamination. Adjust the Transfer Blade Timing as required. (ADJ 9-9). •

Check the exit lip of the Developer Housing for contamination, defective seals, or a physical interference.

•

Ensure that the Bead Rollout Device is free of contaminants and rotates freely.

•

Ensure that the Developer Zone rolls contact the Developer Housing tabs.

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-635

PQ 9-636 Blur RAP

Possible Sources of Contamination

Blur is the scattering of Dry Ink (Toner) particles around individual characters on the Print when background and fusing are acceptable.

Ensure all sources of contamination have been purged from the System to prevent callback for the spots problem. Perform the following actions unless already done while troubleshooting. Paper Dust

Procedure The Blur is a fast scan direction band 15-40 mm wide about 70-100 mm from the trail edge of 81/2 inch prints. Y N The blur is an irregular band centered in the fast scan direction and running in the process direction. Y N The blur is in the central area of the print and is in a band about 25 X 75 mm. Y N Go to the Possible Sources of Contamination checklist at the end of this RAP.

•

Check the paper trays and paper path areas for excessive paper dust. Vacuum the paper Trays and the paper path areas. Wipe areas as required.

Paper Stock •

Adhesive from the paper wrapper can be transferred to the Photoreceptor Belt. If expected as a contaminant, direct the Operator to discard the top and bottom sheets of any new reams of paper added to the Trays.

•

Pre-drilled paper: suggest that paper be drilled after printing if possible.

•

Label stock: adhesives from the labels can cause spots.

•

Carbonless paper is not recommended for use on this system.

The Photoreceptor Belt may be contaminated from the Preclean Dicorotron. Contamination occurs in standby and is due to outgassing (the emission of vapors) from the plastic materials of the Dicorotron which coats the Photoreceptor surface immediately under the dicorotron. Contamination can occur if immediately after a long run the fuser is pulled out and left out for more than five minutes. With the fuser out, the airfoil through the preclean dicorotron is interrupted and the harmful vapors are not carried away. Normally (with the fuser in and all components in place) the fuser provides a convective airflow through the preclean dicorotron which carries the vapors away from the Photoreceptor surface. The blur caused by this type of contamination will eventually (in about a day) go away as the contaminant dissipates. If the defect is unacceptable, replace the Photoreceptor Belt (PL 9.1).

•

Paper stock: certain brands are known spot generators.

•

Spray adhesives: any sprays used near the system can enter the machine air system and can cause spots and damage the Photoreceptor.

•

Feed Belt Spool (PL 7.12)

NOTE: A preventive measure (when the Fuser must be pulled out after a long print run) is to remove the preclean dicorotron and keep it out until the Fuser is reseated.

•

Idler and Retard Brake (PL 7.13)

Check/perform the following: • Check the OZAC Ducts for leaks and blockage.

Tray 1 / Tray 2 Feed Components Oil leaking from the sides of bearings or debris from the following: •

Takeaway Roll (PL 7.13)

•

Feed Belt Idler (PL 7.12)

•

Feed Belt Pulley (PL 7.12)

Belts wearing: •

Takeaway Drive Belt (PL 7.10)

•

Feed Clutch Belt (PL 7.10)

•

Top Transport Belts (4) (PL 7.10)

•

Check for blocked air passages in the dicorotron endblocks.

•

Check for fuser agent (oil) leaks on the Photoreceptor belt. Find and repair the cause of the leak and replace the Photoreceptor Belt (PL 9.1).

Dirt Shield, clean or replace as required (PL 7.10)

•

Check for foreign objects in the dicorotrons. If the problem still exists after repair/ cleaning, replace the Photoreceptor Belt (PL 9.1).

Xerographic

Check/perform the following: • Check the OZAC Ducts for leaks and blockage. •

Check for blocked air passages in the dicorotron endblocks.

•

Check for fuser agent (oil) leaks on the Photoreceptor belt. Find and repair the cause of the leak and replace the Photoreceptor Belt (PL 9.1).

•

Replace the Preclean Dicorotron and Shield (PL 9.10).

•

Enter dC106. Select [Test Patterns and PQ] [Halftone]. Select [Printer Options]. Program a Duplex, 300 print job. Choose a Tray with 14 inch paper. Press Continue. Recheck the blur problem. If the problem still exists, replace the Photoreceptor Belt (PL 9.1).

Section Name

PQ 9-636

CAUTION The Photoreceptor is extremely sensitive to light exposure. Limit the exposure to under two (2) minutes or severe xerographic problems may result. If the belt module will be exposed to light for more than two minutes, remove the photoreceptor from the belt module and place it in the protective bag, or place the bag over the photoreceptor with it on the belt module. •

Photoreceptor Hydraulic Lift assembly. Check for leaks. Replace Lift as required (PL 9.4).

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Preliminary Working Document No Product Name Assigned

PQ 9-637 Slow Scan Magnification Checkout Procedure

CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. •

Remove the Photoreceptor. Clean the DSS and the ESV. Clean the Pretransfer and Precharge Lamps. Clean the Belt Hole Sensor with a clean, water dampened cloth. Vacuum the Photoreceptor Ground Brush.

•

Vacuum the top of the Developer Housing including the seals. Vacuum the paper trays and the paper path area. Ensure that no developer material has accumulated on the BRD roll. Vacuum the Photoreceptor Module area. Reinstall the Photoreceptor Belt, Perform the Xerographic Setup (ADJ 9-3).

Fuser Ensure that Fuser Agent, (oil), or oil leaking from the Fuser/Developer Drive Motor is not contaminating the developer assembly. If any oil is identified in the Developer Assembly, replace the Developer Assembly (PL 9.13). Clean and repair the source of contamination. Perform the Xerographic Setup (ADJ 9-3).

The purpose of this RAP is to determine and repair the cause of slow scan magnification problems.

Initial Actions Observe the Fuser/Developer drive belts in the rear of the IOT. Check for wear or improper operation while running prints.

Procedure Use the Slow Scan Magnification procedure as an aid to locate and repair causes of Slow scan magnification problems. NOTE: If transparencies are not available, two quadrille prints oriented as in Figure 1, can be used to perform the procedure. 1.

Enter dC606 and make one print of the two pixel quadrille test pattern on a transparency, and ten prints on 8.5 X11 inch paper. Enter dC106 and make 5 prints of the Halftone test pattern on 8.5 X 11 inch paper.

2.

Lay the fast scan direction of the transparency on the slow scan direction of the quadrille prints to determine the magnitude and frequency of the variation (Figure 1). Observe the halftone prints for evidence of banding. If a banding problem is observed, go to the PQ 9601, and perform the Motion Quality Diagnostics, after completing this procedure.

3.

Check the IOT to ensure that it is level, Section 3 of the System Printer Installation Manual. Ensure that when the IOT is level that all casters are in contact with the floor.

4.

Ensure that the Fast Scan and Slow Scan magnification are at 100% using the ROS Magnification Setup procedure (ADJ 6-1).

5.

Repeat Steps 1 and 2 after adjusting the magnification to 100% to determine if magnification was a cause of the initial problem. If the problem continues, go to Step 6 below. If the Slow scan magnification is now in specification, the IOT is not the cause of any problem, however, the customer application may be a cause if the problem continues.

NOTE: Even slight key or keyway wear has been identified as a known cause of Slow Scan Magnification problems. 6.

Remove the P/R Drive Assembly (REP 4-31) and check the drive coupling for wear or binding on the "D" shaft, and the shafts and bearings for binding. Check for any key and keyway wear (PL 4.17). The drive will be reinstalled in step 11.

7.

Open and close the Photoreceptor drawer. Observe the cleaner locating pin to ensure that the cleaner and P/R drawer are properly aligned. Handcrank the Cleaner Assembly drive in a Clockwise direction ONLY and check for abnormal resistance. Repair/replace as required (PL 9.22).

8.

Remove the Developer Drive Housing (REP 4-39) and check the coupling, key and keyway for wear and binding (PL 4.17). The drive will be replaced in step 9.

9.

Align the Developer Drive housing. Ensure that the Photoreceptor drawer is closed and latched properly. Align the assembly with the developer coupling, rotating several times while tightening the drive assembly to ensure alignment (REP 4-39).

10. Remove the Fuser Drive Assembly and check for wear or binding (PL 4.17). Install the Fuser Drive Assembly ensuring that the drive and coupling are aligned (REP 4-39).

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-636, PQ 9-637

11. Ensure that the Photoreceptor drawer is closed and latched properly. Insert the Photoreceptor alignment tool, (600T2008) from the rear of the machine, onto the coupling. Install the P/R Drive Assembly, rotating the coupling clockwise while tightening the assembly to ensure proper alignment. 12. Unlatch the P/R drawer and remove the alignment tool. Slide the P/R drawer closed several times, checking proper alignment of the drive and coupling. 13. Adjust the tension of the Fuser/Developer Drive Belt (REP 4-40). 14. Check and adjust the following: •

Top to bottom registration (ADJ 8-2)

•

Side to side registration (ADJ 8-3)

•

ROS Magnification setup (ADJ 6-1)

•

Pretransfer Baffle (ADJ 8-1)

•

ROS Image Squareness (ADJ 6-2).

If the problem continues perform the following: a.

Replace the photoreceptor drive housing (PL 4.17). Inspect the photoreceptor drive shaft, coupling, and drive coupling key. Perform Steps 1 and 2 at the beginning of this RAP to determine if the problem has been resolved, if not continue with step b.

b.

Replace the photoreceptor drive roll (PL 9.3) and check the key for wear. Perform Steps 1 and 2 at the beginning of this RAP to determine if the problem has been resolved, if not continue with step c.

c.

Replace the photoreceptor drive casting assembly (PL 4.17). Perform Steps 1 and 2 at the beginning of this RAP to determine if the problem has been resolved, if not continue with step d.

d.

Replace the bi-pully (PL 4.17). Perform Steps 1 and 2 at the beginning of this RAP to determine if the problem has been resolved, if not continue with step e.

e.

Replace the photoreceptor module drawer assembly. Repeat Steps 6 through 14, and then perform Steps 1 and 2 at the beginning of this RAP.

Section Name

PQ 9-637

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Preliminary Working Document No Product Name Assigned

Print

Transparency (Print if Transparency is not available)

Figure 1 9-637 Slow Scan Magnification Checkout Procedure (4907)

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-637

PQ 9-638 Scratches/Crayoning Fault Analysis

CAUTION This photoreceptor is extremely sensitive to light exposure. Limit the exposure of the photoreceptor to light for two (2) minutes maximum or severe xerographic problems may result. If the belt module will be exposed to light longer than two minutes, remove the photoreceptor from the belt module and place it immediately in the protective photoreceptor bag, or place the bag over the photoreceptor with it on the belt module.

Dark horizontal marks (in the process direction) that resemble fine lines from 0.5 to 10 mm in length and 100 microns wide. The lines print out more in Light Original mode.

Initial Actions •

Enter dC606.

•

Select [Quadrille Patterns]: Press Continue.

•

Make 14 copies with the longest paper available. Press Stop.

•

Make certain that the DP180 Developer Housing is installed.

•

Determine which of the following categories the copies fit into.

NOTE: If the Photoreceptor is damaged at the edge toward the inside of the machine, replace the Photoreceptor (REP 9-35), (PL 9.1), and check for wear on the Shoulder Washer. If there is wear on the Shoulder Washer, replace it (PL 9.3). a.

Ensure that the Cooling Fans are clean and running.

b.

Unlatch and raise the Photoreceptor module.

Procedure

c.

Dump the Developer Material.

Categories

d.

Perform the Developer Housing Inspection Procedure PQ 9-616.

e.

Install the Developer Housing in the machine.

•

Consumable check. Installing new Toner or Developer Material does not mean that the new material is not defective. If diagnostics is not conclusive and if no problems can be found, it could be a consumable problem. Go to STEP 1 in the Diagnostics section.

•

Scratches that are 6 mm to 10 mm long. Usually slightly curved or wavy. Go to STEP 2 in the Diagnostics section.

•

Scratches around the circumference of the Photoreceptor. Go to STEP 3 in the Diagnostics section.

f.

Perform the Developer Zone Roll Adjustment (ADJ 9-1).

g.

Lower and latch the Photoreceptor Module ensuring that the Photoreceptor Module latches properly.

h.

Cleaner Checks:

Diagnostics: 1.

Place white paper under the Cleaner Module.

ii.

Remove the Cleaner Brush (REP 9-23).

iii.

Tap the Cleaner Module with the handle of a screw driver.

iv.

Check the debris on the paper for large contaminants. If large contaminants are found, or if binding, auger problems, and/or toner buildup (banding) on the detoning rolls exist, go to PQ 9-617.

Consumable Checks: a.

b.

c. 2.

i.

Check the Toner Batch number. Refer to past Bulletins and Purge notices to determine if the Toner has been identified as a possible defective batch. If the batch number was listed, perform the following: i.

Remove the Toner Bottle.

ii.

Dump out the Toner in the Hopper, tap the sides of the Hopper with the handle of a screw driver and vacuum.

iii.

Perform the Developer Dump and Thump Procedure (REP 9-6).

iv.

Install new Toner and Developer Material with a different batch number than the removed material.

i. 3.

Perform the STEP 4 at the end of this RAP.

Long Scratches: CAUTION

Check the Developer Material batch Number. Refer to past Bulletins and Purge notices to determine if the Developer has been identified as a possible defective batch. If the batch number was listed, perform the following:

This photoreceptor is extremely sensitive to light exposure. Limit the exposure of the photoreceptor to light for two (2) minutes maximum or severe xerographic problems may result. If the belt module will be exposed to light longer than two minutes, remove the photoreceptor from the belt module and place it immediately in the protective photoreceptor bag, or place the bag over the photoreceptor with it on the belt module.

i.

Perform the Developer Dump and Thump Procedure (REP 9-6).

NOTE: Always replace the Spots Blade (REP 9-57) whenever the PR Belt is replaced for Long Scratch Problems. The blade has probably suffered edge damage. Do not install a new Spots Blade with a new PR Belt. Run dC951 first without the blade. Wipe the new blade with toner before installing to eliminate tuck-under that stresses the blade.

ii.

Install new Developer Material with a different batch number than the removed material.

a.

Perform STEP 4 at the end of this RAP.

Short Scratches/Crayoning:

Section Name

PQ 9-638

0/0/00 ?-70

Inspect the Photoreceptor for scratches. Before replacing the Photoreceptor (PL 9.1) note the position of the scratches and check to see if they line up with any of the components or subsystems around the Photoreceptor area. Some causes of scratches and their corrective actions are: •

Broken/loose components around the Photoreceptor Module, repair/replace as required.

•

The Transfer Assist Blade may be touching the Photoreceptor. Visually check that the blade is not touching the Photoreceptor in Standby. If it is, check for blade damage. Perform the Transfer Blade Timing, (ADJ 9-9).

Preliminary Working Document No Product Name Assigned

•

Ensure that the Developer Housing, Xerographic Drawer, and Photoreceptor Module are positioned properly and locked into the operating position. Ensure that the Cleaner Backup Roll is fully engaged.

•

Check for binding in the Developer Housing. If bound, go to (PQ 9-616).

•

Check for ESV scraping. Perform the ESV Height Adjustment, (ADJ 9-12).

•

Check the Field Stop Brackets for scraping.

•

Check for large particles in the Development Housing area.

• •

•

i.

Replace the Cleaner Brush (REP 9-23).

ii.

Dump out the Toner in the Hopper.

iii.

Tap the sides of the hopper with the handle of a screw driver and vacuum.

iv.

Install new Toner with a different batch number than the removed material.

m.

Perform the Developer Dump and Thump Procedure, (REP 9-6).

n.

Install new Developer Material with a different batch number than the removed material (REP 9-4).

Check the BRD. Handcrank the developer in a Clockwise direction ONLY and check that the BRD rotates.

o.

Install new Toner, (if needed) with a different batch number than the removed material (REP 9-0).

Scraping may be due to Photoreceptor Alignment, perform the PR Module Alignment, (ADJ 9-10), and/or the Photoreceptor Tension Adjustment, (ADJ 911).

p.

Install a new Photoreceptor (PL 9.1) and perform the Xerographic Setup (ADJ 9-3).

q.

Enter dC606, select [White Dusting]. Press Continue

r.

Make 14 copies with the longest paper available. Press Stop.

s.

If spots are present, go to PQ 9-613.

Vacuum the Developer Rolls. NOTE: The spots blade must be adjusted after a Cleaner replacement.

•

b. 4.

Check/clean toner debris/deposits from the Cleaner housing right side (Entrance Baffle). Check that the Spots Blade (brown) contact area is 0.5 mm to 2 mm and adjust as required, (ADJ 9-16).

Perform STEP 4 at the end of this RAP.

End of Call Checks: CAUTION This photoreceptor is extremely sensitive to light exposure. Limit the exposure of the photoreceptor to light for two (2) minutes maximum or severe xerographic problems may result. If the belt module will be exposed to light longer than two minutes, remove the photoreceptor from the belt module and place it immediately in the protective photoreceptor bag, or place the bag over the photoreceptor with it on the belt module. a.

Power OFF the Machine and perform the following:

b.

Open the machine and remove the Photoreceptor (REP 9-35).

c.

Clean the Pretransfer Lamp and the Preclean Lamp.

d.

Clean the Belt Hole Sensor with a soft towel. CAUTION

Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. e.

Clean the DSS, ESV and Patch Generator with a clean, soft, lint free cloth.

f.

Vacuum the Photoreceptor Ground Brush.

g.

Vacuum the Paper Trays and the paper path areas.

h.

Vacuum the Photoreceptor Module area.

i.

Vacuum the general area of the Machine which surrounds the Photoreceptor Module.

j.

Vacuum the top of the Developer Housing including the Seals.

k.

Check that there is no accumulated developer material on the BRD roll.

l.

If no exact cause of the Photoreceptor scratches are found, perform the following:

Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-638

PQ 9-639 MICR Image Quality Analysis Procedure

a.

Place the document at the bottom of the Clearwave Gauge. Line up the right edge of the document with the right edge of the Clearwave Gauge. Observe the left most transit symbol. The right edge of this transit symbol should fall between the dotted lines in boxes 42 and 43 of the Clearwave Gauge (Figure 4).

b.

If the right edge of the Transit Symbol does not fall between the dotted lines in boxes 42 and 43, the entire MICR line is out of horizontal adjustment, (too far to the left or right). If the MICR line is out of adjustment, and the rest of the form is in the correct position, there is a problem in the software program. If all the printing on the document is out of horizontal adjustment (not just the MICR line), there is probably a registration problem. Several documents should be checked before taking action on registration problems.

The purpose of this procedure is to ensure that all MICR print quality specifications are met.

Procedure Ensure that MICR MODE (Print darkness 4) is being used for MICR prints. If available, load 24 lb. (90gsm) paper stock in the feeder. Examine the Clearwave Position and Dimension gauge (600T80025) (Figure 1), and the 8X Comparator (600T80026) (Figure 2) for contamination, and clean the tools if necessary. NOTE: If the customer is not available to print a sample job of a document with a MICR line, all assessments cannot be made. If the customer is not available to print a job, use the MICR Test Form for this procedure. 1.

Ask the customer to send a sample job of a document (MICR line), which will be used to make the following print quality assessments.

2.

When performing the following steps, make a note of all steps in which the assessment did not meet the specification. At the end of the procedure, perform the repair actions for the specification(s) that were not met.

3.

*** ***Physical Dimensions.*** *** a.

Refer to Figure 1 and assess the document for physical dimensions (length and width).

b.

Place the document lengthwise in the Clearwave gauge. Align the right edge of the document with the right edge of the gauge. Ensure that the length is at or between the indicated areas of the gauge.

c.

6.

Character size. a.

Use the 8X Comparator to check for character size specification (the position and width of the stroke). If the character is in specification, the comparator will be able to be moved around so that the vertical and horizontal lines of the character fall outside the small boxes in the grid. The illustration (Figure 5) shows the number "8" within specification, while the small and large font characters are marginally acceptable. Be aware that the difference between the Small, Nominal, and the Large font sizes is subjective. That means that both the nominal and the large fonts would meet specification.

b.

Xerographic MICR characters will usually fall at the upper limits of the specification. This is because Xerographic MICR ink has a lower content of magnetite than lithographic MICR ink and will put more ink on the print in order to maintain proper signal strength. For this reason, most MICR characters may appear to be large.

c.

Use only the 8X comparator to check the character size.

d.

Problems with character size, such as line width or spacing, may have several causes, including:

Place the document (vertically) in the Clearwave gauge. Align the bottom of the document with the right edge of the gauge. Ensure that the width (or the perforation of the document is on or between the indicated areas on the gauge.

•

Motion Quality

•

Using a non Xerox MICR font

Vertical alignment

•

Incorrect ROS power

a.

Use the 8X Comparator or the Clearwave Gauge, to assess the vertical alignment of the MICR character.

•

Dry Ink

•

CD/IG operating incorrectly

Place the document in the Clearwave Gauge. Ensure that the bottom of the MICR characters are positioned within the dash lines of the Vertical Character Alignment reference.

•

Verify that the font and IOT performance is in specification (dC909).

Refer to Figure 1. 4.

7.

If using the 8X Comparator, place the 8X Comparator over the MICR line. The vertical variation from one character to the next must be less than.015 inches up or down, (Figure 2). On the DP180MX MICR printer, this type of variation can be caused by software, image motion, paper effects, fonts and paper feeding. However, it will seldom occur. b.

The vertical variation for the entire MICR line is evaluated with the Clearwave Gauge Figure 1. Line up the right edge of the document with the gauge. Ensure that the bottom of the document is at the bottom of the Clearwave Gauge. Ensure that the bottom of the characters fall between the top and bottom lines of the character boxes (Figure 3).

5.

Xerographic Setup

•

8.

Transit Symbol.

Section Name

PQ 9-639

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Using the 8X Comparator, assess the entire document, especially the Clearband area for white spots (deletions) and black spots. a.

Scan the Clearband area of the document with a magnifying glass.

b.

If there are any spots, place the void (deletion) or ink spot under the Measured specification squares. Ensure that the spots stay within the borders of the measured specification squares.

c.

Ensure that the spots meet the specification in PQ 9-613, less than 0.10" in the Clearband area.

d.

Ensure that the deletions meet the specification in PQ 9-615, in the Clearband area.

e.

If the dry ink is not fixed, go to the 10-608, Dry Ink not fixed RAP.

Assess the Clear Band Area of the document. a.

Place the document in the Clearwave Gauge, aligning the bottom of the check with the bottom of the gauge.

Preliminary Working Document No Product Name Assigned

b. 9.

Ensure that there is no magnetic printing of any kind other than the actual MICR information in the Clear Band Area (this includes the second side of the print).

12. Refer to the Repair Actions at the end of this section, and perform the corrective action for the assessment that did not meet the specification.

Character to Character spacing

13. If all of the assessments met the specification indicated, go to the 0-4 Final Action RAP.

a.

Repair Actions

Using the Clearwave Gauge ensure that the distance from the right edge of one MICR character to the right edge of the next is 0.125 inches +/ 0.010 inches. Each character box on the bottom of the gauge is 0.125 inches wide, (Figure 6) If it is possible to move the document so all characters fall within a character box, then place the right edges of as many characters as possible on the right edges of their character boxes. Look at the entire MICR line and check for any characters that do not have their right edges touching the right edges of their character boxes. A character whose right edge does not touch the right edge of the character box is more or less than 0.125 inches from its next closest character. To find out how much more or less than 0.125 inches it is from the neighboring character, bring the suspected character into character box 15. (Figure 7)

b.

Line up the right edge of the character to its right (in box 14) with the right edge of box 14. Look at the suspect character in box 15 and see if its right edge falls between the two dotted lines on either edge of the character in box 15. If the right edge of the suspect character falls outside of the dotted lines, it is outside of the +/ 0.010" leeway from 0.125” and is out of specification. It is also too close to, or too far away from, the character on its right.

c.

The 8X Comparator may also be used to check the spacing between any two characters. Look through the comparator and place the right edge of the character against the right edge of the vertical line marking 0.125 inches.

1.

Inform the customer that the length and width of the paper supply must meet specifications. 2.

d.

Problems of character to character spacing, like vertical position, may have many causes. If a spacing problem is observed, talk to the appropriate individual at the account to verify that the job was programmed correctly, and that they have the correct MX E13B font. If the problem continues, gather as much information as possible and call for assistance.

Ensure that the correct MICR font is being used. Ensure that the Top to Bottom Registration (ADJ 8-2) is in specification. 3.

To check for line skew, place the document in the Clearwave Gauge. Move the document so that the tops of all the MICR characters touch the line form at the top of the MICR line boxes, (Figure 7).

b.

Once in place, hold the document firmly so it will not slip. The bottom of the document should now bisect the vertical skew scales below boxes 6 and 46. The scales are graduated in 0.5 degree divisions from 0 to 2.5 degrees (not marked). Write down, to the nearest degree, where the check bisects the skew scales. Subtract the smaller number from the larger. The remainder is the degree of line skew. Line skew cannot exceed 1.5 degrees. In Figure 7, the bottom of the check bisects box 46 at 0.5 degrees and box 7 at 2 degrees. Subtracting 0.5 from 2 gives a total skew of 1.5 degrees of line skew.

Transit Symbol If the MICR line is out of Horizontal adjustment and the rest of the form is in alignment, there is an error in the software. If the whole document is out of horizontal alignment, perform the Side to Side Registration (ADJ 8-3).

4.

Character Size Go to the PQ 9-639 RAP.

5.

Spots If the problem is white spots (deletions), go to the PQ 9-615 RAP. If the problem is black spots, go to the PQ 9-613 RAP. If the problem is image rubbing off, go to the10-608, Dry Ink not fixed RAP.

6.

Clear Band Area Advise the customer to change the format of the document so that this area will meet the specification. Recommend the use of a 5/8 inch clearband area in the document design. Ensure that there is no printing on the second side of the print in the clearband area.

7.

Character to Character Spacing Verify the spacing on the MICR11 test pattern, run in @PQ1MX. If the problem is present only on the customer application, change the application program. If not, go to the PQ 9637 Slow Scan Magnification Checkout procedure.

8.

10. Skew. a.

Vertical Alignment Ensure that the prints meet all the print quality specifications in PQ 9-601.

Determine if the right edge of the right character falls within the 0.010" (two of the smallest divisions) from the vertical line marking 0.125”. If the right edge falls less than two small division away from the 0.125” line, it is within specification.

Physical Dimension

Skew Individual skewed characters are not possible on the Printer. If skew is present in the amount field only, it is possible that it is being caused by an impact printer (the amount field is added after the check has been printed). Line skew is possible but the entire line will be skewed not just the MICR line. What may appear to be skew can also be caused by the way the documents are cut.

11. If the call was for Signal Strength failed documents, but no defect was found in the previous steps, the fault may be signal strength. Use the Xerox MICR LPS Signal Strength Tester Correlation Document to verify signal strength is within specification. Go to the PQ 9-640, Signal Strength Tester Correlation Procedure. Preliminary Working Document No Product Name Assigned

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Section Name

PQ 9-639

Vertical Character Alignment Length

Width

Figure 1 Clearwave Gauge

Section Name

PQ 9-639

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Preliminary Working Document No Product Name Assigned

0.030 inch MAXIMUM

0.030 inch MAXIMUM

0.030 inch MAXIMUM

0.030 inch MAXIMUM

0.030 inch MAXIMUM

Figure 2 Individual Character Alignment

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Section Name

PQ 9-639

MICR Line too high

MICR Line centered

MICR Line too low

Figure 3 Vertical Alignment

Section Name

PQ 9-639

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Right edge of transit symbols

Maximum Allowable Tolerance

Ideal Horizontal Alignment

Minimum Allowable Tolerance

Exceeds minimum allowable tolerance, too far to the right

Acceptable MICR Alignment

Exceeds maximum allowable tolerance, too far to the left

Unacceptable MICR Alignment

Figure 4 Transit Symbol

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Section Name

PQ 9-639

Nominal Font Size: average edge of all lines falls between the boxes and does not run through the boxes

Small Font Size: average edge of all lines falls within the boxes

Large Font Size: average edge of al lines falls on the edge of the boxes

Figure 5 Character Size

Section Name

PQ 9-639

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Character to Character Distance

Distance between Characters Character Spacing Tolerance Zone

Acceptable Spacing

Unacceptable spacing too tight

Unacceptable spacing too spread out

Figure 6 Character to Character Spacing

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Section Name

PQ 9-639

Figure 7 Line Skew

Section Name

PQ 9-639

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PQ 9-640 MICR Checkout Procedure The purpose of this procedure is to determine if there are any Image Quality defects that might affect MICR prints.

PQ 9-641 MICR Signal Strength Tester Correlation Procedure

Procedure

The purpose of this procedure is to provide a method to compare signal strength from a print of a MICR line made on the DP180MX and a Correlation document of known Signal Strength on the customers Signal Strength Tester.

Perform the following: • Check the HFSI counters and replace the developer and photoreceptor if required.

Procedure

•

1.

Ensure that the calibration process has been completed successfully, using the vendors signal strength calibration document.

2.

Enter dC106. Select [Test Patterns and Print Quality]. Select [MICR]. Run 14 prints of the MICR Test pattern on 24 pound short grain stock. Select 2 prints at random.

3.

Select the MICR line on the test pattern that is closest to the area that the customer is experiencing the problem in. Run the MICR line through the customers Signal Strength Tester and record the values for:

Run a dC951 Xerographic Setup.

Check the ROS Magnification. The magnification is within specification. Y N Perform the Magnification Setup Procedure (ADJ 6-1). Check the ROS Image squareness. The ROS Image Squareness is within specification. Y N Perform the ROS Image Squareness Setup (ADJ 6-2). Perform the following: • Transfer Blade Timing Adjustment (ADJ 9-9).

4.

a.

Average Signal Strength Value for On Us Symbols in the MICR line.

b.

Average Signal Strength Value for all characters and Symbols in the MICR line.

•

The Fuser Roll Temperature Adjustment (ADJ 10-6).

Run the Xerox 4635MX LPS Signal Strength Tester Correlation Document through the customers Signal Strength Tester and record the values for:

•

The Pressure Roll (Contact Roll) Adjustment (ADJ 10-2).

a.

Average Signal Strength Value for On Us Symbols in the MICR line.

•

If the problem continues, go to the PQ 9-637 Slow Scan Magnification RAP.

b.

Average Signal Strength Value for all characters and Symbols in the MICR line.

5.

Preliminary Working Document No Product Name Assigned

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Compare the values recorded for the MICR line and the values recorded for the Correlation Document. The Signal Strength values recorded for the MICR line should be within +/ - 20 of the values recorded for the MICR line of the Correlation document. a.

If the recorded values are within +/ 20, there is not a problem with the DP180MX system. The customers signal strength tester is suspect. No MICR service action is expected.

b.

If the recorded values are greater than +/ 20, there is a signal strength problem in the DP180MX system. Ensure that all HFSI listed in the HFSI TABLES and service actions are performed. If the problem continues, call for assistance.

Section Name

PQ 9-640, PQ 9-641

Figure 1 9-640 Signal Strength Correlation Document (4912)

Section Name

PQ 9-641

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Test Patterns

Xerographics - An electronic test pattern with Images used for setup and evaluation of ROS Exposure and Xerographics.

Introduction This section of the Service Manual provides the information required for the correct evaluation of the print PQ against the specifications. The PQ Specifications are categorized into 2 groups: •

System Specifications

•

Printer Specifications

Halftone - A uniformly composed electronic test pattern of a dot matrix variety used to evaluate defects, such as charge imbalance and Printer motion quality problems, as well as PQ Quantitative Analysis defects. E Form - Provides edge to edge image quality evaluation.

All evaluations are based on 8.5 x 11 inch prints, unless otherwise stated.

Quadrille - A uniformly composed electronic test pattern consisting of one pixel wide black grid lines that are one pixel wide and repeat every 127 pixels in the fast and slow scan directions. Prints of this pattern have a 1 inch trail edge deletion.

The information is presented in the following manner: •

The PQ parameters are listed alphabetically.

•

Interdependent procedures are identified as prerequisite procedures.

•

A procedure is provided that describes how to set up the machine to check the PQ parameter.

•

An illustration of the test pattern that identifies the specific feature used for the check is provided (if necessary).

•

The specification for the parameter is defined. Specifications for more than one module may be given, such as Registration which has a different system specification from the Printer specification.

Where applicable two levels of a specification are listed. When only one specification is given, it is for the UM and the Setup level. UM level - Corrective action should be taken to restore the module or system to the setup level if the UM level is not being achieved. Prints that are run on Every Service Call should be evaluated against the UM level specification, unless the primary cause of the call is an PQ problems. Setup level - This is the minimum level of acceptance for a given specification, if the primary reason for the service call was for this particular problem. Also, if during a service call, the PQ evaluation detects a specification below UM level the Setup level for that specification must be achieved before Call Closeout. NOTE: If an PQ parameter is not in specification, go to the PQ 9-601 System PQ Entry Level RAP.

Test/Patterns

MICR - Magnetic Ink Character Recognition. A uniformly composed test pattern containing the specifications for MICR printing. The test pattern checks for MICR unique copy quality specifications.

Printer Resident Test Patterns The following test patterns are generated electronically by the Printer SLB/RDR PWB. The test patterns are programmable in Printer dC606. Light Dusting - All white test pattern. Dark Dusting - All black test pattern. Quadrilles - Solid pixel thickness that repeat every 128 pixels in the fast scan direction. The pixel width and background are selectable in dC 606. For 240SPI, pixels repeat every 160 pixels in the fast scan direction and every 128 pixels in the slow scan direction. 300SPI and 240SPI Special Test Patterns, seven separate patterns used to test the 300SPI-to600SPI and 240SPI-to-600SPI Resolution Conversion feature on the C-SLB/RDR PWB. Pattern #7 prints a section of all 7 patterns on the same page. 600SPI 2ON - 2OFF Test Pattern, Three slow scan bands on the inboard, center, and outboard of the print. Each band consists of 2ON - 2OFF black bars, each 8 bytes long in the fast scan direction with 4 bits separation between adjacent bars. The pattern repeats every 34 bytes in the fast scan direction and every 4 lines in the slow scan direction.

Test Pattern Usage

Only use the approved test patterns listed in this specification for assessing the PQ of the machine.

Controller Resident Test Patterns

The purpose of this section is to provide an overview of the hardprint test patterns and the controller resident test patterns, used to evaluate PQ performance and to perform PQ setups. Refer to the PQ Specifications for detailed information on the procedures and specifications of each PQ parameter.

The following test patterns are stored on the Controller disks. These test patterns are loaded during software installation and can be printed in several of the dC programs.

Using the System PQ Test Pattern 82E4161

Dimensional - An electronic test pattern with Images needed for setup and evaluation of the fast and slow scan image placement of the Printer and Controller. Bar Codes are used to check BCR operation.

Preliminary Working Document No Product Name Assigned

See Figure 1. 1.

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Magnification Lines

Section Name

Test Patterns

NOTE: Due to test pattern error, actual dimension is 199.8 mm. The 300mm scale (600T41501) should be used for the measurement. • 2.

Used for evaluating the system 100% magnification. The target 1b is composed of parallel elements that are 200.0 mm apart.

Density Solid Areas Used for evaluating the High Density Solid Area Development and Fusing.

3.

Density and Background References, 8a -8d. Used for evaluating the high density solid area development and background.

4.

References 9a to 9d are used for evaluating the Xerographic controller resident test pattern. (600 SPI Mode) 9a. Printer halftone visual reference - to evaluate Halftone Uniformity.

The following table lists the number of allowable black spots for given spot sizes per any given print. Failure at any size category represents a machine failure. Refer to the Dark Spot Size Reference Scale on 82E4161. Table 2 Allowable Black Spot Specification Spot size in Microns

Setup Level

UM Level

125-200

15

Customer Complaint

200-300

3

Customer Complaint

300-400

1

Customer Complaint

Larger than 400

None

Customer Complaint

All sizes

More Than 2 Per Sq. Inch

Customer Complaint

9b. Printer 1 Black: 2 White reference - to evaluate Exposure, Charge, and Development. 9c. Printer 2 Black: 1 White reference - to evaluate Exposure, Charge, and Development. 9d. Printer 1 Pixel Line Visual reference - to evaluate Printer reproduction of single pixel fine lines.

9h. System Fine Line Visual reference - to evaluate System reproduction of 600 SPI Density Single Pixel Lines.

References 9e to 9h are used to evaluate the following: 9e. Printer Fuse Fix Crease/Fold Test - to evaluate Fusing. Fold one of the prints in half (long edges together) with the image towards the inside. Apply medium pressure along the fold to create a crease. Unfold the print, and lightly rub the crease area of the fold two times with cotton or a soft clean cloth. Rub the crease in the direction of the fold. Ensure that the print meets the following Fuse Fix Specification. Fuse Fix Specification: Referring to the loss of toner at Crease/Fold Reference Scale (9e) on the 82E4161 Test Pattern. •

If there is a loss of Toner along the crease area of the three solid area blocks that is similar to or less than the visual reference on 82E4161 titled "Acceptable Loss of Toner at Crease/Fold," then specification has been met.

•

If there is a loss of Toner along the crease area that is equal to or greater than the visual reference on 82E4161 titled "Acceptable Loss of Toner at Crease/Fold," then specification has not been met. Go to 10-608, Dry Ink Not Fixed RAP.

9f. White Spot Category reference - to evaluate White spots. The following table lists the number of allowable white spots for given spot sizes per any given print. Failure at any size category represents a machine failure. Refer to the White Spot Size Reference Scale on 82E4161. Table 1 Allowable White Spot Specification Spot size in Microns

Setup Level

UM Level

125-250

20

Customer Complaint

250-500

4

Customer Complaint

500 or greater

None

Customer Complaint

All sizes

More Than 2 Per Sq. Inch

Customer Complaint

9g. Black Spot Category reference - to evaluate Black spots.

Section Name

Test Patterns

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Preliminary Working Document No Product Name Assigned

Figure 1 Test pattern 82E4161

Using the "Xerographic" Controller Resident Test Pattern Preliminary Working Document No Product Name Assigned

1.

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Halftones of Six Different Shades Section Name

Test Patterns

Three sets of six, each 15 mm square, halftone targets of the following fractional area coverage: See Figure 2. a.

6/64 (or 6 pixels out of an 8 x 8 sized screen)

b.

10/64

c.

16/64

d.

32/64

e.

48/64

f.

58/64

These are used for evaluating the High frequency ROS imaging noise, charge uniformity and exposure uniformity. 2.

3.

ESV & DSS Read Patches a.

16/64 Halftone is used for 82E4161 comparison.

b.

No image here, ESV and DSS read background in dC909.

c.

All black image, ESV and DSS reads are related to Vddp and the black developed patch.

d.

1 pixel black lines spaced every other scanline for the fast scan direction and 1 pixel lines are spaced every other pixel in the slow scan direction.

e.

48/64 Halftone

High Solid Area Density Blocks Used for charge balance high density area uniformity, and high density solid area development specification check. The reference for Restore and UM is on the 82E4161 test pattern.

4.

Background Check Swatches Exposure Set Up Array is used in manufacturing and the field to evaluate Exposure in dC951 setups. •

5.

Block 1: Slightly Visible

•

Block 2: Visible

•

Block 4: Clearly Visible

Sample Text Paragraphs Avant Garde 10 point Roman and Tiffany 6 point Roman. Used for evaluating a text reproduction.

Section Name

Test Patterns

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Figure 2 XERO11 (Controller resident Test Pattern) 6.

AB/BA Pattern: See Figure 3. Staggered two on/two off Motion Quality AB/BA Array. Used to identify beam A and beam B spacing failures. See Figure 3 for an enlarged illustration and explanation.

7.

8 pixel, 2 pixel and 1 pixel Top-to-Bottom (Fast Scan) and Side-to-Side (Slow Scan) Lines Used for evaluation of print line density and ROS power exposure, relative to photoreceptor charge voltage. The reference for "Restore" level is on the 82E4161 test pattern.

Preliminary Working Document No Product Name Assigned

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Section Name

Test Patterns

Figure 3 AB/BA Target

Using the "Dimensional" Controller Resident Test Pattern 1.

Magnification: See Figure 4. Slow scan distance from line A to line B should be 200.0 mm (+/- 0.5mm) using the average of five consecutive prints. Fast scan distance from line C to line D should be 200.0 mm (+/- 0.4mm).

2.

Lead Edge Arrow:

3.

Registration and Skew Targets:

Used to indicate the lead edge of the page. X1 is used for measuring top-to-bottom (fast scan) Printer registration. X1 and X2 are used for measuring the Printer skew. X1, X2, X3 and X5 are used for measuring the ROS skew. X4 is not currently used for PQ specification checks. 4.

Bar Codes: 00039 and 00128 are used to check the operation of the BCR Assembly.

Section Name

Test Patterns

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Figure 4 DIME11 (Dimensional Controller Test Pattern)

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Section Name

Test Patterns

Using the "Quadrille" dC106 Controller Resident Test Pattern The Quadrille pattern is a repetitive test pattern with single pixel wide lines spaced every 127 pixels in the fast and slow scan directions. This pattern is useful for detecting any open image data lines in the Controller to Printer Image Data cable. Refer to the next page for an expanded use of the Quadrille pattern for any open image data line problems. See Figure 5.

Figure 5 Quadrille (Controller Test Pattern)

Section Name

Test Patterns

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NOTE: The prints of the Quadrille pattern have a one inch trail edge deletion. Using the "Quadrille" Controller Resident Test Pattern for Image Data Line Problems.

Using the "Quadrille" Controller Resident Test Pattern for Image Data Line Problems The Image Data Signals from the Controller can be associated with specific lines on the dC106 Quadrille Test Pattern. On the diagram below, Image Data Bit 2 is shown as defective. Note the effect on the corresponding lines on the prints. Refer to the Controller-Printer Image Data Cable Chart to troubleshoot the corresponding line that is exhibiting the defect. Visually inspect any bent or touching pins at the ends of the cable, the mating connectors on the ROS, and the Backplanes. See Figure 6.

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Section Name

Test Patterns

NOTE: An open Image Data Bit defect has three or four lines printing out when only one line should print, or the line that should be printed is deleted. The pattern will repeat on the entire print for the corresponding image data bit that is defective.

Figure 6 Magnified Quadrille Pattern

Using the "Halftone" Controller Resident Test Pattern 1.

A 25% area coverage halftone, with a spur shaped dot growth as shown in 16 pixel x 16 pixel section.

Lead Edge Arrow

This pattern is used for examining the Printer motion quality problems, halftone exposure, and development uniformity.

Indicates the lead edge of the page 2.

Halftone Bitmap Composition

Section Name

Test Patterns

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Figure 7 HalfTone (Controller Test Pattern)

Using the "MICR" Controller Resident Test Pattern Preliminary Working Document No Product Name Assigned

Refer to MICR Controller Test Pattern (Figure 8).

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Section Name

Test Patterns

1.

Lead Edge Image Disturbance

•

Used to check visual lead edge registration. Not to be used to check for skew. Use the existing skew check (ADJ 8-1). If Horizontal Registration is not correct, go to the PQ 9601 Printer Image Quality Entry RAP.

•

With the right edge of the MICR document positioned against the right edge of the clearwave gauge, the right edge of the left most transit symbol shall fall between the dotted lines of boxes 42 and 43.

Used to determine if there is unacceptable lead edge image disturbance after the first 4.75mm from the lead edge of the document. 2.

Trail Edge Image Disturbance Used to determine if there is unacceptable trail edge image disturbance prior to 4.75mm from the trail edge of the document.

3.

14. Magnification

Motion Quality 106 Dots Per Inch (DPI). Used to determine if there is any visual banding present. If banding is observed, go to the Motion Quality section of the PQ 9-601 Image Quality Entry RAP. motion quality defects.

5, 6 and 27, 28. Signal Strength balance of the MICR line, Character to Character spacing and Vertical Alignment.

•

15. Slow Scan Magnification •

Signal Strength •

Used to check the signal strength of the ON-US characters in the MICR line using the customers signal strength tester.

Vertical Alignment •

Used as a visual assessment to determine if there are slow scan magnification problems. Visually inspect the characters for size and spacing (may be cut on line 19 and inserted into the clearwave gauge). If Slow Scan Magnification problems are present, go to the PQ 9-637 Slow Scan Magnification RAP.

16. Font Name •

Used to determine the proper vertical position in the MICR line. With the right edge of the MICR document positioned against the right edge of the Clearwave gauge, and with the bottom of the MICR document pushed against the bottom of the clearwave gauge, the MICR characters shall fall between the top and bottom lines of the character boxes.

Used as a quick visual assessment of magnification. Use the existing magnification procedure, ROS Magnification Setup (ADJ 6-1) to ensure magnification is in specifications.

Used to verify that the correct MX E13B/CMC7 font and rev is being used.

17, 18, 19, and 20. Cut lines •

Used as a guide for cutting. All cuts should be made as close to the line as possible but always a little above the line.

Character to Character Alignment

22. Landscape cut line

•

•

Used to verify proper character to character alignment of the MICR line. The distance between the right edge of adjacent MICR characters shall be 0.125 +/- 0.010 inches. Check character to character spacing using the Clearwave gauge by positioning the right edge of a given character against the right edge of box 14 and check that the right edge of the adjacent character in box 15 is within the dotted lines.

Used as a guide for cutting. This cut should be made on the line.

23, 24, and 25. Solid area density •

Used as a quick check to visually assess the solid area density.

•

The reference for restore and UM is located on the 82E4161 test pattern.

7 & 8. Dicorotron Balance

26. Landscape MICR Line

•

•

Used as a quick visual check of the Dicor balance. If the Dicorotron balance is incorrect, go to the Charge Dicorotron Balance Procedure (ADJ 9-6).

9 & 10. Line pair balance •

NOTE: This line is not correctly formatted.

Used to determine if the line pair balance is correct. Both 3.5 line pairs should be resolved. If both 3.5 line pairs are not resolved, go to the PQ 9-601 Printer Image Quality Entry RAP.

33. MICR Quality sign off •

Used to record the customers acceptance of MICR quality, the date and the meter readings.

•

The diameter of each individual dot should be Six thousandths. When using the 8X Comparator the "dot" should touch each side of the 0.006" box.

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Stroke Width •

Used to check a landscape MICR line to ensure the signal strength of the ON-US characters in the MICR line using the customers signal strength tester.

The 3.5 X 3.5 Line pairs shall be equal in width and spacing. Using the 8X Comparator, the 3.5 line and the white space between the lines should fall within the Nominal Stroke width Tolerance (0.013"). The maximum Stroke Width Tolerance is 0.015", and the Minimum is 0.011".

11 & 12. Horizontal Registration

Section Name

Test Patterns

No Product Name Assigned

Figure 8 MICR (Controller Test Pattern)

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Section Name

Test Patterns

Registration, Side-To-Side (Slow Scan): Printer Specification Prerequisite Procedure •

Printer Magnification

•

ROS Image Squareness

•

Printer Skew

Procedure Enter Printer dC604. Select [Registration Adjustment], [Start] to make 10 prints of the Dimensional test pattern. With the 150 mm scale, measure the distance (estimate within the nearest 0.25 mm) from the tip of the arrowhead to the edge of the print. Use the eyeloupe if needed. If the X3 arrowhead is off the page, choose a common reference line on the X3 target arrow, and measure it to the print edge. Check the results against the following specifications.

PRINTER SIDE-TO-SIDE (slow scan) REGISTRATION SPECIFICATION

UM Level: Evaluate one print.

The arrowhead tip of the selected print must be within 0.65 mm of the print edge. Setup level: Evaluate five non-consecutive prints. Calculate the average distance for all five prints.

The average distance of the arrowhead tip must be within 0.3 mm of the print edge. No individual print arrowhead tip can be more than 0.65 mm from the print edge.

Section Name

Registration, Side-To-Side (Slow Scan): Printer Spec-

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Figure 1 Printer (slow scan) Registration

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Section Name

Registration, Side-To-Side (Slow Scan): Printer

System Magnification Procedure Procedure Check 1.

TOP TO BOTTOM (Fast Scan) MAGNIFICATION: a.

Enter dC603, [Printer Options], [Test Patterns and PQ], [Dimensional], [Magnification], and press the Continue button.

NOTE: Use the 300mm scale (600T41501) to measure the prints. NOTE: Use A4 (8 1/2 x 11) or larger paper size in tray 1. b. 2.

Measure the C - D (200mm +/- 0.4mm) distance on the prints. Use the 300mm scale (600T41501) for this check.

SIDE-TO-SIDE (Slow Scan) MAGNIFICATION: a.

Enter dC603, [Printer Options], [Test Patterns and PQ], [Dimensional], [Magnification], and press the Continue button.

b.

Measure the A - B (200 mm +/- 0.5 mm) distance on 5 consecutive prints. Using the average of the 5 prints the distance A - B should be 200 mm +/- 0.5 mm using the 300mm scale (600T41501).

Setup Level 1.

TOP-TO-BOTTOM (Fast Scan) MAGNIFICATION:

NOTE: Increasing the range value increases the C-D distance. a. 2.

Adjust the C-D distance to 200mm using the up and down arrows.

SIDE-TO-SIDE (Slow Scan) MAGNIFICATION:

NOTE: Increasing the Range value increases the A-B distance. a.

Adjust the A-B distance to 200mm using the left and right arrows.

Section Name

System Magnification Procedure

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Figure 1 DIME11 (Dimensional Controller Test Pattern)

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Section Name

System Magnification Procedure

Printing Of High Density Solid Areas: Printer Specification

Choose a print of average darkness, and compare the solid areas on the prints to the reference blocks on 82E4161.

Procedure Enter dC106 [Test Patterns and PQ][Xerographic]. Select quantity 10. Press the Continue button. Evaluate the prints.

UM High Density Spec: For a service call, in which a xerographic setup has not been performed, the darkness level of the blocks on the print must be uniform, and be equal to or darker than the block labeled STD/LT:UM on the right edge of 82E4161.

Specification Setup High Density Spec: After xerographic setup, the three blocks must have a darkness level that is equal to or darker than the block labeled STD:RESTORE on the right edge of 82E4161.

Figure 1 System Specification Check Section Name

Printing Of High Density Solid Areas: Printer Specifi-

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Printing Of Single Pixel Fine Lines: Printer Specification

Specification

Procedure Enter dC106 [Test Patterns and PQ][Xerographic]. Select quantity 10. Press the Continue button. Evaluate the prints.

The darkness level of the fast scan or slow scan orientation lines on the print should be uniform, and should be at least as dark as the 1 Pixel Line Visual Reference Scale on 82E4161.

Figure 1 Pixel Lines Specification

Registration Top-to-bottom (Fast Scan): Printer Specification Preliminary Working Document No Product Name Assigned

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Section Name

Printing Of Single Pixel Fine Lines: Printer Specifi-

Prerequisite Procedure •

Printer Magnification

•

ROS Image Squareness

•

Printer Skew

Procedure Enter Printer dC604. Select [Registration Adjustment], and [Start] to make 10 prints of the Dimensional test pattern. With the 150 mm scale, measure the distance (estimate within the nearest 0.25 mm) from the tip of the arrowhead to the edge of the print. Use the eyeloupe if needed. If the X1 arrowhead is off the page, choose a common reference line on a X1 target arrow, and measure it to the print edge. Check the results against the following specification.

Printer Top-To-Bottom (fast scan) Registration Specification UM Level: Evaluate one print. The arrowhead tip of the print selected must be within 0.65 mm of the print edge. Setup level: Evaluate five non-consecutive prints. Calculate the average distance for all five prints from ideal registration. The average distance of the X1 arrowhead tip must be within 0.3 mm of the print edge and no individual print arrowhead tip can be more than 0.65 mm from the print edge.

Section Name

Registration Top-to-bottom (Fast Scan): Printer

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Figure 1 Printer (Fast Scan) Registration

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Section Name

Registration Top-to-bottom (Fast Scan): Printer

ROS Image Squareness: Printer Specification

Align the corner with the number 4 line on targets X1 and X3.

Procedure

Specification

Enter dC 106 (Test pattern and PQ Dimensional). Select quantity 10. Press, Continue. Evaluate the prints.

The edge of the test pattern must be aligned with the #4 line on X5 within +/- 0.5mm.

Align the corner with the number 4 line on targets X2.

Figure 1 ROS Squareness Evaluation

Section Name

ROS Image Squareness: Printer Specification

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Skew: Printer Specification Prerequisite Procedure •

Printer Magnification

•

ROS Image Squareness

Procedure Enter printer dC604. Select [Skew Check], [Start] to make 10 prints of the Dimensional test pattern. The edge skew targets (X1) & (X2) are 200 mm apart, and are located along the end of fast scan (top edge) of print (Figure 1). The targets have marks identified by the numbered graduations. With the 150 mm scale, measure the distance (estimate within the nearest 0.25 mm) from the left target, X1, and the right target, X2, to the edge of the print. Calculate the difference between them. Use the eyeloupe if needed. Check the results against the following specification. Specification UM Level: Evaluate 1 Print. 16 lb. (RX 60 GSM) to 32 lb. (RX 120 GSM) paper: Difference between left target, X1, and right target, X2, is within 0.8 mm. 13 lb. (RX 49 GSM) or 110 lb. (RX 200 GSM) paper: Difference between left target, X1, and right target, X2, is within 1.2 mm. Setup Level: Evaluate five prints. Calculate the average difference for all five prints. 16 lb. (RX 60 GSM) to 32 lb. (RX 120 GSM) paper: The average difference between the left target, X1 and right target, X2 is within 0.5 mm and no individual print target difference is more than 0.8 mm. 13 lb. (RX 49 GSM) or 110 lb. (RX 200 GSM) paper: The average difference between the left target, X1, and right target, X2, is within 0.8 mm. No individual print target difference is more than 1.2 mm. Calculations: Distance (mm) of X1 arrow (mm) from the print edge minus the distance (mm) of X2 arrow from the print edge equals the Printer skew. NOTE: If the arrowhead is not visible on the print, use a reference line from the target to evaluate the skew. Ensure that the same reference line is used for X1 and X2 dimensions. UM Level: Evaluate one print. X1 - X2 - mm skew Setup Level: Calculate the skew for the five prints, add the total, and divide by five for the average skew. [(X1 - X2) + (X1 - X2) + (X1 - X2) + (X1 - X2) + (X1 - X2)] / 5=Average skew

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Section Name

Skew: Printer Specification

NOTE: If X1 - X2 < 0.Clockwise Skew Problem. If X1 - X2 () 0.Counterclockwise Skew Problem

Figure 1 Printer Skew Evaluation

Section Name

Skew: Printer Specification

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Motion Quality Controller Resident Test Pattern (MMQT02) Procedure 1.

Registration Targets for Automated CQM Evaluation of Motion Quality •

2.

High Solid Area Density Blocks •

3.

Used for registering the prints with an automated image quality measurement fixture by Xerox. Not used by the field service personnel. Used for charge balance high density area uniformity, and high density solid area development specification check. The reference for Restore and UM is on the 82E4161 test pattern.

8 Pixel, 2 Pixel and 1 Pixel Top-to-Bottom (Fast Scan) and Side-to-Side (Slow Scan) Lines •

Used for evaluation of print line density and ROS power exposure, relative to photoreceptor charge voltage. The reference for "Restore" level is on the 82E4161 test pattern.

4.

Halftone 106 cycles per inch at 45 degrees - 25% fractional area coverage.

5.

Halftone 134 cycles per inch at 63 degrees - 31% fractional area coverage.

6.

Halftone 141 cycles per inch at 45 degrees - 33% fractional area coverage.

7.

Diagonal lines at 45 degrees. •

This is similar to the 82E4161 test pattern diagonal lines.

8.

Halftone 150 cycles per inch at 90 degrees - 25% fractional area coverage.

9.

Halftone 200 cycles per inch at 90 degrees - 33% fractional area coverage.

10. Ziptone 300 line pairs per inch - 50% fractional area coverage. •

Lines run in the fast scan direction.

11. Ziptone 300 line pairs per inch - 50% fractional area coverage. •

Lines run in the slow scan direction.

12. AB/BA Pattern •

Staggered two on/two off Motion Quality AB/BA array. Used to identify beam A and beam B spacing failures. See Figure 3 for an enlarged illustration and explanation.

13. Quadrille Target •

Single pixel lines spaced every 127 pixels in the fast scan direction. Used as a determination of open or shorted Controller to Printer video line wire pairs. See Figure 4 for an enlarged illustration and explanation.

14. Registration Targets for Automated CQM Evaluation of ROS Beam Distortion •

Used for registering the prints with an automated measurement fixture by Xerox. The ROS targets are item #13. Not used by the field service personnel.

Figure 1 Figure 1 "Motion Quality" Controller Resident Test Pattern Figure 2

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Section Name

Motion Quality Controller Resident Test Pattern

Figure 2 Targets 4, 5, 6, 8, 9, 10 and 11 Figure 3 Section Name

Motion Quality Controller Resident Test Pattern

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Figure 3 AB/BA Target 12

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Section Name

Motion Quality Controller Resident Test Pattern

In Figure 4, the Image Data Signals from the Controller can be associated with specific lines on the dC106 "Motion Quality" Test Pattern. Ignoring the xerographic thinning or other effects on single pixel slow scan lines, the illustrations below show a good target and three failed targets. Note the effect on the corresponding lines on the prints. Refer to the Controller-Printer Image Data Cable Chart to troubleshoot the corresponding line that is exhibiting the defect. Visually inspect any bent or touching pins at the ends of the cable, the mating connectors on the ROS, and the Backplanes.

Section Name

Motion Quality Controller Resident Test Pattern

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Figure 4 Image Data Line Problems - Target 13 NOTE: An open Image Data Bit defect has three or four lines printing out when only one line should print, or the line that should be printed is deleted. The pattern will repeat for the corresponding image data bit that is defective. Preliminary Working Document No Product Name Assigned

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Motion Quality Controller Resident Test Pattern

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Motion Quality Controller Resident Test Pattern

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Background, Blotchy Symptom This defect has a "beehive like" appearance, with small blotches that resemble highly localized areas of high background.

Probable Cause Toner concentration is too high. Development problems

Corrective Action Ensure that the bias lines are connected to the Developer Housing. Decrease the toner concentration by decreasing the MIN NVM location 135 (Patch Generator exposure) by 3 units, and then run 250 prints. NOTE: It may not be possible to make the blotches completely disappear by reducing toner concentration. Do not over reduce toner concentration because it may cause solid area deletions. Go to the PQ 9-616, Development RAP.

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Section Name

Background, Blotchy

Figure 1 Blotchy Background Defect

Section Name

Background, Blotchy

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Background, Halftone (Gray Page) Symptom The size of background "toner" deposits is considered to be smaller than the smallest spots shown on 82E4161. Background is deposited uniformly on the print.

Probable Cause Xerographic Problem. Possible problem with Charge, Photoreceptor or other Xerographic components. However, Fault Codes should be displayed. Resolve all Fault Codes before using this RAP.

Corrective Action Perform ROS Reset procedure: Power Off / Power On the printer. If the defect is still present continue to troubleshoot. Examine the background areas with an eyeloupe. •

If the background is random, go to the Background, Xerographic subsection.

•

If the background is in ordered arrays, the probable cause is that one beam is stuck on the ROS.

•

Try ROS Reset and troubleshoot the problem if it does not work.

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Section Name

Background, Halftone

Figure 1 Halftone Background

Section Name

Background, Halftone

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Background, Xerographic Symptom The size of background "toner" deposits is considered to be smaller than the smallest spots shown on 82E4161. Background may be on the entire print or in localized areas, e.g., the lead or trail edges only. Also, background can be uniformly or nonuniformly deposited on the print, and some areas may have more toner and will be darker than other areas.

Probable Cause Incorrect use of the IQ controls. Xerographic problems such as high toner concentration.

Corrective Action Examine the background areas with an eyeloupe. If the background is random, go to the PQ 9-607/608 Uniform / Nonuniform High Background RAP. If the background is in ordered arrays, go to the Figure 1 subsection.

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Section Name

Background, Xerographic

Figure 1 Xerographic Background

Section Name

Background, Xerographic

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Background, Structured

Probable Cause

Symptom

ROS exposure problem

The background resembles plywood or woodgrain if viewed without using an eyeloupe. Background can be accompanied by fast scan fine lines, and can be on the entire print or in localized areas.

Corrective Action Go to the PQ 9-607/608 Uniform High Background RAP.

Figure 1 Structured Background

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Section Name

Background, Structured

Dark band, Top-To-Bottom (Fast Scan) Direction, Every Belt Revolution Symptom On every seventh print (or every third print for 11x17 inch or A3 paper) a dark band appears on the print in the top-to-bottom (fast scan) direction. The band has the appearance of an area with very high background.

Probable Cause Toner buildup on the photoreceptor ground brush Toner concentration is too high Poor cleaning on the outboard end of the PR belt module

Corrective Action Clean the photoreceptor ground brush. Ensure that the cleaner is operating properly and that toner is not accumulating on the ground brush. Perform the following procedures: Xerographic Setup Adjustment Xerographic Fine Adjustment Photoreceptor Seam Adjustment

Section Name

Dark band, Top-To-Bottom (Fast Scan) Direction, Ev-

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Figure 1 Dark Band (top to bottom) Fast Scan

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Section Name

Dark band, Top-To-Bottom (Fast Scan) Direction,

Dark Band, Side-To-Side (Slow Scan) Direction Symptom A dark line or band appears across the entire print in the side-to-side (slow scan) direction on every print. The thickness can be one pixel wide (1/600 inch) or wider.

Probable Cause Dirt on the ROS exiting window

Corrective Action Enter Printer dC606. Select [Light Dusting], [Start]. Examine the prints. If the defect is present, check the ROS exiting window for contamination. If the problem is not resolved, go to the PQ 9-601 System IQ Entry Level RAP for further defect analysis. Dark Band, 22-30 mm. Wide, Side-To-Side (Slow Scan) Direction Side-to-side (slow scan) dark band that is 22 mm to 30 mm wide is appearing 166 mm to 192 mm from the top edge of the prints. For an extended job, the first seven prints exhibit the problem. This problem usually is accompanied with Fault Code PQ 9-212 or PQ 9-215.

Probable Cause The Patch enable signal is staying on and the PR is not being discharged in the patch area. Suspect a bad Pixel Clock PWB.

Corrective Action Go to the 6-701 in the Service Dialog.

Section Name

Dark Band, Side-To-Side (Slow Scan) Direction

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Figure 1 Dark Band (side to side) Slow Scan

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Section Name

Dark Band, Side-To-Side (Slow Scan) Direction

Figure 2 Dark Band 22-30mm wide Side to Side

Section Name

Dark Band, Side-To-Side (Slow Scan) Direction

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Band Deletion, Side-To-Side (Slow Scan) Direction Symptom On long sustained printing runs, the deletion shows in halftones and in fine lines (usually can be seen on lines that are two pixels or less). This deletion may spread in the top-to-bottom (fast scan) direction as the printing continues.

Probable Cause By-products of the Dicorotron coronas are setting onto the PR. There is an inadequate air flow for removing the by-products.

Corrective Action Go to the PQ 9-615, Deletions RAP. Deletion Band, 22-30 mm Wide, Side-To-Side (Slow Scan) Direction Side-to-side (slow scan) deletion band that is 22 mm to 30 mm wide is appearing 166 mm to 192 mm from the top edge of the prints.

Probable Cause 1. The Patch Generator is staying on. 2. There is a bad Detack/Preclean Dicorotron.

Corrective Action Go to the PQ 9-621 Patch Generator RAP. If the problem still exists, replace the Detack/Preclean Dicorotron. Partial Deletion Band, 22-30 mm Wide, Side-To-Side (Slow Scan) Direction Side-to-side (slow scan) deletion band that is 22 mm to 30 mm wide is appearing 160 mm to 170 mm from the top edge of the prints.

Probable Cause 1. The Digital Patch Generator Enable Signal is missing.

Corrective Action Go to the PQ 9-621 Patch Generator RAP.

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Section Name

Band Deletion, Side-To-Side (Slow Scan) Direction

Figure 1 Process Band Deletion on Halftone Print

Section Name

Band Deletion, Side-To-Side (Slow Scan) Direction

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Figure 2 Deletion Band (slow scan) Side to Side

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Section Name

Band Deletion, Side-To-Side (Slow Scan) Direction

Figure 3 Partial Deletion Band (slow scan) Side to Side

Section Name

Band Deletion, Side-To-Side (Slow Scan) Direction

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Blotch Toner Symptom Toner blotch appears on the print. Toner blotches are deposits of toner placed on the print "outside of development," e.g., toner that has accumulated in the Cleaner Assembly (cleaner droppings). A typical size of a toner blotch is 5 mm to 10 mm. The central area of the blotch will have a concentration of toner surrounded by toner spots. A typical toner spot is less than 0.5 mm and is circular in shape.

Probable Cause •

Excess toner is being dropped from the Cleaner Assembly.

•

Defect on the Photoreceptor.

Corrective Action •

Go to the PQ 9-617, Cleaner RAP.

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Section Name

Blotch Toner

Figure 1 Toner Blotch Defect

Section Name

Blotch Toner

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Fine, Dark Lines, Side-To-Side (Slow Scan) Direction Across Print, Greater Frequency At Top And Bottom (Fast Scan Direction) On Print Sysptom Fine lines are running in the side-to-side (slow scan) direction with a higher frequency toward the top and bottom on the prints. Increasing the print darkness will increase the amount of lines on the prints. NOTE: Problem might initially appear as lines at the top or the bottom of the print, or along an edge. Problem may become more severe, with lines on the whole page or fast scan direction bands.

Probable Cause SLB/RDR PWB malfunction, ESS malfunction.

Corrective Action To be Developed.

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Section Name

Fine, Dark Lines, Side-To-Side (Slow Scan) Direc-

Figure 1 Fine Lines (greater frequency at the top)

Section Name

Fine, Dark Lines, Side-To-Side (Slow Scan) Direction

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Figure 2 Dark fine Lines (every seventh print)

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Section Name

Fine, Dark Lines, Side-To-Side (Slow Scan) Direc-

Figure 3 Digital Image Offset Defect

Section Name

Fine, Dark Lines, Side-To-Side (Slow Scan) Direction

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SLB/RDR Failure Defect Symptom There is fast scan image displacement of approximately 185 mm (area on the print usually displaced from the bottom to the top of the print). There are lightened areas on the prints occurring in bands of varying widths. The lightened areas begin where the image is repeated and shifted. As the failure progresses, part of the print may be completely blackened.

Probable Cause Failed SLB/RDR PWB

Corrective Action Reseat the SLB/RDR PWB. Run the prints and see if the defect still is present. If it is still present, replace the SLB/RDR PWB.

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Section Name

SLB/RDR Failure Defect

Figure 1 SLB/RDR DEFECT

Section Name

SLB/RDR Failure Defect

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4. Repairs and Adjustments 1. Printer Electrical REP 1-0 Autotransformer (T101) (50 HZ) ....................................................................... REP 1-1 Line Interface Module Front Components ........................................................ REP 1-2 Line Interface Module (50 HZ).......................................................................... REP 1-3 Line Interface Module (60 HZ).......................................................................... REP 1-4 HVAC Output Module ....................................................................................... REP 1-5 AC Remote PWBs (TYPICAL).......................................................................... REP 1-6 ADA PWBs (Typical) ........................................................................................ REP 1-7 CORE PWBs (MIN, PHN, FSN) ....................................................................... REP 1-8 DIO PWBs (Typical) ......................................................................................... REP 1-9 HVAC PWB ...................................................................................................... REP 1-10 HVDC PWB .................................................................................................... REP 1-11 MIB PWB ........................................................................................................ REP 1-12 SLB/RDR PWB AND ROS LVPS PWB .......................................................... REP 1-13 EDN PWB....................................................................................................... REP 1-14 Printer Card Cage Assembly .......................................................................... REP 1-16 Low Voltage Power Supply............................................................................. REP 1-17 Low Voltage Power Supply PWBs.................................................................. REP 1-18 Low Voltage Power Supply Cooling Fans ...................................................... REP 1-19 Low Voltage Power Supply Relays (K103/K104) ........................................... REP 1-21 C-Pixel PWB...................................................................................................

4-7 4-8 4-9 4-11 4-13 4-14 4-14 4-15 4-15 4-16 4-17 4-19 4-19 4-21 4-24 4-29 4-31 4-33 4-36 4-38

2. Printer UI REP 2-1 CP IOP PWB .................................................................................................... REP 2-2 Control Panel PWB........................................................................................... REP 2-3 Floppy Disk Drive Assembly ............................................................................. REP 2-4 UIM Core PWB ................................................................................................. REP 2-5 Video Engine PWB ........................................................................................... REP 2-6 Local/Remote Power Switch (S102)................................................................. REP 2-7 UI Front Cover Assembly ................................................................................. REP 2-8 UI Touch Screen Assembly .............................................................................. REP 2-9 UI Video Display Assembly .............................................................................. REP 2-10 UI AC EMI Filter (FL105) ................................................................................ REP 2-11 UI DC EMI Filter (FL106)................................................................................ REP 2-12 Rigid Disk Drive/SMSD Assembly .................................................................. REP 2-13 UI Keyboard Buttons ...................................................................................... REP 2-14 UI Brightness/Contrast Controls ..................................................................... REP 2-15 UI Swivel Wear Ring....................................................................................... REP 2-16 UI Tilt Bar........................................................................................................ REP 2-17 UI Tilt Cap....................................................................................................... REP 2-18 UI Tilt Shoe.....................................................................................................

REP 4-21 Cleaner Drive Support .................................................................................... REP 4-22 Decurler Drive Assembly ................................................................................ REP 4-23 Decurler Drive Belt.......................................................................................... REP 4-24 Decurler Intermediate Drive Belt..................................................................... REP 4-25 Handcranking the Main Drive Motor ............................................................... REP 4-26 Intermediate Drive Belt ................................................................................... REP 4-27 Main Drive Motor (MOT401) ........................................................................... REP 4-28 MIM and PHM Drive Pulleys........................................................................... REP 4-29 MIM Drive Belt ................................................................................................ REP 4-30 PHM Drive Belt, Intermediate Drive Assembly ............................................... REP 4-31 Photoreceptor Drive Assembly ....................................................................... REP 4-32 Photoreceptor Drive Belt................................................................................. REP 4-33 Prefuser Drive Assembly ................................................................................ REP 4-34 Prefuser Drive Belt.......................................................................................... REP 4-35 Top Transport Drive Assembly ....................................................................... REP 4-36 Tray 1 and 2 Feeder Drives ............................................................................ REP 4-38 Vertical Transport Clutch Assembly (CL851).................................................. REP 4-39 Developer Drive Assembly ............................................................................. REP 4-40 Fuser-Developer Drive Belt ............................................................................ REP 4-41 Fuser-Developer Drive Motor (MOT402) ........................................................ REP 4-42 Fuser-Developer Intermediate Drive Belt ....................................................... REP 4-43 Fuser Drive Assembly..................................................................................... REP 4-44 Jackshaft Assembly ........................................................................................ REP 4-45 Fuser-Developer Drive Motor Run and Start Capacitors (C403/C404)(60 HZ) REP 4-46 Main Drive Motor Run and Start Capacitors (C401/402) (60HZ).................... REP 4-47 Fuser-Developer Drive Dirt Shields ................................................................ REP 4-48 Bi-Pulley.......................................................................................................... REP 4-49 Stacker Front Cover........................................................................................ REP 4-50 Stacker Top Cover.......................................................................................... REP 4-51 Stacker Rear Top Cover ................................................................................. REP 4-52 Inverter Top Cover.......................................................................................... REP 4-53 Stacker Rear Top Cover ................................................................................. REP 4-54 Inverter Left Side Cover..................................................................................

4-41 4-41 4-42 4-43 4-44 4-44 4-45 4-46 4-47 4-48 4-49 4-49 4-54 4-55 4-56 4-57 4-57 4-58

REP 6-1 ROS Assembly ................................................................................................. REP 6-2 VLD/Collimator Assembly ................................................................................. REP 6-3 Polygon Motor (MOT601) ................................................................................. REP 6-4 EOS and SOS PWBs........................................................................................ REP 6-5 ROS Control Module (RCM) PWB.................................................................... REP 6-6 ROS Profile EPROM.........................................................................................

4-59 4-60 4-61 4-62 4-63

REP 7-0 Feed Head Assembly ....................................................................................... REP 7-1 Tube Shaft ........................................................................................................ REP 7-2 Retard Brake, Retard Roll, and Entry Guide..................................................... REP 7-3 Feed Belt .......................................................................................................... REP 7-4 Feed Belt Latch Arm .........................................................................................

6. ROS

Revision DocuPrint 180F Service Manual

4-121 4-123 4-124 4-125 4-127 4-131

7. Paper Trays 1 and 2

4. Covers and Drives REP 4-0 Printer Right Top Cover.................................................................................... REP 4-1 Printer Side Covers and Rear Covers .............................................................. REP 4-2 Printer Left Top Cover ...................................................................................... REP 4-3 Electrical Module Top Cover ............................................................................ REP 4-20 Cleaner Drive Belt ..........................................................................................

4-66 4-67 4-68 4-69 4-70 4-71 4-72 4-74 4-75 4-76 4-80 4-81 4-82 4-83 4-86 4-88 4-89 4-91 4-93 4-94 4-97 4-100 4-101 4-103 4-106 4-109 4-111 4-112 4-113 4-116 4-118 4-118 4-119

11/00 4-1

4-135 4-137 4-138 4-139 4-140

Repairs and Adjustments

REP 7-5 Feed Belt Pulley ............................................................................................... REP 7-6 Feed Belt Idler .................................................................................................. REP 7-7 Feed Belt Spool ................................................................................................ REP 7-8 Feed Clutch Pulley ........................................................................................... REP 7-9 Feed Clutch Belt ............................................................................................... REP 7-10 Feed Clutch (CL811/821) ............................................................................... REP 7-11 Takeaway Idler Roll ........................................................................................ REP 7-12 Takeaway Drive Belt....................................................................................... REP 7-13 Takeaway Roll ................................................................................................ REP 7-14 Length Guide .................................................................................................. REP 7-15 Elevator Up Limit Switch (S714/724) .............................................................. REP 7-16 Elevator Belt ................................................................................................... REP 7-17 Elevator Drive Motor (MOT711/721) .............................................................. REP 7-18 Elevator MOTOR Capacitor (C711/721)......................................................... REP 7-19 Lock Arm and Lock Actuator .......................................................................... REP 7-20 Stack Relief Solenoid (SOL811/821) .............................................................. REP 7-21 Stack Height Sensor (Q711/721).................................................................... REP 7-22 Tray 1 and 2 Front Covers.............................................................................. REP 7-23 Lead Screws (Front), Bearings, and the Lift Nuts........................................... REP 7-24 Lead Screws (Rear), Bearings, and the Lift Nuts ........................................... REP 7-25 Elevator Assembly.......................................................................................... REP 7-26 Paper Plate..................................................................................................... REP 7-27 Tray Capacity PWB ........................................................................................ REP 7-28 Elevator Drive Belt ..........................................................................................

4-140 4-141 4-142 4-142 4-143 4-145 4-146 4-147 4-148 4-150 4-151 4-151 4-153 4-154 4-155 4-155 4-156 4-156 4-157 4-160 4-162 4-165 4-166 4-166

7. High Capacity Trays REP 7-34 HCT Elevator Assembly ................................................................................. REP 7-35 HCT Elevator Drive Belt ................................................................................. REP 7-36 HCT Elevator Drive Motor (MOT731) ............................................................. REP 7-37 HCT Lead Screws .......................................................................................... REP 7-38 HCT Switch Assembly .................................................................................... REP 7-39 HCT Paper Plate ............................................................................................ REP 7-40 HCT Slides ..................................................................................................... REP 7-41 HCT Front Cover ............................................................................................ REP 7-42 Tray Capacity PWB ........................................................................................

4-169 4-170 4-171 4-172 4-173 4-174 4-174 4-175 4-175

8. Paper Feeding REP 8-0 Vertical Transport Assembly............................................................................. REP 8-1 Vertical Transport Drive Belt............................................................................. REP 8-2 Turn Baffle ........................................................................................................ REP 8-3 Registration Transport Assembly ..................................................................... REP 8-4 Cross Rolls Assembly....................................................................................... REP 8-5 Pretransfer Baffle.............................................................................................. REP 8-6 NIP Release Solenoid (SOL851) ...................................................................... REP 8-7 NIP Release Solenoid Assembly and Idler Bracket..........................................

4-177 4-178 4-179 4-180 4-182 4-183 4-184 4-185

8. IFS, FS Lower Transports REP 8-15 Blower Motor (MOT832)/O-Ring Pulley .......................................................... REP 8-16 Blower Assembly ............................................................................................ REP 8-17 O-Ring Drive Belt............................................................................................ REP 8-18 Feeder Clutch ................................................................................................. REP 8-20 Feeder Main Drive Motor (MOT831) ..............................................................

Repairs and Adjustments

4-187 4-188 4-189 4-189 4-190

REP 8-21 Feeder Motor Drive Belt.................................................................................. REP 8-22 Feeder Main Drive Belt ................................................................................... REP 8-24 Feeder Assembly............................................................................................ REP 8-40 Lower Preregistration Transport ..................................................................... REP 8-41 Registration Baffle Assembly.......................................................................... REP 8-43 Lower Preregistration Transport Corrugator Rolls .......................................... REP 8-45 Lower Preregistration Transport Flexible Drive Shaft ..................................... REP 8-46 Registration Assembly .................................................................................... REP 8-47 Corrugator Roll Drive Shafts And Belt ............................................................ REP 8-50 Intermediate Horizontal Transport .................................................................. REP 8-55 Horizontal Transport (IFS) .............................................................................. REP 8-56 Horizontal Transport (FS) ............................................................................... REP 8-59 Horizontal Transport Pivot Baffle (IFS) ........................................................... REP 8-60 Horizontal Transport Pivot Baffle (FS) ............................................................ REP 8-65 Lower Turn Transport (IFS/FS)....................................................................... REP 8-66 Lower Turn Transport Baffle/pivot Shaft/springs (IFS/FS).............................. REP 8-67 Lower Turn Transport Upper Drive Shaft........................................................ REP 8-68 Lower Turn Transport Lower Drive Shaft........................................................ REP 8-69 Lower Turn Transport Sensor Assembly ........................................................ REP 8-75 Vertical Transport (IFS/FS)............................................................................. REP 8-76 Vertical Transport Upper Baffle/Pivot Shaft/Spring (IFS/FS) .......................... REP 8-77 Vertical Transport Lower Baffle/Pivot Shaft (IFS/FS) ..................................... REP 8-78 Vertical Transport Lower Baffle Release Assembly Components .................. REP 8-79 Vertical Transport Sensor Assembly .............................................................. REP 8-80 Vertical Transport Drive Belt/drive Shafts.......................................................

4-191 4-192 4-193 4-195 4-198 4-199 4-199 4-200 4-201 4-202 4-205 4-208 4-210 4-211 4-213 4-215 4-216 4-217 4-217 4-218 4-221 4-223 4-225 4-227 4-227

9. Xerographics REP 9-0 Toner Bottle ...................................................................................................... REP 9-1 Toner Thumper Solenoid (SOL901) ................................................................. REP 9-2 Toner Dispenser Assembly............................................................................... REP 9-3 Toner Dispenser Motor (MOT902).................................................................... REP 9-4 Developer Material............................................................................................ REP 9-5 Developer Assembly......................................................................................... REP 9-6 Developer Dump And Thump ........................................................................... REP 9-7 Front Bearing Clamp......................................................................................... REP 9-8 BRD Roll (w/Tag P-118 and Tag P-300) .......................................................... REP 9-9 Developer Roll 1 or 2 ........................................................................................ REP 9-10 Developer Roll 3 ............................................................................................. REP 9-11 Trimmer Bar.................................................................................................... REP 9-12 Paddle Wheel ................................................................................................. REP 9-13 Mixing Auger................................................................................................... REP 9-14 Low Toner Sensor (Q903) .............................................................................. REP 9-15 Waste Bottle Full Sensor (Q906) .................................................................... REP 9-16 Waste Compactor Shield ................................................................................ REP 9-17 Upper Waste Toner Duct ................................................................................ REP 9-18 Waste Compactor Drive Belt .......................................................................... REP 9-19 Waste Compactor Motor Bracket.................................................................... REP 9-20 Waste Compactor Auger ................................................................................ REP 9-21 Waste Compactor Motor (MOT903) ............................................................... REP 9-22 Lower Waste Toner Duct ................................................................................ REP 9-23 Cleaner Brush................................................................................................. REP 9-24 Cleaner Manifold.............................................................................................

11/00 4-2

4-229 4-230 4-230 4-231 4-232 4-234 4-236 4-236 4-237 4-239 4-240 4-242 4-242 4-244 4-245 4-245 4-246 4-247 4-249 4-250 4-251 4-252 4-253 4-253 4-254

Revision DocuPrint 180F Service Manual

REP 9-25 Cleaner Augers or Blade ................................................................................ REP 9-26 Cleaner Module .............................................................................................. REP 9-27 Cleaner Drive Gears ....................................................................................... REP 9-28 Toner Filter Bag.............................................................................................. REP 9-29 Toner Filter Assembly..................................................................................... REP 9-30 Toner Filter Blower Motor (MOT905).............................................................. REP 9-31 Toner Filter Blower ......................................................................................... REP 9-32 Waste Bottle ................................................................................................... REP 9-33 Flicker Bar ...................................................................................................... REP 9-34 Xerographic Drawer........................................................................................ REP 9-35 Photoreceptor Belt .......................................................................................... REP 9-36 Patch Generator ............................................................................................. REP 9-37 ESV ................................................................................................................ REP 9-38 DSS ................................................................................................................ REP 9-39 Dicorotron and Shield ..................................................................................... REP 9-40 Dicorotron Connectors W- P287..................................................................... REP 9-41 OZAC Duct ..................................................................................................... REP 9-42 Ozone Filter Assembly ................................................................................... REP 9-43 Ozone Blower (MOT904)................................................................................ REP 9-44 Cavity Cooling Fan (MOT105)........................................................................ REP 9-45 PR Edge Guides or Tension Roll.................................................................... REP 9-46 PR Module...................................................................................................... REP 9-47 Xerographic Drawer Slides ............................................................................. REP 9-48 Transfer Blade ................................................................................................ REP 9-49 Transfer Dicorotron......................................................................................... REP 9-50 Transfer Assist Device.................................................................................... REP 9-51 Transfer Solenoids 1-4 (SOL903/904/905/906).............................................. REP 9-52 Xerographic Drawer Latch Cable ................................................................... REP 9-53 Discharge Lamps PWB (PS902) .................................................................... REP 9-54 Hydraulic Lift Assembly .................................................................................. REP 9-55 Photoreceptor Spot Cleaning ......................................................................... REP 9-56 Transfer Blade Sensor (Q907) ....................................................................... REP 9-57 Spots Blade .................................................................................................... REP 9-58 Spots Blade Guide.......................................................................................... REP 9-59 PR Mini-rug..................................................................................................... REP 9-60 POP Sensor (Q904) Cleaning ........................................................................ REP 9-61 Cleaner Detoning Rolls or Bearing Plates ...................................................... REP 9-62 Transfer Solenoids (SOL903/SOL904/SOL905/SOL906) ..............................

4-257 4-259 4-265 4-267 4-268 4-269 4-271 4-273 4-273 4-274 4-275 4-278 4-279 4-281 4-282 4-284 4-285 4-289 4-290 4-291 4-291 4-292 4-294 4-295 4-296 4-299 4-302 4-305 4-307 4-308 4-310 4-313 4-315 4-318 4-319 4-320 4-321 4-323

10. Print Transports and Fuser REP 10-0 Camshaft ........................................................................................................ REP 10-1 Fuser Roll and Heat Rod (HTR1001) ............................................................. REP 10-2 Metering Assembly ......................................................................................... REP 10-3 Metering Assembly Cleaning.......................................................................... REP 10-4 Metering Roll .................................................................................................. REP 10-5 Metering Blade ............................................................................................... REP 10-6 Air Knife Manifold Cleaning ............................................................................ REP 10-7 Fuser Wick and Fuser Agent Filter ................................................................. REP 10-8 Fuser Sensor (Q1010) CLEANING ................................................................ REP 10-9 Left and Right Drawer Slide............................................................................ REP 10-10 MIM Compressor (MOT1002)....................................................................... REP 10-11 Top Transport Assembly .............................................................................. Revision DocuPrint 180F Service Manual

4-329 4-330 4-333 4-334 4-335 4-336 4-338 4-339 4-340 4-341 4-343 4-345

REP 10-12 Prefuser Transport Assembly ....................................................................... REP 10-13 Exit Transport Assembly............................................................................... REP 10-14 Decurler Assembly........................................................................................ REP 10-15 Decurler Belts ............................................................................................... REP 10-16 Flexible Coupling .......................................................................................... REP 10-17 Duplex Inverter Assembly............................................................................. REP 10-18 Inverter Gear Box Drive Belt and Inverter Reversing Roll Drive Belt............ REP 10-19 Inverter Gear Box Assembly.........................................................................

4-347 4-348 4-349 4-351 4-352 4-353 4-355 4-357

11A. IFS, FS Upper Transports REP 11-1 Inverter Transport ........................................................................................... 4-359 REP 11-2 Inverter Gate Solenoid (SOL1108) ................................................................. 4-362 REP 11-3 Inverter Drive Motor (MOT1111)..................................................................... 4-363 REP 11-4 Inverter Latch Assembly ................................................................................. 4-364 REP 11-5 Inverter Top and Bottom Hinges..................................................................... 4-365 REP 11-6 Inverter Pivoting Assembly ............................................................................. 4-366 REP 11-7 Inverter Passive Gate ..................................................................................... 4-367 REP 11-8 Inverter Bottom Drive Shaft ............................................................................ 4-369 REP 11-9 Inverter Top and Middle Shafts....................................................................... 4-370 REP 11-10 Stacker Main Drive Motor (MOT1110).......................................................... 4-373 REP 11-11 Post Inverter Transport ................................................................................. 4-374 REP 11-12 Post Inverter Transport Gear Bracket/Main Drive Belt/Lower Shaft ............. 4-378 REP 11-13 Post Inverter Upper Drive Shaft/Sample Tray Drive Shaft............................ 4-382 REP 11-14 Inverter Drive Belt/Short Shaft ...................................................................... 4-382 REP 11-15 Sample Tray Gate Solenoid (SOL1110)/Actuator Arm Assembly ................ 4-383 REP 11-16 Sample Tray Gate/Sample Tray Gate Actuator ............................................ 4-384 REP 11-20 Stacker Preregistration Transport................................................................. 4-385 REP 11-21 Stacker Preregistration Transport Drive Pulley Assembly ............................ 4-388 REP 11-22 Prestacker Drive Roll Shaft........................................................................... 4-389 REP 11-23 Stacker Preregistration Transport Flexible Drive Shaft................................. 4-389 REP 11-25 Post Inverter Sensor (Q1156)....................................................................... 4-390 REP 11-26 Registration Assembly .................................................................................. 4-391 REP 11-27 Stacker Preregistration Transport Corrugator Rolls...................................... 4-392 REP 11-28 Corrugator Roll Drive Shafts and Belts......................................................... 4-393 REP 11-29 Stacker Lead in Baffle/Trail Edge Assist Idler Roll/Disk Sheet Sensor (Q1106) (Purge and Bypass Transport) ........................................................................................ 4-394 REP 11-30 Chute Baffle (IFS/FS) ................................................................................... 4-395 REP 11-31 Bypass Transport Top Baffle ........................................................................ 4-396 REP 11-32 Purge Transport Top Baffle .......................................................................... 4-399 REP 11-33 Bypass Transport/Purge Transport............................................................... 4-400 REP 11-34 BYPASS LEAD IN BAFFLE.......................................................................... 4-402 REP 11-35 Bypass/Purge Transport Gate ...................................................................... 4-403 REP 11-36 Disk Gate ...................................................................................................... 4-404 REP 11-37 Bypass/Purge Transport Gate Solenoid (SOL1104)..................................... 4-405 REP 11-38 Trail Edge Assist Drive Shaft (Bypass or Purge Transport).......................... 4-406 REP 11-39 Trail Edge Assist Belts (Bypass or Purge Transport) ................................... 4-407 REP 11-40 Telescopic Drive Shaft.................................................................................. 4-408 REP 11-41 Middle Drive Shaft (Bypass or Purge Transport) .......................................... 4-409 REP 11-42 Right Drive Shaft (Bypass or Purge Transport) ............................................ 4-410 REP 11-43 Left Drive Shaft (Bypass or Purge Transport)............................................... 4-411 REP 11-44 Purge Output Drive Shaft.............................................................................. 4-412 REP 11-45 Purge Lead in Baffle ..................................................................................... 4-414

11/00 4-3

Repairs and Adjustments

REP 11-46 Inverter Transport Motor Fan........................................................................ REP 11-47 Blower Assembly ..........................................................................................

4-415 4-415

11B. Print Stacking REP 11-58 Pallet Lift Frame ........................................................................................... 4-417 REP 11-59 Stacker Elevator Motor (MOT1106).............................................................. 4-418 REP 11-60 Stacker Elevator Drive Belt........................................................................... 4-419 REP 11-61 Lead Screw................................................................................................... 4-420 REP 11-62 Stacker Overtravel Down Switch (S1141)/Stacker Elevator Down Sensor (Q1125) 4-421 REP 11-63 Stacker Overtravel up Switch (S1140) ......................................................... 4-421 REP 11-64 Container Size Sensors (Q1126, Q1127, Q1128) ........................................ 4-422 REP 11-68 Stack Height Sensor (Q1122)....................................................................... 4-423 REP 11-70 Back Guide ................................................................................................... 4-424 REP 11-71 Front Guide................................................................................................... 4-426 REP 11-72 Right Guide................................................................................................... 4-427 REP 11-73 Disk Stepper Motor ....................................................................................... 4-430 REP 11-74 Right Guide Tamper Motor (MOT1113)........................................................ 4-431 REP 11-75 Right Guide Drive Belt .................................................................................. 4-433 REP 11-85 Disk Module Weldment (IFS)........................................................................ 4-434 REP 11-86 Disk Module Weldment (FS)......................................................................... 4-436

7A. Paper Trays 1 2 ADJ 7-0 Feed Clutch Belt and Takeaway Drive Belt....................................................... ADJ 7-1 Takeaway Shaft Endplay................................................................................... ADJ 7-2 Down/Low Paper Sensor (Q714/724) ............................................................... ADJ 7-3 Elevator Up Limit Switch (S714/724)................................................................. ADJ 7-4 Length Guide Position ....................................................................................... ADJ 7-5 Length Guide Tension ....................................................................................... ADJ 7-6 Auto Latch ......................................................................................................... ADJ 7-7 Front Cover Frame ............................................................................................ ADJ 7-8 Front Cover Support.......................................................................................... ADJ 7-9 Paper Feed Setup ............................................................................................. ADJ 7-10 Lock Assembly ................................................................................................ ADJ 7-11 Elevator Drive Belt...........................................................................................

7B. High Capacity Trays ADJ 7-30 Elevator Drive Belt........................................................................................... ADJ 7-31 Stack Height/stack Height Sensor (Q735)....................................................... ADJ 7-32 Latch Assembly ............................................................................................... ADJ 7-33 Low Paper Sensor (Q738)............................................................................... ADJ 7-34 Front Cover ..................................................................................................... ADJ 7-35 HIGH CAPACITY TRAY SWITCH ASSEMBLY ..............................................

2. Printer UI ADJ 2-0 Printer UI Tilt .....................................................................................................

4-441 4-442 4-445 4-446 4-447 4-447 4-449 4-450 4-452 4-453 4-454 4-456 4-457 4-458 4-459 4-460 4-461 4-464 4-465 4-468

6. ROS ADJ 6-1 ROS Magnification Setup.................................................................................. ADJ 6-2 ROS Image Squareness ................................................................................... ADJ 6-3 ROS Low Correction Factor .............................................................................. ADJ 6-4 ROS Power Calibration .....................................................................................

Repairs and Adjustments

4-505 4-505 4-509 4-511 4-512 4-514

8. Paper Feeding 4-439

4. Covers and Drives ADJ 4-0 Printer Right Top Cover .................................................................................... ADJ 4-1 Printer Right Door Latch.................................................................................... ADJ 4-2 Printer Rear Covers .......................................................................................... ADJ 4-3 Interlock Actuator .............................................................................................. ADJ 4-4 Stacker Top Cover Counterbalances ................................................................ ADJ 4-5 Stacker Doors Interlock Switches (S1138) & (S1163) ...................................... ADJ 4-10 Cleaner Drive Belt ........................................................................................... ADJ 4-11 Decurler Drive Belt .......................................................................................... ADJ 4-12 Decurler Intermediate Drive Belt ..................................................................... ADJ 4-13 Decurler Intermediate Drive Pulley ................................................................. ADJ 4-14 Intermediate Drive Assembly .......................................................................... ADJ 4-15 Intermediate Drive Belt.................................................................................... ADJ 4-16 MIM Drive Belt................................................................................................. ADJ 4-17 PHM Drive Belt................................................................................................ ADJ 4-18 PHM/MIM Drive Pulleys .................................................................................. ADJ 4-19 Prefuser Drive Belt .......................................................................................... ADJ 4-20 Tray 1 and 2 Feeder Drives ............................................................................ ADJ 4-21 Fuser-Developer Drive Belt ............................................................................. ADJ 4-22 Fuser-Developer Drive Pulley ......................................................................... ADJ 4-23 Fuser-developer Intermediate Drive................................................................

4-475 4-476 4-478 4-479 4-481 4-482 4-483 4-484 4-485 4-487 4-502 4-503

4-469 4-471 4-474 4-474

ADJ 8-0 Registration Transport Upper Baffles ................................................................ ADJ 8-1 Pretransfer Baffle .............................................................................................. ADJ 8-2 Top-to-Bottom Registration ............................................................................... ADJ 8-3 Side-to-Side Registration .................................................................................. ADJ 8-4 Registration Transport....................................................................................... ADJ 8-5 Paper Width Timing........................................................................................... ADJ 8-6 NIP Release Solenoid (SOL851).......................................................................

4-523 4-524 4-526 4-527 4-528 4-532 4-532

8. IFS, FS Lower Transports ADJ 8-9 Lower Preregistration Transport Registration Baffle Assembly......................... ADJ 8-10 Lower Preregistration Transport Pivot Baffle................................................... ADJ 8-11 Lower Preregistration Transport Corrugator Rolls........................................... ADJ 8-12 Lower Preregistration Transport Pivot Baffle Bumper ..................................... ADJ 8-13 Tray 3 Oversize NIP Release Solenoid (SOL852) .......................................... ADJ 8-14 IFS/FS Horizontal Transport Pivot Baffle ........................................................ ADJ 8-15 Intermediate Horizontal Transport Pivot Baffle................................................

4-535 4-537 4-541 4-542 4-543 4-545 4-548

9. Xerographics ADJ 9-0 Toner Thumper.................................................................................................. ADJ 9-1 Developer Zone Roll.......................................................................................... ADJ 9-2 NVM Read/Write ............................................................................................... ADJ 9-3 Xerographic Setup............................................................................................. ADJ 9-5 Patch Generator Timing .................................................................................... ADJ 9-6 Charge Dicorotron Balance ............................................................................... ADJ 9-7 Charge Dicorotron Height.................................................................................. ADJ 9-8 Photoreceptor Seam Timing.............................................................................. ADJ 9-9 Transfer Blade Timing ....................................................................................... ADJ 9-10 PR Module Positioning Tool Instructions, TAG P-318..................................... ADJ 9-11 Photoreceptor Tension .................................................................................... ADJ 9-12 ESV Height......................................................................................................

11/00 4-4

4-549 4-550 4-552 4-553 4-556 4-557 4-559 4-561 4-561 4-565 4-568 4-569

Revision DocuPrint 180F Service Manual

ADJ 9-13 DSS Saturation ............................................................................................... ADJ 9-14 DSS Timing ..................................................................................................... ADJ 9-15 NVM Node Initialization Recovery (60HZ, 50HZ)............................................ ADJ 9-16 Spots Blade Contact ....................................................................................... ADJ 9-17 PR Mini-rug Height .......................................................................................... ADJ 9-18 Preclean Dicorotron Height ............................................................................. ADJ 9-19 Developer Drive Assembly Alignment .............................................................

4-571 4-572 4-573 4-574 4-576 4-577 4-580

10. Print Transports and Fuser ADJ 10-0 Fuser Roll Thermostat (THS1002) .................................................................. ADJ 10-1 Metering Roll Overheat Thermostat (THS1001) ............................................. ADJ 10-2 Pressure Roll (Contact ARC) .......................................................................... ADJ 10-4 Air Knife Manifold and Fuser Roll.................................................................... ADJ 10-5 Air Knife Pressure, Pressure Regulator, Compressor (MOT1002) ................. ADJ 10-6 Fuser Roll Temperature .................................................................................. ADJ 10-7 Metering Roll Temperature ............................................................................. ADJ 10-8 Decurler Exit Baffle ......................................................................................... ADJ 10-9 Duplex Gate and Solenoid (SOL1002)............................................................ ADJ 10-10 Decurler Sensor (Q1011) .............................................................................. ADJ 10-11 Left and Right Drawer Slide .......................................................................... ADJ 10-12 Fuser Latch Assembly................................................................................... ADJ 10-13 Donor Roll Contact ARC ............................................................................... ADJ 10-14 Duplex Timing ............................................................................................... ADJ 10-15 Stripper Finger Baffle Clearance................................................................... ADJ 10-16 Relief Valve ................................................................................................... ADJ 10-17 Thermistor Cal............................................................................................... ADJ 10-18 Prefuser Transport ........................................................................................

4-581 4-582 4-583 4-585 4-587 4-588 4-589 4-591 4-592 4-593 4-593 4-597 4-599 4-600 4-600 4-603 4-605 4-606

ADJ 11-33 Back Guide Squareness................................................................................ ADJ 11-34 Right Guide Moving Wall Squareness........................................................... ADJ 11-35 Stacker Module Paper Path Adjustment ......................................................

4-654 4-656 4-657

13. Transition Module ADJ 13-1 Bypass Transport Stacker Output Gate: ......................................................... ADJ 13-2 Bypass Transport Purge Baffle: ...................................................................... ADJ 13-3 Bypass Transport Exit Baffle: .......................................................................... ADJ 13-4 Transition Module Main Drive Motor: .............................................................. ADJ 13-5 Transition Module Height: ............................................................................... ADJ 13-6 Transition Module Inboard/Outboard Position:................................................

4-661 4-663 4-664 4-665 4-666 4-668

11. IFS, FS Upper Transports ADJ 11-1 Inverter Gate Solenoid (SOL1108).................................................................. ADJ 11-2 Gate Flat Spring .............................................................................................. ADJ 11-3 Inverter Output Baffle ...................................................................................... ADJ 11-4 Inverter Top And Bottom Hinges ..................................................................... ADJ 11-6 Stacker Preregistration Transport Corrugator Rolls ........................................ ADJ 11-7 Inverter Pivoting Assembly Alignment............................................................. ADJ 11-8 Sample Tray Gate Solenoid (SOL1110) ......................................................... ADJ 11-9 A3 NIP Release Solenoid (SOL1111) ............................................................. ADJ 11-10 Bypass Transport/Purge Transport ............................................................... ADJ 11-11 Bypass/Purge Transport Gate Solenoid (SOL1104) ..................................... ADJ 11-12 Post Inverter Latch ........................................................................................ ADJ 11-13 Sample Tray and Purge Tray Corrugator Rolls ............................................. ADJ 11-14 Inverter Transport Motor Belt Tension ..........................................................

4-611 4-613 4-614 4-616 4-618 4-620 4-621 4-622 4-624 4-628 4-629 4-632 4-636

11. Print Stacking ADJ 11-25 Disk Home Position ....................................................................................... ADJ 11-26 Disk Gate Height ........................................................................................... ADJ 11-27 Stack Height .................................................................................................. ADJ 11-28 Right Guide ................................................................................................... ADJ 11-29 Back Guide.................................................................................................... ADJ 11-30 Stacker Overtravel Up Switch (S1140) ......................................................... ADJ 11-31 Pallet Lift Frame Parallelism ......................................................................... ADJ 11-32 Container Size Sensors (Q1126, Q1127, Q1128).........................................

Revision DocuPrint 180F Service Manual

4-639 4-641 4-643 4-644 4-645 4-646 4-648 4-649

11/00 4-5

Repairs and Adjustments

Repairs and Adjustments

11/00 4-6

Revision DocuPrint 180F Service Manual

REP 1-0 Autotransformer (T101) (50 HZ) Parts List on PL 1.1 Removal 1.

REMOVE ALL SYSTEM POWER.

2.

REMOVE THE LINE INTERFACE MODULE (REP 1-2).

3.

REMOVE THE AUTOTRANSFORMER (Figure 1).

1 DISCONNECT

2 REMOVE THE SCREWS (2)

3 REMOVE THE AUTOTRANSFORMER ASSEMBLY

Figure 1 Removing the Autotransformer Assembly

Preliminary Working Document No Product Name Assigned

0/0/00 ?-7

Section Name

REP 1-0

REP 1-1 Line Interface Module Front Components

Parts List on PL 1.1 Removal 1.

REMOVE ALL SYSTEM POWER.

2.

ACCESS THE LINE INTERFACE MODULE COMPONENTS (Figure 1).

2 REMOVE THE EM TOP COVER

3 REMOVE THE EM INNER PANEL

4 REMOVE THE EM FRONT TRIM STRIP

5 TURN THE QUARTERTURN FASTENER

6 SLIDE THE DRAWER OUT OF THE MACHINE

1 OPEN THE EM FRONT DOOR

Figure 1 Accessing the Line Interface Module Components

Section Name

REP 1-1

0/0/00 ?-8

Preliminary Working Document No Product Name Assigned

REP 1-2 Line Interface Module (50 HZ) Parts List on PL 1.1 Removal 1.

1 DISCONNECT

REMOVE ALL SYSTEM POWER.

2.

REMOVE THE EM REAR COVER.

3.

REMOVE THE TONER FILTER ASSEMBLY (REP 9-29).

4.

REMOVE THE POWER CORD ISOLATION BOX (Figure 1).

2

3

DISCONNECT THE WIRES (5)

REMOVE THE ISOLATION BOX

3 DISCONNECT

1 LOOSEN THE STRAING RELIEF SCREWS

2 REMOVE THE SCREWS (2)

Figure 2 Preparing to Remove the Line Interface Module 6.

REMOVE THE EM INNER PANEL.

7.

REMOVE THE EM TRIM STRIP.

8.

REMOVE THE LINE INTERFACE MODULE (Figure 3).

Figure 1 Removing the Isolation Box 5.

PREPARE TO REMOVE THE LINE INTERFACE MODULE (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-9

Section Name

REP 1-2

3 MOVE THE PWB PANEL AWAY FROM THE PRINTER

4 DISCONNECT THE AIR LINES (2)

5 SLIDE THE MODULE OUTWARDS

2 REMOVE THE PWB PANEL SCREWS (4)

1 REMOVE THE MOUNTING SCREW

Figure 3 Removing the Line Interface Module (50 HZ)

Replacement

REP 1-3 Line Interface Module (60 HZ)

1.

Parts List on PL 1.1 Removal

ENSURE THAT THE LEADS FROM THE LINE INTERFACE MODULE ARE CONNECTED TO THE FOLLOWING TERMINALS OF TB101: a.

the brown lead (marked L1) to terminal 1

b.

the black lead (marked L2) to terminal 2

c.

the black lead (marked L3) to terminal 3

d.

the blue lead to terminal 4

e.

the green lead to the ground terminal

Section Name

REP 1-2

1.

REMOVE ALL SYSTEM POWER.

2.

LIFT AND SLIDE THE ELCI ASSEMBLY OFF OF THE SUPPORT BRACKETS OF THE PRINTER REAR COVER.

3.

REMOVE THE EM REAR COVER.

4.

REMOVE THE TONER FILTER ASSEMBLY (REP 9-29).

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Preliminary Working Document No Product Name Assigned

5.

REMOVE THE POWER CORD ISOLATION BOX (Figure 1).

1 DISCONNECT

3 SLIDE OUT THE ISOLATION BOX

2 DISCONNECT THE WIRES (6)

3 DISCONNECT THE GROUND WIRE(S)

1 LOOSEN THE SCREWS (4)

2 REMOVE THE SCREWS (2)

Figure 2 Preparing to Remove the Line Interface Module Figure 1 Removing the Isolation Box 7. 6.

PREPARE TO REMOVE THE LINE INTERFACE MODULE (Figure 2).

Preliminary Working Document No Product Name Assigned

REMOVE THE EM INNER PANEL.

8.

REMOVE THE EM TRIM STRIP.

9.

REMOVE THE LINE INTERFACE MODULE (Figure 3).

0/0/00 ?-11

Section Name

REP 1-3

2 DISONNECT THE AIR LINES (2)

3 SLIDE THE MODULE OUTWARDS

1 REMOVE THE MOUNTINT SCREW

Figure 3 Removing the Line Interface Module (60 HZ)

Replacement

REP 1-4 HVAC Output Module

1.

Parts List on PL 1.7 Removal

ENSURE THAT THE LEADS FROM THE LINE INTERFACE MODULE ARE ATTACHED TO THE FOLLOWING TERMINALS OF TB101: a.

the black lead to terminal 1

b.

the red lead to terminal 2

c.

the white lead to terminal 3

d.

the black lead to terminal 4

e.

the red lead to terminal 5

f.

the white lead to terminal 6

g.

the green lead to the ground terminal

Section Name

REP 1-3

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE PRINTER RIGHT REAR COVER.

3.

REMOVE THE PRINTER LEFT REAR COVER.

4.

OPEN THE XEROGRAPHIC CARD CAGE.

5.

OPEN THE TONER FILTER HOUSING.

6.

REMOVE THE HVAC OUTPUT MODULE (Figure 1).

a.

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Disconnect P203, P200, and P238 to allow the card cage to swing out fully.

Preliminary Working Document No Product Name Assigned

3 REMOVE THE HVAC OUTPUT MODULE

2 DISCONNECT

1 REMOVE THE MOUNTING SCREWS (5)

Figure 1 Removing the HVAC Output Module

Preliminary Working Document No Product Name Assigned

0/0/00 ?-13

Section Name

REP 1-4

REP 1-5 AC Remote PWBs (TYPICAL)

REP 1-6 ADA PWBs (Typical)

Parts List on PL 1.4 and PL 1.7 Removal

Parts List on PL 1.8 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

DISCONNECT THE PWB CONNECTORS.

2.

DISCONNECT THE PWB CONNECTORS.

NOTE: AC Remote PWBs are interchangeable.

NOTE: ADA #1 and ADA #2 are interchangeable PWBs.

3.

3.

REMOVE THE AC REMOTE PWB.

Section Name

REP 1-5, REP 1-6

0/0/00 ?-14

REMOVE THE ADA PWB.

Preliminary Working Document No Product Name Assigned

REP 1-7 CORE PWBs (MIN, PHN, FSN)

REP 1-8 DIO PWBs (Typical)

Parts List on PL 1.4 and PL 1.8 Removal

Parts List on PL 1.4 Removal

1.

SWITCH OFF THE PRINTER POWER.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

DISCONNECT THE CORE PWB CONNECTORS.

2.

DISCONNECT THE DIO PWB CONNECTORS.

3.

REMOVE THE CORE PWB.

3.

REMOVE THE DIO PWB.

Replacement

Replacement CAUTION

CAUTION

Ensure that the Printer Power Cords are disconnected. Reconnecting the PWB connectors with power applied can damage the CORE PWB.

Ensure that the Printer Power Cords are disconnected. Reconnecting the PWB connectors with power applied can damage the DIO PWB.

1.

REINSTALL THE CORE PWB. RECONNECT THE PWB CONNECTORS.

1.

2.

POSITION THE J2 TERMINATION JUMPER AS FOLLOWS.

REINSTALL THE DIO PWB. RECONNECT THE PWB CONNECTORS.

NOTE: The IFS, MIN, and PHN DIO PWBs are interchangeable.

WITH A 2 MODULE SYSTEM: a.

MIN CORE PWB - Connect the J2 Termination Jumper across pin 1 and pin 2 (NORM).

b.

PHN CORE PWB - Connect the J2 Termination Jumper across pin 1 and pin 2 (NORM)

c.

FSN CORE PWB - Connect the J2 Termination Jumper across pin 2 and pin 3 (TEST)

2.

RECONNECT ALL PRINTER POWER CORDS. SWITCH ON THE PRINTER POWER.

WITH A 3 OR 4 MODULE SYSTEM: a.

STEPS a AND b FROM THE FIRST BULLET LIST

b.

FSN CORE PWB #1 - Connect the J2 Termination Jumper across pin 1 and pin 2 (NORMAL)

c.

FSN CORE PWB #2 - Connect the J2 Termination Jumper across pin 2 and pin 3 (TEST)

WITH A BTM CORE PWB:

3.

a.

STEPS a AND b FROM THE SECOND BULLET LIST

b.

FSN CORE PWB #2 - Connect the J2 Termination Jumper across pin 1 and pin 2 (NORMAL)

c.

BTM CORE PWB - Connect the J2 Termination Jumper across pin 2 and pin 3 (TEST)

RESTORE THE PRINTER POWER.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-15

Section Name

REP 1-7, REP 1-8

REP 1-9 HVAC PWB Parts List on PL 1.7 Removal

P231

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE PRINTER RIGHT REAR COVER.

3.

MOVE THE TONER FILTER HOUSING AWAY TO ACCESS THE XEROGRAPHIC CARD CAGE.

4.

OPEN THE XEROGRAPHIC CARD CAGE (Figure 1).

RIBBON CABLE P294

2

1

MOVE

LOOSEN

Figure 2 Disconnecting the HVAC PWB Connectors 6.

REMOVE THE HVAC PWB (Figure 3).

Figure 1 Opening the Xerographic Card Cage 5.

DISCONNECT THE HVAC PWB CONNECTORS (Figure 2).

Section Name

REP 1-9

0/0/00 ?-16

Preliminary Working Document No Product Name Assigned

REP 1-10 HVDC PWB Parts List on PL 1.7 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE PRINTER RIGHT REAR COVER.

3.

MOVE THE TONER FILTER HOUSING AWAY TO ACCESS THE XEROGRAPHIC CARD CAGE.

4.

OPEN THE XEROGRAPHIC CARD CAGE (Figure 1).

5.

DISCONNECT THE HVDC PWB CONNECTORS (Figure 1).

HVDC HVAC

P291

Figure 3 Removing the HVAC PWB from the Xerographic Card Cage

Replacement 1.

P293

WHEN INSTALLING A NEW PWB, REPLACE THE OLD CALIBRATION CARD IN THE MACHINE LOG BOOK WITH A CARD FROM THE NEW PWB.

RIBBON CABLE

NOTE: When installing the HVAC PWB, ensure that the PWB is in the upper and lower guides in the Card Cage.

P200 P203

NOTE: Ensure that at least one calibration card is attached to the HVAC PWB. 2.

INSTALL THE HVAC PWB.

3.

RECONNECT THE HVAC PWB CONNECTORS.

4.

CLOSE THE XEROGRAPHIC CARD CAGE.

5.

RECONNECT THE POWER.

6.

SWITCH ON THE PRINTER.

7.

WHEN INSTALLING A NEW HVAC PWB, PERFORM THE FOLLOWING: a.

Enter dC314.

b.

Using the values from the new calibration card, reset the NVM values in dC314.

Preliminary Working Document No Product Name Assigned

Figure 1 Disconnecting the HVAC and the HVDC PWB Connectors

WARNING Do not touch any components or soldered connections on the high voltage area of the HVDC PWB. It is possible to receive an electrical shock if the area shown is touched (Figure 2). 6.

0/0/00 ?-17

REMOVE THE HVDC PWB (Figure 3).

Section Name

REP 1-9, REP 1-10

WARNING DO NOT TOUCH THE PWB IN THIS AREA

HVDC HVAC

Figure 2 Shock Area on the HVDC PWB

Figure 3 Removing the HVAC or HVDC PWB

Replacement 1.

WHEN INSTALLING A NEW PWB, REPLACE THE OLD CALIBRATION CARD IN THE MACHINE LOG BOOK WITH A CARD FROM THE NEW HVDC PWB.

NOTE: When installing the HVDC PWB, ensure that the PWB is in the upper and lower guides in the Card Cage. NOTE: Ensure that at least one calibration card remains attached to the HVDC PWB. 2.

INSTALL THE HVDC PWB.

NOTE: Ensure that the HVDC PWB is fully seated in the HVDC Cable connector. 3.

CLOSE THE XEROGRAPHIC CARD CAGE.

5.

RECONNECT THE PRINTER POWER.

6.

SWITCH ON THE PRINTER.

7.

Section Name

REP 1-10

RECONNECT THE HVDC PWB CONNECTORS.

4.

0/0/00 ?-18

WHEN INSTALLING A NEW HVDC PWB, PERFORM THE FOLLOWING: a.

Enter dC314.

b.

Using the values from the new calibration card, reset the NVM values in dC314.

Preliminary Working Document No Product Name Assigned

REP 1-11 MIB PWB

REP 1-12 SLB/RDR PWB AND ROS LVPS PWB

Parts List on PL 1.8 Removal

Parts List on PL 1.11 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT SIDE COVER.

To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Components and Functions section.

3.

OPEN THE ELECTRICAL MODULE PWB PANEL.

4.

DISCONNECT ALL MIB PWB CONNECTORS.

5.

REMOVE THE MIB PWB.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

ACCESS THE PRINTER CARD CAGE (

Replacement CAUTION

3.

Ensure that the Printer Power Cords are disconnected. Reconnecting the PWB connectors with power applied can damage the MIB PWB. 1.

INSTALL THE MIB PWB. RECONNECT THE PWB CONNECTORS.

2.

RESTORE ALL PRINTER POWER.

a.

Open the EM Front Door.

b.

Remove the EM Top Cover.

OPEN THE CARD CAGE (Figure 1).

3 REMOVE THE PWB ACCESS PANEL

1 DISCONNECT THE CARD CAGE CONNECTOR (P284)

2 REMOVE THE SCREWS (3)

Figure 1 Opening the Card Cage 4.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-19

REMOVE THE APPROPRIATE PWB (Figure 2).

Section Name

REP 1-11, REP 1-12

ROS LVPS PWB PIXEL PWB

SLB/RDR PWB EDN PWB

Figure 2 Removing the Appropriate PWB

Section Name

REP 1-12

0/0/00 ?-20

Preliminary Working Document No Product Name Assigned

REP 1-13 EDN PWB 3

Parts List on PL 1.11 Removal

REMOVE THE PWB ACCESS PANEL

To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Components and Functions section. 1.

1 DISCONNECT THE CARD CAGE CONNECTOR (P284)

Perform the following steps to backup the machine setup parameters. Do not use the floppy disk that was stored in the system and previously used to store the save setup parameters. a.

Enter service mode.

b.

Enter dC101.

c.

Perform clean disk drive.

d.

Format a new floppy disk via the floppy disk format routine.

e.

Save the machine setup parameters via the save setup parameters routine to the floppy disk that was formatted in step d.

2 REMOVE THE SCREWS (3)

NOTE: Record the meter A value: f.

Select the dC file cabinet icon.

g.

Enter dC103.

h.

Record the Meter A value for future reference in this procedure.

i.

Select the SCP file cabinet icon.

NOTE: During the time the message (Please Wait NVM Upload is in progress. Do not power off system until completed) is being displayed an image of the current NVM values resident on the EDN PWB is being stored on the IOT Disk Drive. These values are needed so they can be downloaded from the IOT Printer Disk Drive to the replacement EDN PWB later in the procedure. j.

Select the service mode exit icon and wait until the message (Please Wait NVM Upload is in Progress. Do not Power off System until Completed) clears.

Figure 1 Opening the Card Cage 5.

REMOVE THE EDN PWB (Figure 2).

CAUTION Electrostatic Discharge precautions must be followed for these procedures. 2. 3.

4.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. ACCESS THE PRINTER CARD CAGE. a.

Open the EM Front Door.

b.

Remove the EM Top Cover.

OPEN THE CARD CAGE (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-21

Section Name

REP 1-13

ROS LVPS PWB PIXEL PWB

SLB/RDR PWB EDN PWB

Figure 2 Removing the EDN PWB

Replacement 1.

CLEAR NVM VALUES ON REPLACEMENT EDN PWB. a.

Using a set of Easy Hook jumpers and a Meter Probe, short the Negative (-) battery terminal to the solder pad on the right side of the surface-mount resistor R46 for at least 25 seconds. Refer to Figure 3.

Figure 3 Clearing NVM on EDN PWB 2. Section Name

REP 1-13

0/0/00 ?-22

INSTALL THE EDN PWB. Preliminary Working Document No Product Name Assigned

NOTE: Watch UIM display while Printer boots. Ensure a 03-361 fault is briefly (2 sec) displayed on UIM before being automatically reset. This verifies NVM was properly cleared on replacement EDN PWB. If fault display was missed, select SCP [Initial] screen and press [Update Data]. Review [Last 50] shutdowns screen to ensure the 03-361 fault is logged. 3.

c.

8.

RESTORE THE PRINTER POWER. CAUTION

If service mode is entered to isolate and correct the Systems Communications Failure do not exit diagnostics until steps 5b and 5c are performed. Exiting diagnostics without initializing the EDN PWB via dC323 will result in permanent loss of Billing Meter Values, Machine Setup Data, HFSI, dC107 counter values and other backup data stored on the IOT Disk Drive. 4.

9.

UPDATE THE PROCESSOR SERIAL NUMBER. a.

Enter dC105.

b.

Select [Processor Serial Number].

c.

Enter the correct Processor Serial Number.

RESTORE THE [SAVE SETUP PARAMETERS]. a.

Select the dC File Cabinet icon.

b.

Enter dC101.

c.

If the Save Setup Parameters were successfully stored on a floppy disk at beginning of procedure continue with step 9d if not go to step 9i.

d.

Insert the floppy disk, made at beginning of procedure with the saved setup parameters into the Floppy Disk Drive.

Next step: Continue with step 7.

e.

Select [Restore Setups-Source Floppy].

Message: Not ready - No message or any other messages posted.

f.

Select [Confirm].

Next Step: Continue with step 5.

g.

Press Continue. The system will automatically go into slumber mode and exit dC101 displaying a Not Ready Please Wait System communications Failure as part of the Restore Setups process. If an 03-471 is displayed, press R (reset) button on the IOT Printer control panel. After approximately two minutes all shadows reappear on the diagnostic main menu file folders and stackers are initialized. Remove the floppy disk. If Restore Setups-Source Floppy is successful continue with step 10. If unsuccessful go to Step 9h.

h.

Get the backup floppy disk stored in the machine containing the Save Setup Parameters from a previous call and continue with step 9i.

i.

Insert the backup floppy disk stored in the machine with the saved Setup Parameters into the Floppy Disk Drive.

j.

Select [Restore Setups-Source Floppy].

PERFORM THE EDN INSTALLATION PROCEDURE AS SHOWN IN THE MESSAGE ON THE UI. Message: Not ready- Systems Communications Failure. Next step: Repair the Systems Communications Failure and continue with step 5. Message: Not ready - 03-362 EDN NVM NOT Initialized.

Message: Ready - No message or any other messages posted. 5.

INITIALIZE THE REPLACEMENT EDN PWB. CAUTION Do not exit service mode until steps 5b and 5c are performed. Exiting diagnostics without initializing the EDN PWB via dC323 will result in permanent loss of Billing Meter Values, Machine Setup Data, HFSI, dC107 Counter Values and other backup data stored on the IOT Disk Drive.

6.

7.

Select [03-362 NVM Reset]. This NVM Reset Button only appears in dC131 when an 03-362 fault is declared. The system will go into slumber mode and return to the diagnostic main menu screen. Wait until all shadows reappear on the diagnostic main menu folders before going to next step.

a.

Enter the service mode at the IOT Printer UI.

b.

Enter dC323.

c.

Select Initialize. The system will automatically go into slumber mode and exit dC323 displaying a Not Ready Please Wait System Communications Failure as part of the EDN PWB initialization process. Wait about two minutes until all shadows reappear on the diagnostic main menu file folders and the stackers are initialized.

CHECK TO VERIFY THAT THE NVM IMAGE WAS TRANSFERRED FROM THE IOT PRINTER DISK DRIVE TO THE REPLACEMENT NVM PWB. a.

Enter dC103.

b.

Verify the Meter A value recorded at beginning of procedure is equal to present Meter A value. If the values are not equal any meter change information will need to be reported to the customer and appropriate organizations.

c.

Select the SCP File Cabinet icon.

d.

Select the Update Data to update all SCP data. After the shadows on the SCP screen reappear continue with the next step.

e.

If any problems occurred during the EDN Initialization process (step 5) go to step 8. Otherwise continue to step 10.

k.

Select [Confirm].

l.

Press Continue. The system will automatically go into slumber mode and exit dC101 displaying a Not Ready Please Wait system communications failure as part of the restore setups process. If an 03-471 is displayed press the (R) reset button on the IOT Printer Control Panel. After approximately two minutes all shadows reappear on the diagnostic main menu file folders and stackers are initialized. Remove the floppy disk.

10. THE EDN PWB REPLACEMENT PROCESS IS COMPLETE. VERIFY MACHINE OPERATION AND REPORT ANY METER CHANGE INFORMATION TO THE APPROPRIATE PERSONNEL.

AT THE IOT PRINTER UI ONLY IF AN 03-362 FAULT IS SHOWN. a.

Enter service mode.

b.

Enter dC131.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-23

Section Name

REP 1-13

REP 1-14 Printer Card Cage Assembly

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 1.11 Removal

2.

ACCESS THE PRINTER CARD CAGE ASSEMBLY (Figure 1).

To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Components and Functions section.

1 OPEN THE EM FRONT DOOR

5 REMOVE THE EM TOP COVER

4 REMOVE THE PRINTER LEFT REAR COVER

2 REMOVE THE EM INNER PANEL

3 REMOVE THE EM LEFT COVER

Figure 1 Accessing the Printer Card Cage 3.

DISCONNECT THE CARD CAGE ELECTRICAL CONNECTORS (Figure 2).

Section Name

REP 1-14

0/0/00 ?-24

Preliminary Working Document No Product Name Assigned

P284

P2113/J111 J103/J104 VIDEO CABLES (2) P2112/J112 P/J101 PRINTE INTERFACE CABLE

P213J113

P2116/J114 P2102/J102

J105 SHARED LINE (MIN CORE)

J108 SHARED LINE (MIN DIO) Figure 2 Printer Card Cage Electrical Connectors

4.

PREPARE THE REAR OF THE CARD CAGE FOR REMOVAL (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-25

Section Name

REP 1-14

2 DISCONNET THE WIRES (4)

1 DISCONNET THE FAN CONNECTOR (P282)

1 REMOVE THE SCREWS (3)

3 LOOSEN (2)

Figure 3 Preparing the rear of the Card Cage for Removal 5.

REMOVE THE CARD CAGE FRONT MOUNTING SCREWS (Figure 4).

Section Name

REP 1-14

Figure 4 Removing the Card Cage Front Mounting Screws 6.

0/0/00 ?-26

REMOVE THE CARD CAGE ASSEMBLY (Figure 5).

Preliminary Working Document No Product Name Assigned

1 LIFT

3 REMOVE

2 ROTATE

Figure 5 Removing the Printer Card Cage Assembly

Replacement 1.

REINSTALL THE CARD CAGE ASSEMBLY.

2.

RECONNECT THE CARD CAGE DC POWER WIRES (Figure 6).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-27

Section Name

REP 1-14

P120 P115

Figure 6 Reconnecting the Card Cage DC Power Connectors (Shown with the Fan Assembly removed)

Section Name

REP 1-14

0/0/00 ?-28

Preliminary Working Document No Product Name Assigned

REP 1-16 Low Voltage Power Supply

1.

SWITCH OFF THE PRINTER POWER.

Parts List on PL 1.9 Removal

2.

REMOVE THE PRINTER RIGHT REAR COVER.

3.

OPEN THE PRINTER PWB PANEL.

4.

LOWER THE AC DISTRIBUTION PANEL.

5.

DISCONNECT THE CONNECTORS AT THE LOW VOLTAGE POWER SUPPLY (Figure 1).

To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Components and Functions section.

P/J395 P/J503/503A/ IN LINE PIGTAIL

J681/P430

P/J251

P/J505A GROUND WIRE(S) SCREW P/J298

P4222/J58/J481 P315

P354

Figure 1 Disconnecting the Low Voltage Power Supply CAUTION When removing the Low Voltage Power Supply, ensure that the Mechanical Copy Meter is not damaged. 6.

REMOVE THE LOW VOLTAGE POWER SUPPLY (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-29

Section Name

REP 1-16

2 SLIDE THE POWER SUPPLY OUT OF THE PRINTER

1 REMOVE THE POWER SUPPLY MOUNTING SCREWS (2)

Figure 2 Removing the Low Voltage Power Supply

Replacement

REP 1-17 Low Voltage Power Supply PWBs

1.

SLIDE THE LOW VOLTAGE POWER SUPPLY INTO THE MACHINE.

2.

ENSURE THAT THE ALIGNMENT PIN, LOCATED ON THE FRONT OF THE BOTTOM BRACKET, SEATS PROPERLY INTO THE FRONT OF THE SUPPLY.

Parts List on PL 1.10 Removal

3.

RECONNECT THE POWER SUPPLY CONNECTORS.

To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Components and Functions section. 1.

Section Name

REP 1-16

REMOVE ALL SYSTEM POWER.

2.

REMOVE THE LOW VOLTAGE POWER SUPPLY (REP 1-16).

3.

REMOVE THE LOW VOLTAGE POWER SUPPLY RIGHT SIDE COVER (Figure 1).

0/0/00 ?-30

Preliminary Working Document No Product Name Assigned

1 REMOVE THE MOUNTING SCREWS (7) FOR THE RIGHT SIDE ACCESS PANEL

2 REMOVE THE ACCESS PANEL

Figure 1 Removing the Right Side Access Panel for the Low Voltage Power Supply 4.

REMOVE THE REQUIRED PWB (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-31

Section Name

REP 1-17

PULL THE PWB RETRACTING LEVERS (2) SIMULTANEOUSLY AND REMOVE THE PWB (TYPICAL)

Figure 2 Removing a Low Voltage Power Supply PWB (typical)

Section Name

REP 1-17

0/0/00 ?-32

Preliminary Working Document No Product Name Assigned

REP 1-18 Low Voltage Power Supply Cooling Fans

Parts List on PL 1.10 Removal 1.

REMOVE ALL SYSTEM POWER.

2.

ACCESS THE LOW VOLTAGE POWER SUPPLY FANS (Figure 1).

1 OPEN THE PRINTER RIGHT FRONT DOOR

2 REMOVE THE PRINTER TRANSPORT INNER PANEL

Figure 1 Accessing the Front of the Low Voltage Power Supply NOTE: Only one Cooling Fan is shown in the procedure illustrations. This procedure is used for removing each Cooling Fan. 3.

REMOVE THE AIR FILTER (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-33

Section Name

REP 1-18

PULL THE FILTER AWAY FROM THE FAN

Figure 2 Removing a Low Voltage Power Supply Air Filter (typical) 4.

REMOVE THE LOW VOLTAGE POWER SUPPLY COOLING FAN (Figure 3).

Section Name

REP 1-18

0/0/00 ?-34

Preliminary Working Document No Product Name Assigned

1

4

REMOVE THE FAN MOUNTING SCREWS (4)

REMOVE THE FAN

3 DISCONNECT THE FAN POWER CONNECTOR

2 REMOVE THE FILTER HOUSING

Figure 3 Removing a Low Voltage Power Supply Cooling Fan (typical)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-35

Section Name

REP 1-18

REP 1-19 Low Voltage Power Supply Relays (K103/K104)

2.

REMOVE THE PRINTER RIGHT REAR COVER.

Parts List on PL 1.10 Removal

3.

DISCONNECT P/J395, P/J503, P4221/P430, P4222/J431, AND P354 FROM THE LOW VOLTAGE POWER SUPPLY (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

P/J395 P/J503/503A/ IN LINE PIGTAIL

J681/P430

P/J251

P/J505A GROUND WIRE(S) SCREW P/J298

P4222/J58/J481 P315

P354

Figure 1 Disconnecting the Low Voltage Power Supply 4.

REMOVE THE REAR ACCESS COVER FOR THE LVPS (Figure 2).

Section Name

REP 1-19

0/0/00 ?-36

Preliminary Working Document No Product Name Assigned

1 REMOVE THE MOUNTING SCREWS (3) FOR THE REAR ACCESS PANEL

2 ROTATE TO REMOVE THE ACCESS PANEL

Figure 2 Removing the Rear Access Panel for the Low Voltage Power Supply 5.

REMOVE THE REQUIRED RELAY.

REP 1-21 C-Pixel PWB Parts List on PL 1.11 Removal To see additional information go to Printer Card Cage in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

ACCESS THE PRINTER CARD CAGE. a.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-37

Open the EM Front Door. Section Name

REP 1-19

b. 3.

Remove the EM Top Cover.

OPEN THE CARD CAGE (Figure 1).

3 REMOVE THE PWB ACCESS PANEL

1 DISCONNECT THE CARD CAGE CONNECTOR (P284)

2 REMOVE THE SCREWS (3)

Figure 1 Opening the Card Cage 4.

REMOVE THE APPROPRIATE PWB (Figure 2).

Section Name

REP 1-21

0/0/00 ?-38

Preliminary Working Document No Product Name Assigned

ROS LVPS PWB C-PIXEL PWB

SLB/RDR PWB EDN PWB

Figure 2 Removing the C-Pixel PWB

Replacement 1.

INSTALL THE C-PIXEL PWB.

2.

RESTORE THE PRINTER POWER.

3.

CHECK/ADJUST THE TOP-TO-BOTTOM REGISTRATION (ADJ 8-2)

4.

CHECK/ADJUST ROS MAGNIFICATION SETUP (ADJ 6-1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-39

Section Name

REP 1-21

Section Name

REP 1-21

0/0/00 ?-40

Preliminary Working Document No Product Name Assigned

REP 2-1 CP IOP PWB

REP 2-2 Control Panel PWB

Parts List on PL 2.1 Removal

Parts List on PL 2.2 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI REAR HOUSING COVER.

2.

REMOVE THE UI REAR HOUSING COVER.

3.

DISCONNECT ALL CP IOP PWB CONNECTORS.

4.

REMOVE THE CP IOP PWB.

CAUTION Place the UI Front Cover Assembly on a flat surface before removing the Control Panel PWB to ensure that the Keyboard Buttons are not disturbed. 3.

REMOVE THE UI FRONT COVER ASSEMBLY (REP 2-7).

4.

REMOVE THE CONTROL PANEL PWB (Figure 1).

1 PLACE THE FRONT COVER ON FLAT SURFACE

2 REMOVE HEX SCREWS (5)

3 REMOVE THE CONTROL PANEL PWB

Figure 1 Removing the Control Panel PWB

Preliminary Working Document No Product Name Assigned

0/0/00 ?-41

Section Name

REP 2-1, REP 2-2

REP 2-3 Floppy Disk Drive Assembly

2.

REMOVE THE UI BASE REAR COVER.

Parts List on PL 2.3 Removal

3.

REMOVE THE UI CARD CAGE COVER.

1.

CAUTION Do not scrape the UIM Core PWB when removing the Disc Drive.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE UI FLOPPY DISC DRIVE ASSEMBLY (Figure 1).

1 REMOVE (1)

2 SLIDE ASSEMBLY OUT

4

3

CAUTION REMOVE

DISCONNECT

Figure 1 Removing the Floppy Disc Drive Assembly 5.

REMOVE THE BASE PLATE FROM THE FLOPPY DISC DRIVE ASSEMBLY.

Replacement 1.

INSTALL THE BASE PLATE ON THE FLOPPY DISC DRIVE ASSEMBLY.

2.

CONNECT THE RIBBON AND HARNESS CABLES TO THE FLOPPY DISC DRIVE.

3.

REPLACE THE FLOPPY DISC ASSEMBLY.

REP 2-4 UIM Core PWB Parts List on PL 2.2 Removal 1.

ENTER dC101.

2.

INSERT A NEW FLOPPY DISK INTO THE FLOPPY DISK DRIVE.

NOTE: Do not use a disk that has been previously used for the SAVE SET-UP PARAMETERS. NOTE: If you are unable to perform this step, the previously SAVED SET-UP PARAMETERS should be used when installing the new board. 3.

Section Name

REP 2-3

0/0/00 ?-42

SELECT [Floppy Disk Format], [Confirm], AND PRESS the Continue BUTTON.

Preliminary Working Document No Product Name Assigned

REP 2-5 Video Engine PWB

4.

AFTER FORMATTING IS COMPLETE SELECT [Save Setup Parameters], [Confirm], AND PRESS the Continue BUTTON.

5.

AFTER ALL FILES HAVE BEEN COPIED, REMOVE THE FLOPPY DISK FROM THE FLOPPY DISK DRIVE. LABEL IT AS THE MOST RECENT SAVED SET-UP PARAMETERS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

6.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI BASE REAR COVER.

7.

REMOVE THE UI BASE REAR COVER.

3.

REMOVE THE UI CARD CAGE COVER.

8.

REMOVE THE UI CARD CAGE COVER.

4.

DISCONNECT ALL VIDEO ENGINE PWB CONNECTORS.

9.

DISCONNECT ALL UIM CORE PWB CONNECTORS.

5.

DISCONNECT THE UIM CORE PWB CONNECTORS AS REQUIRED.

6.

REMOVE THE VIDEO ENGINE PWB.

10. REMOVE THE UIM CORE PWB.

Parts List on PL 2.2 Removal

Replacement 1.

INSTALL THE UIM CORE PWB.

NOTE: Check the Termination Jumper, J5, on the UIM Core PWB to determine if it is properly connected. The jumper should be on pin 1 (NORM) and pin 2. 2.

CONNECT ALL UIM CORE PWB CONNECTORS.

3.

SWITCH ON THE PRINTER.

4.

ENTER dC323, [Initialize].

5.

PRESS the Continue BUTTON.

6.

WHEN dC323---00 IS DISPLAYED ON THE DIGITAL DISPLAY, REMOVE THE DIAGNOSTIC UTILITY DISK FROM THE FLOPPY DISK DRIVE.

7.

PRESS the Stop BUTTON TWICE TO REBOOT THE MACHINE.

8.

IF A 03-362 FAULT CODE IS DISPLAYED, PERFORM THE FOLLOWING: a.

Enter dC131.

b.

Select [03-362 RESET].

c.

Enter dC105 [Serial number and Service Phone].

d.

Select [Printer Serial Number].

e.

Enter the eleven digit machine serial number, and press [Enter].

f.

Enter dC101.

g.

Insert the floppy diskette into the Floppy Disk Drive that was used to store the latest save setup parameters.

h.

Select [Restore Setups-Source] [Floppy], [Confirm], and press the Continue button.

i.

When the message "All files have been copied. Remove the floppy disk from the floppy drive." appears on the Video Display, remove the floppy diskette from the Floppy Disk Drive.

j.

Switch off the Printer Circuit Breakers.

k.

Switch on the Printer.

NOTE: All current Top 15 fault screens, all the current HFSI counters, all the current counters in dC107, all counters on the SCP Entry screen, the Billing counters, and the current session information for the Auditron account are reset to zero. The Auditron mode is also reset to the off mode. This information resides in NVM and is therefore invalid when 03-0362 faults are declared. 9.

INSTALL THE UI CARD CAGE COVER.

10. INSTALL THE UI BASE REAR COVER. Preliminary Working Document No Product Name Assigned

0/0/00 ?-43

Section Name

REP 2-5, REP 2-6

REP 2-6 Local/Remote Power Switch (S102)

2.

REMOVE THE UI BASE REAR COVER.

Parts List on PL 2.4 Removal

3.

REMOVE THE UI CARD CAGE COVER.

1.

4.

OPEN THE UI BASE FRONT COVER.

5.

REMOVE THE LOCAL/REMOTE POWER SWITCH (Figure 1).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3 PUSH TOWARDS THE FRONT OF THE COVER

1 REMOVE SCREWS (2)

2 DISCONNECT THE GROUND STRAP

Figure 1 Removing the Local/Remote Power Switch

Replacement

REP 2-7 UI Front Cover Assembly

NOTE: Ensure that the switch is installed with pins 1 and 4 up.

Parts List on PL 2.2 Removal

1.

REPLACE THE LOCAL/REMOTE POWER SWITCH.

Section Name

REP 2-7

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI REAR HOUSING COVER.

3.

REMOVE THE UI FRONT COVER ASSEMBLY (Figure 1).

0/0/00 ?-44

Preliminary Working Document No Product Name Assigned

2 REMOVE

3 DISCONNECT AND SLIDE THE RIBBON CABLE OUT

1 LOOSEN SCREWS (2 EACH SIDE)

Figure 1 Removing the UI Front Cover Assembly

REP 2-8 UI Touch Screen Assembly Parts List on PL 2.2 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI FRONT COVER ASSEMBLY (REP 2-7).

3.

REMOVE THE UI TOUCH SCREEN ASSEMBLY (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-45

Section Name

REP 2-8

REP 2-9 UI Video Display Assembly Parts List on PL 2.1 Removal

1

2

LOOSEN SCREWS (2)

REMOVE SPRINGS (2) TOP AND (2) BOTTOM

CAUTION Ensure that the power has been disconnected for a minimum of 120 seconds before removing the Printer UI housing cover. Residual voltage is a shock hazard and could damage the electrical components. 1.

REMOVE ALL SYSTEM POWER.

WARNING Do not touch the CRT high voltage anode. Residual voltage will remain on the CRT high voltage anode after power is disconnected. Residual voltage is a shock hazard. 2.

REMOVE THE UI HOUSING COVER.

3.

REMOVE THE UI FRONT COVER ASSEMBLY (REP 2-7).

4.

REMOVE THE UI TOUCH SCREEN ASSEMBLY (REP 2-8).

5.

PREPARE TO REMOVE THE VIDEO DISPLAY ASSEMBLY (Figure 1).

3 MOVE AWAY

5

4

REMOVE

DISCONNECT

Figure 1 Removing the Touch Screen Assembly

Section Name

REP 2-9

0/0/00 ?-46

Preliminary Working Document No Product Name Assigned

1 DISCONNECT THE VIDEO CABLES (4)

2

5

DISCONNECT

DISCONNECT THE POTENTIOMETER HARNESS

3

4

DISCONNECT (4)

REMOVE CP IOP PWB

Figure 1 Preparing to remove the Video Display Assembly 6.

REMOVE THE VIDEO DISPLAY ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-47

Section Name

REP 2-9

REP 2-10 UI AC EMI Filter (FL105) Parts List on PL 2.3 Removal

2

1

REMOVE THE VIDEO DISPLAY

REMOVE CHASSIS SCREWS (4)

1.

REMOVE ALL SYSTEM POWER.

2.

REMOVE THE UI BASE REAR COVER.

3.

REMOVE THE UI CARD CAGE COVER.

4.

REMOVE THE UIM CORE PWB (REP 2-4).

5.

REMOVE THE VIDEO ENGINE PWB (REP 2-5).

6.

REMOVE THE AC EMI FILTER.

Figure 2 Removing the Video Display Assembly

Replacement NOTE: When reinstalling the Potentiometer Harness, ensure that Pin 1 on the Harness aligns with Pin 1 on the Potentiometer.

Section Name

REP 2-9, REP 2-10

0/0/00 ?-48

Preliminary Working Document No Product Name Assigned

REP 2-11 UI DC EMI Filter (FL106)

REP 2-12 Rigid Disk Drive/SMSD Assembly

Parts List on PL 2.3 Removal

Parts List on PL 2.3 Removal

1.

REMOVE ALL SYSTEM POWER.

1.

2.

REMOVE THE UI BASE REAR COVER.

3.

REMOVE THE UI CARD CAGE COVER.

NOTE: Be prepared to insert the Diagnostic Diskette into the Floppy Disk Drive during the time the 8s are displayed on the Digital Display.

4.

REMOVE THE UIM CORE PWB (REP 2-4).

5.

REMOVE THE VIDEO ENGINE PWB (REP 2-5).

6.

REMOVE THE DC EMI FILTER.

SWITCH OFF THE PRINTER POWER SWITCH AND WAIT 15 SECONDS.

NOTE: The Magenta Diagnostic Diskette (701P16850) MUST be used with the SMSD. Previous versions of the Diagnostic Diskette cannot be used. NOTE: The current Burgundy Diagnostic Disk supersedes the Orange Diagnostic Disk and supports all Rigid Disk drives 540 MB and above. 2.

SWITCH ON THE PRINTER POWER SWITCH. INSERT THE DIAGNOSTIC DISKETTE INTO THE FLOPPY DISK DRIVE DURING THE TIME THE 8s ARE DISPLAYED ON THE DIGITAL DISPLAY.

3.

PERFORM dC 325 SAVE CRITICAL DISK FILES. a. b.

Press the [F5] button to scroll to dC325. When dC325 is displayed on the Digital Display, press the Continue button. If the new Diagnostic Disk is being used: i.

When the digital Display reads San1 Edn2, Press 2 on the keyboard.

ii.

When the digital Display reads Edn, Press the Continue button.

c.

When InS FLOPPy is displayed on the Digital Display, remove the Diagnostic Diskette, and insert a formatted floppy diskette.

d.

Press the Continue button.

NOTE: When the program is complete, dC325---00, will be displayed on the Digital Display. If an error occurs refer to dC 325, Save Critical Disk Files in the Service Manual. 4.

REMOVE THE FLOPPY DISKETTE.

5.

SWITCH OFF THE PRINTER AND THE PRINTER CIRCUIT BREAKERS.

6.

REMOVE THE UI BASE REAR COVER.

7.

REMOVE THE UI CARD CAGE COVER.

8.

REMOVE THE UIM CORE PWB (REP 2-4).

9.

REMOVE THE VIDEO ENGINE PWB (REP 2-5). CAUTION

The Rigid Disk Drive/SMSD Assembly is extremely delicate. If the assembly is dropped from a distance of 1 inch (25.4 mm) or more, possible damage could occur. 10. REMOVE THE RIGID DISK DRIVE/SMSD ASSEMBLY (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-49

Section Name

REP 2-11, REP 2-12

3 SLIDE THE DRIVE TOWARDS REAR OF CARD CAGE TO REMOVE

2

1

LOOSEN THE NUTS (2)

DISCONNECT THE CABLES (2)

Figure 1 Removing the Rigid Disk Drive/SMSD Assembly CAUTION Do not handle the PWB on the Rigid Disk Drive/SMSD in the removal procedure. 11. REMOVE THE BOTTOM PLATE FROM THE RIGID DISK DRIVE/SMSD ASSEMBLY BY UNDOING THE 4 SCREWS.

Replacement NOTE: No jumper is used on the SMSD drive. 1.

CHECK THE POSITION OF THE JUMPER ON THE RIGID DISK DRIVE ASSEMBLY (Figure 2).

Section Name

REP 2-12

0/0/00 ?-50

Preliminary Working Document No Product Name Assigned

THE JUMPER IS POSITIONED AS SHOWN

Figure 2 The Correct Position of the Rigid Disk Drive Jumper (2.1 GB) 2.

IF PROVIDED RECORD THE INFORMATION ON THE BAD BLOCK TABLE LABEL THAT APPEARS ON THE TOP OF THE RIGID DISK DRIVE ASSEMBLY.

3.

MOUNT THE BOTTOM PLATE WITH 4 SCREWS TO THE RIGID DISK DRIVE/SMSD ASSEMBLY.

4.

INSTALL THE RIGID DISK DRIVE/SMSD ASSEMBLY.

5.

CONNECT THE RIBBON CABLE AND POWER CONNECTOR (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-51

Section Name

REP 2-12

RIBBON CABLE

POWER CONNECTOR

PIN 1

1 ENSURE THAT THE SIDE OF THE CABLE WITH THE RED STRIPE GOES TO PIN 1 OF THE CONNECTOR

Figure 3 Connecting the Ribbon Cable 6.

REINSTALL THE VIDEO ENGINE PWB, AND UIM CORE PWB.

7.

PERFORM dC 322 RIGID DISK FORMATTER.

NOTE: If dEFAULt bb is not displayed, refer to dC 322, Rigid Disk Formatter (Floppy Disk Routine).

a.

Switch on the printer.

b.

Insert the Diagnostic Diskette into the Floppy Disk Drive during the time the 8s are displayed on the Digital Display.

c.

When dC322 is displayed on the Digital Display, press the Continue button.

d.

NOTE: The Digital Display will cycle down to 000 and then cycle back up again before the program is complete. e. 8.

Section Name

REP 2-12

When dEFAULt bb is displayed, press the Continue button.

0/0/00 ?-52

When dC322---00 is displayed, press the Stop button.

REMOVE THE DIAGNOSTIC DISKETTE FROM THE FLOPPY DISK DRIVE.

Preliminary Working Document No Product Name Assigned

9.

PERFORM AN ENTIRE SOFTWARE UPGRADE. a.

Press the Stop button.

b.

Insert Software Upgrade Diskette number one into the Floppy Disk Drive during the time the 8s are being displayed on the Digital Display. When Full upgrade appears press continue.

c. d.

e.

When a flashing d followed by 02 is displayed on the Digital Display, remove the Software Upgrade Diskette number one from the Floppy Disk Drive. Insert the remaining Software Upgrade Diskettes into the Floppy Disk Drive in the order they are displayed on the Digital Display. The number that follows the flashing d will indicate the next Software Upgrade Diskette to be inserted. When the Digital Display indicates that the software upgrade is complete, Remove the last Software Upgrade Diskette. (The revision level is displayed on the digital display i.e. 70.xx).

10. PRESS the Continue BUTTON. INSERT THE DIAGNOSTIC DISKETTE INTO THE FLOPPY DISK DRIVE DURING THE TIME THE 8s ARE BEING DISPLAYED ON THE DIGITAL DISPLAY. 11. PERFORM dC 326, RESTORE CRITICAL DISK FILES: a.

Press the F5 button to scroll to dC326.

b.

When dC326 is displayed on the Digital Display, press the Continue button.

c.

When InS FLOPPy is displayed, remove the Diagnostic Diskette and insert the floppy diskettes used in Step 3 of the removal procedure into the Floppy Disk Drive.

d.

Press the Continue button.

NOTE: When the program is complete, dC326---00 will be displayed on the Digital display. If an error occurs, refer to dC 326, Restore Critical Disk Files. 12. PRESS the Stop BUTTON. REMOVE THE FLOPPY DISKETTE FROM THE FLOPPY DISK DRIVE. 13. SWITCH OFF THE PRINTER POWER SWITCH AND WAIT 15 SECONDS. 14. SWITCH ON THE PRINTER POWER SWITCH.

REP 2-13 UI Keyboard Buttons Parts List on PL 2.2 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI REAR HOUSING COVER.

3.

REMOVE THE UI FRONT COVER ASSEMBLY (REP 2-7). CAUTION

If the new Diagnostic Disk is being used:

Place the Front Cover Assembly on a flat surface to ensure that the Keyboard Buttons are not disturbed. The Keyboard Buttons are held in place by the Control Panel PWB.

When the digital Display reads San1 Edn2, Press 2 on the keyboard.

4.

REMOVE THE CONTROL PANEL PWB (Figure 1).

When the digital Display reads Edn, Press the Continue button.

5.

REMOVE THE UI KEYBOARD BUTTONS.

Figure 1 The Positions of the Keyboard Buttons

Preliminary Working Document No Product Name Assigned

0/0/00 ?-53

Section Name

REP 2-12

REP 2-14 UI Brightness/Contrast Controls Parts List on PL 2.1 Removal 1.

2 ADJUST

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI REAR HOUSING COVER.

3.

REMOVE THE UI FRONT COVER ASSEMBLY (REP 2-7).

4.

DISCONNECT THE WIRES THAT ARE CONNECTED TO THE CONTROL TERMINALS.

5.

REMOVE THE BRIGHTNESS/CONTRAST CONTROL ASSEMBLY (Figure 1).

1 ENSURE ADEQUATE CLEARANCE

2 REMOVE SPRING

3 TIGHTEN

1 REMOVE NUTS (2)

Figure 2 Adjusting the Brightness/Contrast Control Assembly

3 2.

REMOVE

CONNECT THE WIRES TO THE BRIGHTNESS/CONTRAST CONTROLS (Figure 3).

Figure 1 Removing the Brightness/Contrast Control Assembly

Replacement 1.

ADJUST THE POSITION OF THE BRIGHTNESS/CONTRAST CONTROL ASSEMBLY BRACKET TO ENSURE THAT THE UI FRONT COVER DOES NOT INTERFERE WITH THE CONTROL KNOBS (Figure 2).

Section Name

REP 2-14

0/0/00 ?-54

Preliminary Working Document No Product Name Assigned

REP 2-15 UI Swivel Wear Ring Parts List on PL 2.2 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UIM CORE PWB (REP 2-4).

3.

REMOVE THE VIDEO ENGINE PWB (REP 2-5).

4.

REMOVE THE VIDEO DISPLAY ASSEMBLY (REP 2-9).

5.

REMOVE THE UI TILT SHOE (REP 2-18).

6.

REMOVE THE UI TILT CAP (REP 2-17).

7.

REMOVE THE SWIVEL WEAR RING.

WIRE 1253

WIRE 1254

BLANK

WIRE 1250 WIRE 1251 WIRE 1252 Figure 3 Wiring of the Brightness/Contrast Control

Preliminary Working Document No Product Name Assigned

0/0/00 ?-55

Section Name

REP 2-14, REP 2-15

REP 2-16 UI Tilt Bar

REP 2-17 UI Tilt Cap

Parts List on PL 2.2 Removal

Parts List on PL 2.2 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UIM CORE PWB (REP 2-4).

2.

REMOVE THE UIM CORE PWB (REP 2-4).

3.

REMOVE THE VIDEO ENGINE PWB (REP 2-5).

3.

REMOVE THE VIDEO ENGINE PWB (REP 2-5).

4.

REMOVE THE VIDEO DISPLAY ASSEMBLY (REP 2-9).

4.

REMOVE THE UI VIDEO DISPLAY ASSEMBLY (REP 2-9).

5.

REMOVE THE SHOULDER BOLT.

5.

REMOVE THE UI TILT SHOE (REP 2-18).

6.

REMOVE THE UI TILT BAR.

6.

REMOVE THE UI TILT CAP.

Section Name

REP 2-16, REP 2-17

0/0/00 ?-56

Preliminary Working Document No Product Name Assigned

REP 2-18 UI Tilt Shoe Parts List on PL 2.2 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UIM CORE PWB (REP 2-4).

3.

REMOVE THE VIDEO ENGINE PWB (REP 2-5).

4.

REMOVE THE UI VIDEO DISPLAY ASSEMBLY (REP 2-9).

5.

REMOVE THE UI TILT BAR (REP 2-16).

6.

REMOVE THE UI TILT SHOE.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-57

Section Name

REP 2-18

Section Name

REP 2-18

0/0/00 ?-58

Preliminary Working Document No Product Name Assigned

REP 4-0 Printer Right Top Cover

Parts List on PL 4.5 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE RIGHT TOP COVER (Figure 1).

3 LOOSEN THE SCREWS (4), AND REMOVE THE COVER

2 1 DISCONNECT PINS (2), AND LOWER THE BAFFLES (2)

REMOVE THE SCREWS (4), AND THE SAMPLE TRAY

Figure 1 Removing the Right Top Cover

Replacement

REP 4-1 Printer Side Covers and Rear Covers

1.

INSTALL THE TOP COVER.

2.

ADJUST THE PRINTER RIGHT TOP COVER (ADJ 4-0).

Parts List on PL 4.7 PL 4.8 Removal 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-59

REMOVE THE SIDE AND REAR COVERS (Figure 1).

Section Name

REP 4-0

BRACKET

COVER COVER

1 USING A SCREWDRIVER, RELEASE THE QUARTERTURN LATCH

PIN

FRAME CHANNEL

2 REMOVE THE COVER

Figure 1 Removing the Side Covers and the Rear Covers

Replacement

REP 4-2 Printer Left Top Cover

1.

Parts List on PL 4.6 Removal

ADJUST THE PRINTER REAR COVERS (ADJ 4-2).

NOTE: Protect the Photoreceptor Belt from exposure to the light.

Section Name

REP 4-2

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE LEFT TOP COVER (Figure 1).

0/0/00 ?-60

Preliminary Working Document No Product Name Assigned

4 OPEN THE PRINTER RIGHT TOP COVER

5 REMOVE THE COVER

3 LOOSEN THE NUTS (2)

1 OPEN THE FRONT DOORS

LATCH BRACKET

2 REMOVE THE INNER PANEL

Figure 1 Removing the Printer Left Top Cover

REP 4-3 Electrical Module Top Cover Parts List on PL 4.2 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE ELECTRICAL MODULE TOP COVER (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-61

Section Name

REP 4-3

2 REMOVE THE ELECTRICAL MODULE TOP COVER

1 LOOSEN THE SCREW (1)

Figure 1 Removing the Electrical Module Top Cover

REP 4-20 Cleaner Drive Belt

NOTE: Do not completely remove the Prefuser Drive Belt.

Parts List on PL 4.16 Removal

7.

1.

LOOSEN THE PREFUSER DRIVE BELT (Figure 1).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer then protect the PR Belt. 2.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER.

3.

REMOVE THE PRINTER REAR COVERS (REP 4-1). CAUTION

To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor in a counterclockwise direction. 4.

REMOVE THE PHOTORECEPTOR DRIVE BELT (REP 4-32).

5.

REMOVE THE DECURLER INTERMEDIATE DRIVE BELT (REP 4-24).

6.

OPEN THE PHN PWB PANEL.

Section Name

REP 4-20

0/0/00 ?-62

Preliminary Working Document No Product Name Assigned

2 MOVE UP THE IDLER WHILE TIGHTENING THE BOLT

1 LOOSEN BOLT

Figure 1 Loosening the Prefuser Drive Belt NOTE: Remove the Cleaner Drive Belt by sliding the belt under the loosened Prefuser Drive Belt, and then sliding the belt off the Prefuser Drive Assembly. 8.

REMOVE THE CLEANER DRIVE BELT (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-63

Section Name

REP 4-20

1

2

LOOSEN BOLT

MOVE DOWN THE IDLER WHILE TIGHTENING THE BOLT

3 REMOVE THE BELT

Figure 2 Removing the Cleaner Drive Belt

Replacement

REP 4-21 Cleaner Drive Support

1.

ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).

2.

ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).

Parts List on PL 4.16 Removal

3.

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).

4.

INSTALL THE PHOTORECEPTOR DRIVE BELT (REP 4-32).

5.

CLOSE THE XEROGRAPHIC DRAWER.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE PRINTER LEFT REAR COVER.

3.

REMOVE THE UPPER WASTE TONER DUCT (REP 9-17). CAUTION

Ensure that the Locking Key is not lost when removing the Cleaner Support. 4.

Section Name

REP 4-20

0/0/00 ?-64

REMOVE THE CLEANER DRIVE SUPPORT (Figure 1).

Preliminary Working Document No Product Name Assigned

1

10

LOOSEN BOLT

CAUTION REMOVE THE LOCKING KEY

2 MOVE BRACKET

9 LOOSEN THE SETSCREW AND REMOVE THE SUPPORT

3 REMOVE BELT FROM IDLER PULLLEY

8 REMOVE NUTS (3)

7 NOTE: REMOVE THE PULLEY

4 ALLOW IDLER BRACKET TO MOVE

6 5 WARNING

LOOSEN THE SETSCREW

REMOVE THE CAP

Figure 1 Removing the Cleaner Drive Support

Replacement

WARNING

NOTE: Position the Locking Key on the flat of the shaft with the closed end inward and the open end flush with the bearing surface. Ensure that the setscrew in the support bearing is centered between the legs of the key before tightening. 1.

REINSTALL THE CLEANER SUPPORT.

Preliminary Working Document No Product Name Assigned

The Cleaner Drive Support Cap must be reinstalled to protect against electrical shock during machine operation. NOTE: Push the pulley and the ground clip onto the shaft until the pulley just contacts the bearing support and then tighten the setscrew. 2.

REINSTALL THE PULLEY AND CAP.

3.

REINSTALL AND ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).

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Section Name

REP 4-21, REP 4-22

REP 4-22 Decurler Drive Assembly Parts List on PL 4.16 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL OUT THE FUSER.

3.

REMOVE THE DECURLER INTERMEDIATE DRIVE BELT (REP 4-24).

4.

REMOVE THE DECURLER DRIVE BELT (REP 4-23).

5.

REMOVE THE DECURLER DRIVE ASSEMBLY (Figure 1).

4 REMOVE THE ASSEMBLY

3 REMOVE THE BOLTS (2)

2 REMOVE THE TENSION SPRING

1 LOOSEN BOLTS (2)

Figure 1 Removing the Decurler Drive Assembly

Replacement 1.

ADJUST THE DECURLER DRIVE BELT (ADJ 4-11).

2.

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).

Section Name

REP 4-21, REP 4-22

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Preliminary Working Document No Product Name Assigned

REP 4-23 Decurler Drive Belt

2.

PULL OUT THE FUSER.

Parts List on PL 4.16 Removal

3.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

1.

4.

NOTE: Open the Printer Right and Left Top Covers in order to remove the Belt.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

REMOVE THE DECURLER DRIVE BELT (Figure 1).

10 NOTE: REMOVE THE BELT

9 TIGHTEN THE BOLTS

1 REMOVE THE SCREWS (2)

8 MOVE THE DRIVE ASSEMBLY

2 REMOVE THE FAN

7 LOOSEN THE BOLTS (2)

3

6

REMOVE THE FAN SUPPORT

TIGHTEN BOLT

5 4 LOOSEN BOLT

MOVE THE IDLER BRACKET

Figure 1 Removing the Decurler Drive Belt

Replacement

REP 4-24 Decurler Intermediate Drive Belt

1.

ADJUST THE DECURLER DRIVE BELT (ADJ 4-11).

2.

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).

Parts List on PL 4.16 Removal 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-67

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. Section Name

REP 4-23

2.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

3.

ACCESS THE MIM DRIVE PULLEY BY OPENING THE AC DISTRIBUTION PANEL.

NOTE: Handcrank the Main Drive Motor in the clockwise direction only when removing the Decurler Intermediate Drive Belt. 4.

REMOVE THE DECURLER INTERMEDIATE DRIVE BELT (Figure 1).

2 MOVE AND HOLD THE IDLER

1 LOOSEN BOLT

3

4

TIGHTEN BOLT

REMOVE THE BELT

Figure 1 Removing the Decurler Intermediate Drive Belt

Replacement

REP 4-25 Handcranking the Main Drive Motor

1.

Parts List on PL 4.18 Removal

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES. CAUTION

Pull out the Xerographic Drawer, then protect the Photoreceptor Belt. 3.

Section Name

REP 4-25

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HANDCRANK THE MAIN DRIVE MOTOR FROM THE FRONT (Figure 1).

Preliminary Working Document No Product Name Assigned

CAUTION HANDCRANK THE MAIN DRIVE MOTOR

MAIN DRIVE MOTOR

CAUTION HANDCRANK THE MAIN DRIVE MOTOR

Figure 1 Handcranking the Main Drive Motor from the Front 4.

Figure 2 Handcranking the Main Drive Motor from the Rear

HANDCRANK THE MAIN DRIVE MOTOR FROM THE REAR (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-69

Section Name

REP 4-25

REP 4-26 Intermediate Drive Belt

2.

Parts List on PL 4.19 Removal

NOTE: Loosen the bolts just enough to allow the drive assembly to pivot.

1.

3.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

REMOVE INTERMEDIATE DRIVE BELT (Figure 1).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1

4 REMOVE THE BELT

NOTE: LOOSEN THE BOLTS (2)

3 TIGHTEN THE BOLT (1)

2 MOVE AND HOLD THE DRIVE

REAR VIEW

Figure 1 Removing the Intermediate Drive Belt

Replacement

REP 4-27 Main Drive Motor (MOT401)

1.

Parts List on PL 4.18 Removal

ADJUST THE INTERMEDIATE DRIVE BELT (ADJ 4-15).

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

Section Name

REP 4-26

1.

PARTIALLY PULL OUT TRAY 1, AND TRAY 2.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

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Preliminary Working Document No Product Name Assigned

NOTE: The Left Cross Roll Solenoid and the Nip Release Solenoid must be moved temporarily in order to remove the Main Drive Motor. Ensure that the wire harness for the Nip Release Solenoid is not positioned under the Main Drive Motor. 3.

MOVE THE LEFT CROSS ROLL SOLENOID, AND THE NIP RELEASE SOLENOID (Figure 1).

4 MAKE SCRIBE LINES (2)

THE MAIN DRIVE MOTOR

3 MOVE SOLENOID ASSEMBLY

5 REMOVE NUTS (2), AND MOVE THE NIP RELEASE SOLENOID ASSEMBLY

2 NOTE: DO NOT DISCONNECT THE ELECTRICAL CONNECTORS

1 REMOVE NUTS (2)

Figure 1 Moving the Cross Roll/Solenoid Assemblies 4.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER.

5.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

6.

OPEN THE AC DISTRIBUTION PANEL, AND THE PHN PANEL DOOR.

7.

REMOVE THE MIM, AND PHM DRIVE PULLEYS (REP 4-28).

NOTE: Ensure that the motor harness is not damaged during removal. Position the motor with the gear box vent hole up to prevent lubricant from leaking. Replace cable ties as required. 8.

PREPARE TO REMOVE THE MOTOR (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-71

Section Name

REP 4-27

4 3 LOOSEN BOLT (1)

NOTE: REMOVE THE MOTOR

2 NOTE: DISCONNECT MOTOR CONNECTOR

3 ROTATE AND LIFT THE MOTOR, AND REMOVE BOLT FROM THE FRAME

2 CAUTION POSITION THE HARNESS

1

4 REMOVE BOLTS (2)

PULL CONNECTOR THROUGH FRAME

1 REMOVE COVER

Figure 2 Preparing To Remove the Motor

Figure 3 Removing the Motor from the Frame

NOTE: Access the motor from the rear of the Printer, with Tray 1 and Tray 2 fully opened. Lift and pull the motor away from the frame, and gently lower it onto the Registration Transport. 9.

Replacement 1.

REMOVE THE VENT HOLE PLUG FROM THE MOTOR GEAR BOX, AND INSTALL THE NEW MOTOR.

2.

ADJUST THE PHM/MIM DRIVE PULLEYS (ADJ 4-18).

REMOVE THE MOTOR FROM THE FRAME (Figure 3).

Section Name

REP 4-27

3.

ADJUST THE PHM DRIVE BELT (ADJ 4-17).

4.

ADJUST THE MIM DRIVE BELT (ADJ 4-16)

5.

ALIGN THE NIP RELEASE SOLENOID ASSEMBLY WITH THE SCRIBE LINES, ON THE TOP OF THE REGISTRATION TRANSPORT, AND TIGHTEN THE MOUNTING HARDWARE.

6.

RESTORE THE PRINTER POWER.

7.

CHECK/ADJUST THE NIP RELEASE SOLENOID ASSEMBLY (ADJ 8-6).

8.

INSTALL THE LEFT CROSS ROLL SOLENOID ASSEMBLY.

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Preliminary Working Document No Product Name Assigned

REP 4-28 MIM and PHM Drive Pulleys Parts List on PL 4.18 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

1

4

LOOSEN BOLT

CAUTION DISCONNECT THE BELT

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER.

3.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL AND THE PHN PWB PANEL.

5.

REMOVE THE MIM DRIVE BELT FROM MIM PULLEY (Figure 1).

4 CAUTION DISCONNECT THE BELT

2

3 TIGHTEN BOLT

MOVE THE IDLER BRACKET

Figure 2 Removing the PHM Drive Belt from PHM Pulley

3 TIGHTEN IDLER BOLT

1

7.

REMOVE THE PULLEYS (Figure 3).

LOOSEN THE IDLER BOLT

2 MOVE THE IDLER BRACKET

Figure 1 Removing the MIM Drive Belt from MIM Pulley 6.

REMOVE THE PHM DRIVE BELT FROM PHM PULLEY (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-73

Section Name

REP 4-28

REP 4-29 MIM Drive Belt 2 REMOVE THE PULLEYS

Parts List on PL 4.17 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer then protect the PR Belt. 2.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER

3.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL. CAUTION

1 LOOSEN THE SETSCREWS

Do not handcrank the Main Drive Motor in a counterclockwise direction. 5.

REMOVE THE PHOTORECEPTOR DRIVE BELT (REP 4-32).

6.

REMOVE THE MIM DRIVE BELT (Figure 1).

3 CAUTION REMOVE THE BELT

Figure 3 Removing the Pulleys

Replacement 1.

ADJUST THE PHM AND MIM DRIVE PULLEYS (ADJ 4-18).

2.

ADJUST THE PHM DRIVE BELT (ADJ 4-17).

3.

ADJUST THE MIM DRIVE BELT (ADJ 4-16).

4.

CLOSE THE XEROGRAPHIC DRAWER.

2 MOVE IDLER AND TIGHTEN BOLT

1 LOOSEN BOLT

Figure 1 Removing the MIM Drive Belt

Replacement 1.

Section Name

REP 4-28, REP 4-29

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ADJUST THE MIM DRIVE BELT (ADJ 4-16).

Preliminary Working Document No Product Name Assigned

NOTE: Handcrank the Main Drive Motor in a clockwise direction only while reinstalling the Photoreceptor Drive Belt. 2.

INSTALL THE PHOTORECEPTOR DRIVE BELT (REP 4-32).

3.

CLOSE THE XEROGRAPHIC DRAWER.

REP 4-30 PHM Drive Belt, Intermediate Drive Assembly Parts List on PL 4.18 PL 4.19 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER.

3.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL AND THE PHM PWB PANEL.

5.

REMOVE THE INTERMEDIATE DRIVE BELT (REP 4-26). CAUTION

Do not handcrank the Main Drive Motor in a counterclockwise direction. 6.

REMOVE THE MIM DRIVE BELT FROM THE MIM PULLEY (REP 4-29).

NOTE: Cut, and replace cable ties as required. 7.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-75

REMOVE THE PHM DRIVE BELT (Figure 1).

Section Name

REP 4-29, REP 4-30

5 REMOVE THE BELT

1 DISCONNECT CLUTCH CONNECTOR

3 2

MOVE, AND HOLD THE IDLER

LOOSEN BOLT

4 TIGHTEN BOLT

Figure 1 Removing the PHM Drive Belt 8.

REMOVE THE INTERMEDIATE DRIVE ASSEMBLY (Figure 2).

Section Name

REP 4-30

0/0/00 ?-76

Preliminary Working Document No Product Name Assigned

1 LOOSEN SCREW, AND MOVE IDLER

4 DISCONNECT THE SPRING, AND REMOVE THE ASSEMBLY

2 REMOVE INVERTER DRIVE BELT

3 REMOVE BOLTS (2)

Figure 2 Removing the Intermediate Drive Assembly CAUTION Do not loose the key, when removing the small gear. 9.

REMOVE THE PHM DRIVE BELT (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-77

Section Name

REP 4-30

6

5

3

REMOVE BELT

MOVE

REMOVE

4

2

LOOSEN SETSCREW

LOOSEN SETSCREW

1 REMOVE

CAUTION DO NOT LOSE KEY Figure 3 Removing the PHM Drive Belt

Replacement 1.

REPLACE THE PHM DRIVE BELT.

2.

ADJUST THE INTERMEDIATE DRIVE ASSEMBLY (ADJ 4-14). CAUTION

When reinstalling the spring, ensure that the outward hook is installed into the frame hole, otherwise damage may occur to the spring. NOTE: When installing the Intermediate Drive Assembly, ensure that the rear edge of the bearing is positioned in the hole of the frame, so that the assembly sits evenly against the frame. 3.

INSTALL THE INTERMEDIATE DRIVE ASSEMBLY.

4.

ADJUST THE INTERMEDIATE DRIVE BELT (ADJ 4-15).

5.

ADJUST THE PHM DRIVE BELT (ADJ 4-17).

6.

INSTALL, AND TIGHTEN THE INVERTER DRIVE BELT.

7.

ADJUST THE MIM DRIVE BELT (ADJ 4-16).

Section Name

REP 4-30

0/0/00 ?-78

Preliminary Working Document No Product Name Assigned

REP 4-31 Photoreceptor Drive Assembly

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 4.17 Removal

2.

REMOVE THE BI-PULLEY (REP 4-48 ).

3.

REMOVE THE PHOTORECEPTOR DRIVE ASSEMBLY (Figure 1).

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

NOTE: DIRT SHIELD

2 REMOVE THE BOLTS

3 PULL THE LOWER END OF THE ASSEMBLY OUT, AND REMOVE FROM THE PREFUSER DRIVE BELT

1 LOOSEN THE BOLT, AND DISENGAGE THE SPRING

Figure 1 Removing the Drive Assembly NOTE: Replace the Photoreceptor Drive Assembly with the Xerographic Drawer closed. This will ensure that the Photoreceptor Drive Couplings align properly before tightening the bolts for the Photoreceptor Drive Assembly.

NOTE: Apply lubricant, as required, onto the drive coupling teeth, and the sliding coupler contact surface on the shaft. 4.

LUBRICATE THE PHOTORECEPTOR DRIVE ASSEMBLY WITH 70P31 LUBRICANT IF REQUIRED.

NOTE: Reinstall the Dirt Shield behind the washer of the top bolt.

Replacement 1.

a.

Ensure that the Photoreceptor drawer is closed and properly latched. Insert the Photoreceptor alignment tool (600T2008) from the rear of the machine, onto the coupling. Install the P/R Drive Assembly, rotating the coupling clockwise while tightening the assembly to ensure proper alignment.

b.

Unlatch the P/R drawer and remove the alignment tool. Slide the P/R drawer closed several times, checking for proper alignment of the drive and coupling.

REPLACE THE PHOTORECEPTOR DRIVE ASSEMBLY.

2.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-79

INSTALL THE BI-PULLEY (REP 4-48 ).

Section Name

REP 4-31

3.

ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).

REP 4-32 Photoreceptor Drive Belt

4.

ADJUST THE MIM DRIVE BELT (ADJ 4-17).

5.

INSTALL THE PHOTORECEPTOR DRIVE BELT.

Parts List on PL 4.16 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER

3.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL. CAUTION

Do not handcrank the Main Drive Motor in a counterclockwise direction. 5.

REMOVE THE PHOTORECEPTOR DRIVE BELT (Figure 1).

2 PULL THE BELT FROM THE PULLEY, WHILE SLOWLY HANDCRANKING THE MAIN DRIVE MOTOR

1 CAUTION HANDCRANK SLOWLY IN A CLOCKWISE DIRECTION ONLY

Figure 1 Removing the Photoreceptor Drive Belt

Section Name

REP 4-31, REP 4-32

0/0/00 ?-80

Preliminary Working Document No Product Name Assigned

REP 4-33 Prefuser Drive Assembly

Replacement

Parts List on PL 4.16 Removal

NOTE: Position the Prefuser Drive coupler onto the transport coupler in order to ensure proper coupler engagement. Install the bottom bolts (2) first, in order to position the assembly. Ensure that the assembly is flat against the frame.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL OUT THE FUSER.

1.

ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).

3.

REMOVE THE DECURLER INTERMEDIATE DRIVE BELT FROM THE PREFUSER DRIVE ASSEMBLY (REP 4-24).

2.

ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).

3.

ADJUST THE DECURLER INTERMEDIATE DRIVE PULLEY (ADJ 4-13).

4.

REMOVE THE PREFUSER DRIVE BELT FROM THE PREFUSER DRIVE ASSEMBLY (REP 4-34).

4.

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).

5.

CONNECT THE PRECLEAN DICOROTRON CONNECTOR.

5.

REMOVE THE CLEANER DRIVE BELT (REP 4-20).

6.

REMOVE THE PREFUSER DRIVE ASSEMBLY (Figure 1).

NOTE: Replace cable ties as required. 6.

CONNECT THE OZAC AND THE CLEANER EXHAUST DUCTS. CAUTION

To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor in a counterclockwise direction.

1 REMOVE THE BOLTS (4)

7.

INSTALL THE PHOTORECEPTOR DRIVE BELT WHILE SLOWLY HANDCRANKING THE MAIN DRIVE MOTOR.

8.

PUSH IN, AND LATCH THE FUSER.

9.

INSTALL THE PRECLEAN DICOROTRON.

2 REMOVE THE ASSEMBLY

Figure 1 Removing the Prefuser Drive Assembly NOTE: Apply lubricant, as required, onto the gear teeth, drive coupling teeth and the sliding coupler contact surface on the shaft. 7.

LUBRICATE THE PREFUSER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-81

Section Name

REP 4-33

REP 4-34 Prefuser Drive Belt

4.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

Parts List on PL 4.16 Removal

5.

REMOVE THE DECURLER INTERMEDIATE DRIVE BELT (REP 4-26). CAUTION

Do not handcrank the Main Drive Motor in a counterclockwise direction.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRECLEAN DICOROTRON (REP 9-39).

3.

PARTIALLY PULL OUT THE XEROGRAPHIC DRAWER.

6.

REMOVE THE PHOTORECEPTOR DRIVE BELT (REP 4-32).

7.

DISCONNECT THE OZAC, AND CLEANER EXHAUST DUCTS (Figure 1).

1 CUT CABLE TIE

2 LOOSEN HOSE CLAMP, AND DISCONNECT THE DUCT

5 DISCONNECT THE PRECLEAN DICOROTRON

3 CUT CABLE TIE

4 DISCONNECT THE DUCT

Figure 1 Disconnecting the Ozac and Cleaner Exhaust Ducts 8.

OPEN THE PHN PWB PANEL.

9.

LOOSEN THE PREFUSER DRIVE BELT (Figure 2).

Section Name

REP 4-34

0/0/00 ?-82

Preliminary Working Document No Product Name Assigned

2 MOVE UP THE IDLER WHILE TIGHTENING THE BOLT

1 LOOSEN BOLT

Figure 2 Loosening the Prefuser Drive Belt CAUTION Do not lose the Shaft key when removing the Decurler Intermediate Drive Pulley. 10. REMOVE THE PREFUSER DRIVE BELT (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-83

Section Name

REP 4-34

1 LOOSEN SETSCREW

3 CAUTION REMOVE THE PULLEY

2 REMOVE THE RETAINING RING

4 REMOVE THE BELT

Figure 3 Removing the Prefuser Drive Belt

Replacement 1.

ADJUST THE PREFUSER DRIVE BELT (ADJ 4-19).

NOTE: Ensure that the key is positioned between the pulley, and the shaft. 2.

ADJUST THE DECURLER INTERMEDIATE DRIVE PULLEY (ADJ 4-13).

3.

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (ADJ 4-12).

4.

CONNECT THE PRECLEAN DICOROTRON CONNECTOR.

NOTE: Replace cable ties as required. 5.

CONNECT THE OZAC, AND THE CLEANER EXHAUST DUCTS. CAUTION

Do not handcrank the Main Drive Motor in a counterclockwise direction. 6.

INSTALL THE PHOTORECEPTOR DRIVE BELT WHILE SLOWLY HANDCRANKING THE MAIN DRIVE MOTOR.

7.

CLOSE THE XEROGRAPHIC DRAWER.

8.

INSTALL THE PRECLEAN DICOROTRON.

Section Name

REP 4-34

0/0/00 ?-84

Preliminary Working Document No Product Name Assigned

REP 4-35 Top Transport Drive Assembly

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

Parts List on PL 4.19 Removal

3.

REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0).

4.

PARTIALLY INSTALL THE PRINTER LEFT TOP COVER IN ORDER TO PROTECT THE PHOTORECEPTOR BELT FROM THE LIGHT.

1.

5.

REMOVE THE TOP TRANSPORT DRIVE BELT (Figure 1).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1 LOOSEN THE IDLER, AND REMOVE THE BELT FROM THE DRIVE ASSEMBLY

TOP TRANSPORT DRIVE ASSEMBLY

Figure 1 Removing the Top Transport Drive Belt 6.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

NOTE: Loosen the bolts (2) just enough to allow the Intermediate Drive Assembly to move. 7.

REMOVE THE TOP TRANSPORT DRIVE ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-85

Section Name

REP 4-35

3

4

TIGHTEN THE BOLT (1)

REMOVE THE BELT TRANSPORT DRIVE ASSEMBLY

5 REMOVE THE BOLTS (2), AND THE DRIVE ASSEMBLY

2 MOVE, AND HOLD THE INTERMEDIATE DRIVE ASSEMBLY

1 NOTE: LOOSEN THE BOLTS (2)

Figure 2 Removing the Top Transport Drive Assembly

Replacement

REP 4-36 Tray 1 and 2 Feeder Drives

1.

ADJUST THE INTERMEDIATE DRIVE BELT (ADJ 4-15).

2.

INSTALL AND TIGHTEN THE TOP TRANSPORT DRIVE BELT.

3.

INSTALL ALL COVERS.

Parts List on PL 4.18 Removal

Section Name

REP 4-35

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL OUT THE XEROGRAPHIC DRAWER.

3.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL AND THE PHN PWB PANEL.

0/0/00 ?-86

Preliminary Working Document No Product Name Assigned

NOTE: Cut and replace cable ties on Tray 2 Feeder Drive, as required. 5.

REMOVE THE FEEDER DRIVE (Figure 1).

4 REMOVE THE BELT

5 REMOVE THE BOLTS (2)

6 REMOVE THE DRIVE

3 TIGHTEN THE BOLT

1 LOOSEN THE BOLT

2 MOVE THE BRACKET

Figure 1 Removing the Feeder Drive

Replacement

REP 4-38 Vertical Transport Clutch Assembly (CL851)

NOTE: Apply lubricant, as required, onto the shaft where the sliding coupler contacts the shaft. LUBRICATE THE FUSER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

Parts List on PL 4.18 Removal

2.

ADJUST THE TRAY 1 OR 2 FEEDER DRIVE (ADJ 4-20).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

ADJUST THE PHM DRIVE BELT (ADJ 4-17).

2.

PULL OUT THE XEROGRAPHIC DRAWER.

4.

INSTALL THE PRINTER REAR COVER (REP 4-1).

3.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL AND THE PHN PWB PANEL.

1.

NOTE: Access the Vertical Transport Drive Belt from the front of the Printer. 5.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-87

PREPARE TO REMOVE THE CLUTCH ASSEMBLY (Figure 1).

Section Name

REP 4-38

OPPOSITE SIDE OF FRAME

10 REMOVE THE PULLEY

9

8

LOOSEN THE SETSCREW

REMOVE THE VERTICAL TRANSPORT DRIVE BELT

7

6

TIGHTEN THE BOLT

MOVE THE IDLER BRACKET

5 LOOSEN THE BOLT

4 DISCONNECT THE PHM DRIVE BELT

3 1 LOOSEN THE BOLT

TIGHTEN THE BOLT

2 MOVE THE IDLER BRACKET

Figure 1 Preparing To Remove the Clutch Assembly NOTE: Cut and replace cable ties as required. 6.

REMOVE THE CLUTCH ASSEMBLY (Figure 2).

Section Name

REP 4-38

0/0/00 ?-88

Preliminary Working Document No Product Name Assigned

NOTE: POSITION OF THE CLUTCH

1 NOTE: DISCONNECT CONNECTOR

2 REMOVE THE NUTS (4)

3 REMOVE CLUTCH ASSEMBLY (CL 851)

Figure 2 Removing the Clutch Assembly

Replacement NOTE: Position the clutch with the tab in the slot as shown in Figure 2. 1.

REPLACE THE CLUTCH ASSEMBLY.

2.

INSTALL AND TIGHTEN THE VERTICAL TRANSPORT DRIVE BELT. CAUTION

Do not handcrank the Main Drive Motor in a counterclockwise direction. 3.

ADJUST THE PHM DRIVE BELT (ADJ 4-17).

4.

CLOSE THE XEROGRAPHIC DRAWER.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-89

Section Name

REP 4-38

REP 4-39 Developer Drive Assembly

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assembly. Toner will fall from assembly connection.

Parts List on PL 4.17 Removal

3.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

NOTE: Squeeze the Belt together near the center with the hand to aid in loosening

OPEN THE TONER FILER ASSEMBLY, AND THE XEROGRAPHIC CARD CAGE.

4.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

5.

LOOSEN THE FUSER-DEVELOPER DRIVE BELT (Figure 1).

2 MOVE THE IDLER, AND TIGHTEN THE BOLT

3 DISCONNECT THE BELT FROM THE DRIVE PULLEY

1 LOOSEN THE BOLT

THE DEVELOPER DRIVE ASSEMBLY

Figure 1 Loosening the Fuser-Developer Drive Belt 6.

REMOVE THE DEVELOPER DRIVE ASSEMBLY (Figure 2).

Section Name

REP 4-39

0/0/00 ?-90

Preliminary Working Document No Product Name Assigned

WARNING THE INSULATING CAP

1 REMOVE THE BOLTS (4), AND WASHERS (4)

2 REMOVE THE ASSEMBLY

Figure 2 Removing the Developer Drive Assembly

Replacement NOTE: Push the coupler in, and apply lubricant, as required, onto the shaft where the sliding coupler contacts the shaft. 1.

LUBRICATE THE DEVELOPER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

WARNING Ensure that the Insulating Cap is installed. An electrical shock hazard exists, if the drive pulley is contacted during machine run operation. 2.

ENSURE THAT THE XEROGRAPHIC DRAWER IS IN THE CLOSED POSITION, AND INSTALL THE DEVELOPER DRIVE ASSEMBLY.

3.

PERFORM THE DEVELOPER DRIVE ASSEMBLY ALIGNMENT (ADJ 9-19).

4.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

5.

CONNECT THE OZAC DUCT TO THE OZONE FILTER.

6.

REPLACE THE CABLE TIES AS REQUIRED, AND ENSURE THAT THE CLEANER HOSES AND OZAC HOSES ARE AWAY FROM MOVING PARTS.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-91

Section Name

REP 4-39

REP 4-40 Fuser-Developer Drive Belt

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assembly. Toner will fall from assembly connection.

Parts List on PL 4.17 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL OUT THE XEROGRAPHIC DRAWER.

3.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

NOTE: Squeeze the Belt together near the center with the hand to aid in loosening

4.

OPEN THE TONER FILTER ASSEMBLY.

5.

OPEN THE XEROGRAPHIC CARD CAGE.

6.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

7.

REMOVE THE FUSER-DEVELOPER DRIVE BELT (Figure 1).

2 MOVE THE IDLER, AND TIGHTEN THE BOLT

1 LOOSEN THE BOLT

3 DISCONNECT THE BELT FROM THE IDLER

6 REMOVE THE BELT

5 REMOVE THE SPRINGS (2)

4 LOOSEN THE BOLT

Figure 1 Removing the Fuser-Developer Belt

Replacement 1.

ADJUST THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).

Section Name

REP 4-40

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Preliminary Working Document No Product Name Assigned

NOTE: Handcrank the Drive Pulley in a clockwise direction in order to ensure that the belt is seated. 2.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

3.

CONNECT THE OZAC DUCT TO THE OZONE FILTER.

REP 4-41 Fuser-Developer Drive Motor (MOT402) Parts List on PL 4.20 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: Replace cable ties as required, and ensure that the Cleaner and Ozac hoses are away from moving parts.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE THE ROS ASSEMBLY (REP 6-1).

4.

4.

REMOVE THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).

5.

PULL OUT THE XEROGRAPHIC DRAWER.

CLOSE THE XEROGRAPHIC DRAWER.

CAUTION To prevent lubricant from leaking, store the motor with the gear box vent hole up. 6.

Preliminary Working Document No Product Name Assigned

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REMOVE THE FUSER-DEVELOPER DRIVE MOTOR (Figure 1).

Section Name

REP 4-40, REP 4-41

5 LOOSEN THE BOLTS (3)

4 6

REMOVE THE BELT FROM THE PULLEY

REMOVE THE MOTOR

2 LOOSEN THE SCREW

1 DISCONNECT CONNECTORS (2)

3 MOVE THE IDLER THEN TIGHTEN THE SCREW

Figure 1 Removing the Fuser-Developer Drive Motor 7.

CAUTION

REMOVE THE MOTOR PULLEY, AND THE MOUNTING SCREWS.

Replacement

Remove the vent hole plug from the motor gear box when replacing the motor.

WARNING

2.

INSTALL, AND CONNECT THE NEW DRIVE MOTOR.

To prevent possible personal injury, do not move your fingers along the sharp edges of the keyway.

3.

INSTALL, AND TIGHTEN THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT.

4.

CENTER THE INTERMEDIATE DRIVE BELT ON THE MOTOR PULLEY (Figure 2).

NOTE: Ensure that the key is positioned between the pulley and shaft. Do not tighten the setscrew of the pulley at this time. 1.

INSTALL THE MOTOR PULLEY ON THE MOTOR SHAFT.

Section Name

REP 4-41

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Preliminary Working Document No Product Name Assigned

3 REAR VIEW

TOP FRONT VIEW

TIGHTEN THE SETSCREW

1

2

ROTATE THE PULLEY FIVE FULL REVOLUTIONS IN A COUNTERCLOCKWISE DIRECTION

CENTER THE BELT ON THE PULLEY

Figure 2 Positioning the Belt on the Pulley 5.

INSTALL THE ROS ASSEMBLY (REP 6-1).

REP 4-42 Fuser-Developer Intermediate Drive Belt

6.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

Parts List on PL 4.20 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assembly. 3.

Preliminary Working Document No Product Name Assigned

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OPEN THE TONER FILTER ASSEMBLY.

Section Name

REP 4-41

4.

OPEN THE XEROGRAPHIC CARD CAGE.

5.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

6.

LOOSEN THE FUSER-DEVELOPER DRIVE BELT (Figure 1).

2 MOVE THE IDLER, AND TIGHTEN THE BOLT

3 DISCONNECT THE BELT FROM THE DRIVE PULLEY

1 LOOSEN THE BOLT

Figure 1 Loosening the Fuser-Developer Belt 7.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

8.

REMOVE THE ROS ASSEMBLY (REP 6-1).

9.

REMOVE THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).

10. LOOSEN THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (Figure 2).

Section Name

REP 4-42

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Preliminary Working Document No Product Name Assigned

LEFT REAR VIEW TOP FRONT VIEW

1 3 REMOVE THE BELT FROM THE PULLEY

LOOSEN THE SCREW

2 MOVE THE IDLER, AND TIGHTEN THE SCREW

Figure 2 Loosening the Fuser-Developer Intermediate Belt NOTE: If a new Jackshaft Assembly is being installed, it will not be necessary to remove the Intermediate Drive Belt from the Printer. 11. REMOVE THE BELT (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 4-42

1 PUSH THE BELT THROUGH THE CUTOUT AND OVER THE DRIVE PULLEY

2 REMOVE THE BELT

TOP FRONT VIEW

Figure 3 Removing the Belt

Replacement 1.

ADJUST THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (ADJ 4-23).

2.

ADJUST THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).

3.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

4.

CONNECT THE OZAC DUCT TO THE OZONE FILTER.

NOTE: Replace cable ties as required, and ensure that the Cleaner hoses and Ozac hoses are away from moving parts. 5.

INSTALL THE ROS ASSEMBLY (REP 6-1).

6.

INSTALL THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).

7.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

Section Name

REP 4-42

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Preliminary Working Document No Product Name Assigned

REP 4-43 Fuser Drive Assembly

NOTE: Place a drop cloth under the rear of the Printer before opening the Toner Filter Assembly.

Parts List on PL 4.17 Removal

3.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

5 REMOVE THE FUSER DRIVE ASSEMBLY

OPEN THE TONER FILTER ASSEMBLY AND THE XEROGRAPHIC CARD CAGE.

4.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

5.

REMOVE THE FUSER-DEVELOPER DRIVE ASSEMBLY (Figure 1).

4 REMOVE THE BOLTS (4)

3 REMOVE THE BELT FROM THE DRIVE PULLEY

1 LOOSEN BOLT

2 MOVE THE IDLER, AND TIGHTEN THE BOLT

Figure 1 Removing the Fuser Drive Assembly

Replacement

1.

NOTE: Apply lubricant, as required, onto the shaft where the sliding coupler contacts the shaft.

Preliminary Working Document No Product Name Assigned

LUBRICATE THE FUSER DRIVE ASSEMBLY WITH 70P31 LUBRICANT.

2.

CLOSE THE FUSER, AND INSTALL THE FUSER DRIVE ASSEMBLY.

3.

ADJUST THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).

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Section Name

REP 4-43

4.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

REP 4-44 Jackshaft Assembly Parts List on PL 4.20 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

NOTE: Place a drop cloth under the rear of the Printer before opening the Toner Filter Assembly. 3.

OPEN THE TONER FILTER ASSEMBLY, AND THE XEROGRAPHIC CARD CAGE.

4.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

5.

LOOSEN THE FUSER-DEVELOPER DRIVE BELT (Figure 1).

NOTE: Do not remove the belt completely. 6.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

7.

REMOVE THE ROS ASSEMBLY (REP 6-1).

8.

REMOVE THE FUSER-DEVELOPER DRIVES DIRT SHIELD (REP 4-47).

9.

REMOVE THE FUSER-DEVELOPER DRIVE MOTOR (REP 4-41).

NOTE: Do not remove the Drive Motor Pulley from the motor shaft. 10. REMOVE THE JACKSHAFT ASSEMBLY (Figure 1).

Section Name

REP 4-43, REP 4-44

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Preliminary Working Document No Product Name Assigned

1

FRONT TOP VIEW

REMOVE BOLTS (3)

2 REMOVE THE JACKSHAFT AND THE BELT

REAR VIEW

Figure 1 Removing the Jackshaft Assembly 11. REMOVE THE DRIVE PULLEY FROM THE OLD JACKSHAFT ASSEMBLY.

6.

ADJUST THE FUSER-DEVELOPER DRIVE PULLEY (ADJ 4-22).

Replacement

7.

ADJUST THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).

1.

INSTALL THE FUSER-DEVELOPER DRIVE PULLEY LOOSELY ON THE NEW JACKSHAFT ASSEMBLY.

8.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

2.

INSTALL THE NEW JACKSHAFT ASSEMBLY.

3.

INSTALL THE FUSER-DEVELOPER DRIVE MOTOR (REP 4-41).

NOTE: Replace cable ties as required, and ensure that the Cleaner hoses and Ozac hoses are away from moving parts. 9.

CONNECT THE OZAC DUCT TO THE OZONE FILTER.

NOTE: Ensure that the motor connectors are reconnected.

10. INSTALL THE ROS ASSEMBLY (REP 6-1).

4.

ADJUST THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (ADJ 4-23).

11. INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

5.

INSTALL THE FUSER-DEVELOPER DRIVES DIRT SHIELD (REP 4-47).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-101

Section Name

REP 4-44

REP 4-45 Fuser-Developer Drive Motor Run and Start Capacitors (C403/C404)(60 HZ) Parts List on PL 4.20 Removal 1.

2.

REMOVE THE ROS UPPER INNER PANEL.

3.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2). CAUTION

Do not interchange the wires. 4.

REMOVE THE RUN CAPACITOR (C403) (Figure 1).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4

FRONT TOP VIEW

REMOVE THE RUN CAPACITOR

THE START CAPACITOR

3 LOOSEN SCREW

1 PULL BACK THE INSULATOR

2 DISCONNECT THE FASTONS (4)

C1-1 C1-2

Figure 1 Removing the Run Capacitor 5.

REMOVE THE START CAPACITOR (C404) (Figure 2).

Section Name

REP 4-45

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Preliminary Working Document No Product Name Assigned

3 DISCONNECT THE FASTONS (2)

1 REMOVE THE CAPACITOR FROM THE BRACKET

2 REMOVE THE CAP

Figure 2 Removing the Start Capacitor

Replacement NOTE: Do not interchange the wires. Ensure that the lip of the Run Capacitor does not touch the frame. 1.

INSTALL THE NEW RUN CAPACITOR (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 4-45

3

2 TIGHTEN THE SCREW

NOTE: CONNECT THE FASTONS (4)

C1-2 NOTE: POSITION THE CAPACITOR 5.0 mm MAXIMUM FROM THE FRONT OF THE FRAME

4 INSTALL THE INSULATOR C1-1

Figure 3 Installing the Run Capacitor 2.

CONNECT THE WIRES FOR THE START CAPACITOR.

3.

INSTALL THE END CAP.

4.

PUSH THE CAPACITOR INTO THE MOUNTING BRACKET. ENSURE THAT THE END CAPS ARE SEATED IN THE DETENTS.

Section Name

REP 4-45

REP 4-46 Main Drive Motor Run and Start Capacitors (C401/402) (60HZ) Parts List on PL 4.19 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

3.

OPEN THE AC DISTRIBUTION PANEL AND THE PHN PANEL DOOR.

4.

REMOVE THE RUN CAPACITOR (Figure 1).

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Preliminary Working Document No Product Name Assigned

3 DISCONNECT FASTONS (4)

4 LOOSEN SCREW

5 REMOVE THE CAPACITOR

2 OBSERVE THE WIRING

1 PULL BACK THE INSULATOR

Figure 1 Removing the Run Capacitor 5.

REMOVE THE START CAPACITOR (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-105

Section Name

REP 4-46

1 REMOVE THE CAPACITOR FROM THE BRACKET

3 DISCONNECT THE FASTONS (2)

2 REMOVE THE CAP

Figure 2 Removing the Start Capacitor

Replacement NOTE: Ensure that the lip of the Run Capacitor does not touch the frame. Do not interchange the wires. 1.

INSTALL THE RUN CAPACITOR (Figure 3).

Section Name

REP 4-46

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Preliminary Working Document No Product Name Assigned

2 POSITION CAPACITOR 5.0 MM MAXIMUM FROM THE FRONT OF THE PLATE

3 TIGHTEN SCREW

1 NOTE: CONNECT THE FASTONS (4)

4 INSTALL THE INSULATOR

Figure 3 Installing the Run Capacitor 2.

CONNECT THE START CAPACITOR.

REP 4-47 Fuser-Developer Drive Dirt Shields

3.

INSTALL THE END CAP.

4.

PUSH THE CAPACITOR INTO THE MOUNTING BRACKET. ENSURE THAT THE END CAPS ARE SEATED IN THE DETENTS.

Parts List on PL 4.20 Removal

5.

CLOSE THE AC DISTRIBUTION PANEL, AND THE PHN PANEL DOOR.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

INSTALL THE PRINTER RIGHT REAR COVER (REP 4-1).

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

4.

PULL OUT THE FUSER.

6.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-107

Section Name

REP 4-46

NOTE: Carefully remove the dirt shield in order to prevent any buildup of debris within the Shield from falling into the Printer. Move the Right Dirt Shield forward, rotate it in a clockwise direction, and remove it from the Printer. 5.

REMOVE THE DIRT SHIELDS (Figure 1).

1 NOTE: LOOSEN THE FASTENERS (2), AND REMOVE THE SHIELD

2 NOTE: LOOSEN THE FASTENER, AND REMOVE THE SHIELD

FRONT TOP VIEW

Figure 1 Removing the Dirt Shields

Replacement 1.

WIPE THE INSIDE SURFACES OF THE DIRT SHIELDS WITH FILM REMOVER (43P45).

2.

INSTALL THE DIRT SHIELDS (Figure 2).

Section Name

REP 4-47

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Preliminary Working Document No Product Name Assigned

2

1

POSITION THE RIGHT DIRT SHIELD HERE

INSTALL THE LEFT DIRT SHIELD, AND SEAT THE FASTENER

3 INSTALL THE RIGHT DIRT SHIELD

4 ENSURE THAT THE SHIELDS ARE CORRECTLY MATED

Figure 2 Installing the Dirt Shields 3.

PUSH IN THEN LATCH THE FUSER.

REP 4-48 Bi-Pulley

4.

INSTALL THE PRINTER LEFT TOP COVER (REP 4-2).

5.

INSTALL THE ROS UPPER INNER PANEL.

6.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

Parts List on PL 4.17 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE FOLLOWING: a.

Printer Rear Covers (REP 4-1).

NOTE: Place a dropcloth under the waste compactor motor bracket. Partially remove the waste compactor motor bracket to access the Bi-pulley. b.

Preliminary Working Document No Product Name Assigned

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Waste Compactor Motor Bracket (REP 9-19).

c.

Upper Waste Toner Duct (REP 9-17).

d.

The Flywheel (Figure 1).

Section Name

REP 4-47

2 NOTE: LOOSEN AND MOVE THE LOWER DUCT

1 HOLD THE SLOTTED STUD, AND REMOVE THE NUT

2 REMOVE THE FLYWHEEL

Figure 1 Removing the Flywheel

3.

1

3

REMOVE THE RETAINING RING

REMOVE THE BI-PULLEY

Figure 2 Removing the Bi-pulley

e.

Photoreceptor Drive Belt (REP 4-32).

Replacement

f.

MIM Drive Belt (REP 4-29).

1.

REPLACE THE BI-PULLEY.

REMOVE THE BI-PULLEY (Figure 2).

2.

ADJUST THE MIM DRIVE BELT (ADJ 4-16).

3.

INSTALL THE PHOTORECEPTOR DRIVE BELT (REP 4-32).

NOTE: Ensure that the Waste Toner Duct is properly clamped and that the Lower Waste Toner Duct mounting bolts are tight.

Section Name

REP 4-48

4.

INSTALL WASTE TONER DUCT AND THE WASTE COMPACTOR MOTOR BRACKET.

5.

INSTALL THE REAR COVERS (REP 4-1).

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Preliminary Working Document No Product Name Assigned

REP 4-49 Stacker Front Cover Parts List on PL 4.12 Removal

1 DISCONNECT

CAUTION Do not remove the Stacker Front Cover when the Pallet Lift Frame is positioned all the way down. The Front Doors Interlock Switch Brackets could be damaged.

2

1.

PARTIALLY RAISE THE PALLET LIFT FRAME.

DISCONNECT

2.

SWITCH OFF THE PRINTER POWER.

3.

RAISE THE APPROPRIATE STACKER TOP COVER.

3 DISCONNECT (2)

CAUTION Do not allow the Stacker Front Cover to drop after the 10mm screws are removed. 4.

REMOVE THE TWO 10 mm SCREWS SECURING THE TOP OF THE STACKER FRONT COVER.

5.

WITH THE BOTTOM BRACKETS ON THE FRONT COVER INSTALLED, LOWER THE TOP OF THE FRONT COVER AWAY FROM THE FRAME, AND DISCONNECT THE CONNECTORS LOCATED BEHIND THE COVER (Figure 1).

4 DISCONNECT

Figure 1 Disconnecting the Front Cover Connectors

Preliminary Working Document No Product Name Assigned

0/0/00 ?-111

Section Name

REP 4-49

REP 4-50 Stacker Top Cover

Parts List on PL 4.14 Removal 1.

REMOVE THE FS UPPER REAR COVER.

2.

REMOVE THE STACKER REAR TOP COVER (Figure 1).

1

2

LOOSEN NUTS (4)

REMOVE THE COVER

Figure 1 Removing the Rear Top Cover 3.

OPEN THE STACKER TOP COVER. CAUTION

Do not allow the Bypass Transport Top Baffle to drop after unlatching it from the Stacker Top Cover. 4.

UNLATCH AND LOWER THE BYPASS TRANSPORT TOP BAFFLE (Figure 2).

Section Name

REP 4-50

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Preliminary Working Document No Product Name Assigned

1 UNLATCH THE BYPASS TRANSPORT TOP BAFFLE

2 CAUTION LOWER THE BAFFLE

Figure 2 Unlatching the Baffle 5.

REMOVE THE STACKER TOP COVER (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 4-50

1 LOOSEN NUTS (4)

2 REMOVE THE COVER

Figure 3 Removing the Top Cover

Replacement

REP 4-51 Stacker Rear Top Cover

NOTE: Ensure that the Stacker Top Cover studs are fully seated in the slots of the Counterbalance Brackets before tightening the nuts.

Parts List on PL 4.14 Removal

1.

1.

OPEN THE PURGE TRAY TOP COVER.

2.

REMOVE THE NUT AND DISCONNECT THE CABLE SECURING THE PURGE TRANSPORT TOP BAFFLE TO THE PURGE TRAY TOP COVER. LOWER THE BAFFLE.

3.

REMOVE THE FS UPPER REAR COVER.

4.

REMOVE THE STACKER REAR TOP COVER (Figure 1).

REINSTALL THE STACKER TOP COVER AND TIGHTEN THE NUTS.

Section Name

REP 4-50

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Preliminary Working Document No Product Name Assigned

1 REMOVE NUTS (4)

2 REMOVE THE COVER

Figure 1 Removing the Rear Top Cover 5.

REMOVE THE PURGE TRAY TOP COVER (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-115

Section Name

REP 4-51

2 REMOVE THE COVER

1 REMOVE NUTS (4)

Figure 2 Removing the Purge Tray Top Cover

Replacement

REP 4-52 Inverter Top Cover

NOTE: Ensure that the Stacker Top Cover studs are fully seated in the slots of the Counterbalance Brackets before tightening the nuts.

Parts List on PL 4.14 Removal

1.

1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE INVERTER DOOR.

3.

REMOVE THE INVERTER TOP COVER (Figure 1).

REINSTALL THE PURGE TRAY TOP COVER AND TIGHTEN THE NUTS.

Section Name

REP 4-51

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Preliminary Working Document No Product Name Assigned

REP 4-53 Stacker Rear Top Cover 3 LIFT THE FRONT UP SLIGHTLY

4

2

PULL THE COVER OUT, AND REMOVE

LOOSEN NUT

Parts List on PL 4.14 Removal 1.

REMOVE THE STACKER UPPER REAR COVER.

2.

REMOVE THE STACKER REAR TOP COVER (Figure 1).

1 DISCONNECT

Figure 1 Removing the Top Cover

Preliminary Working Document No Product Name Assigned

0/0/00 ?-117

Section Name

REP 4-52, REP 4-53

REP 4-54 Inverter Left Side Cover

Parts List on PL 4.10 Removal 1.

REMOVE THE INVERTER TOP COVER (REP 4-52).

2.

REMOVE THE INVERTER LEFT SIDE COVER (Figure 1).

2 REMOVE THE COVER

1 LOOSEN SCREWS (2)

Figure 1 Removing the Cover

Section Name

REP 4-54

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Preliminary Working Document No Product Name Assigned

REP 6-1 ROS Assembly

CAUTION

Parts List on PL 6.1 Removal To see additional information go to Imaging in the DocuPrint 180 Unique Components and Functions section.

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure of the PR Belt to under two (2) minutes. If the PR Belt will be exposed to light a longer period, remove the Photoreceptor from the belt module and place it immediately in the protective bag, or place the bag over the Photoreceptor with it on the belt module. 1.

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL POWER CORDS.

2.

REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

4.

PREPARE TO REMOVE THE ROS ASSEMBLY (Figure 1).

1 DISCONNECT THE CONNECTORS (2)

2 DISCONNECT THE VIDEO Figure 1 Preparing to Remove the ROS Assembly 5.

REMOVE THE ROS ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 6-1

3 LIFT THE ROS ASSEMBLY OUT OF THE MACHINE

2 MOVE (2)

1 LOOSEN (2)

Figure 2 Removing the ROS Assembly

Replacement 1.

REINSTALL THE ROS ASSEMBLY.

2.

REINSTALL THE PHOTORECEPTOR BELT (REP 9-35).

3.

REINSTALL ALL MACHINE COVERS.

4.

PERFORM THE FOLLOWING ADJUSTMENTS: a.

ROS Image Squareness Setup (ADJ 6-2).

b.

Side-to-Side (Slow Scan) Registration Setup (ADJ 8-3).

c.

Top-to-Bottom (Fast Scan) Registration Setup (ADJ 8-2).

d.

Belt Seam Timing (ADJ 9-8).

e.

ROS Magnification Setup (ADJ 6-1).

f.

ROS Power Calibration (ADJ 6-4).

g.

Xerographic Setup (ADJ 9-3).

Section Name

REP 6-1

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Preliminary Working Document No Product Name Assigned

REP 6-2 VLD/Collimator Assembly

1.

Parts List on PL 6.1 Removal

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL POWER CORDS.

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

3.

REMOVE THE ROS INNER PANEL.

To see additional information go to Imaging in the DocuPrint 180 Unique Components and Functions section.

4.

REMOVE THE VLD ASSEMBLY (Figure 1).

4 3 DISCONNECT THE CONNECTOR

REMOVE THE SCREWS (3)

5 TILT THE ASSEMBLY AWAY FROM THE HOUSING AND REMOVE

2 REMOVE THE COVER

1 REMOVE THE SCREWS (4)

Figure 1 Removing the VLD/Collimator Assembly

Replacement

3.

PERFORM THE ROS POWER CALIBRATION (ADJ 6-4).

1.

INSTALL THE VLD/COLLIMATOR ASSEMBLY.

4.

PERFORM THE XEROGRAPHIC SETUP PROCEDURE (ADJ 9-3).

2.

INSTALL A NEW ROS PROFILE EPROM (REP 6-6).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 6-2

REP 6-3 Polygon Motor (MOT601)

2.

REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).

Parts List on PL 6.1 Removal

3.

REMOVE THE ROS ASSEMBLY (REP 6-1). CAUTION

To see additional information go to Imaging in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL POWER CORDS.

Use extreme care when accessing the internal optical components of the ROS Assembly. Dirt and smudges on the laser optical components can cause print quality problems and disturb the operation of the ROS system. Avoid all contact with any laser optical path component. 4.

REMOVE THE POLYGON MOTOR (Figure 1).

1

2

REMOVE THE LIGHT SHIELD

REMOVE THE COVER SCREWS (7)

3

6

REMOVE THE COVER

REMOVE THE POLYGON MOTOR

5 REMOVE THE POLYGON MOTOR SCREWS (3)

4 DISCONNECT THE POLYGON MOTOR CONNECTOR Figure 1 Removing the Polygon Motor

REP 6-4 EOS and SOS PWBs

Replacement CAUTION Use care when handling the Polygon Motor. If the motor is dropped, it will be damaged and cause image quality problems. 1.

INSTALL THE POLYGON MOTOR.

2.

PERFORM THE ROS MAGNIFICATION SETUP (ADJ 6-1).

Section Name

REP 6-3

Parts List on PL 6.1 Removal To see additional information go to Imaging in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL POWER CORDS.

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

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Preliminary Working Document No Product Name Assigned

3.

PREPARE TO REMOVE THE SCAN DETECTOR PWBs (Figure 1).

1 DISCONNECT THE SCAN DETECTOR PWB CONNECTOR

2 REMOVE THE SCREWS (4) AND WASHERS (4)

Figure 1 Preparing to Remove the Scan Detector PWBs 4.

REMOVE THE SCAN DETECTOR PWB (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 6-4

EOS PWB

SOS PWB

1 REMOVE

Figure 2 Removing the Scan Detector PWBs

Replacement

REP 6-5 ROS Control Module (RCM) PWB

1.

INSTALL THE SCAN DETECTOR PWB.

2.

REINSTALL ALL MACHINE COVERS.

Parts List on PL 6.1 Removal

3.

CHECK/PERFORM THE FOLLOWING ADJUSTMENTS: a.

ROS Magnification Setup (ADJ 6-1).

b.

Top-to-Bottom (Fast Scan) Registration (ADJ 8-2).

c.

If the SOS PWB has been replaced, perform ROS Power Calibration (ADJ 6-4).

d.

Xerographic Setup (ADJ 9-3).

Section Name

REP 6-4

To see additional information go to Imaging in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. DISCONNECT ALL POWER CORDS.

2.

REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).

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Preliminary Working Document No Product Name Assigned

3.

REMOVE THE ROS ASSEMBLY (REP 6-1).

4.

IF INSTALLING A NEW RCM PWB, REMOVE THE ROS PROFILE EPROM FROM OLD PWB TO BE INSTALLED IN THE NEW PWB (Figure 1).

1 INSERT INDEX FINGER INTO RING AT THE TOP OF THE EXTRATION TOOL

RCM PWB

3 GENTLY SQUEEZE TOOL WITH THUMB AND MIDDLE FINGER AND PULL UPWARD TO REMOVE THE EPROM

2 INSERT THE EXTRACTION TOOL TIPS INTO SLOTS AT CORNERS OF SOCKET

Figure 1 Removing the ROS Profile EPROM

Preliminary Working Document No Product Name Assigned

0/0/00 ?-125

Section Name

REP 6-5

5.

REMOVE THE ROS CONTROL MODULE PWB (Figure 2).

3 DISCONNECT

1 REMOVE BRACKET

2

4

DISCONNECT

DISCONNECT

5 REMOVE THE SCREWS (7) AND REMOVE PWB

Figure 2 Removing the ROS Control Module PWB

Replacement 1.

INSTALL THE NEW ROS CONTROL MODULE PWB. CAUTION

Ensure that the EPROM is installed in the correct position, to avoid damage to the EPROM or the PWB. Use both indicators: the Flattened Corners on both the EPROM and the Socket; and the Pin 1 Indicator Spot on both the EPROM and the Socket. 2.

INSTALL THE ROS PROFILE EPROM (Figure 3).

Section Name

REP 6-5

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Preliminary Working Document No Product Name Assigned

EPROM

PIN 1 INDICATOR SPOTS

EXTRACTION SLOT

FLATTENED CORNERS

OCATOR ARROW

SOCKET

Figure 3 Installing the ROS Profile EPROM 3.

ADJUST THE ROS POWER CALIBRATION (ADJ 6-4).

REP 6-6 ROS Profile EPROM Parts List on PL 6.1 Removal To see additional information go to Imaging in the DocuPrint 180 Unique Components and Functions section.

Preliminary Working Document No Product Name Assigned

1.

REMOVE THE ROS ASSEMBLY (REP 6-1).

2.

REMOVE THE ROS PROFILE EPROM (Figure 1).

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Section Name

REP 6-5

1 INSERT INDEX FINGER INTO RING AT THE TOP OF THE EXTRATION TOOL

RCM PWB

3 GENTLY SQUEEZE TOOL WITH THUMB AND MIDDLE FINGER AND PULL UPWARD TO REMOVE THE EPROM

2 INSERT THE EXTRACTION TOOL TIPS INTO SLOTS AT CORNERS OF SOCKET

Figure 1 Removing the ROS Profile EPROM

Section Name

REP 6-6

0/0/00 ?-128

Preliminary Working Document No Product Name Assigned

Replacement CAUTION Ensure that the EPROM is installed in the correct position, to avoid damage to the EPROM or the PWB. Use both indicators: the Flattened Corners on both the EPROM and the Socket; and the Pin 1 Indicator Spot on both the EPROM and the Socket. 1.

INSTALL THE ROS PROFILE EPROM (Figure 2).

EPROM

PIN 1 INDICATOR SPOTS

EXTRACTION SLOT

FLATTENED CORNERS

OCATOR ARROW

SOCKET

Figure 2 Installing the ROS Profile EPROM

Preliminary Working Document No Product Name Assigned

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Section Name

REP 6-6

Section Name

REP 6-6

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Preliminary Working Document No Product Name Assigned

REP 7-0 Feed Head Assembly Parts List on PL 7.10 Removal 1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FEED HEAD (Figure 1).

2

1 REMOVE THE RETAINER

REMOVE THE COVER

3 DISCONNECT THE CONNECTOR

4

5 REMOVE THE FEED HEAD

REMOVE THE RETAINER

Figure 1 Removing the Feed Head

Replacement 1.

POSITION THE STACK RELIEF SOLENOID PIN (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-131

Section Name

REP 7-0

NOTE: POSITION THE SOLENOID PIN IN FRONT OF THE TABS ON THE TRAY FRAME

Figure 2 Positioning the Stack Relief Solenoid Pin 2.

POSITION THE FRONT BEARING IN THE SLOT OF THE BEARING MOUNT.

REP 7-1 Tube Shaft

3.

ENSURE THAT THE FEED HEAD MOVES FREELY, AND THAT THE WIRES DO NOT INTERFERE WITH THE FEED HEAD CASTING.

4.

IF INSTALLING A NEW FEED HEAD CHECK/ADJUST THE FOLLOWING:

Parts List on PL 7.11 Removal

a.

Tray 1 and 2 Feeder Drives (ADJ 4-20).

1.

b.

Auto Latch (ADJ 7-6).

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

c.

Paper Feed Setup (ADJ 7-9).

3.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).

4.

REMOVE THE SAFETY COVERS FROM THE TUBE SHAFT.

5.

REMOVE THE TUBE SHAFT (Figure 1).

Section Name

REP 7-0

0/0/00 ?-132

PULL OUT THE TRAY.

Preliminary Working Document No Product Name Assigned

4 REMOVE THE SHAFT

3 REMOVE THE RETAINING RING, AND HOLD THE PULLEY AND BELT

1 REMOVE THE RETAINING RING, AND LOOSEN THE SETSCREW

2 MOVE THE IDLER AWAY

Figure 1 Removing the Tube Shaft

Replacement CAUTION Before the idler is tightened, rotate the Takeaway Drive Belt five revolutions. In order to prevent damage to the idler, do not manually apply extra tension to the idler. 1.

INSTALL THE TUBE SHAFT.

2.

CHECK/ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-133

Section Name

REP 7-1

REP 7-2 Retard Brake, Retard Roll, and Entry Guide

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 7.13 Removal

3.

REMOVE THE RETARD BRAKE AND THE ENTRY GUIDE (Figure 1).

1.

PULL OUT THE TRAY.

1 UNLATCH

SLOTS (2) ON THE FEED HEAD FRAME

ENTRY GUIDE

2 ENTRY GUIDE NOTCHES (2)

LIFT AND ROTATE TO THE LEFT

Figure 1 Removing the Retard Brake and Entry Guide 4.

REMOVE THE RETARD ROLL (Figure 2).

Section Name

REP 7-2

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Preliminary Working Document No Product Name Assigned

REP 7-3 Feed Belt Parts List on PL 7.10 Removal

1 REMOVE THE RETAINING RING

1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE SAFETY COVER FROM THE TUBE SHAFT. CAUTION

2

Body oil from the hands can contaminate the belt. Do not place a sharp bend in the feed belt.

REMOVE THE RETARD ROLL

4.

REMOVE THE FEED BELT (Figure 1).

2

1

REMOVE

REMOVE

RETARD BRAKE

5 TURN, AND PULL

Figure 2 Removing the Retard Roll

Replacement 4

NOTE: Ensure that the two notches on either side of the Entry Guide are installed into the slots of the Feed Head frame. 1.

PRESS DOWN

3 RELEASE, AND RAISE

INSTALL THE RETARD ROLL AND ENTRY GUIDE.

Figure 1 Removing the Feed Belt

Replacement 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-135

IF A NEW FEED BELT WAS INSTALLED PERFORM THE PAPER FEED SETUP (ADJ 79).

Section Name

REP 7-2, REP 7-3

REP 7-4 Feed Belt Latch Arm

REP 7-5 Feed Belt Pulley

Parts List on PL 7.11 Removal

Parts List on PL 7.12 Removal

1.

PULL OUT THE TRAY.

1.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE SAFETY COVER FROM THE FEED HEAD.

3.

REMOVE THE TWO SAFETY COVERS FROM THE FEED HEAD.

4.

REMOVE THE FEED BELT LATCH ARM AND THE SPRING (Figure 1).

4 REMOVE THE ARM AND SPRING

PULL OUT THE TRAY.

CAUTION Body oil from the hands can contaminate the belt, and induce misfeeds. Do not bend or twist the belt. 4.

REMOVE THE FEED BELT (REP 7-3).

5.

PREPARE TO REMOVE THE FEED BELT PULLEY (Figure 1).

TORSION SPRING

4 REMOVE THE E-RING AND THE SPACER

3 REMOVE THE SHAFT

1 UNLATCH THE FEED BELT

2 REMOVE THE ERING

2

3 DISENGAGE THE BELT

Figure 1 Removing the Feed Belt Latch Arm and Spring

MOVE THE IDLER AWAY FROM THE BELT

1 LOOSEN THE SCREW

Replacement 1.

PERFORM THE PAPER FEED SETUP (ADJ 7-9).

2.

CHECK/ADJUST THE AUTO LATCH (ADJ 7-6).

Figure 1 Preparing to Remove the Feed Belt Pulley 6.

Section Name

REP 7-4, REP 7-5

0/0/00 ?-136

REMOVE THE FEED BELT PULLEY (Figure 2).

Preliminary Working Document No Product Name Assigned

REP 7-6 Feed Belt Idler Parts List on PL 7.12 Removal

3

1.

REMOVE THE FEED BELT PULLEY

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE SAFETY COVER FROM THE TUBE SHAFT. CAUTION

Body oil from the hands can contaminate the belt, and induce misfeeds. 4.

REMOVE THE FEED BELT (REP 7-0).

5.

REMOVE THE FEED BELT IDLER (Figure 1).

4 REMOVE THE FEED BELT SPOOL BRACKET, FEED BELT IDLER, AND TWO WASHERS

2 1 CUT THE CABLE TIE

PUSH THE SHAFT TOWARD THE FRONT

1 REMOVE

2 PUSH THE FEED BELT SPOOL BRACKET DOWN UNTIL THE SLOT CLEARS THE PIN Figure 2 Removing the Feed Belt Pulley

Replacement

3 LIFT SLOWLY, AND REMOVE THE SPRING

NOTE: Ensure that the collar of the Feed Clutch is installed on the flat part of the shaft on the Feed Head frame, and that the locating pin of the clutch is engaged in the casting. 1.

INSTALL THE FEED BELT PULLEY WITH THE PART NUMBER TOWARDS THE REAR SO THAT THE PULLEY ROTATES ONLY IN A COUNTERCLOCKWISE DIRECTION.

2.

ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).

PIN

Figure 1 Removing the Feed Belt Idler

Replacement 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-137

REINSTALL THE FEED BELT IDLER WITH THE PART NUMBER TOWARDS THE REAR SO THAT THE IDLER ROTATES ONLY IN A COUNTERCLOCKWISE DIRECTION.

Section Name

REP 7-5, REP 7-6

REP 7-7 Feed Belt Spool

REP 7-8 Feed Clutch Pulley

Parts List on PL 7.12 Removal

Parts List on PL 7.12 Removal

1.

PULL OUT THE TRAY.

1.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FEED BELT (REP 7-3).

3.

4.

REMOVE THE FEED BELT SPOOL (Figure 1).

REMOVE THE SAFETY COVERS FROM THE TUBE SHAFT, AND REMOVE THE FEED HEAD.

PULL OUT THE TRAY.

CAUTION Do not bend or twist the Feed Clutch Belt. 4.

REMOVE THE FEED CLUTCH PULLEY (Figure 1).

2

5

REMOVE THE SHAFT AND THE SPOOL

1

NOTE: REMOVE THE FEED CLUTCH PULLEY

RAISE

4 REMOVE THE BELT FROM THE FEED CLUTCH PULLEY

2 LOOSEN THE SCREW

1 REMOVE THE RETAINING RING

3 MOVE THE IDLER AWAY FROM THE

Figure 1 Removing the Feed Belt Spool

Replacement Figure 1 Preparing to Remove the Feed Clutch

NOTE: Install the spool with the wider flange towards the front of the printer. 1.

INSTALL THE SPOOL.

Replacement NOTE: Rotate the Feed Clutch Belt five revolutions. Do not apply additional tension to the idler. 1.

Section Name

REP 7-7, REP 7-8

0/0/00 ?-138

INSTALL THE FEED CLUTCH PULLEY.

Preliminary Working Document No Product Name Assigned

REP 7-9 Feed Clutch Belt

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 7.10 Removal

3.

REMOVE THE TWO FEED HEAD SAFETY COVERS, AND REMOVE THE SUPPORT BRACKET (Figure 1).

1.

PULL OUT THE TRAY.

1 REMOVE THE TWO SAFETY COVERS

2 REMOVE THE SUPPORT BRACKET

Figure 1 Removing the Two Safety Covers and the Support Bracket CAUTION Do not bend or twist the Feed Clutch Belt. 4.

REMOVE THE FEED CLUTCH BELT (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-139

Section Name

REP 7-9

4

5

SECURE THE IDLER AWAY FROM THE FEED CLUTCH BELT

REMOVE THE FEED CLUTCH BELT FROM THE FEED CLUTCH PULLEY

3 LOOSEN THE SCREW

2 REMOVE THE TAKEAWAY ROLL SENSOR

1 DISCONNECT THE CONNECTOR

Figure 2 Removing the Feed Clutch Belt

Replacement

REP 7-10 Feed Clutch (CL811/821)

1.

Parts List on PL 7.12 Removal

ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).

1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE TWO FEED HEAD SAFETY COVERS AND THE SUPPORT BRACKET. CAUTION

Do not bend or twist the Feed Clutch Belt. NOTE: Push the shaft of the Feed Clutch to the rear when removing the Feed Clutch.

Section Name

REP 7-9

4.

PREPARE TO REMOVE THE FEED CLUTCH (Figure 1).

5.

REMOVE THE FEED CLUTCH (Figure 1).

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Preliminary Working Document No Product Name Assigned

REP 7-11 Takeaway Idler Roll Parts List on PL 7.13 Removal

4 REMOVE THE FEED CLUTCH

1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0). CAUTION

The springs are under high tension. Holding the idler bracket while removing the screws will prevent damage to the springs. 4.

REMOVE THE TAKEAWAY IDLER ROLL (Figure 1).

1 CUT THE CABLE TIE

2 REMOVE THE SCREWS

3 DISCONNECT THE CONNECTOR

Figure 1 Removing the Feed Clutch

Replacement NOTE: Ensure that the Thrust Washer is installed on the flat part of the shaft, and that the locating pin of the clutch is engaged in the casting. 1.

INSTALL THE FEED CLUTCH.

2.

ADJUST THE FEED CLUTCH BELT AND THE TAKEAWAY DRIVE BELT (ADJ 7-0).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-141

Section Name

REP 7-11

REP 7-12 Takeaway Drive Belt 3 4

REMOVE THE TAKEAWAY IDLER ROLL TENSIONING SPRINGS (2)

REMOVE THE TAKEAWAY IDLER ROLL

Parts List on PL 7.10 Removal 1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE TWO FEED HEAD SAFETY COVERS AND THE SUPPORT BRACKET. CAUTION

Do not bend or twist the Feed Clutch Belt. 4.

REMOVE THE TAKEAWAY DRIVE BELT (Figure 1).

2 1 SECURE THE IDLER AWAY FROM THE TAKEAWAY DRIVE BELT

CAUTION REMOVE THE RETAINER, BELT, AND PULLEY

1 CAUTION REMOVE THE SCREWS

2 REMOVE THE IDLER BRACKET

3 NOTE: REMOVE THE WASHERS

Figure 1 Removing the Takeaway Idler Roll (A)

5 REMOVE THE TAKEAWAY PULLEY

4 REMOVE THE BELT

Figure 1 Removing the Takeaway Drive Belt

Section Name

REP 7-12

0/0/00 ?-142

Preliminary Working Document No Product Name Assigned

Replacement

REP 7-13 Takeaway Roll

NOTE: Ensure that the tab of the large washer is positioned below the idler pulley (A).

Parts List on PL 7.10 Removal

1.

ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).

1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FOLLOWING: a.

Safety Covers and Support Bracket.

b.

Feed Head Assembly (REP 7-0).

c.

Takeaway Idler Roll (REP 7-11). CAUTION

Do not bend the Feed Clutch Belt or the Takeaway Drive Belt. 4.

PREPARE TO REMOVE THE TAKEAWAY ROLL (Figure 1).

1 RAISE

2 LOOSEN THE SCREW

3 SECURE THE IDLER AWAY FROM THE FEED CLUTCH BELT

4 LOOSEN THE SETSCREW

Figure 1 Preparing to Remove the Takeaway Roll

Preliminary Working Document No Product Name Assigned

5.

REMOVE THE TAKEAWAY DRIVE BELT (REP 7-12).

6.

REMOVE THE TAKEAWAY ROLL (Figure 2).

0/0/00 ?-143

Section Name

REP 7-13

2 REMOVE THE TAKEAWAY ROLL

1 MOVE THE SHAFT TO THE REAR

Figure 2 Removing the Takeaway Roll

Replacement

REP 7-14 Length Guide

1.

ADJUST THE TAKEAWAY SHAFT ENDPLAY (ADJ 7-1).

2.

ADJUST THE FEED CLUTCH BELT AND TAKEAWAY DRIVE BELT (ADJ 7-0).

Parts List on PL 7.2 Removal 1.

OPEN THE PRINTER RIGHT DOOR.

NOTE: Pull out Tray 1 to access the Tray 1 and/or Tray 2 Interlock Switches. 2.

PULL OUT THE TRAY.

WARNING Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal injury, and ensure that the elevator does not move when the Elevator Interlock Switch is cheated.

Section Name

REP 7-13

3.

CHEAT THE ELEVATOR INTERLOCK SWITCH.

4.

TRAY 2 ONLY: PUSH TRAY 1 INTO PRINTER.

5.

RAISE THE PAPER PLATE. ENTER dC330, [7-8]. SELECT [Tray 1 Elevator UP] OR [Tray 2 Elevator UP]. PRESS THE Continue BUTTON.

6.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

0/0/00 ?-144

Preliminary Working Document No Product Name Assigned

7.

MOVE THE LENGTH GUIDE TO THE REAR OF THE TRAY.

REP 7-15 Elevator Up Limit Switch (S714/724)

8.

REMOVE THE LENGTH GUIDE (Figure 1).

Parts List on PL 7.6 Removal

5 REMOVE THE LENGTH GUIDE SO THAT IT CLEARS THE PAPER TRAY

4

1.

REMOVE THE SCREWS (4)

2.

PULL OUT THE TRAY. SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).

4.

REMOVE THE ELEVATOR UP LIMIT SWITCH (Figure 1).

3

1

DISCONNECT THE CONNECTORS (2)

DISCONNECT THE CONNECTOR

2 REMOVE THE SCREWS AND THE SWITCH

1 LOOSEN THE SCREWS (2)

2 REMOVE THE COVER

Figure 1 Removing the Elevator Up Limit Switch

Replacement

Figure 1 Removing the Length Guide

1.

Replacement

ADJUST THE ELEVATOR UP LIMIT SWITCH (ADJ 7-3).

NOTE: Do not tighten the mounting screws (4) before adjusting the Length Guide. 1.

INSTALL THE LENGTH GUIDE SO THAT THE GUIDE IS CENTERED (SIDE-TO-SIDE) IN THE PAPER PLATE OPENING.

2.

ADJUST THE LENGTH GUIDE POSITION (ADJ 7-4).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-145

Section Name

REP 7-15, REP 7-16

REP 7-16 Elevator Belt Parts List on PL 7.8 Removal 1.

OPEN THE PRINTER RIGHT DOOR.

2.

PULL OUT THE TRAY.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE ELEVATOR (REP 7-25). CAUTION

Do not press down with excessive force or move the elevator across the work surface when the elevator is upside down. The release lever on the Length Guide may break. NOTE: There are five screws for Tray 2. 5.

REMOVE THE BOTTOM PLATE (Figure 1).

2 REMOVE THE SCREWS (2)

3 REMOVE THE BOTTOM PLATE

1 NOTE: REMOVE THE SCREWS (6)

Figure 1 Removing the Bottom Plate NOTE: The lead screw may move down when the pulley is pressed. If this occurs, hold the top of the lead screw. 6.

REMOVE THE ELEVATOR BELT (Figure 2).

Section Name

REP 7-15, REP 7-16

0/0/00 ?-146

Preliminary Working Document No Product Name Assigned

4 REMOVE THE BELT

1 NOTE: REMOVE THE RETAINERS

3 MOVE THE IDLER AWAY FROM THE BELT

2 REMOVE THE PULLEYS AND BELT

Figure 2 Removing the Elevator Belt

Replacement

REP 7-17 Elevator Drive Motor (MOT711/721)

1.

Parts List on PL 7.7 Removal

PERFORM THE PAPER FEED SETUP (ADJ 7-9).

1.

OPEN THE PRINTER RIGHT DOOR.

2.

PULL OUT THE TRAY.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: The Elevator Drive Motor of Tray 2 can be removed without removing the elevator. For better access, remove the elevator. 4.

TRAY 1 ONLY: REMOVE THE ELEVATOR (REP 7-25).

NOTE: There are five screws for Tray 2. 5.

TRAY 1 ONLY: REMOVE THE BOTTOM PLATE FROM THE ELEVATOR (Figure 1).

NOTE: The lead screw may move down when the pulley is pressed. If this occurs, hold the top of the lead screw. 6.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-147

REMOVE THE ELEVATOR MOTOR (Figure 1).

Section Name

REP 7-16

1

2 REMOVE THE RETAINING RINGS

NOTE: PUSH DOWN THE PULLEY

5 DISCONNECT, AND REMOVE

4 REMOVE THE SCREWS (4)

3 REMOVE THE PULLEYS (2) AND THE BELT

Figure 1 Removing the Elevator Motor

Replacement 1.

ADJUST THE ELEVATOR DRIVE BELT (ADJ 7-11).

Section Name

REP 7-17

0/0/00 ?-148

Preliminary Working Document No Product Name Assigned

REP 7-18 Elevator MOTOR Capacitor (C711/721)

NOTE: There are five screws for Tray 2.

Parts List on PL 7.7 Removal

5.

1.

OPEN THE PRINTER RIGHT DOOR.

2.

PULL OUT THE TRAY.

Discharge the Elevator Motor Capacitor with a screwdriver before touching the terminals. This will prevent an electrical shock.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE ELEVATOR (REP 7-25).

REMOVE THE BOTTOM PLATE (Figure 1).

WARNING

6.

REMOVE THE ELEVATOR MOTOR CAPACITOR (Figure 1).

1 WARNING DISCONNECT THE LEADS

3 REMOVE THE CAPACITOR

410A GROUND WIRE

410 411A 411

2 2 REMOVE THE SCREWS (4)

Figure 1 Removing the Elevator Motor Capacitor

Preliminary Working Document No Product Name Assigned

0/0/00 ?-149

Section Name

REP 7-18

REP 7-19 Lock Arm and Lock Actuator

REP 7-20 Stack Relief Solenoid (SOL811/821)

Parts List on PL 7.3 Removal

Parts List on PL 7.1 Removal

1.

PULL OUT THE TRAY.

1.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE TRAY 1 AND 2 FRONT COVERS (REP 7-22).

3.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).

4.

REMOVE THE TRAY LOCK ARM AND LOCK ACTUATOR (Figure 1).

4.

REMOVE THE STACK RELIEF SOLENOID (Figure 1).

PULL OUT THE TRAY.

3 REMOVE THE SOLENOID ASSEMBLY CAUTION LOCK ACTUATOR

1 LOOSEN THE SETSCREW

1 2

REMOVE THE SCREWS (2)

DISCONNECT THE CONNECTOR

2 REMOVE THE SHAFT

Figure 1 Removing the Tray Lock Arm and Lock Actuator

Figure 1 Removing the Stack Relief Solenoid

Replacement

Replacement CAUTION

1.

PERFORM THE PAPER FEED SETUP (ADJ 7-9).

Do not allow the actuator to bind. Ensure that the Lock Actuator Return Spring and the Lock Actuator are under the tab on the Paper Plate Support. 1.

REINSTALL THE LOCK ARM AND ACTUATOR.

Section Name

REP 7-19, REP 7-20

0/0/00 ?-150

Preliminary Working Document No Product Name Assigned

REP 7-21 Stack Height Sensor (Q711/721)

REP 7-22 Tray 1 and 2 Front Covers

Parts List on PL 7.1 Removal

Parts List on PL 7.3 Removal

1.

PULL OUT THE TRAY.

1.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).

3.

REMOVE THE FRONT COVER (Figure 1).

4.

REMOVE THE TRAY 1 AND 2 FRONT COVERS (REP 7-22).

PULL OUT THE TRAY.

NOTE: Make a scribe mark around the washers (2) before removing the screws (2). 5.

THE LABEL PANEL

REMOVE THE STACK HEIGHT SENSOR (Figure 1).

2 DISCONNECT THE CONNECTOR

1 NOTE: REMOVE THE SCREWS (2)

1 3

2

REMOVE THE COVER

DISCONNECT, AND REMOVE THE SENSOR

LOOSEN THE SCREWS (2)

Figure 1 Removing the Front Cover

Figure 1 Removing the Stack Height Sensor

Replacement NOTE: Install the sensor so that the washers of the mounting screws are aligned with the scribe marks on the frame. 1.

INSTALL THE SENSOR IN THE ORIGINAL POSITION.

2.

PERFORM THE PAPER FEED SETUP (ADJ 7-9).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-151

Section Name

REP 7-21, REP 7-22

REP 7-23 Lead Screws (Front), Bearings, and the Lift Nuts Parts List on PL 7.5 Removal 1.

OPEN THE PRINTER RIGHT DOOR.

2.

PULL OUT THE TRAY.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE ELEVATOR (REP 7-25). CAUTION

Do not press down with excessive force or move the elevator across the work surface when the elevator is upside down. The release lever on the Length Guide may break. 5.

REMOVE THE BOTTOM PLATE (Figure 1).

6.

RAISE THE PAPER PLATE HALF WAY UP THE LEAD SCREWS.

7.

REMOVE THE TRAY FRONT COVER AND THE LABEL PANEL.

8.

REMOVE THE LEAD SCREW PULLEY (Figure 1).

3 REMOVE THE PULLEYS (2), THE SPRINGS (2), AND THE SPACERS (2)

1 SECURE THE IDLER AWAY FROM THE BELT

2 REMOVE THE RETAINING RINGS (2)

Figure 1 Removing the Lead Screw Pulley 9.

REMOVE THE PAPER PLATE (Figure 2).

Section Name

REP 7-23

0/0/00 ?-152

Preliminary Working Document No Product Name Assigned

2 REMOVE THE SCREWS (5)

PAPER PLATE

PAPER PLATE SUPPORT

1 REMOVE THE NUT AND GROUND WIRE

4 3

REMOVE THE PAPER PLATE

REMOVE THE NUT

Figure 2 Removing the Paper Plate 10. REMOVE THE LEAD SCREW (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 7-23

1

3

REMOVE THE RETAINER

REMOVE THE LEAD SCREW

3 HOLD THE NUT

2 INSTALL THE RETAINER

1 INSTALL THE LEAD SCREW AND THE LIFT NUT

2 REMOVE THE SUPPORT

4 ROTATE THE LEAD SCREW TO CENTER THE NUT

BEARING LATCH ASSEMBLY

Figure 3 Removing the Lead Screw 11. REMOVE THE LIFT NUT FROM THE LEAD SCREW.

Figure 4 Installing the Lead Screw 3.

INSTALL THE PAPER PLATE SUPPORT (Figure 5).

12. REMOVE THE CLAMPS AND REMOVE THE BEARINGS, IF REQUIRED.

Replacement 1.

INSTALL THE LIFT NUT AND THE RETAINER ONTO THE LEAD SCREW.

2.

INSTALL THE LEAD SCREW, AND POSITION THE LIFT NUT (Figure 4).

Section Name

REP 7-23

0/0/00 ?-154

Preliminary Working Document No Product Name Assigned

REP 7-24 Lead Screws (Rear), Bearings, and the Lift Nuts Parts List on PL 7.6 Removal

2 INSTALL THE SUPPORT

1 CENTER THE OTHER NUT ON THE LEAD SCREW

1.

OPEN THE PRINTER RIGHT DOOR.

2.

PULL OUT THE TRAY.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE ELEVATOR (REP 7-25). CAUTION

Do not press down with excessive force or move the elevator across the work surface when the elevator is upside down. The release lever on the Length Guide may break. NOTE: There are five screws for Tray 2. 5.

3 ROTATE THE LEAD SCREWS UNTIL THE SUPPORT IS LEVEL

REMOVE THE BOTTOM PLATE FROM THE ELEVATOR (Figure 1).

6.

RAISE THE PAPER PLATE HALF WAY UP BY MOVING THE ELEVATOR DRIVE BELT.

7.

REMOVE THE PULLEY FROM EITHER THE LEFT OR THE RIGHT LEAD SCREW (Figure 1).

GROUND STRAP

1

2

SECURE THE IDLER AWAY FROM THE BELT

REMOVE THE PULLEYS AND THE BELT

Figure 5 Installing the Paper Plate Support NOTE: The retainer of the left rear lead screw must be removed in order to rotate the lift nut. 4.

ROTATE THE REAR LIFT NUTS TO THE CENTER OF THE LEAD SCREWS.

5.

INSTALL THE SPACER, SPRING, AND PULLEY.

NOTE: Ensure that the lead screw pulleys do not rotate in the clockwise direction. 6.

INSTALL THE ELEVATOR DRIVE BELT, AND POSITION THE IDLER.

7.

INSTALL THE BOTTOM PLATE.

8.

INSTALL THE ELEVATOR.

4 3 REMOVE THE PULLEY, SPRING, AND SPACER

NOTE: The Paper Plate will be reinstalled when performing the Paper Plate Parallelism in the Paper Feed Setup Series. Check/adjust the Feed Belt Tension first, then proceed to the Paper Plate Parallelism Adjustment. 9.

REMOVE THE RETAINER, PULLEY, AND BELT

PERFORM THE PAPER FEED SETUP (ADJ 7-9).

Figure 1 Removing the Lead Screw Pulleys 8. Preliminary Working Document No Product Name Assigned

0/0/00 ?-155

REMOVE THE PAPER PLATE (Figure 2). Section Name

REP 7-23, REP 7-24

9.

REMOVE THE LEFT OR THE RIGHT LEAD SCREW (Figure 2).

2

BEARING (2)

REMOVE THE RETAINERS

CLAMP (2)

1

3 REMOVE THE LEAD SCREWS

REMOVE THE SUPPORTS

Figure 2 Removing the Lead Screw 10. REMOVE THE LIFT NUT FROM THE LEAD SCREW. 11. REMOVE THE CLAMPS, AND REMOVE THE BEARINGS IF REQUIRED (Figure 2).

Replacement NOTE: Perform Steps 1 and 2 to reinstall the left and the right rear lead screws. 1.

INSTALL THE LIFT NUT AND THE RETAINER ONTO THE LEAD SCREW.

NOTE: Do not install the left rear lead screw retainer until you position the lift nut. 2.

INSTALL THE LEAD SCREW, AND POSITION THE LIFT NUT (Figure 3).

Section Name

REP 7-24

0/0/00 ?-156

Preliminary Working Document No Product Name Assigned

REP 7-25 Elevator Assembly 2 INSTALL THE RETAINER

Parts List on PL 7.1 Removal 1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).

NOTE: The two screws secure the ribbon cable to the cover only. 4.

PREPARE TO ACCESS THE RIBBON CABLE CONNECTOR (Figure 1).

3 NOTE: LOOSEN THE SCREWS (2)

3

1

ROTATE THE LIFT NUT UNTIL IT TOUCHES THE TOP OF THE ELEVATOR

INSTALL THE LEAD SCREW

2 LIFT AND PUSH TO THE REAR

Figure 3 Installing the Lead Screw 3.

INSTALL THE SPACER, SPRING, AND PULLEY.

NOTE: Ensure that the lead screw pulleys do not rotate in the clockwise direction. 4.

INSTALL THE ELEVATOR BELT, AND POSITION THE IDLER.

5.

INSTALL THE ELEVATOR DRIVE BELT AND PULLEYS.

6.

INSTALL THE BOTTOM PLATE.

7.

INSTALL THE ELEVATOR.

8.

PERFORM THE PAPER FEED SETUP (ADJ 7-9).

4 PUSH THE SCREWS THROUGH THE HOLES IN THE COVER

1 REMOVE THE SCREW

Figure 1 Preparing to Access the Ribbon Cable Connector

Preliminary Working Document No Product Name Assigned

0/0/00 ?-157

Section Name

REP 7-24, REP 7-25

5.

DISCONNECT THE RIBBON CABLE CONNECTORS (Figure 2).

1

2

TURN THE COVER ON ITS SIDE

DISCONNECT THE CABLE

1 2

PULL THE RIBBON OUT OF THE ELEVATOR

PUSH (2), AND REMOVE THE ELEVATOR

3 PUSH THE GUIDE AND CABLE DOWN INTO THE PRINTER

Figure 3 Removing the Elevator

Replacement 1.

HOLD THE RAILS, AND SLIDE THE ELEVATOR IN UNTIL IT IS SECURED BY THE CLIPS.

NOTE: To prevent the guide from being misaligned with the ribbon cable support, do not pull the plastic guide into the elevator farther than necessary. 2.

INSTALL THE RIBBON CABLE AND GUIDE (Figure 4).

Figure 2 Disconnecting the Ribbon Cable Connectors 6.

REMOVE THE ELEVATOR (Figure 3).

Section Name

REP 7-25

0/0/00 ?-158

Preliminary Working Document No Product Name Assigned

2 CONNECT THE CONNECTORS (2)

3

2 PUSH THE RIBBON AND TABS UNDER THE FRAME

NOTE: PULL THE GUIDE UNTIL THE TAB PASSES THE COVER STOP

3 INSTALL THE SCREW

1

THE COVER STOP

SECURE THE SCREWS IN THE SLOTS

1 PULL THE RIBBON THROUGH THE REAR OF THE ELEVATOR

Figure 4 Installing the Ribbon Cable and Guide

Figure 5 Installing the Ribbon Cable Clamp on the Cover

NOTE: Ensure that the clamp is properly positioned so that tab is in the slot in the cable, then secure the clamp to the cover. 3.

4. 5.

INSTALL THE RIBBON CABLE CLAMP AND THE COVER (Figure 5).

Preliminary Working Document No Product Name Assigned

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INSTALL THE FEED HEAD ASSEMBLY (REP 7-0). IF A NEW ELEVATOR WAS INSTALLED CHECK/ADJUST THE FOLLOWING: a.

Auto Latch (ADJ 7-6).

b.

Paper Feed Setup (ADJ 7-9).

Section Name

REP 7-25

REP 7-26 Paper Plate

4.

TRAY 2 ONLY: PUSH TRAY 1 INTO THE PRINTER.

Parts List on PL 7.2 Removal

5.

RAISE THE PAPER PLATE. ENTER dC330, AND SELECT [Tray 1 Elevator UP] OR [Tray 2 Elevator UP]. PRESS THE Continue BUTTON.

6.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1.

OPEN THE PRINTER RIGHT DOOR.

NOTE: To improve access to the Tray 2 Interlock Switch, pull out Tray 1.

NOTE: Do not remove the supports from the Lift Nuts. Removing the supports may misadjust the paper plate parallelism.

2.

7.

PULL OUT THE TRAY, AND REMOVE THE PAPER.

REMOVE THE PAPER PLATE (Figure 1).

WARNING Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal injury, and ensure that the elevator does not move when the Tray Interlock Switch is cheated. 3.

CHEAT THE TRAY 1 OR TRAY 2 INTERLOCK SWITCH.

2 REMOVE THE SCREWS (5)

PAPER PLATE

PAPER PLATE SUPPORT

1 REMOVE THE NUT AND GROUND WIRE

4 3

REMOVE THE PAPER PLATE

REMOVE THE NUT

Figure 1 Removing the Paper Plate

Replacement

REP 7-27 Tray Capacity PWB

1.

INSTALL THE PAPER PLATE WITH THE LENGTH GUIDE IN THE CENTER (SIDE-TOSIDE) OF THE PAPER PLATE OPENING.

2.

PERFORM THE PAPER FEED SETUP SERIES (ADJ 7-9).

Parts List on PL 7.3 Removal 1.

Section Name

REP 7-26

0/0/00 ?-160

PULL OUT THE TRAY. Preliminary Working Document No Product Name Assigned

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

REP 7-28 Elevator Drive Belt

3.

REMOVE THE TRAY 1 AND 2 FRONT COVERS (REP 7-22).

4.

REMOVE THE PWB (Figure 1).

Parts List on PL 7.7 Removal 1.

1 REMOVE THE SCREWS (4)

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE ELEVATOR ASSEMBLY OF TRAY 1 (REP 7-25). CAUTION

Do not press down with excessive force or move the elevator across the work surface when the elevator is upside down. The release lever on the Length Guide may break. NOTE: There are only five screws on Tray 2. 4.

REMOVE THE BOTTOM PLATE OF THE ELEVATOR FROM TRAY 1 (Figure 1).

NOTE: The lead screw may move down when the pulley is pressed. If this occurs, hold the top of the lead screw. 5.

REMOVE THE ELEVATOR DRIVE BELT (Figure 1).

1 2

NOTE:

REMOVE THE PWB

PUSH DOWN THE PULLEY

Figure 1 Removing the PWB

3 REMOVE THE PULLEYS (2) AND BELTS

2 REMOVE THE RETAINING RINGS (2) Figure 1 Removing the Elevator Drive Belt

Preliminary Working Document No Product Name Assigned

0/0/00 ?-161

Section Name

REP 7-27, REP 7-28

Replacement 1.

ADJUST THE ELEVATOR DRIVE BELT (ADJ 7-10).

Section Name

REP 7-28

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Preliminary Working Document No Product Name Assigned

REP 7-34 HCT Elevator Assembly

3.

REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.

Parts List on PL 7.14 Removal

4.

LOWER THE FS RELAY PANEL.

1.

PULL OUT THE HCT.

2.

REMOVE ALL PAPER FROM THE TRAY.

NOTE: Position the Harness Bridge so that it will not be damaged as the Elevator Assembly is removed. 5.

PREPARE TO REMOVE THE ELEVATOR ASSEMBLY (Figure 1).

HARNESS BRIDGE

1

6

REMOVE SAFETY SHIELD

REMOVE THE GROUND SCREW

5 NOTE: REMOVE THE BOLTS (2)

4 DISCONNECT J445

2

3

DISCONNECT J414

DISCONNECT J476

Figure 1 Preparing To Remove the Elevator Assembly NOTE: A Slide Latch is located on each slide. 6.

PULL UP ON THE SLIDE LATCHES AND PULL OUT AND REMOVE THE HCT.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-163

Section Name

REP 7-34

REP 7-35 HCT Elevator Drive Belt

Replacement CAUTION Do not damage the Harnesses when reinstalling the HCT.

Parts List on PL 7.18 Removal

NOTE: The Elevator Assembly will push in hard when it is reinstalled. When reinstalling the Elevator Assembly, ensure that the Rails on the Elevator Assembly are aligned with the slides.

1. 2.

REMOVE THE HCT BOTTOM COVER.

1.

3.

LOWER THE HORIZONTAL TRANSPORT DOOR.

4.

LOOSEN THE ELEVATOR DRIVE BELT IDLER.

PUSH THE ELEVATOR ASSEMBLY INTO THE SLIDES UNTIL THE SLIDES ARE LATCHED.

PULL OUT THE APPROPRIATE HCT.

NOTE: It may be necessary to disconnect one end of the Idler Spring before removing the Drive Belt. 5.

REMOVE THE ELEVATOR DRIVE BELT.

Replacement

Section Name

REP 7-34, REP 7-35

1.

REINSTALL THE ELEVATOR DRIVE BELT.

2.

CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

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Preliminary Working Document No Product Name Assigned

REP 7-36 HCT Elevator Drive Motor (MOT731)

8.

DISCONNECT AND REMOVE THE ELEVATOR DRIVE MOTOR.

Replacement

Parts List on PL 7.18 Removal 1.

PULL OUT THE APPROPRIATE HCT.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE ELEVATOR DRIVE BELT (REP 7-35).

1.

REINSTALL THE ELEVATOR DRIVE MOTOR.

2.

REINSTALL THE ELEVATOR DIVE BELT.

3.

CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

REP 7-37 HCT Lead Screws

4.

REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.

5.

LOWER THE FS RELAY PANEL.

Parts List on PL 7.17 Removal

6.

REMOVE THE AC SAFETY SHIELD.

1.

PULL OUT THE APPROPRIATE HCT.

NOTE: Position the HCT towards the rear of the FS to allow access to the four motor mounting screws.

2.

REMOVE THE PAPER PLATE (REP 7-39).

3.

REMOVE THE ELEVATOR DRIVE BELT (REP 7-35).

7.

NOTE:

REMOVE THE FOUR SCREWS SECURING THE ELEVATOR DRIVE MOTOR.

4 REMOVE THE LEAD SCREW

1 REMOVE THE SCREW AND THE BUSHING

2

3

REMOVE THE SCREW AND THE BEARING RETAINER

LIFT THE LEAD SCREW UNTIL THE LOWER BEARING CLEARS THE ELEVATOR ASSEMBLY BASE

Figure 1 Removing the Lead Screw

Replacement 1.

REINSTALL THE ELEVATOR DRIVE BELT.

2.

REINSTALL THE PAPER PLATE.

Preliminary Working Document No Product Name Assigned

3.

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CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

Section Name

REP 7-36

REP 7-38 HCT Switch Assembly

6.

REMOVE THE HCT PAPER PLATE (REP 7-39).

Parts List on PL 7.17 Removal

7.

REMOVE THE SWITCH ASSEMBLY (Figure 2).

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE FS LOWER REAR COVER.

3.

PREPARE TO REMOVE THE SWITCH ASSEMBLY (Figure 1).

1 2 REMOVE SWITCH ASSEMBLY

1

2

DISCONNECT

DISCONNECT

REMOVE THE SCREWS (2)

Figure 2 Removing the Switch Assembly

Replacement 1. Figure 1 Preparing to Remove the Switch Assembly 4.

MANUALLY UNLATCH AND PUSH OUT THE HCT.

5.

REMOVE ALL OF THE PAPER FROM THE TRAY.

Section Name

REP 7-38

REINSTALL THE SWITCH ASSEMBLY.

2.

REINSTALL THE PAPER PLATE.

3.

CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

4.

CHECK/ADJUST THE LOW PAPER SENSOR (Q738) (ADJ 7-33).

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Preliminary Working Document No Product Name Assigned

REP 7-39 HCT Paper Plate

REP 7-40 HCT Slides

Parts List on PL 7.15 Removal

Parts List on PL 7.18 Removal

1.

PULL OUT THE APPROPRIATE HCT.

1.

REMOVE THE ELEVATOR ASSEMBLY (REP 7-34).

2.

REMOVE THE PAPER FROM THE TRAY.

2.

3.

SWITCH OFF THE PRINTER POWER.

REMOVE THE TRAY CLOSED SWITCH (S730) AND MOUNTING BRACKET FROM THE REAR OF THE LEFT SLIDE.

4.

HANDCRANK THE PAPER PLATE DOWN TO APPROXIMATELY THE HALFWAY POSITION.

3.

REMOVE THE TWO BOLTS SECURING EACH SLIDE, AND REMOVE THE SLIDES.

NOTE: Secure the Retaining Clips, located under the Paper Plate, when removing the four screws.

1.

REPLACE THE RIGHT SLIDE, AND TIGHTEN THE TWO BOLTS.

2.

REPLACE THE LEFT SLIDE. DO NOT COMPLETELY TIGHTEN THE TWO BOLTS AT THIS TIME.

5. 6.

REMOVE THE FOUR SCREWS AND RETAINING CLIPS SECURING THE PAPER PLATE. REMOVE THE PAPER PLATE.

Replacement 1.

REINSTALL THE PAPER PLATE.

2.

CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

Preliminary Working Document No Product Name Assigned

Replacement

3.

REPLACE THE ELEVATOR ASSEMBLY.

4.

POSITION THE LEFT SLIDE FOR THE BEST ELEVATOR ASSEMBLY MOVEMENT.

5.

TIGHTEN THE TWO BOLTS SECURING THE LEFT SLIDE.

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Section Name

REP 7-39, REP 7-40

REP 7-41 HCT Front Cover

REP 7-42 Tray Capacity PWB

Parts List on PL 7.15 Removal

Parts List on PL 7.15 Removal

1.

PULL OUT THE HCT.

1.

PULL OUT THE APPROPRIATE HCT.

2.

SWITCH OFF THE PRINTER POWER.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE MANOMETER.

3.

REMOVE THE HCT FRONT COVER (REP 7-41).

4.

SCRIBE A LINE ON EACH MOUNTING BRACKET ALONG THE EDGE OF EACH COVER SUPPORT BRACKET.

4.

REMOVE THE FOUR SCREWS SECURING THE TRAY CAPACITY PWB.

5.

REMOVE THE TRAY CAPACITY PWB.

LOOSEN THE FOUR NUTS SECURING THE FRONT COVER.

Replacement

5.

NOTE: The Tray Capacity PWB Safety Shield may have to be removed to disconnect the connector. 6.

REMOVE THE FRONT COVER FROM THE SUPPORT BRACKETS AND DISCONNECT THE TRAY CAPACITY PWB CONNECTOR.

Replacement 1.

REINSTALL THE FRONT COVER.

2.

ADJUST THE FRONT COVER IF REQUIRED.

Section Name

REP 7-41, REP 7-42

NOTE: The Tray Unlock Button may fall out when the PWB is removed. Ensure that the button is reinstalled properly, before replacing the capacity PWB. 1.

REINSTALL THE TRAY CAPACITY PWB.

2.

REINSTALL THE HCT FRONT COVER.

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Preliminary Working Document No Product Name Assigned

REP 8-0 Vertical Transport Assembly Parts List on PL 8.1 Removal

1

MAGNETIC SKIS

INSTALL GUIDE BETWEEN VERTICAL XPORT BELTS AND MAGNETIC SKIS AND TURN THE BAFFLE

To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section. NOTE: See PL 8.1 through PL 8.32. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS.

3.

REMOVE THE PRINT TRANSPORT INNER PANEL.

4.

REMOVE THE SPRING FROM THE TURN BAFFLE.

NOTE: Ensure plastic wear element does not fall out of coupling. Also ensure that the Switch Actuator does not get damaged. 5.

REMOVE THE VERTICAL TRANSPORT ASSEMBLY (Figure 1).

2 DISCONNECT

4 REMOVE THE TRANSPORT SWITCH ACTUATOR

3 REMOVE SCREWS (2)

Figure 1 Removing the Transport

Replacement 1.

CHECK THAT THE SWITCH ACTUATOR IS TIGHT. IF NOT, PUSH ON SPRING RETAINER TO TIGHTEN.

NOTE: The Guide for the Replacement is stored in the parts cabinet. NOTE: Ensure that plastic wear element is positioned fully clockwise in coupling when replacing transport. 2.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-169

INSTALL THE GUIDE AGAINST THE MAGNETIC SKIS, AND CAREFULLY PUSH THE VERTICAL TRANSPORT INTO THE PRINTER.

Section Name

REP 8-0

3.

4.

FOR NEW BELT INSTALLATION ONLY:

REP 8-1 Vertical Transport Drive Belt

a.

Enter [SCP], [HFSI Status].

b.

Select [P08-808 Vertical Transport Belts], and press [Reset].

Parts List on PL 8.1 Removal

CHECK/ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).

To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section. NOTE: See PL 8.1 through PL 8.32. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL THE VERTICAL TRANSPORT ASSEMBLY OUT APPROXIMATELY 1 INCH (REP 8-0).

3.

REMOVE THE BELT (Figure 1).

2 REMOVE THE BELT

1 LOOSEN THE SCREW

Figure 1 Removing the Belt

Section Name

REP 8-0, REP 8-1

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Preliminary Working Document No Product Name Assigned

REP 8-2 Turn Baffle

2.

OPEN THE PRINTER FRONT DOORS.

Parts List on PL 8.1 Removal

3.

REMOVE THE PRINT TRANSPORT INNER PANEL.

NOTE: See PL 8.1 through PL 8.32. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE REGISTRATION TRANSPORT INNER PANEL.

5.

REMOVE THE VERTICAL TRANSPORT (REP 8-0).

6.

REMOVE THE NIP RELEASE SOLENOID ASSEMBLY AND THE IDLER BRACKET (REP 8-7).

7.

REMOVE THE TURN BAFFLE (Figure 1).

CAUTION

4 REMOVE THE BAFFLE

3 2

1

REMOVE THE SCREW

DISENGAGE THE SPRING

RAISE THE HANDLE

Figure 1 Removing the Turn Baffle

Replacement

2.

INSTALL THE NIP RELEASE ASSEMBLY.

1.

3.

ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).

REPLACE THE TURN BAFFLE.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-171

Section Name

REP 8-2

REP 8-3 Registration Transport Assembly Parts List on PL 8.3 Removal To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section. NOTE: See PL 8.1 through PL 8.32. 1. 2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. REMOVE THE FOLLOWING: a.

Cross Rolls Assembly (REP 8-4).

b.

Vertical Transport Assembly (REP 8-0).

c.

Disconnect the cable on the Nip Release Sol851 (REP 8-6).

3.

REMOVE THE PRINTER RIGHT REAR COVER.

4.

DISCONNECT THE ELECTRICAL CONNECTORS FOR THE REGISTRATION TRANSPORT (REAR) (Figure 1).

2

3

DISCONNECT (2)

RETRACT CABLES THROUGH THE HOLE IN FRAME

1 OPEN THE AC DISTRIBUTION PANEL

Figure 1 Disconnecting the Transport (Rear) 5.

REMOVE THE REGISTRATION TRANSPORT (Figure 2).

Section Name

REP 8-3

0/0/00 ?-172

Preliminary Working Document No Product Name Assigned

3

2

REMOVE THE BAFFLES (2)

4 REMOVE NUTS (2), AND RAISE BRACKET

RELEASE THE HINGE CLIPS (2)

1 DISCONNECT GROUND WIRE PRETRANSFER BAFFLE

8

CAUTION BRACKET EASILY BROKEN

5 DISCONNECT THE ELECTRICAL CONNECTIONS (5)

REMOVE THE TRANSPORT

6 REMOVE THE SHOULDER SCREW AT THE NIP SOLENOID BRACKET TO DISCONNECT THE CABLE BETWEEN THE BRACKET AND THE MAGNETIC SKIS

7 REMOVE THE SCREWS (2)

CAUTION ENSURE THE CABLES DO NOT CATCH ON THE MACHINE FRAME

Figure 2 Removing the Registration Transport

Replacement

4. CAUTION

Ensure that the white plastic Transition Strips (6) are all positioned into the opening of the Pretransfer Baffle, and that the black plastic Lift Block is positioned under the Pretransfer Baffle Upper Baffle.

CLOSE THE AC DISTRIBUTION PANEL, AND REINSTALL THE PRINTER RIGHT REAR COVER.

5.

INSTALL THE VERTICAL TRANSPORT ASSEMBLY (REP 8-0).

6.

INSTALL THE TURN BAFFLE (REP 8-2).

7.

INSTALL THE CROSS ROLLS ASSEMBLY (REP 8-4).

1.

REPLACE THE REGISTRATION TRANSPORT.

8.

SWITCH ON THE PRINTER.

2.

INSTALL THE BRACKET, AND TIGHTEN HARDWARE.

9.

ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).

3.

CONNECT THE ELECTRICAL CONNECTORS FOR THE REGISTRATION TRANSPORT.

10. IF INSTALLING A NEW REGISTRATION TRANSPORT ASSEMBLY CHECK/ADJUST THE FOLLOWING:

Preliminary Working Document No Product Name Assigned

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Section Name

REP 8-3

a.

Pretransfer Baffle (ADJ 8-1).

REP 8-4 Cross Rolls Assembly

b.

Top to Bottom Registration (ADJ 8-2).

c.

Side to Side Registration (ADJ 8-3).

Parts List on PL 8.3 Removal To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section. NOTE: See PL 8.1 through PL 8.32. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS.

3.

REMOVE THE REGISTRATION TRANSPORT INNER PANEL.

4.

REMOVE THE CROSS ROLLS ASSEMBLY (Figure 1).

1 REMOVE (4)

2 DISCONNECT THE CONNECTOR WHILE REMOVING THE ASSEMBLY

Figure 1 Removing the Cross Rolls Assembly 5.

FOR NEW CROSS ROLL INSTALLATION ONLY: a.

Enter Printer Diagnostics, [SCP], [HFSI Status].

b.

Select [P08-816 Registration Cross Rolls], and press [Reset].

Section Name

REP 8-3, REP 8-4

REP 8-5 Pretransfer Baffle

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Preliminary Working Document No Product Name Assigned

Parts List on PL 8.8 Removal

2.

REMOVE BAFFLE (Figure 1).

NOTE: See PL 8.1 through PL 8.32. 1.

REMOVE PHOTORECEPTOR BELT (REP 9-35).

3 REMOVE PRETRANSFER BAFFLE

2

TRANSITION STRIPS (6)

LOWER THE BELT MODULE

UPPER BAFFLE

1

THE LIFT BLOCK

REMOVE SCREW

Figure 1 Removing the Pretransfer Baffle

Replacement CAUTION Ensure that the Pretransfer Baffle is positioned under the white plastic Transition Strips (6), and that the Upper Baffle is positioned over the black plastic Lift Block (Figure 1). Also ensure that the Baffle is latched into the spring clip before pushing the Photoreceptor Drawer back into the Printer. 1.

REPLACE THE BAFFLE.

2.

INSTALL THE PHOTORECEPTOR BELT.

3.

CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-175

Section Name

REP 8-5

REP 8-6 NIP Release Solenoid (SOL851)

Parts List on PL 8.5 Removal NOTE: See PL 8.1 through PL 8.32. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE NIP RELEASE SOLENOID (Figure 1).

FRONT VIEW

3 REMOVE THE SOLENOID

NOTE: LINKAGE

1 DISCONNECT THE CONNECTOR

2 REMOVE THE SCREWS (2)

Figure 1 Removing the Nip Release Solenoid (SOL851)

Replacement NOTE: Ensure that the pin in the solenoid plunger is seated in the linkage.

Section Name

REP 8-6

1.

INSTALL THE NEW NIP RELEASE SOLENOID.

2.

CHECK/ADJUST THE NIP RELEASE SOLENOID (SOL851) (ADJ 8-6).

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Preliminary Working Document No Product Name Assigned

REP 8-7 NIP Release Solenoid Assembly and Idler Bracket

2.

Parts List on PL 8.5 Removal

REMOVE THE NIP RELEASE SOLENOID ASSEMBLY AND THE IDLER BRACKET (Figure 1).

NOTE: See PL 8.1 through PL 8.32. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2 3 REMOVE THE NUTS (2)

REMOVE THE SCREW, AND DISCONNECT THE CABLE

1 REMOVE THE SPRING

FRONT VIEW

4

6

DISCONNECT THE CONNECTOR

REMOVE THE NUTS AND THE IDLER BRACKET

5 REMOVE THE SOLENOID ASSEMBLY

Figure 1 Removing the Nip Release Solenoid Assembly and the Idler Bracket

Replacement

NOTE: Do not tighten the mounting nuts for the solenoid assembly at this time.

1.

2.

INSTALL THE NEW NIP RELEASE SOLENOID ASSEMBLY AND IDLER BRACKET.

3.

CHECK/ADJUST THE NIP RELEASE SOLENOID (ADJ 8-6).

INSTALL THE NEW IDLER BRACKET.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-177

Section Name

REP 8-7

Section Name

REP 8-7

0/0/00 ?-178

Preliminary Working Document No Product Name Assigned

REP 8-15 Blower Motor (MOT832)/O-Ring Pulley

5.

REMOVE THE BLOWER MOTOR (Figure 2).

Parts List on PL 8.15 Removal

1

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

3.

REMOVE THE O-RING DRIVE BELT.

REMOVE THE SCREWS (4)

NOTE: If removing just the O-Ring Pulley, perform only steps 2 and 3 of Figure 1. 4.

PREPARE TO REMOVE THE BLOWER MOTOR (Figure 1).

2 ROTATE CENTER SCREW WITH SCREWDRIVER WHILE HOLDING O-RING PULLEY TO LOOSEN

2 REMOVE THE MOTOR

Figure 2 Removing the Blower Motor

3

1

UNSCREW AND REMOVE PULLEY

DISCONNECT

Replacement 1.

REINSTALL THE BLOWER MOTOR.

NOTE: Ensure that the O-Ring Pulley is reinstalled with the Smaller diameter groove facing towards the rear of the FS. 2.

REINSTALL THE O-RING PULLEY.

3.

REINSTALL THE O-RING DRIVE BELT (REP 8-17).

Figure 1 Preparing to Remove the Blower Motor

Preliminary Working Document No Product Name Assigned

0/0/00 ?-179

Section Name

REP 8-15

REP 8-16 Blower Assembly

Replacement

Parts List on PL 8.15 Removal

1.

REINSTALL THE BLOWER ASSEMBLY.

2.

REINSTALL THE O-RING DRIVE BELT (REP 8-17).

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE FS LOWER REAR COVER.

3.

REMOVE THE TWO AIR DUCTS FROM THE BLOWER ASSEMBLY.

4.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

5.

REMOVE THE O-RING DRIVE BELT.

6.

REMOVE THE BLOWER ASSEMBLY (Figure 1).

1 REMOVE THE SCREWS (3)

2 REMOVE BLOWER ASSEMBLY

Figure 1 Removing the Blower Assembly Section Name

REP 8-16

0/0/00 ?-180

Preliminary Working Document No Product Name Assigned

REP 8-17 O-Ring Drive Belt

REP 8-18 Feeder Clutch

Parts List on PL 8.14 Removal

Parts List on PL 8.15 Removal

1.

SWITCH OFF THE PRINTER POWER.

1.

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

3.

REMOVE THE O-RING DRIVE BELT.

3.

REMOVE THE FEEDER MOTOR DRIVE BELT (REP 8-21).

SWITCH OFF THE PRINTER POWER.

Replacement

4.

REMOVE THE APPROPRIATE FEEDER ASSEMBLY (REP 8-24).

1.

5.

REMOVE THE FEEDER MAIN DRIVE BELT.

6.

REMOVE THE FEEDER CLUTCH ASSEMBLY (Figure 1).

2.

IF THE O-RING DRIVE BELT IS BEING INSTALLED ON A 60 HZ MACHINE, ROUTE THE BELT AROUND THE REAR GROOVE OF THE BLOWER PULLEY AND AROUND THE SMALLER DIAMETER GROOVE OF THE BLOWER MOTOR PULLEY. IF THE O-RING DRIVE BELT IS BEING INSTALLED ON A 50 HZ MACHINE, ROUTE THE BELT AROUND THE FRONT GROOVE OF THE BLOWER PULLEY AND AROUND THE LARGER DIAMETER GROOVE OF THE BLOWER MOTOR PULLEY.

2

1

REMOVE THE BOLTS (2)

DISCONNECT

3 REMOVE CLUTCH ASSEMBLY

Figure 1 Removing the Feeder Clutch 7.

REMOVE THE TWO SCREWS SECURING THE FEEDER CLUTCH TO THE MOUNTING BRACKET AND REMOVE THE CLUTCH.

Replacement

Preliminary Working Document No Product Name Assigned

1.

REINSTALL THE FEEDER MAIN DRIVE BELT (REP 8-22).

2.

REINSTALL THE FEEDER ASEMBLY.

3.

REINSTALL THE FEEDER MOTOR DRIVE BELT.

4.

REINSTALL THE VERTICAL TRANSPORT.

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Section Name

REP 8-17, REP 8-18

REP 8-20 Feeder Main Drive Motor (MOT831) Parts List on PL 8.14 Removal 1.

2 LOOSEN IDLER MOUNTING SCREW

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER REAR DRIVES INNER COVER (PL 11.21

3.

REMOVE THE APPROPRIATE STACKER UPPER REAR COVER AND LOWER REAR COVER.

4.

SWING OUT THE STEPPER PWB PANEL.

5.

REMOVE THE STACKER REAR INNER COVER (PL 11.21

NOTE: In Figure 1, one Capacitor has been removed for clarity. 6.

PREPARE TO REMOVE THE FEEDER MAIN DRIVE MOTOR (Figure 1).

1 DISCONNECT

Figure 1 Preparing to Remove the Motor 7.

Section Name

REP 8-20

0/0/00 ?-182

REMOVE THE FEEDER MAIN DRIVE MOTOR (Figure 2).

Preliminary Working Document No Product Name Assigned

REP 8-21 Feeder Motor Drive Belt 2 REMOVE THE SCREWS (4)

Parts List on PL 8.14 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

3.

REMOVE THE APPROPRIATE STACKER REAR DRIVES INNER COVER (PL 11.21

NOTE: In Figure 1, one Capacitor has been removed for clarity. 4.

LOOSEN THE FEEDER MOTOR DRIVE BELT IDLER (Figure 1).

3 REMOVE THE MOTOR

1 REMOVE THE DRIVE BELT

LOOSEN THE IDLER MOUNTING SCREW Figure 2 Removing the Motor Figure 1 Loosening the Idler 5.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-183

REMOVE THE FEEDER MOTOR DRIVE BELT.

Section Name

REP 8-20, REP 8-21

REP 8-22 Feeder Main Drive Belt Parts List on PL 8.14 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

3.

REMOVE THE FEEDER MOTOR DRIVE BELT (REP 8-21).

4.

REMOVE THE APPROPRIATE FEEDER ASSEMBLY (REP 8-24).

5.

REMOVE THE FEEDER MAIN DRIVE BELT.

Replacement NOTE: Ensure that the Drive Belt is routed around all of the components shown in Figure 1 in preparation for the Vertical Transport reinstallation. 1.

REINSTALL THE FEEDER MAIN DRIVE BELT (Figure 1).

1 ROUTE THE BELT AROUND ALL THE COMPONENTS

2 REPOSITION THE TABS IN REAR AS SHOWN

Figure 1 Routing the Drive Belt

Section Name

REP 8-22

0/0/00 ?-184

Preliminary Working Document No Product Name Assigned

REP 8-24 Feeder Assembly

2.

Parts List on PL 8.15 PL 8.16 Removal

3.

MANUALLY UNLATCH THE HIGH CAPACITY TRAY, AND PUSH IT OPEN.

4.

BEGIN TO REMOVE THE FEEDER ASSEMBLY (Figure 1).

1.

REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.

SWITCH OFF THE PRINTER POWER.

2 DISCONNECT

1 REMOVE THE AIR DUCTS

Figure 1 Preparing to Remove the Feeder 5.

REMOVE THE FEEDER ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-185

Section Name

REP 8-24

1 DISCONNECT (J415)

2 REMOVE THE NUTS (2)

3 REMOVE FEEDER ASSEMBLY

Figure 2 Removing the Feeder

Replacement

REP 8-40 Lower Preregistration Transport

NOTE: Ensure that the Feeder Drive Coupling aligns with the coupling on the shaft of the Feeder Drive Motor.

Parts List on PL 8.24 Removal

1.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER REAR COVER.

3.

OPEN THE INVERTER PWB PANEL.

4.

ACCESS THE REAR OF THE LOWER PREREGISTRATION TRANSPORT (Figure 1).

REINSTALL THE FEEDER ASSEMBLY.

Section Name

REP 8-24

0/0/00 ?-186

Preliminary Working Document No Product Name Assigned

3 LOOSEN THE SCREWS (2)

5 REMOVE THE SHIELD

VIEWED FROM THE FRONT OF THE STACKER WITH THE INVERTER DOOR OPEN

2 REMOVE THE SHIELD

4 LOOSEN THE BOLTS (2)

1 LOOSEN THE SCREWS (2)

Figure 1 Accessing the Transport 5.

PREPARE THE REAR OF THE LOWER PREREGISTRATION TRANSPORT FOR REMOVAL (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-187

Section Name

REP 8-40

2 LOOSEN IDLER MOUNTING SCREW

3 REMOVE THE BELT

1 LOOSEN

Figure 2 Preparing the Rear of the Transport 6.

OPEN THE INVERTER DOOR.

NOTE: After removing the two nuts (step 4, Figure 3), position the Baffle Spring Support on the transport and secure it with your hand during removal. 7.

REMOVE THE LOWER PREREGISTRATION TRANSPORT (Figure 3).

Section Name

REP 8-40

0/0/00 ?-188

Preliminary Working Document No Product Name Assigned

4 NOTE: REMOVE THE NUTS (2)

3 REMOVE

1

2

LOOSEN

DISCONNECT

Figure 3 Removing the Transport

Replacement

REP 8-41 Registration Baffle Assembly

NOTE: After the transport is positioned in the machine, it may be necessary to position the rear tab under the bolt from the rear of the IFS.

Parts List on PL 8.26 Removal

1.

1.

REINSTALL THE LOWER PREREGISTRATION TRANSPORT.

Preliminary Working Document No Product Name Assigned

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE PREREGISTRATION TRANSPORT (REP 8-40).

3.

REMOVE THE REGISTRATION ASSEMBLY (REP 8-46).

4.

REMOVE THE REGISTRATION BAFFLE ASSEMBLY (Figure 1).

0/0/00 ?-189

Section Name

REP 8-40

1 REMOVE THE NUTS (4)

2 REMOVE THE REGISTRATION BAFFLE ASSEMBLY

Figure 1 Removing the Registration Baffle

Replacement NOTE: Ensure that the Registration Baffle Assembly is positioned fully against the tabs on the front of the Lower Preregistration Transport before tightening the four nuts. 1.

REINSTALL THE REGISTRATION BAFFLE ASSEMBLY.

REP 8-43 Lower Preregistration Transport Corrugator Rolls Parts List on PL 8.25 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).

3.

REMOVE THE REGISTRATION ASSEMBLY (REP 8-46).

4.

LOSEN THE SETSCREW AND REMOVE THE CORRUGATOR ROLL.

Replacement NOTE: Replace the Corrugator Roll by pushing it on the drive shaft as far as it will go, then tighten the setscrew.

Section Name

REP 8-43, REP 8-45

1.

REINSTALL THE CORRUGATOR ROLL.

2.

REINSTALL THE LOWER PREREGISTRATION TRANSPORT.

0/0/00 ?-190

Preliminary Working Document No Product Name Assigned

REP 8-45 Lower Preregistration Transport Flexible Drive Shaft

4.

LOOSEN THE SETSCREW LOCATED AT EACH END OF THE FLEXIBLE DRIVE SHAFT.

5.

REMOVE THE FLEXIBLE DRIVE SHAFT.

Parts List on PL 8.25 Removal

REP 8-46 Registration Assembly

1.

Parts List on PL 8.25 Removal

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).

3.

POSITION THE LOWER PREREGISTRATION TRANSPORT ON A FLAT SURFACE WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).

1 LOOSEN THE SETSCREW

3

2

REMOVE REGISTRATION ASSEMBLY

REMOVE THE NUTS (2)

Figure 1 Removing the Registration Assembly

REP 8-47 Corrugator Roll Drive Shafts And Belt Parts List on PL 8.25 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).

3.

REMOVE THE REGISTRATION ASSEMBLY (REP 8-46).

4.

REMOVE THE CORRUGATOR ROLL DRIVE SHAFTS AND BELTS (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-191

Section Name

REP 8-46

3 LOOSEN RETAINER MOUNTING SCREW (2 PLACES)

4 REMOVE THE DRIVE SHAFTS AND BELT

2

1

REMOVE SCREW AND SPRING RETAINER

REMOVE THE CORRUGATOR ROLLS (2)

Figure 1 Removing the Shafts and Belts

Replacement

REP 8-50 Intermediate Horizontal Transport

NOTE: Replace the Corrugator Rolls by pushing it on the drive shaft as far as it will go, then tighten the setscrew.

Parts List on PL 8.26 Removal

1.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER LOWER REAR COVER FROM THE FS.

REINSTALL THE CORRUGATOR ROLLS.

Section Name

REP 8-50

3.

MANUALLY UNLATCH TRAY 4, AND PUSH IT OPEN.

4.

LOWER THE AC RELAY PANEL.

5.

REMOVE THE AC SAFETY SHIELD (Figure 1).

0/0/00 ?-192

Preliminary Working Document No Product Name Assigned

2 REMOVE THE SHIELD

1 REMOVE NUTS (2)

Figure 1 Removing the Shield 6.

PREPARE TO REMOVE THE INTERMEDIATE HORIZONTAL TRANSPORT (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-193

Section Name

REP 8-50

5 REMOVE NUT AND THE LINK SPRING

4 DISCONNECT

3 LOOSEN

1 LOOSEN THE IDLER MOUNTING SCREW

2 REMOVE THE BELT

Figure 2 Preparing to Remove the Transport 7.

PUSH IN TRAY 4, AND LOWER THE FS HORIZONTAL TRANSPORT DOOR. CAUTION

Do not damage the Intermediate Horizontal Transport or the Jam Sensor (Q854B) when removing or installing the transport. 8.

REMOVE THE INTERMEDIATE HORIZONTAL TRANSPORT (Figure 3).

Section Name

REP 8-50

0/0/00 ?-194

Preliminary Working Document No Product Name Assigned

1 REMOVE

2 CAUTION REMOVE THE TRANSPORT

Figure 3 Removing the Transport

Replacement NOTE: After the Intermediate Horizontal Transport has been placed inside the FS from the front, it will have to be guided into mounting position from the rear. 1.

REINSTALL THE INTERMEDIATE HORIZONTAL TRANSPORT.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-195

Section Name

REP 8-50

REP 8-55 Horizontal Transport (IFS)

3.

MANUALLY UNLATCH AND PUSH OPEN TRAY 3.

Parts List on PL 8.27 Removal

4.

LOWER THE IFS RELAY PANEL.

5.

REMOVE THE IFS AC SAFETY SHIELD (Figure 1).

6.

SWING OUT THE INVERTER PWB PANEL.

7.

ACCESS THE REAR OF THE LOWER PREREGISTRATION TRANSPORT (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER REAR COVER AND THE IFS LOWER REAR COVER.

3 LOOSEN THE SCREWS (2)

5 REMOVE THE SHIELD

2 REMOVE THE SHIELD

4 LOOSEN THE BOLTS (2)

1 LOOSEN THE SCREWS (2)

Figure 1 Accessing the Transport 8.

LOOSEN THE IDLER ON THE REAR OF THE LOWER PREREGISTRATION TRANSPORT AND REMOVE THE LOWER PREREGISTRATION TRANSPORT DRIVE BELT FROM THE IFS HORIZONTAL TRANSPORT.

9.

LOOSEN THE IDLER ON THE REAR OF THE IFS VERTICAL TRANSPORT AND REMOVE THE VERTICAL TRANSPORT DRIVE BELT FROM THE IFS HORIZONTAL TRANSPORT.

10. PREPARE THE REAR OF THE HORIZONTAL TRANSPORT FOR REMOVAL (Figure 2).

Section Name

REP 8-55

0/0/00 ?-196

Preliminary Working Document No Product Name Assigned

1 DISCONNECT (J482)

2 REMOVE THE BOLTS (2)

Figure 2 Preparing the Transport 11. PUSH IN TRAY 3 AND LOWER THE IFS HORIZONTAL TRANSPORT DOOR. NOTE: Scribe a line along the top of the Interlock Bracket (step 2, Figure 3) to ensure that it is positioned correctly when it is reinstalled. 12. REMOVE THE IFS HORIZONTAL TRANSPORT (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-197

Section Name

REP 8-55

2

1 DISCONNECT INTERLOCK CONNECTORS (2)

NOTE: REMOVE THE INTERLOCK SWITCH AND THE MOUNTING BRACKET ASSEMBLY

4 REMOVE TRANSPORT

3 REMOVE BOLTS (2)

Figure 3 Removing the Transport

Replacement

REP 8-56 Horizontal Transport (FS)

NOTE: It will be necessary to guide the IFS Horizontal Transport into the correct mounting position from the rear of the IFS.

Parts List on PL 8.20 Removal

1.

1.

REINSTALL THE IFS HORIZONTAL TRANSPORT.

Section Name

REP 8-55

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE FS LOWER REAR COVER.

3.

MANUALLY UNLATCH AND PUSH OPEN TRAY 4.

4.

LOWER THE FS RELAY PANEL.

5.

REMOVE THE FS AC SAFETY SHIELD (Figure 1).

0/0/00 ?-198

Preliminary Working Document No Product Name Assigned

6.

LOOSEN THE IDLER ON THE REAR OF THE FS VERTICAL TRANSPORT AND REMOVE THE VERTICAL TRANSPORT DRIVE BELT FROM THE FS HORIZONTAL TRANSPORT.

7.

PREPARE THE REAR OF THE HORIZONTAL TRANSPORT FOR REMOVAL (Figure 1).

1 REMOVE THE NUT AND THE LINK SPRING

2 LOOSEN IDLER MOUNTING SCREW

3 REMOVE THE BELT

4 REMOVE BOLTS (2)

Figure 1 Preparing the Transport 8.

PUSH IN TRAY 4 AND LOWER THE FS HORIZONTAL TRANSPORT DOOR.

NOTE: Scribe a line along the top of the Interlock Bracket (step 2, Figure 2) to ensure that it is positioned correctly when it is reinstalled. 9.

REMOVE THE FS HORIZONTAL TRANSPORT (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-199

Section Name

REP 8-56

1

2

DISCONNECT INTERLOCK THE CONNECTORS (2)

NOTE: REMOVE THE INTERLOCK SWITCH AND MOUNTING BRACKET ASSEMBLY

4 REMOVE TRANSPORT

3 REMOVE THE BOLTS (2)

Figure 2 Removing the Transport

Replacement

REP 8-59 Horizontal Transport Pivot Baffle (IFS)

NOTE: It will be necessary to guide the FS Horizontal Transport into the correct mounting position from the rear of the FS.

Parts List on PL 8.29 Removal

1.

1.

PULL OUT THE HCT.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE IFS LOWER REAR COVER.

REINSTALL THE FS HORIZONTAL TRANSPORT.

Section Name

REP 8-56

4.

LOWER THE IFS RELAY PANEL.

5.

REMOVE THE AC SAFETY SHIELD.

0/0/00 ?-200

Preliminary Working Document No Product Name Assigned

CAUTION Do not damage the Sensor Actuator Spring. Ensure that the Sensor is removed from the bracket and positioned on the baffle before removal. Do not damage any harnesses when removing the Pivot Baffle. NOTE: There is spring tension on the Lift Assembly Mounting Bracket. 6.

REMOVE THE IFS HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 1).

1 REMOVE LIFT ASSEMBLY BRACKET NUTS (3)

2 NOTE: REMOVE LIFT ASSEMBLY BRACKET

3 CAUTION REMOVE THE SENSOR FROM THE MOUNTING BRACKET AND POSITION ON THE PIVOT BAFFLE

CAUTION 6 REMOVE PIVOT BAFFLE

5 REMOVE NUTS (6) AND GROUND STRAP

4 DISCONNECT (2)

Figure 1 Removing the Pivot Baffle

Replacement

formed.

NOTE: Do not tighten the six rear nuts on the Pivot Baffle until the adjustment has been per-

1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-201

REINSTALL THE PIVOT BAFFLE.

Section Name

REP 8-59, REP 8-60

2.

Adjust the Horizontal Transport Pivot Baffle (ADJ 8-14).

REP 8-60 Horizontal Transport Pivot Baffle (FS) Parts List on PL 8.22 Removal 1.

PULL OUT THE HCT.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE FS LOWER REAR COVER.

4.

LOWER THE FS RELAY PANEL.

5.

REMOVE THE AC SAFETY SHIELD. CAUTION

Do not damage any harnesses when removing the Pivot Baffle. NOTE: There is spring tension on the Lift Assembly Mounting Bracket. 6.

Section Name

REP 8-59, REP 8-60

0/0/00 ?-202

REMOVE THE FS HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 1).

Preliminary Working Document No Product Name Assigned

1 REMOVE LIFT ASSEMBLY BRACKET NUTS (3)

2 NOTE: REMOVE LIFT ASSEMBLY BRACKET

3 REMOVE NUT AND LINK SPRING

CAUTION 5 REMOVE PIVOT BAFFLE

4 REMOVE NUTS (6) AND GROUND STRAP

Figure 1 Removing the Pivot Baffle

Replacement

REP 8-65 Lower Turn Transport (IFS/FS)

NOTE: Do not tighten the six rear nuts on the Pivot Baffle until the adjustment has been performed.

Parts List on PL 8.16 Removal

1.

REINSTALL THE PIVOT BAFFLE.

1.

2.

Adjust the Horizontal Transport Pivot Baffle (ADJ 8-14).

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

3.

PREPARE THE REAR OF THE LOWER TURN TRANSPORT FOR REMOVAL (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-203

SWITCH OFF THE PRINTER POWER.

Section Name

REP 8-60

3 REMOVE THE SHIELD

2 LOOSEN

1 LOOSEN

4 DISCONNECT (J483)

Figure 1 Preparing the Rear of the Transport NOTE: Scribe a line along the edge of the Interlock Mounting Bracket to ensure that it is positioned correctly when it is reinstalled. 4.

REMOVE THE VERTICAL TRANSPORT DOOR INTERLOCK SWITCH AND THE MOUNTING BRACKET FROM THE FRAME.

5.

IF THE FS LOWER TURN TRANSPORT IS BEING REMOVED, REMOVE THE FS LOWER SIDE COVER.

6.

REMOVE THE LOWER TURN TRANSPORT (Figure 2).

Section Name

REP 8-65

0/0/00 ?-204

Preliminary Working Document No Product Name Assigned

3 REMOVE THE TRANSPORT

1 REMOVE

2 REMOVE

Figure 2 Removing the Transport

Replacement NOTE: It will be necessary to guide the Lower Turn Transport into the correct mounting position from the rear of the FS. 1.

REINSTALL THE LOWER TURN TRANSPORT.

REP 8-66 Lower Turn Transport Baffle/pivot Shaft/springs (IFS/FS) Parts List on PL 8.19 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE VERTICAL TRANSPORT (REP 8-75).

3.

REMOVE THE LOWER TURN TRANSPORT (REP 8-65).

4.

POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAFFLE FACING UPWARDS.

NOTE: Ensure to notice the position of the Torsion Springs before removing the Baffle Pivot Shaft. The Torsion Springs must be reinstalled in the same position to operate correctly. 5.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-205

REMOVE THE BAFFLE, PIVOT SHAFT AND SPRINGS (Figure 1).

Section Name

REP 8-65

1

6

REMOVE NUT AND GROUND STRAP FROM REAR OF TRANSPORT

REMOVE THE BAFFLE

5 REMOVE SHAFT WHEN REAR END OF SHAFT IS FREE OF FRAME AND BAFFLE

2 REMOVE CLIP

4 PULL SHAFT TOWARDS FRONT OF TRANSPORT WHILE ROTATING THE SHAFT CLOCKWISE AND COUNTERCLOCKWISE

3 PLACE A 5.5mm WRENCH ON FLATS OF THE SHAFT

Figure 1 Removing the Baffle, Pivot Shaft and Springs

Replacement

REP 8-67 Lower Turn Transport Upper Drive Shaft

NOTE: Ensure to install tension on the Torsion Springs when reinstalling the Pivot Shaft.

Parts List on PL 8.19 Removal

1.

REINSTALL THE BAFFLE, PIVOT SHAFT AND SPRINGS.

Section Name

REP 8-67

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

3.

REMOVE THE LOWER TURN TRANSPORT (REP 8-65).

4.

POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAFFLE FACING UPWARDS.

0/0/00 ?-206

Preliminary Working Document No Product Name Assigned

5.

REMOVE THE UPPER DRIVE SHAFT (Figure 1).

4 REMOVE THE DRIVE SHAFT

3 REMOVE BEARING RETAINER

1 REMOVE SCREWS (2) AND THE BRUSH BRACKET

2 REMOVE THE SCREW

Figure 1 Removing the Upper Drive Shaft

Preliminary Working Document No Product Name Assigned

0/0/00 ?-207

Section Name

REP 8-67

REP 8-68 Lower Turn Transport Lower Drive Shaft

REP 8-69 Lower Turn Transport Sensor Assembly

Parts List on PL 8.19 Removal

Parts List on PL 8.19 Removal

1.

SWITCH OFF THE PRINTER POWER.

1.

2.

REMOVE THE APPROPRIATE VERTICAL TRANSPORT (REP 8-75).

2.

REMOVE THE LOWER TURN TRANSPORT (REP 8-65).

3.

REMOVE THE LOWER TURN TRANSPORT (REP 8-65).

3.

4.

POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAFFLE FACING UPWARDS.

POSITION THE LOWER TURN TRANSPORT ON A FLAT SURFACE WITH THE BAFFLE FACING DOWNWARD.

4.

REMOVE THE TWO SCREWS SECURING THE SENSOR ASSEMBLY.

5.

LOOSEN THE MOUNTING SCREW AND REMOVE THE RETAINER SECURING THE LOWER DRIVE SHAFT.

NOTE: Ensure to note the position of the Sensor Assembly before removal. Cut and replace cable ties as required.

6.

REMOVE THE LOWER DRIVE SHAFT. 5.

SWITCH OFF THE PRINTER POWER.

DISCONNECT AND REMOVE THE SENSOR ASSEMBLY.

Replacement NOTE: Ensure that the Sensor Assembly is reinstalled in the same position as it was before removal. 1.

Section Name

REP 8-68, REP 8-69

0/0/00 ?-208

REINSTALL THE SENSOR ASSEMBLY.

Preliminary Working Document No Product Name Assigned

REP 8-75 Vertical Transport (IFS/FS)

5.

Parts List on PL 8.16 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE FS LOWER REAR COVER.

3.

MANUALLY UNLATCH THE APPROPRIATE HCT.

4.

PREPARE THE LOWER REAR PORTION OF THE VERTICAL TRANSPORT FOR REMOVAL (Figure 1).

PREPARE THE UPPER REAR PORTION OF THE VERTICAL TRANSPORT FOR REMOVAL (Figure 2).

1 LOOSEN IDLER MOUNTING SCREW

2 REMOVE THE BELT

3 DISCONNECT (J484)

Figure 1 Preparing the Lower Portion

Preliminary Working Document No Product Name Assigned

0/0/00 ?-209

Section Name

REP 8-75

1 LOOSEN

4 MOVE TAB COMPLETELY

2 UNLATCH IDLER TENSIONER

3 MOVE TAB COMPLETELY

Figure 2 Preparing the Upper Portion 6.

REMOVE THE APPROPRIATE STACKER FRONT COVER (REP 4-49).

7.

OPEN THE VERTICAL TRANSPORT DOOR.

NOTE: Scribe a line along the top of the Latch Bracket (step 2, Figure 3) to ensure that it is positioned correctly when it is reinstalled. 8.

REMOVE THE VERTICAL TRANSPORT (Figure 3).

Section Name

REP 8-75

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Preliminary Working Document No Product Name Assigned

1

2

REMOVE SCREW AND BRACKET

NOTE: REMOVE SCREWS (2) AND BRACKET

3 REMOVE BOLT

6 SLIDE OUT AND REMOVE TRANSPORT

4

5

REMOVE SCREW

OPEN THE HCT

Figure 3 Removing the Transport

Replacement NOTE: It will be necessary to guide the Vertical transport into the correct mounting position from the rear of the FS.

REP 8-76 Vertical Transport Upper Baffle/Pivot Shaft/ Spring (IFS/FS)

REINSTALL THE VERTICAL TRANSPORT.

Parts List on PL 8.18 Removal

2.

REINSTALL THE TOP MOUNTING BOLT BUT DO NOT TIGHTEN.

1.

SWITCH OFF THE PRINTER POWER.

3.

REINSTALL THE BOTTOM MOUNTING SCREW AND TIGHTEN.

2.

REMOVE THE VERTICAL TRANSPORT (REP 8-75).

4.

TIGHTEN THE TOP MOUNTING BOLT.

3.

POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES FACING UPWARDS.

1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-211

Section Name

REP 8-75

NOTE: Ensure to notice the position of the Torsion Spring before removing the Upper Baffle Pivot Shaft. The Torsion Spring must be reinstalled in the same position to operate correctly. 4.

REMOVE THE UPPER BAFFLE, PIVOT SHAFT AND SPRING (Figure 1).

2

3

REMOVE CLIP NOTE: REMOVE THE PIVOT SHAFT

1 REMOVE THE NUT AND THE GROUND STRAP FROM THE REAR OF THE TRANSPORT

5

4

REMOVE THE UPPER BAFFLE

LIFT THE LOWER BAFFLE

Figure 1 Removing the Upper Baffle

Replacement NOTE: Rotating the pivot shaft counterclockwise will install tension on the Torsion Spring and align the "D" end of the shaft with the D-Hole in the frame. 1.

REINSTALL THE UPPER BAFFLE, PIVOT SHAFT AND SPRING (Figure 2).

Section Name

REP 8-76

0/0/00 ?-212

Preliminary Working Document No Product Name Assigned

6

3

REINSTALL CLIP

POSITION REAR END OF THE SHAFT THROUGH THE BAFFLE

2 INSERT FRONT END OF PIVOT SHAFT THROUGH THE BAFFLE AND THE FRAME

7 REINSTALL THE GROUND STRAP ANDTHE NUT

1 POSITION THE UPPER BAFFLE UNDER THE LOWER BAFFLE

5 NOTE: ROTATE SHAFT COUNTERCLOCKWISE TO TENSION SPRING AND INSERT "D" END OF SHAFT THROUGH D-HOLE IN FRAME

4 PLACE A 5.5mm WRENCH ON FLATS OF THE SHAFT

Figure 2 Reinstalling the Upper Baffle

Preliminary Working Document No Product Name Assigned

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Section Name

REP 8-76

REP 8-77 Vertical Transport Lower Baffle/Pivot Shaft (IFS/ FS) Parts List on PL 8.18 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.

3.

PREPARE TO REMOVE THE LOWER BAFFLE AND PIVOT SHAFT (Figure 1).

REMOVE E-RING

Figure 1 Preparing to Remove the Lower Baffle 4.

MANUALLY UNLATCH THE HCT.

5.

OPEN THE VERTICAL TRANSPORT DOOR.

6.

REMOVE THE LOWER BAFFLE AND PIVOT SHAFT (Figure 2).

Section Name

REP 8-77

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Preliminary Working Document No Product Name Assigned

3 REMOVE E-RING

1 REMOVE NUT AND GROUND STRAP FROM REAR OF THE TRANSPORT

4 REMOVE SHAFT

5

2

SLIDE OUT THE HCT

UNLATCH LOWER BAFFLE

6 REMOVE THE BAFFLE

Figure 2 Removing the Lower Baffle

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Section Name

REP 8-77

REP 8-78 Vertical Transport Lower Baffle Release Assembly Components Parts List on PL 8.17 PL 8.18 Removal 1.

2.

REMOVE THE VERTICAL TRANSPORT (REP 8-75).

3.

POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES FACING DOWNWARDS.

4.

BEGIN TO REMOVE THE RELEASE ASSEMBLY COMPONENTS (Figure 1).

SWITCH OFF THE PRINTER POWER.

4 REMOVE THE SPRING PLATE SUPPORT

5 REMOVE THE SPRING PLATE

3 REMOVE NUTS (3)

2 REMOVE THE REAR LATCH ARM

1 REMOVE NUT

Figure 1 Beginning to Remove the Release Assembly Components 5.

REMOVE THE RELEASE ASSEMBLY SHAFTS (Figure 2).

Section Name

REP 8-78

0/0/00 ?-216

Preliminary Working Document No Product Name Assigned

2 REMOVE THE NUT AND FRONT LATCH

3 REMOVE CLIP

4

1

REMOVE SHAFTS

REMOVE CLIP

Figure 2 Removing the Release Assembly Shafts 6.

REMOVE THE CLIPS SECURING THE SHAFT LINKS ON THE SHAFTS AND REMOVE THE LINKS.

REP 8-79 Vertical Transport Sensor Assembly

Replacement

Parts List on PL 8.17 Removal

NOTE: Ensure that the Front Latch and the Rear Latch Arm engage the shaft on the Lower Baffle.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE VERTICAL TRANSPORT (REP 8-75).

1.

3.

POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES FACING DOWNWARD.

4.

REMOVE THE TWO SCREWS SECURING THE SENSOR ASSEMBLY.

REINSTALL THE RELEASE ASSEMBLY COMPONENTS.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-217

Section Name

REP 8-78

NOTE: Ensure to note the position of the Sensor Assembly before removal. Cut and replace cable ties as required. 5.

DISCONNECT AND REMOVE THE SENSOR ASSEMBLY.

Replacement NOTE: Ensure that the Sensor Assembly is reinstalled in the same position as it was before removal. 1.

REP 8-80 Vertical Transport Drive Belt/drive Shafts Parts List on PL 8.17 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPRORIATE VERTICAL TRANSPORT (REP 8-75).

3.

POSITION THE VERTICAL TRANSPORT ON A FLAT SURFACE WITH THE BAFFLES FACING UPWARDS.

4.

LOOSEN THE IDLER MOUNTING SCREW ON THE REAR OF THE TRANSPORT AND REMOVE THE DRIVE BELT.

5.

LOOSEN THE APPROPRIATE RETAINER MOUNTING SCREW AND REMOVE THE APPROPRIATE SHAFT RETAINER.

6.

REMOVE THE APPROPRIATE DRIVE SHAFT.

REINSTALL THE SENSOR ASSEMBLY.

Section Name

REP 8-79, REP 8-80

0/0/00 ?-218

Preliminary Working Document No Product Name Assigned

REP 9-0 Toner Bottle

4.

Parts List on PL 25.1 Removal

REDUCE THE TONER LEVEL IN THE DISPENSER RESERVOIR BY APPROXIMATELY 10 MM.

5.

CLEAN THE SEAL, AND CLEAN THE AREA SURROUNDING THE RESERVOIR WITH THE VACUUM CLEANER.

NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE XEROGRAPHIC DRAWER (REP 9-34).

3.

REMOVE TONER BOTTLE (Figure 1).

3 REMOVE THE BOTTLE

2 TURN HANDLE

1 PULL THE BOTTLE AGAINST THE STOP

Figure 1 Removing the Toner Bottle

Preliminary Working Document No Product Name Assigned

0/0/00 ?-219

Section Name

REP 9-0

REP 9-1 Toner Thumper Solenoid (SOL901)

REP 9-2 Toner Dispenser Assembly

Parts List on PL 9.19 Removal

Parts List on PL 9.13 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180.

2.

REMOVE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE TONER BOTTLE (REP 9-0).

4.

REMOVE THE TONER THUMPER SOLENOID ASSEMBLY (Figure 1).

1 REMOVE THE SOLENOID LEADS

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE, AND CLEAN THE DEVELOPER CATCH TRAY.

4.

REMOVE TONER BOTTLE (REP 9-0).

5.

USE THE VACUUM CLEANER IN ORDER TO CLEAN THE TONER FROM THE TONER DISPENSER ASSEMBLY.

6.

REMOVE THE ASSEMBLY (Figure 1).

1 DISCONNECT THE CONNECTOR

2 LOOSEN THE TWO RIGHT NUTS COMPLETELY

2 REMOVE THE SCREW

4

3

REMOVE THE ASSEMBLY

REMOVE THE TWO LEFT NUTS

Figure 1 Removing the Solenoid Assembly 5.

REMOVE THE TWO SCREWS THAT HOLD THE SOLENOID TO BRACKET.

6.

REMOVE SOLENOID AND THE PLUNGER.

7.

REPLACE TONER THUMPER ASSEMBLY, IF THE PIVOT HAS EXCESSIVE WEAR. Figure 1 Removing the Dispenser

Replacement 1.

INSTALL THE TONER BOTTLE.

2.

ADJUST THE TONER THUMPER (ADJ 9-0).

3.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

Section Name

REP 9-1, REP 9-2

Replacement 1.

PUSH THE DISPENSER ASSEMBLY TOWARD THE LEFT WHILE TIGHTENING THE FOUR NUTS.

2.

CHECK THAT ALL TERMINALS OF THE DEVELOPER BIAS HARNESS ARE CONNECTED.

0/0/00 ?-220

Preliminary Working Document No Product Name Assigned

3.

INSTALL THE TONER BOTTLE.

REP 9-3 Toner Dispenser Motor (MOT902)

4.

IF A NEW DISPENSER WAS INSTALLED, CHECK/ADJUST THE TONER THUMPER (ADJ 9-0).

5.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

Parts List on PL 9.19 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE THE PRINTER LEFT DOOR.

4.

REMOVE TONER BOTTLE (REP 9-0).

5.

REMOVE THE TONER DISPENSER MOTOR (Figure 1).

3 REMOVE THE MOTOR

2 DISCONNECT THE CONNECTOR

1 REMOVE THE NUTS (2)

Figure 1 Removing the Motor

Preliminary Working Document No Product Name Assigned

0/0/00 ?-221

Section Name

REP 9-2, REP 9-3

REP 9-4 Developer Material Parts List on PL 25.1 Removal

GEAR GUARD REMOVED

NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180. 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

POSITION THE DROPCLOTH UNDER THE XEROGRAPHIC DRAWER.

NOTE: Install a clean Dump Tray when using the same Developer material again. 4.

CLEAN THE DEVELOPER CATCH TRAY.

NOTE: Pushing in the nut, and then handcranking it clockwise will open the Dump Door. Do not use the Dump Door Handle to open the Door. 5.

OPEN THE DEVELOPER DUMP DOOR (Figure 1).

1 PUSH THE DUMP TRAY INTO THE RAIL AND UNDER THE DUMP DOOR

DUMP TRAY SHOWN CUT AWAY

2 PUSH IN THE CRANK, ROTATE 30 DEGREES CLOCKWISE TO OPEN THE DOOR

Figure 1 Opening the Dump Door NOTE: Gently thump the sides of the Developer Housing, open and close the Dump Door several times in order to shake loose any remaining Developer Material. 6.

Section Name

REP 9-4

0/0/00 ?-222

PURGE ALL DEVELOPER MATERIAL FROM THE HOUSING (Figure 2).

Preliminary Working Document No Product Name Assigned

1 RAISE AND PUSH THE HANDLE LIGHTLY CLOCKWISE

2 ROTATE CW 2 REVOLUTIONS, THEN CCW 2 REVOLUTIONS. REPEAT SEVERAL TIMES

1 ROTATE THE DEVELOPER DRIVE GEAR CW 12 REVOLUTIONS, THEN CCW 3 REVOLUTIONS

2 PUSH TO THE REAR, AND ROTATE COUNTERCLOCKWISE UNTIL THE DOOR IS LATCHED

Figure 2 Purging the Developer Material 7.

8.

Figure 3 Closing the Dump Door

IF THE DEVELOPER IS REPLACED DUE TO A CLEANER FAILURE, DEBRIS CENTERED DELETIONS, OR A PROCESS DIRECTION SCRATCH ON THE PR BELT, PERFORM THE DUMP AND THUMP (REP 9-6). USE THE VACUUM CLEANER, AND CLEAN THE FOLLOWING:

NOTE: If the Manifold is heavily covered with toner, check for obstructions in the Manifold Holes, the operation of the Filter Blower, a clogged Filter Bag or Vacuum Duct. a.

Disconnect the Exhaust Tube, clean the Exhaust Tube and the Vacuum Manifold.

b.

Clean the area between the BRD Roll and Roll 3.

c.

Clean the Top Surface of the Lower Right Housing Plate.

d.

Clean the Front Seal, the Rear Seal, and the PR Ground Wiper.

CAUTION If this is a MICR Developer Housing, DO NOT handcrank the Developer Housing slowly, there may be lumping of the developer material. If lumping occurs, the lumps should be loosened by hand. CAUTION Do not crank the Developer Housing in the counterclockwise direction, or pour the material between Roll 1 and Roll 2. The Developer Material can compact and can permanently stay on the Rolls. NOTE: Two Bottles of Developer Material must be installed. 2.

POUR THE DEVELOPER (Figure 4).

Replacement 1.

CLOSE THE DUMP DOOR (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-223

Section Name

REP 9-4

REP 9-5 Developer Assembly Parts List on PL 9.13 Removal NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT DOOR.

3.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

4.

DUMP THE DEVELOPER MATERIAL (REP 9-4).

5.

REMOVE THE TONER DISPENSER ASSEMBLY (REP 9-2).

6.

REMOVE THE DEVELOPER MANIFOLD (Figure 1).

2 REMOVE THE SCREWS (2)

2 1 HANDCRANK CLOCKWISE ONLY WHILE POURING THE DEVELOPER MATERIAL

CAUTION POUR DEVELOPER IN THIS LOCATION ONLY

Figure 4 Installing the Developer CAUTION Ensure that the Developer Rolls are evenly covered with Developer material before closing the PR Module.

1

3.

CLEAN THE DUMP TRAY. DISCARD THE USED DEVELOPER MATERIAL AND THE DROPCLOTH.

3 WARNING

4.

IF INSTALLING THE NEW DEVELOPER MATERIAL, SELECT [SCP], [HFSI], [Cleaner/ Developer], [09-825 R Developer], AND [Reset Count].

REMOVE MANIFOLD

5.

PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

LOOSEN THE CLAMP AND REMOVE VACUUM HOSE FROM MANIFOLD

Figure 1 Removing the Manifold 7.

Section Name

REP 9-4, REP 9-5

0/0/00 ?-224

REMOVE THE DEVELOPER ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

2

3 LIFT DEVELOPER ASSEMBLY OFF THE LOCATING PINS

2

LOOSEN SCREWS AND RAISE HOLD DOWN BRACKETS

CAUTION PUSH THE MANIFOLD DOWN, AND TIGHTEN THE SCREWS (2)

1

1

3

SLIDE THE MANIFOLD INTO HOUSING

REINSTALL THE VACUUM HOSE AND TIGHTEN THE CLAMP

REMOVE THE SCREWS

Figure 3 Reinstalling the Manifold

Figure 2 Removing the Developer Assembly

Replacement

4. CAUTION

WHEN INSTALLING A NEW DEVELOPER ASSEMBLY LOOSEN THE DEVELOPER DRIVE ASSEMBLY (REP 4-39).

5.

ALIGN THE DEVELOPER DRIVE ASSEMBLY (ADJ 9-19).

6.

INSTALL THE PHOTORECEPTOR.

NOTE: Do not release the Xerographic Drawer Latch while installing the Developer Housing. Check that the Developer Housing is seated flat on the clean mounting pads.

7.

CHECK THAT THE DEVELOPER ROLLS ARE EVENLY COVERED WITH DEVELOPER BEFORE CLOSING THE PR MODULE.

1.

INSTALL THE DEVELOPER HOUSING.

8.

INSTALL THE TONER DISPENSER ASSEMBLY.

2.

REINSTALL 2 SCREWS AND SECURE HOLD DOWN BRACKETS.

9.

3.

REINSTALL THE DEVELOPER MANIFOLD (Figure 3).

IF A NEW DEVELOPER ASSEMBLY, OR NEW DEVELOPER, WAS INSTALLED, PERFORM THE FOLLOWING:

The DP180MX has a unique Developer Housing and it is not compatible with the DP180.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-225

a.

Enter dC107, select [Xero], [Developer], and press [Reset counter to zero and update History.].

b.

The Xerographic Set-up (ADJ 9-3).

Section Name

REP 9-5

REP 9-6 Developer Dump And Thump

REP 9-7 Front Bearing Clamp

Removal

Parts List on PL 9.15 Removal

NOTE: MICR (DP180MX) Machines use a Red Toner Bottle that is not compatible with DP180. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

DUMP THE DEVELOPER MATERIAL (REP 9-4). CAUTION

If this is a MICR Developer Housing, DO NOT handcrank the Developer Housing slowly, there may be lumping of the developer material. If lumping occurs, the lumps should be loosened by hand. CAUTION

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE DEVELOPER GEAR GUARD.

4.

REMOVE THE PR GROUND STRIP CLEANER.

NOTE: Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if necessary. 5.

REMOVE THE BEARING CLAMP (Figure 1).

Do not crank the Developer Housing in the counterclockwise direction, or pour the material between Roll 1 and Roll 2. The Developer Material can compact and can permanently stay on the Rolls. 3.

1

HANDCRANK THE DEVELOPER ASSEMBLY CLOCKWISE APPROXIMATELY 20 REVOLUTIONS IN ORDER TO CLEAN OUT THE AUGER.

4.

HANDCRANK THE DEVELOPER ASSEMBLY, AND CLEAN THE ROLLS WITH THE VACUUM CLEANER.

5.

REMOVE THE DEVELOPER ASSEMBLY (REP 9-5).

6.

PLACE THE DEVELOPER ASSEMBLY ON A DROPCLOTH, AND CAREFULLY OPEN THE DUMP DOOR.

7.

RAISE THE REAR OF THE ASSEMBLY APPROXIMATELY 60 DEGREES, AND SHAKE THE ASSEMBLY IN ORDER TO DISLODGE ANY MATERIAL CAUGHT AT THE REAR OF THE ASSEMBLY.

8.

RAISE THE FRONT, AND SHAKE THE ASSEMBLY IN ORDER TO DUMP THE TONER FROM THE AUGER.

9.

PLACE THE ASSEMBLY ON ITS REAR SURFACE, AND GENTLY TAP THE LEFT AND THE RIGHT SIDES OF THE HOUSING WITH THE HANDLE OF A SCREWDRIVER.

2 REMOVE THE SCREWS (5)

REMOVE THE PR GROUND CLEANER

10. REPEAT STEPS 7 TO 9 UNTIL ALL MATERIAL HAS BEEN REMOVED FROM THE ASSEMBLY, AND INSTALL THE DEVELOPER ASSEMBLY (REP 9-5). 11. INSTALL THE DEVELOPER MATERIAL (REP 9-4). 12. INSTALL THE PHOTORECEPTOR BELT (REP 9-35), CLOSE THE XEROGRAPHIC DRAWER, SWITCH ON THE PRINTER, AND MAKE 1 PRINT. DO NOT SWITCH OFF THE PRINTER UNTIL THE XEROGRAPHIC SET-UP HAS BEEN PERFORMED.

3

13. PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

REMOVE THE BEARING CLAMP

Figure 1 Removing the Bearing Clamp

Replacement NOTE: Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the distance between the Developer Roll and the Photoreceptor, which will cause a print quality problem. 1. Section Name

REP 9-6, REP 9-7

0/0/00 ?-226

CHECK THAT ALL BEARINGS ARE SEATED IN THEIR CAVITIES. Preliminary Working Document No Product Name Assigned

NOTE: Do not tighten the screws too much, the threaded inserts can pull out.

REP 9-8 BRD Roll (w/Tag P-118 and Tag P-300)

2.

Parts List on PL 9.15 Removal

3.

INSTALL THE SHORT SCREW IN THE FAR RIGHT HOLE OF THE BEARING CLAMP, THEN INSTALL THE REMAINING FOUR SCREWS. INSTALL THE PR GROUND STRIP CLEANER. a.

Clean the Bearing Clamp between the two screw holes in front of Developer Roll 3 with the film remover.

NOTE: It is not necessary to remove the Developer Assembly if only the Gears, Front Bearing Clamp, the BRD One-Way Clutch or the Front Bearings of the Developer Roll will be removed.

b.

Align the two bosses of the Cleaner in the two screw holes in front of Roll 3, and push the Cleaner into position.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE DEVELOPER ASSEMBLY (REP 9-5).

3.

REMOVE THE FRONT BEARING CLAMP (REP 9-7).

4.

REMOVE THE DRIVE GEAR FROM ROLL 3.

5.

REMOVE THE SCREW FROM REAR OF BRD ROLL SHAFT.

6.

ROTATE ROLL 3 IN ORDER TO PLACE THE HIGH POINT OF THE CAM UPWARDS.

7.

REMOVE BRD ROLL (Figure 1).

3 REMOVE THE CAM FOLLOWER

2 HIGH POINT OF CAM UP

ONE-WAY CLUTCH

4 REMOVE THE BRD ROLL

1 REMOVE THE GEAR

Figure 1 Removing the BRD Roll

Preliminary Working Document No Product Name Assigned

0/0/00 ?-227

Section Name

REP 9-7, REP 9-8

Replacement CAUTION 1.

Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the distance between the Developer Roll and the Photoreceptor, which will cause a print quality problem.

2.

Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if required.

1.

CLEAN THE BEARING CAVITIES.

2.

ALIGN THE FLAT ON THE REAR SHAFT WITH REAR HOUSING, AND INSERT THE ROLL.

3.

INSTALL THE ONE-WAY CLUTCH WITH THE PLASTIC SEAL TOWARD THE REAR SO THAT THE CLUTCH ROTATES IN THE CLOCKWISE DIRECTION.

4.

SEAT THE ONE-WAY CLUTCH AND FRONT OF BRD SHAFT IN FRONT HOUSING. PUSH THE CLUTCH TOWARD THE REAR.

5.

INSTALL THE BRD BIAS WIRE (Figure 2).

1 CHECK CONTINUITY BETWEEN THE BRD ROLL AND BIAS TAB

BRD SHAFT

Figure 3 Checking the Continuity 7.

INSTALL THE CAM ON ROLL 3 SHAFT. INSTALL CAM FOLLOWER ON BRD SHAFT.

8.

INSTALL THE SCREW IN REAR SHAFT.

9.

INSTALL THE DRIVE GEAR FOR ROLL 3 WITH THE RECESS TOWARD THE FRONT.

10. INSTALL FRONT BEARING CLAMP. 11. INSTALL THE DEVELOPER ASSEMBLY (REP 9-5). 12. INSTALL THE TONER DISPENSER ASSEMBLY. 13. INSTALL THE PHOTORECEPTOR BELT (REP 9-35). WIRE BETWEEN SHOULDER AND SCREW WIRE AGAINST VERTICAL RIB

Figure 2 Installing the Bias Wire 6.

CHECK THE CONTINUITY BETWEEN THE BRD ROLL AND THE BIAS TAB (Figure 3).

REP 9-9 Developer Roll 1 or 2 Section Name

REP 9-8

0/0/00 ?-228

Preliminary Working Document No Product Name Assigned

Parts List on PL 9.15 Removal

Replacement

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

1.

Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the distance between the Developer Roll and the Photoreceptor, which will cause a print quality problem.

2.

Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if required.

CAUTION

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE DEVELOPER ASSEMBLY (REP 9-5).

4.

REMOVE THE FRONT BEARING CLAMP (REP 9-7).

5.

REMOVE THE DRIVE GEAR. GENTLY LIFT THE FRONT SHAFT IN ORDER TO REMOVE THE BEARING.

6.

REMOVE THE REAR BEARING CLAMP (Figure 1).

1.

CLEAN THE BEARING CAVITIES.

2.

INSERT THE REAR SHAFT IN THE REAR PLATE.

NOTE: Check that the slots in shafts are aligned with the keys of the Rear Bearing Clamp. 3.

1 REMOVE THE SCREWS (3) AND THE CLAMP THE BIAS LEAD

INSTALL THE REAR BEARING CLAMP. a.

Place a hex wrench between the vertical faces of the slot in the rear shaft. Rotate the wrench until it just jams in the slot. Rotate the shaft for the preliminary alignment.

b.

Position the Clamp so that the two metal keys are aligned in the slots in rear shafts. Gently tighten the three screws, in order to move the Clamp into position.

4.

CONNECT THE BIAS LEAD.

5.

INSTALL THE FRONT BEARING WITH THE PROTRUDING END OF THE INNER RACE TOWARD THE REAR. SEAT THE BEARING IN CAVITY IN THE FRONT PLATE.

6.

INSTALL THE DRIVE GEAR WITH THE FLAT SURFACE TOWARD FRONT.

7.

INSTALL FRONT BEARING CLAMP.

8.

INSTALL DEVELOPER ASSEMBLY (REP 9-5).

9.

INSTALL THE TONER DISPENSER ASSEMBLY.

10. INSTALL PHOTORECEPTOR BELT (REP 9-35).

Figure 1 Removing the Rear Bearing Clamp. 7.

PUSH THE REAR SHAFT TOWARD THE FRONT IN ORDER TO REMOVE THE ROLL.

8.

REMOVE ROLL 1 OR ROLL 2.

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-9

REP 9-10 Developer Roll 3

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

Parts List on PL 9.15 Removal

3.

HANDCRANK THE DEVELOPER ASSEMBLY IN A CLOCKWISE DIRECTION ONLY AND CLEAN THE ROLLS WITH THE VACUUM CLEANER.

4.

REMOVE THE FRONT BEARING CLAMP (REP 9-7).

NOTE: The DP180MX has a unique Developer Roll 3 and it is not compatible with the DP180.

5.

REMOVE THE DRIVE GEAR, CAM FOLLOWER, AND CAM (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

ROLL 3

2 REMOVE THE CAM FOLLOWER

1 REMOVE THE GEAR

3 REMOVE THE CAM

Figure 1 Removing the Drive Gear, Cam Follower, and Cam 6.

LIFT THE FRONT SHAFT, AND REMOVE THE BEARING.

7.

REMOVE THE REAR BEARING CLAMP (Figure 2).

Section Name

REP 9-10

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Preliminary Working Document No Product Name Assigned

6.

1 REMOVE REAR BEARING CLAMP (2 SCREWS)

BIAS LEAD

INSTALL THE FRONT BEARING WITH THE PROTRUDING END OF THE INNER RACE TOWARD THE REAR. SEAT THE BEARING IN THE CAVITY IN FRONT HOUSING PLATE.

7.

INSTALL THE CAM AND CAM FOLLOWER.

8.

INSTALL THE DRIVE GEAR WITH THE RECESS TOWARD THE FRONT.

9.

INSTALL THE FRONT BEARING CLAMP.

HOUSING BIAS TAB

Figure 2 Removing the Rear Bearing Clamp 8.

PUSH THE REAR SHAFT TOWARD THE FRONT, AND REMOVE DEVELOPER ROLL 3.

Replacement CAUTION 1.

Ensure that the bearing cavities are clean before seating a Bearing. Use the Vacuum Cleaner and a cotton swab to remove all dirt. Dirt in a bearing cavity can change the distance between the Developer Roll and the Photoreceptor, which will cause a print quality problem.

2.

Inspect the Front Bearing Clamp for any cracks on the mounting surface and replace if required.

1.

CLEAN THE BEARING CAVITIES.

2.

INSERT THE REAR SHAFT IN THE REAR PLATE.

3.

ALIGN THE REAR SHAFT SO THAT THE SLOT IS ALIGNED WITH THE KEY OF THE CLAMP.

4.

INSTALL THE REAR BEARING CLAMP.

5.

CONNECT THE BIAS LEAD TO THE HOUSING BIAS TAB.

REP 9-11 Trimmer Bar Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-10

REP 9-12 Paddle Wheel

Parts List on PL 9.16 Removal SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 9.18 Removal

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

1.

3.

REMOVE DEVELOPER MATERIAL (REP 9-5).

4.

REMOVE DEVELOPER ROLL 1 (REP 9-9).

5.

REMOVE THE TRIMMER BAR (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS AND DISCONNECT ALL THE POWER CORDS. NOTE: Do not remove the Paddle Wheel when replacing only the front and rear bearings.

2.

REMOVE THE FOLLOWING: a.

The Developer Material (REP 9-4).

2

b.

Developer Assembly (REP 9-5).

PRY THE REAR CAP BACKWARD

c.

Developer Rolls 1 and 2 (REP 9-9).

d.

Trimmer Bar (REP 9-11).

1 REMOVE REAR CAP (2 SCREWS)

3.

REMOVE THE DRIVE GEAR FROM THE FRONT OF PADDLE WHEEL ASSEMBLY.

4.

REMOVE THE BEARING HOUSING, THE BEARING RETAINER AND THE FRONT BEARING (Figure 1).

3

1

REMOVE THE TRIMMER BAR

REMOVE THE SCREWS (3)

Figure 1 Removing the Trimmer Bar

Replacement

2

1.

REMOVE THE BEARING RETAINER

LOOSELY INSTALL THE TRIMMER BAR WITH THE MARK TOP ON TOP, AND WITH THE TAPERED EDGE TOWARD ROLL 1.

2.

PUSH THE TRIMMER BAR TOWARD THE BRD ROLL, AND TIGHTEN THE CAPS.

3.

INSTALL DEVELOPER ROLL 1.

4.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35). Figure 1 Removing the Front Bearing 5.

Section Name

REP 9-11, REP 9-12

0/0/00 ?-232

REMOVE THE DEVELOPER DRIVE COUPLING (Figure 2).

Preliminary Working Document No Product Name Assigned

1 RAISE THE WIRE, AND REMOVE THE SHAFT TOWARD THE FRONT

1 LOOSEN THE SCREW

2 REMOVE THE COUPLING

Figure 2 Removing the Developer Drive Coupling 6.

Figure 3 Removing the Shaft

CHECK THE DRIVE SHAFT, REMOVE ANY BURRS (BY THE DRIVE COUPLING).

9.

NOTE: Gently hit the rear end of the shaft with the handle of a screwdriver while raising the wire out of the slot in shaft. When the wire will no longer fall back into the slot, reinstall the drive gear in order to provide a temporary handle. 7.

REMOVE THE REAR BEARING RETAINER AND THE REAR BEARING.

8.

REMOVE PADDLE WHEEL SHAFT (Figure 3).

REMOVE THE PADDLE WHEEL.

10. REMOVE THE AUGER FROM THE REAR HOUSING PLATE HUB (SAVE TO INSTALL NEW PARTS). 11. CHECK THE DEVELOPER SUMP FOR FOREIGN OBJECTS.

Replacement 1.

DROP IN THE NEW PADDLE WHEEL.

2.

INSTALL THE NEW PADDLE WHEEL DRIVE SHAFT.

NOTE: Take care not damage the Augers while inserting the Paddle Wheel Shaft. Install the drive gear on the shaft in order to provide a temporary handle. 3.

CHECK THAT THE RETAINING WIRE IS SEATED IN THE SLOT OF THE DRIVE SHAFT. CAUTION

Align the Bearing Retainer with the locating pin of the bearing housing.

Preliminary Working Document No Product Name Assigned

4.

INSTALL THE FRONT BEARING, THE FRONT BEARING RETAINER AND THE BEARING HOUSING.

5.

TIGHTEN THE SCREWS (3).

0/0/00 ?-233

Section Name

REP 9-12

6.

REP 9-13 Mixing Auger

INSTALL THE DRIVE GEAR.

7.

INSTALL THE NEW (BLACK) REAR AUGER, PRESS TO SHOULDER ON THE SHAFT.

Parts List on PL 9.16 Removal

8.

INSTALL THE TOLERANCE RING IN THE REAR END GROOVE ON THE SHAFT.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE DEVELOPER ASSEMBLY (REP 9-5).

3.

REMOVE THE MIXING AUGER GEAR.

4.

REMOVE THE MIXING AUGER (Figure 1).

NOTE: Use the old Auger as a tool to push the new Auger onto the shaft.

NOTE: Use the old Auger as a tool to position the new Auger onto the shaft. Gently hit the old Auger with a soft faced mallet or the handle of a screwdriver until the Bearing is seated in the rear housing. 9.

INSTALL THE REAR BEARING.

10. INSTALL THE REAR BEARING RETAINER. TIGHTEN THE SCREWS (3).

2

11. INSTALL THE DRIVE COUPLING. TIGHTEN THE SCREW (1).

1

12. ENSURE THE PADDLE WHEEL TURNS FREELY.

REMOVE THE SCREWS (3)

13. INSTALL TRIMMER BAR (REP 9-11).

REMOVE THE BEARING CAP

14. INSTALL DEVELOPER ROLLS 1 AND 2 (REP 9-9). 15. INSTALL DEVELOPER ASSEMBLY (REP 9-5).

3 4

REMOVE THE BEARING RETAINER

REMOVE THE AUGER

Figure 1 Removing the Mixing Auger

Replacement

Section Name

REP 9-12, REP 9-13

1.

SECURE THE HARNESS WITH A CABLE CLAMP AT THE TOP SCREW OF THE BEARING CLAMP.

2.

INSTALL DEVELOPER ASSEMBLY (REP 9-5).

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Preliminary Working Document No Product Name Assigned

REP 9-14 Low Toner Sensor (Q903)

REP 9-15 Waste Bottle Full Sensor (Q906)

Parts List on PL 9.19 Removal

Parts List on PL 9.7 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE PHOTORECEPTOR BELT (REP 9-35).

2.

OPEN THE XEROGRAPHIC DRAWER (REP 9-34).

3.

REMOVE THE TONER BOTTLE (REP 9-0).

3.

OPEN THE PR MODULE, AND COVER THE DEVELOPER CAVITY.

4.

CLEAN THE TONER INSIDE THE TONER HOPPER WITH THE VACUUM CLEANER.

4.

PROTECT THE PHOTORECEPTOR BELT AS SHOWN IN THE REMOVAL PROCEDURE OF THE PHOTORECEPTOR BELT (REP 9-35).

5.

PULL THE RIGHT END OF THE WASTE BOTTLE FULL SENSOR OUT OF THE CUTOUT IN BRACKET. THEN LIFT THE RIGHT END, AND REMOVE THE SENSOR TOWARD THE LEFT (Figure 1).

CAUTION Use caution when handling the Low Toner Sensor. Do not touch the sensor portion. 5.

CLEAN THE FOAM SEAL OF THE TONER DISPENSER, AND CLEAN THE SURROUNDING AREA AFTER REMOVING THE BOTTLE, AND BEFORE INSTALLING IT.

6.

REMOVE THE LOW TONER SENSOR (Figure 1).

2 2

PULL THE RIGHT END OUT OF THE CUTOUT THEN REMOVE SENSOR TOWARD THE LEFT

REMOVE THE SCREWS

1 DISCONNECT THE CONNECTOR

1

3

DISCONNECT THE CONNECTOR

REMOVE THE SENSOR

Figure 1 Removing the Sensor Figure 1 Removing the Sensor

Preliminary Working Document No Product Name Assigned

0/0/00 ?-235

Section Name

REP 9-14, REP 9-15

REP 9-16 Waste Compactor Shield

3.

PULL THE WASTE COMPACTOR SHIELD FROM WASTE COMPACTOR BRACKET.

Replacement

Parts List on PL 9.23 Removal

1.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

REMOVE THE OLD ADHESIVE, AND CLEAN THE TOP SURFACE OF THE BRACKET WITH THE CLEANING SOLVENT.

2.

REMOVE THE PROTECTIVE FILM FROM THE NEW SHIELD.

3.

INSTALL THE SHIELD (Figure 1).

1

2

3

CLEAN THE TOP OF THE BRACKET

REMOVE THE PROTECTIVE FILM

ALIGN THE LEFT AND THE REAR EDGES, AND ATTACH SHIELD

SHIELD

4

REAR VIEW

POSITION THE FLAP

Figure 1 Installing the Shield 4.

POSITION THE D-SHAPED FLAP SO THAT IT COVERS THE LARGER, RECTANGULAR LEFT END OF THE SHIELD.

Section Name

REP 9-16

REP 9-17 Upper Waste Toner Duct Parts List on PL 9.23 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

0/0/00 ?-236

Preliminary Working Document No Product Name Assigned

CAUTION Do not bend the Agitator Spring. 3.

REMOVE UPPER WASTE TONER DUCT (Figure 1).

1 REMOVE THE SCREW

UPPER WASTE TONER DUCT

2 CAUTION PUSH TOP OF WASTE DUCT TOWARD PRINTER WHILE PULLING DUCT UP, AND THEN OUT

Figure 1 Removing the Waste Toner Duct 4.

REMOVE THE AGITATOR SPRING (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-237

Section Name

REP 9-17

2 SLIDE THE AGITATOR COIL SPRING ONTO THE WIRE

1 REMOVE THE AGITATOR COIL SPRING

1 SEAT THE RETAINING END OF AGITATOR WIRE IN RECESSES

2 CAREFULLY PULL THE RETAINING END OF AGITATOR WIRE OUT OF RECESSES

Figure 3 Installing the Waste Agitator Springs

Figure 2 Removing the Waste Agitator Spring

Replacement 1.

INSTALL THE AGITATOR SPRING (Figure 3).

CAUTION Do not bend the Agitator Spring. 2.

INSTALL THE UPPER WASTE TONER DUCT.

REP 9-18 Waste Compactor Drive Belt

NOTE: Push the Motor out of the tensioning hole of the Bracket in order to provide belt slack.

Parts List on PL 9.23 Removal

3.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE PRINTER LEFT REAR COVER (REP 4-1).

Section Name

REP 9-17

0/0/00 ?-238

REMOVE THE WASTE COMPACTOR DRIVE BELT (Figure 1).

Preliminary Working Document No Product Name Assigned

1

3

LOOSEN THE SCREWS AT LEAST 3 REVOLUTIONS

REMOVE BELT (CLOCKWISE ROTATION)

3

1

TIGHTEN THE SCREWS (2)

INSTALL THE BELT

2 PULL THE MOTOR INTO THE TENSIONING HOLE

2 PUSH THE PULLEY TOWARD THE FRONT

Figure 2 Installing the Drive Belt

Figure 1 Removing the Belt

Replacement

2.

CHECK THAT THE D-SHAPED FLAP OF THE SHIELD COVERS THE LARGER, RECTANGULAR LEFT END OF THE SHIELD.

NOTE: Position the hub of Motor into the tensioning hole of the Bracket. Pivot the Motor in a counterclockwise direction, and seat its positioning hub in the tensioning hole of the bracket. Hold the Motor, while tightening the screws. 1.

INSTALL THE DRIVE BELT (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-239

Section Name

REP 9-18

REP 9-19 Waste Compactor Motor Bracket

Replacement

Parts List on PL 9.23 Removal

NOTE: Install the Clutch Bearing Retainer with the tapered end up so that the tangs push against the bearing. Slide the tangs of retainer over the clutch shaft. Lower the Bracket into position behind the two screws.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

3.

REMOVE THE WASTE COMPACTOR DRIVE BELT (REP 9-18).

4.

REMOVE WASTE COMPACTOR MOTOR BRACKET (Figure 1).

1.

POSITION THE ASSEMBLY IN PRINTER, AND INSTALL THE BRACKET (Figure 2).

2 TIGHTEN THE SCREWS (3)

4

POSITION THE RETAINER AND THE BRACKET

REMOVE THE SCREW

5 REMOVE THE BRACKET WITH THE MOTOR

1

3 LOOSEN THE SCREWS (2)

1 LOOSEN THE SCREWS (2)

4

2 CUT CABLE TIE, AND DISCONNECT CONNECTOR

CONNECT THE CONNECTOR, INSTALL THE CABLE TIE

3 TIGHTEN THE SCREWS (2)

Figure 2 Installing the Bracket Figure 1 Removing the Bracket

Section Name

REP 9-19

NOTE: Set the positioning hub of Motor into the tensioning hole of the Bracket. 2.

INSTALL THE DRIVE BELT.

3.

CHECK THAT THE D-SHAPED FLAP OF THE SHIELD COVERS THE LARGER, RECTANGULAR LEFT END OF THE SHIELD.

0/0/00 ?-240

Preliminary Working Document No Product Name Assigned

REP 9-20 Waste Compactor Auger Parts List on PL 9.23 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2

2.

REMOVE PRINTER LEFT REAR COVER (REP 4-1).

3.

REMOVE THE WASTE COMPACTOR DRIVE BELT (REP 9-18).

REMOVE THE SCREW

4.

REMOVE UPPER WASTE TONER DUCT (REP 9-17).

1 LOOSEN THE SCREWS (2)

NOTE: Do not bend the Agitator Spring during removal or replacement. 5.

REMOVE WASTE AGITATOR SPRINGS (Figure 1).

1 REMOVE THE AGITATOR COIL SPRING

3 PULL OUT THE AUGER

2 CAREFULLY PULL THE RETAINING END OF AGITATOR WIRE OUT OF RECESSES

Figure 2 Removing the Compactor Auger

Replacement 1.

ALIGN THE KEYED ONE-WAY CLUTCH OF THE COMPACTOR AUGER IN THE KEYED SEAT IN THE LOWER WASTE TONER DUCT. THEN PUSH THE AUGER INTO POSITION.

NOTE: Install the bearing clamp for Auger with the tapered corner up so that the tangs push against the bearing. 2.

INSTALL THE AUGER BEARING CLAMP.

NOTE: Position the hub of Motor in the tensioning hole of the bracket.

Figure 1 Removing the Waste Agitator Springs 6.

3.

INSTALL THE DRIVE BELT.

4.

CHECK THAT THE D-SHAPED FLAP OF THE WASTE COMPACTOR SHIELD COVERS THE LARGER, RECTANGULAR LEFT END OF THE SHIELD.

5.

INSTALL THE WASTE AGITATOR SPRINGS (Figure 3).

REMOVE WASTE COMPACTOR AUGER (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-241

Section Name

REP 9-20

REP 9-21 Waste Compactor Motor (MOT903) Parts List on PL 9.23 Removal 1.

1 POSITION THE MOTOR AS SHOWN, AND LOOSELY INSTALL THE SCREWS (2)

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE PRINTER LEFT REAR COVER (REP 4-1).

3.

REMOVE THE WASTE COMPACTOR DRIVE BELT (REP 9-18).

4.

REMOVE WASTE COMPACTOR MOTOR BRACKET (REP 9-19).

NOTE: Push the motor pulley through clearance hole in bracket in order to remove Motor. 5.

REMOVE THE MOTOR (Figure 1).

1 REMOVE SCREWS (2) AND REMOVE MOTOR

FRONT VIEW

Figure 2 Installing a Motor 2.

POSITION THE MOTOR IN THE TENSIONING HOLE OF THE BRACKET WHILE INSTALLING THE DRIVE BELT.

3.

CHECK THAT THE D-SHAPED FLAP OF THE SHIELD COVERS THE LARGER, RECTANGULAR LEFT END OF THE SHIELD.

Figure 1 Removing the Motor

Replacement NOTE: Align the Motor so that the leads entering the housing are at the four o'clock position (viewed from the front). 1.

INSTALL THE MOTOR (Figure 2).

Section Name

REP 9-21

0/0/00 ?-242

Preliminary Working Document No Product Name Assigned

REP 9-22 Lower Waste Toner Duct

REP 9-23 Cleaner Brush

Parts List on PL 9.23 Removal

Parts List on PL 9.24 Removal

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UPPER WASTE TONER DUCT (REP 9-17).

2.

OPEN THE XEROGRAPHIC DRAWER (REP 9-34).

3.

REMOVE THE WASTE COMPACTOR MOTOR BRACKET (REP 9-19).

3.

COVER THE AREA UNDER THE CLEANER BRUSH WITH PAPER.

4.

REMOVE WASTE COMPACTOR AUGER (REP 9-20).

5.

REMOVE THE LOWER WASTE TONER DUCT (Figure 1).

NOTE: Store the Brush on its rear hub if it will be reinstalled. Do not place the brush on its bristles. Store the brush on the rear hub. 4.

PARTIALLY CLOSE THE DRAWER, AND REMOVE THE CLEANER BRUSH (Figure 1).

1

2

COVER THE PHOTORECEPTOR

LOOSEN THUMB SCREWS (2)

1 REMOVE THE SCREWS (2) AND REMOVE THE DUCT

3 REMOVE THE FRONT COVER

4 CAUTION REMOVE THE BRUSH Figure 1 Removing the Lower Waste Toner Duct Figure 1 Removing the Cleaner Brush

Replacement WARNING Wash the hands with soap and water after installing a new Brush. Residues of acids used in the manufacturing of the fibers could cause mild irritation.

Preliminary Working Document No Product Name Assigned

1.

CLEAN THE NEW OR USED BRUSH WITH THE VACUUM CLEANER.

2.

INSTALL THE USED BRUSH IN THE SAME DIRECTION OF ROTATION.

0/0/00 ?-243

Section Name

REP 9-22, REP 9-23

NOTE: Rotate the Brush in order to seat it on the rear arbor.

REP 9-24 Cleaner Manifold

3.

Parts List on PL 9.24 Removal

TAKE OUT THE PAPER PROTECTING THE AREA UNDER THE CLEANER BRUSH.

NOTE: Running 500 Prints is not required if performing the Xerographic Set-up. 4. 5.

IF INSTALLING A NEW BRUSH RUN AT LEAST 500 PRINTS. IF A NEW BRUSH WAS INSTALLED, ENTER [SCP], SELECT [HFSI], [Cleaner/Developer], [09-801 R Cleaner Brush and Blades], AND PRESS [Reset Count].

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS.

3.

REMOVE THE PHOTORECEPTOR INNER PANEL.

4.

COVER THE FLOOR WITH A DROPCLOTH.

5.

REMOVE THE FUSER OIL DRIP PAN (Figure 1).

2 OPEN THE FUSER, AND REMOVE THE DRIP PAN

1 LOOSEN THE SCREW FACING TOWARD THE RIGHT

Figure 1 Removing the Drip Pan 6.

Section Name

REP 9-23, REP 9-24

0/0/00 ?-244

REMOVE THE CLEANER MANIFOLD (Figure 2).

Preliminary Working Document No Product Name Assigned

2 1 PIVOT THE THREE LATCHES

MOVE THE LATCH TO THE REAR

3 MOVE THE LATCH TO THE FRONT AND SECURE WITH RETAINER

4 PULL OFF THE HOSE FROM THE ADAPTER TUBE

Figure 2 Removing the Manifold

Replacement 1.

CLEAN THE MANIFOLD AND THE DUCT WITH THE VACUUM CLEANER.

2.

REMOVE IMPACTED TONER FROM FLICKER BAR WITH THE FILM REMOVER.

NOTE: Check that the Manifold is latched securely, and check that the exhaust duct is seated in order to form a tight seal. Air leaks anywhere in the toner exhaust system will cause a Cleaner failure. Install the left edge of the Manifold first, then continue with a rocking motion toward the lower right side. 3.

INSTALL AND CHECK THE MANIFOLD (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-245

Section Name

REP 9-24

3 THE EXHAUST DUCT IS INSTALLED TIGHTLY ON THE ADAPTER TUBE

2 ALL 4 LATCHES HOLD DOWN THE MANIFOLD

1 NOTE: NO GAP BETWEEN THE MANIFOLD AND HOUSING

Figure 3 Installing and Checking the Manifold Installation 4.

INSTALL THE DRIP PAN.

REP 9-25 Cleaner Augers or Blade

5.

CLOSE AND LATCH THE FUSER.

6.

INSTALL THE PHOTORECEPTOR INNER PANEL.

Parts List on PL 9.24 Removal

Section Name

REP 9-24

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR INNER PANEL.

3.

PROTECT THE PHOTORECEPTOR BELT (REP 9-35), LEAVE THE XEROGRAPHIC DRAWER PARTIALLY OPENED.

4.

REMOVE AND STORE THE CLEANER BRUSH (REP 9-23).

5.

ACCESS THE WASTE TONER AUGERS (Figure 1).

0/0/00 ?-246

Preliminary Working Document No Product Name Assigned

1

1

REMOVE THE SCREWS (2)

CAUTION REMOVE BLADE

2 GRASP WITH NEEDLENOSE PLIERS, AND REMOVE THE CLEANER AUGER

2 REMOVE AUGER GEAR HOUSING Figure 1 Accessing the Components

Figure 2 Removing the Auger or the Blade

CAUTION

Clean

Rotate the Auger in a clockwise direction during removal or replacement in order to prevent the stretching of the spring. Prevent dirt by holding the nozzle of the vacuum cleaner near the opening while pulling out any of these components. 6.

REMOVE THE CLEANER BLADE OR THE AUGER (Figure 2).

CAUTION Do not touch the bristles of the Brush with the hands. Store the Brush only on the rear hub. Reinstall the brush so that it will rotate in the original direction. 1.

CLEAN THE BRUSH AND OTHER COMPONENTS WITH THE VACUUM CLEANER. USE THE VACUUM ADAPTER TUBE IN ORDER TO CLEAN THE INSIDE OF THE AUGER CAVITIES.

Replacement CAUTION Do not damage the thin sealing strip during installation of the Auger. Clean the Cleaner Brush Housing before installing the components. 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-247

INSTALL THE AUGERS WITH THE TWO ALIGNMENT FINS SEATED IN THE TWO HOUSING SLOTS (Figure 3).

Section Name

REP 9-25

NOTE: THE LONG TABS TOWARD THE FRONT

1 2 SEAT THE FINS IN SLOTS IN ORDER TO INSTALL AUGER

ROTATE AUGER CLOCKWISE DURING STEP 2

Figure 3 Installing the Auger or the Blade CAUTION Rotate the Auger in a clockwise direction during installation. 2.

ENSURE THAT THE AUGERS TURN FREELY BEFORE INSTALLING THE GEAR HOUSING.

3.

ALIGN THE AUGER DRIVE SHAFTS, AND SEAT THEM IN THEIR DRIVE GEARS WHEN REINSTALLING THE GEAR HOUSING.

4.

REINSTALL THE CLEANER BRUSH (REP 9-23).

5.

CLOSE THE PR MODULE.

6.

INSTALL THE PHOTORECEPTOR INNER PANEL.

7.

RESTORE THE PRINTER POWER.

8.

IF NEW BLADES WERE INSTALLED, ENTER [SCP], [HFSI], SELECT [Cleaner/Developer], [09-802 R Cleaner Brush and Blades], AND PRESS [Reset Count].

Section Name

REP 9-25

0/0/00 ?-248

Preliminary Working Document No Product Name Assigned

REP 9-26 Cleaner Module

3.

Parts List on PL 9.22 Removal

REMOVE PHOTORECEPTOR BELT (REP 9-35), AND COVER THE PR MODULE UNDER THE CLEANER MODULE WITH PAPER.

4.

REMOVE THE CLEANER MANIFOLD (REP 9-24).

5.

REMOVE THE UPPER WASTE TONER DUCT (REP 9-17).

1.

6.

REMOVE THE PRECLEAN DICOROTRON CONNECTOR (REP 9-40).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: Do not remove the Cleaner Module if only a cleaning procedure will be performed. 2.

REMOVE PRECLEAN DICOROTRON (REP 9-39).

7.

REMOVE THE WASTE TONER DUCT SLIDE (PL 9.23

8.

REMOVE THE CLEANER DRIVE BELT (Figure 1).

2

1

MOVE AND HOLD THE IDLER

LOOSEN THE BOLT

3 TIGHTEN THE BOLT NOTE: THE CLEANER AND OZAC DUCTS ARE NOT SHOWN

4 REMOVE THE BELT

Figure 1 Removing the Cleaner Drive Belt 9.

PREPARE THE REAR OF THE MODULE FOR REMOVAL (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-249

Section Name

REP 9-26

7

6

REMOVE SCREW

REMOVE THE DRIVE SUPPORT

5 REMOVE NUTS AND WASHERS (3)

4 REMOVE PULLEY AND THE CLIP

1 DISCONNECT CLEANER HARNESS

3 LOOSEN THE SETSCREW

2 REMOVE THE CAP

Figure 2 Preparing the Rear of the Module for Removal 10. CLOSE THE XEROGRAPHIC DRAWER, AND PREPARE THE FRONT OF THE MODULE FOR REMOVAL (Figure 3).

Section Name

REP 9-26

0/0/00 ?-250

Preliminary Working Document No Product Name Assigned

20. INSERT A ROLLED SHEET OF 14 INCH PAPER INTO THE CLEANER CAVITY IN ORDER TO TEMPORARILY BLOCK THE AIR FLOWING THROUGH THE MANIFOLD. PULL THE PAPER AWAY QUICKLY SEVERAL TIMES IN ORDER TO DISLODGE ACCUMULATED TONER BY DISTURBING THE AIR FLOW.

1 REMOVE THE SCREWS (2)

21. USE THE SAME TECHNIQUE IN ORDER TO CLEAN THE DEVELOPER MANIFOLD AND EXHAUST DUCT. 22. INSPECT THE FLICKER BAR. IF IMPACTED TONER IS VISIBLE REMOVE THE CLEANER MANIFOLD (REP 9-24), AND REPLACE THE FLICKER BAR (REP 9-33). 23. ENSURE THAT THE PAPER IS REMOVED FROM THE DEVELOPER MANIFOLD AFTER COMPLETING THE CLEANING PROCEDURE. 24. IF INSTALLING A NEW CLEANER MODULE REMOVE THE FOLLOWING COMPONENTS AND INSTALL THEM ON THE NEW MODULE: a.

Preclean Dicorotron Rail and Spacers.

NOTE: Do not install the Spots Blade at this time. b.

Spots Blade Guides (REP 9-58).

Replacement 1.

INSTALL THE AUGERS WITH THE TWO ALIGNMENT TABS SEATED IN THE TWO HOUSING SLOTS CAUTION

2

3 PULL ASSEMBLY OFF THE LOCATING PINS

Rotate the Auger in a clockwise direction during installation.

REMOVE SCREW AND THE DRIVE SUPPORT

Figure 3 Preparing the Front of Module for Removal 11. GENTLY PULL OUT XEROGRAPHIC DRAWER UNTIL RESISTANCE IS DETECTED.

2.

ENSURE THAT THE AUGERS TURN FREELY BEFORE INSALLING THE GEAR HOUSING.

3.

ALIGN THE AUGER DRIVE SHAFTS AND SEAT THEM IN THEIR DRIVE GEARS WHEN REINSTALLING THE GEAR HOUSING

4.

POSITION THE CLEANER MODULE ON THE XEROGRAPHIC DRAWER.

5.

GENTLY PUSH IN THE DRAWER UNTIL THERE IS RESISTANCE TO MOTION.

6.

PULL THE HARNESS CONNECTOR THROUGH THE GEAR CLEARANCE HOLE IN REAR FRAME.

7.

SEAT THE REAR OF THE MODULE IN THE TWO LOCATING HOLES.

12. FEED THE HARNESS THROUGH THE OPENING IN THE REAR FRAME.

WARNING

13. PULL OUT XEROGRAPHIC DRAWER, AND REMOVE THE CLEANER MODULE.

The Cleaner Insulating Cap must be reinstalled in order to protect against electrical shock during Printer operation.

NOTE: The following Steps (14-24) are for the Cleaning only.

NOTE: Push the pulley and the clip onto the shaft until pulley just contacts the Drive Support, and then tighten the setscrew.

14. ACCESS THE CLEANER AUGERS AND BLADES CAUTION Keep the area clean by holding the nozzle of the vacuum cleaner near the opening while pulling out any of these components.

8.

INSTALL REAR OF THE CLEANER MODULE (Figure 4).

15. REMOVE CLEANER BLADE AND AUGER. 16. REMOVE THE CLEANER BRUSH (REP 9-23), AND CLEAN THE INSIDE OF THE CLEANER HOUSING WITH THE VACUUM CLEANER. 17. USE THE VACUUM CLEANER IN ORDER TO CLEAN THE SLOTS ABOVE AND BELOW EACH DETONING ROLL. 18. COVER THE HOLES IN THE DEVELOPER MANIFOLD WITH PAPER. 19. INSERT THE NOZZLE OF THE VACUUM CLEANER IN THE EXHAUST ADAPTER FOR THE TONER FILTER. SWITCH ON THE VACUUM CLEANER.

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-26

2 INSTALL SUPPORT BRACKET LOOSELY

1 FINGERTIGHTEN THE SCREW

3 INSTALL PULLEY AND CLIP

6 DO NOT TIGHTEN THE IDLER AT THIS TIME

5

4 WARNING

CONNECT THE CLEANER HARNESS

INSTALL THE CAP

Figure 4 Installing the Rear of the Cleaner Module NOTE: Loosely install the three screws securing the tripod and the screw securing the Cleaner Module. Do not tighten the four screws until the front support bracket has been reinstalled. Ensure that the anti-rattle clip is reinstalled between the wide (8 mm) flat on shaft and the bearing. 9.

INSTALL THE CLEANER BRUSH AND THE FRONT SUPPORT BRACKET OF THE CLEANER MODULE (Figure 5).

Section Name

REP 9-26

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Preliminary Working Document No Product Name Assigned

2 SECURE THE BRACKET (3 SCREWS)

1 LATCH THE DRAWER

Figure 5 Installing the Front Support 10. OPEN THE FUSER. TIGHTEN THE 3 SCREWS SECURING THE TRIPOD BRACKET AND TIGHTEN THE SCREW SECURING THE CLEANER MODULE TO REAR FRAME. 11. INSTALL THE PRECLEAN DICOROTRON CONNECTOR (REP 9-40). 12. INSTALL THE WASTE TONER DUCT SLIDE (PL 9.23). 13. INSTALL AND TIGHTEN THE CLEANER DRIVE BELT (REP 4-20). 14. INSTALL THE UPPER WASTE TONER DUCT (REP 9-17). 15. ROUTE THE CLEANER HARNESS THROUGH OPENING BETWEEN TUBES OF THE WASTE TONER DUCT. 16. CONNECT THE OZAC DUCT AND THE CLEANER EXHAUST DUCT. 17. CONNECT THE CLEANER EXHAUST DUCT. 18. INSTALL THE CLEANER MANIFOLD AND THE FUSER DRIP PAN (REP 9-24). 19. INSTALL THE PRECLEAN DICOROTRON (REP 9-39). 20. CHECK/ADJUST THE PRECLEAN DICOROTRON HEIGHT (ADJ 9-18). 21. CHECK THAT ALL CONNECTIONS IN THE TONER EXHAUST SYSTEM ARE TIGHT. 22. REPLACE THE CABLE TIES AS REQUIRED (Figure 6).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-26

1 REPLACE THE CABLE TIES (2)

Figure 6 Replacing the Cable Ties 23. PERFORM THE DEVELOPER DUMP AND THUMP PROCEDURE AS REQUIRED (REP 9-6). 24. REINSTALL THE PHOTORECEPTOR BELT (REP 9-35). 25. ENTER [SCP], [HFSI]. SELECT [Cleaner/Developer], [09-826 C Cleaner Housing, Manifold and hose]. PRESS [Reset Count].

REP 9-27 Cleaner Drive Gears Parts List on PL 9.25 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

26. CHECK/ADJUST THE SPOTS BLADE CONTACT (ADJ 9-16).

2.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

27. PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

3.

REMOVE THE UPPER WASTE TONER DUCT (REP 9-17).

4.

DISCONNECT THE CLEANER DRIVE BELT, AND REMOVE THE DRIVE SUPPORT (Figure 1).

Section Name

REP 9-26

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Preliminary Working Document No Product Name Assigned

3 REMOVE THE DRIVE SUPPORT

2 REMOVE THE SCREWS (3)

1 REMOVE

Figure 1 Removing the Cleaner Drive Support 5.

REMOVE THE CLEANER GEARS (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-27

4.

LOOSEN A DETONING GEAR CLOCKWISE (LEFT HAND THREAD)

RESTORE ALL PRINTER POWER.

LOOSEN AN IDLER GEAR COUNTERCLOCKWISE

LOOSEN THE SETSCREW IN ORDER TO REMOVE THE DRIVE GEAR

1 HOLD SHAFT IN ORDER TO REMOVE A DETONING OR IDLER GEAR

Figure 2 Removing the Gears

Replacement 1.

INSTALL THE DRIVE SUPPORT.

WARNING The Cleaner Insulating Cap must be reinstalled in order to protect against electrical shock during Printer operation. NOTE: Push the pulley and the clip onto the shaft until pulley just contacts the Drive Support, and then tighten the setscrew. 2.

INSTALL PULLEY, CLIP, AND CLEANER DRIVE CAP.

3.

ADJUST THE CLEANER DRIVE BELT (ADJ 4-10).

Section Name

REP 9-27

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Preliminary Working Document No Product Name Assigned

REP 9-28 Toner Filter Bag Parts List on PL 9.21 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE ELECTRICAL MODULE REAR COVER (REP 4-1).

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Housing. Toner will fall from the Housing connection. 3.

OPEN THE TONER FILTER HOUSING, AND CAREFULLY PULL THE TONER FILTER BAG OUT.

4.

DISCARD THE OLD FILTER IN THE PLASTIC BAG.

5.

INSERT THE HOSE OF THE VACUUM CLEANER IN THE FILTER COUPLING, AND CLEAN THE TONER EXHAUST DUCT.

6.

CLEAN THE INSIDE OF THE FILTER HOUSING.

7.

ACCESS THE STATIONARY END OF THE DEVELOPER VACUUM COUPLING BY PULLING OUT THE XEROGRAPHIC DRAWER A SUFFICIENT DISTANCE. CLEAN THE OPENING WITH THE VACUUM CLEANER.

8.

CLEAN THE MATING END OF THE EXHAUST TUBE AND THE TOP SURFACE OF THE VACUUM MANIFOLD. CHECK THAT THE HOLES IN THE VACUUM MANIFOLD ARE NOT OBSTRUCTED.

Replacement NOTE: Do not disturb a Filter after it is installed. Once a filter is installed, the seal will conform to the coupling adapter, and the seal will leak if the bag is disturbed. 1.

DO NOT INSTALL A USED FILTER.

2.

INSTALL THE NEW FILTER.

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-28

REP 9-29 Toner Filter Assembly

2.

REMOVE THE ELECTRICAL MODULE REAR COVER (REP 4-1).

Parts List on PL 9.20 Removal

3.

PLACE A DROPCLOTH ON THE FLOOR, AND REMOVE THE TONER FILTER ASSEMBLY (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2 DISCONNECT THE CONNECTOR

3 LIFT AND REMOVE THE ASSEMBLY

TONER FILTER BAG

TOP REAR VIEW

1 UNLATCH AND OPEN THE ASSEMBLY

Figure 1 Removing the Toner Filter Assembly

Section Name

REP 9-29

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Preliminary Working Document No Product Name Assigned

REP 9-30 Toner Filter Blower Motor (MOT905)

2.

Parts List on PL 9.20 Removal

REMOVE THE ELECTRICAL MODULE REAR COVER, AND REMOVE THE BLOWER PULLEY GUARD.

3.

PREPARE TO REMOVE THE MOTOR (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1 DISCONNECT THE CONNECTOR

3 ROTATE THE PULLEY TO THE LEFT AND REMOVE THE PULLEY

2 REMOVE THE O-RING BELTS

Figure 1 Preparing to Remove the Motor NOTE: Observe the orientation of the motor capacitor. 4.

REMOVE THE MOTOR (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-30

1 NOTE: OBSERVE THE ORIENTATION OF THE MOTOR CAPACITOR

3

2

REMOVE THE MOTOR

REMOVE THE SCREWS (4)

Figure 2 Removing the Motor

Replacement

REP 9-31 Toner Filter Blower

NOTE: Ensure that the orientation of the motor is correct. 1.

INSTALL THE MOTOR ONTO THE BRACKET.

Parts List on PL 9.20 Removal

2.

INSTALL THE MOTOR PULLEY AND THE BELTS.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

CONNECT THE MOTOR, AND INSTALL THE PULLEY GUARD.

2.

REMOVE THE ELECTRICAL MODULE REAR COVER (REP 4-1).

4.

INSTALL THE ELECTRICAL MODULE REAR COVER.

3.

REMOVE THE TONER FILTER ASSEMBLY (REP 9-29).

5.

AFTER INSTALLING NEW BELTS, ENTER [SCP], [HFSI], SELECT [Cleaner/Developer], [09-807 R Cleaner Blower O-ring Drive Belts], AND PRESS [Reset Count].

4.

REMOVE THE TONER FILTER BAG.

5.

REMOVE THE FILTER HOUSING FROM THE BLOWER BRACKET AND TONER FILTER BLOWER (Figure 1).

Section Name

REP 9-30

0/0/00 ?-260

Preliminary Working Document No Product Name Assigned

2 SEPARATE AND REMOVE FILTER HOUSING

1 REMOVE THE SCREWS (4)

Figure 1 Removing the Filter Housing from the Blower and Bracket. 6.

REMOVE THE PULLEY GUARD AND THE O-RING BELTS.

7.

REMOVE THE BLOWER PULLEY.

8.

a.

Hold the vanes inside the Blower.

b.

Rotate the Pulley in a clockwise direction (left hand thread).

REMOVE THE BLOWER (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-31

1 OBSERVE ORIENTATION OF THE DISCHARGE DUCT

3 REMOVE THE BLOWER

2 REMOVE THE SCREWS (3)

Figure 2 Removing the Blower

Replacement

REP 9-32 Waste Bottle

1.

REPLACE THE BLOWER.

2.

INSTALL THE BLOWER PULLEY.

Parts List on PL 9.22 Removal

a.

Hold the vanes inside the Blower.

b.

Rotate the Pulley in a counterclockwise direction (Left hand thread).

3.

INSTALL THE O-RING BELTS AND THE PULLEY GUARD.

4.

INSTALL THE FILTER HOUSING ONTO THE BLOWER AND BLOWER BRACKET.

5.

INSTALL THE TONER FILTER ASSEMBLY.

6.

INSTALL THE TONER FILTER, AND CONNECT THE MOTOR.

7.

INSTALL THE ELECTRICAL MODULE REAR COVER.

Section Name

REP 9-31

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS, AND PULL OUT THE WASTE BOTTLE.

3.

SEAL THE BOTTLE WITH THE CAP FROM THE NEW BOTTLE.

Replacement 1.

CHECK THAT THE BOTTLE IS SEATED COMPLETELY.

2.

IF A NEW BOTTLE WAS INSTALLED, RESET THE FOLLOWING:

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a.

Enter dC107.

b.

Select [Xero], [Waste Bottle], and press [Reset counter to zero and update History].

Preliminary Working Document No Product Name Assigned

REP 9-33 Flicker Bar

Replacement

Parts List on PL 9.24 Removal

1.

CHECK THAT THE FLICKER BAR IS INSTALLED CORRECTLY, AND CHECK THAT IT IS SEATED ON THE ALIGNMENT PADS (Figure 1).

2.

IF A NEW FLICKER BAR WAS INSTALLED, ENTER [SCP], [HFSI], SELECT [Cleaner/ Developer], [09-808 R Cleaner Flicker Bar], AND PRESS [Reset Count].

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE CLEANER MANIFOLD (REP 9-24).

3.

REMOVE THE FLICKER BAR (STEP 1, Figure 1).

FRONT STOP

1 REMOVE SCREWS (2) AND THE BAR

FRONT VIEW

2 THE CORRECT LOCATION OF THE BAR

Figure 1 Removing and Installing the Flicker Bar

Preliminary Working Document No Product Name Assigned

0/0/00 ?-263

Section Name

REP 9-33, REP 9-34

REP 9-34 Xerographic Drawer Parts List on PL 9.1 Removal

2 PULL OUT DRAWER COMPLETELY

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

WARNING Close the drawer when it is unattended. Someone could fall over the extended drawer. 2.

OPEN THE PRINTER FRONT DOORS, AND PREPARE TO OPEN THE XEROGRAPHIC DRAWER (Figure 1).

2 LOCK PREFUSER TRANSPORT IN THE DISENGAGED POSITION

1 3 DEPRESS THE LATCH AND CLOSE THE DRAWER

1

PULL OUT KNOB, AND ROTATE

Figure 2 Opening the Xerographic Drawer

LATCH THE PRETRANSFER BAFFLE

Replacement 1.

DEPRESS THE DRAWER LATCH IN ORDER TO CLOSE THE DRAWER. CAUTION

Close and latch the Xerographic Drawer as gently as possible to reduce the possibility of damage to lamp filaments. 2.

Figure 1 Preparing to Open the Drawer

ENSURE THAT THE DRAWER IS SECURED: a.

Gently push in the Drawer until it is seated.

b.

Rotate the PR Module Latch handle clockwise, and push in the knob.

c.

Pull out the Prefuser Transport knob, and release the transport.

d.

Push the Pretransfer Baffle to the left into the operating position.

CAUTION Protect the Photoreceptor Belt from light shock, and then cover the developer cavity in order to prevent contamination of Developer Material. 3.

OPEN THE XEROGRAPHIC DRAWER (Figure 2).

Section Name

REP 9-34, REP 9-35

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Preliminary Working Document No Product Name Assigned

REP 9-35 Photoreceptor Belt Parts List on PL 9.1 Removal

2 RELEASE THE PR BELT TENSION

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1. 2.

1 RAISE STRIPPER FINGER ASSEMBLY

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. OBSERVE THE FOLLOWING GUIDELINES WHEN HANDLING A PR BELT. a.

Do not expose a good PR Belt to the light for more than a few minutes in order to prevent the light shock.

b.

Do not touch the photoconductive surface of the PR Belt except at the front and rear edges.

c.

Handle a PR Belt by the inside surface when ever possible.

d.

Do not buckle or crease the PR Belt. Protect the PR Belt from surface defects that can cause image quality problems.

e.

Do not wash the PR Belt. CAUTION

Protect the PR Belt from the light fatigue, and cover the Developer Cavity in order to prevent contamination of the Developer Material. f.

3

Protect the PR Belt from solvent vapors or ammonia vapors.

CAUTION REMOVE THE PR BELT

WARNING Close the Xerographic Drawer when you are not working in the immediate area; someone could fall over the open drawer. Do not work below the PR Module unless the module is supported securely. Support the module securely until it is seated in one of the detents above an angle of 30 degrees. Below this angle the module will fall freely. 3.

OPEN THE XEROGRAPHIC DRAWER (REP 9-34). Figure 1 Removing the PR Belt

CAUTION Protect the Photoreceptor from a light shock. Do not pinch the Photoreceptor or touch it in the photoconductive area. Handle the Photoreceptor only by grasping the edges. 4.

PUSH THE PR MODULE LATCH TO THE RIGHT, RAISE THE PR MODULE FULLY, AND REMOVE THE PR BELT (Figure 1).

5.

COVER THE DEVELOPER CAVITY.

Replacement WARNING Do not touch the ESV if the Printer is switched on. High voltage is present on the ESV when the Printer is in the operating mode. 1.

Preliminary Working Document No Product Name Assigned

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BEFORE INSTALLING THE PHOTORECEPTOR, PERFORM THE FOLLOWING: a.

Inspect the PR Module and the Xerographic Drawer components for dirt.

b.

Use the vacuum cleaner in order to clean any dirty areas of the PR Module, the Developer Assembly, and the Xerographic Drawer.

c.

Wipe the smooth rolls in the PR Module with a cleaning towel.

d.

Check the surfaces of the PR Edge Guides for loose or fused toner and clean them as required.

Section Name

REP 9-35

CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. e.

Clean the following components with a clean, soft, lint free cloth: •

The DSS

•

The ESV

•

The Patch Generator

•

Empty any Developer Material from the Developer Catch Tray.

•

Clean any stray Developer Material from the Developer Housing.

WARNING Use caution when working in the area below the PR Module. Ensure that the Xerographic Door Knob is fully rotated to the left. Do not attempt to lower a raised Photoreceptor module by downward pressure or the lever latch bracket will be damaged. To lower this module depress the lever release behind the handle while raising the module slightly, then lower the Photoreceptor module slowly until it is seated on the Xerographic Drawer. f. 2.

If the Photoreceptor must be replaced because of process direction scratches, perform the Developer Dump and Thump procedure (REP 9-6).

INSTALL THE PHOTORECEPTOR (Figure 2).

Section Name

REP 9-35

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Preliminary Working Document No Product Name Assigned

2 ENSURE THAT THE PR BELT IS POSITIONED BETWEEN THE FRONT GUIDE AND THE REAR GUIDE

4 SEAT THE STRIPPER FINGER ASSEMBLY AND GENTLY LOWER THE PR MODULE

5

3 LATCH THE PR TENSIONER

LOWER THE PR MODULE

1 INSTALL THE PR BELT WITH THE BELT HOLE TOWARD THE FRONT

Figure 2 Installing the PR Belt NOTE: Push the tall rear brush off the rear developer seals toward the front before closing the PR module. 3. 4.

5.

CLOSE THE XEROGRAPHIC DRAWER (REP 9-34). IF A NEW PR BELT WAS INSTALLED, RESET THE FOLLOWING:

REP 9-36 Patch Generator Parts List on PL 9.10 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

a.

Enter dC107.

b.

Select [Xero], [P/R Belt], and press [Reset counter to zero and update History.].

IF A NEW PR BELT WAS INSTALLED, PERFORM THE FOLLOWING:

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

a.

The Photoreceptor Seam Timing (ADJ 9-8).

2.

REMOVE THE ROS ASSEMBLY (REP 6-1).

b.

The Xerographic Set-up (ADJ 9-3).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-35

3.

COVER THE PR WITH PAPER COVER IN ORDER TO PROTECT THE PR BELT FROM THE LIGHT DAMAGE.

WARNING High voltage is present on the ESV when the Printer is in the operating mode. 4.

REMOVE THE PATCH GENERATOR (Figure 1).

3 PUSH AGAINST THE FITTING WHILE PULLING THE INLET PURGE TUBE

2 PUSH AGAINST THE FITTING WHILE PULLING THE PURGE TUBE

4

5 1 DISCONNECT THE CONNECTOR

REMOVE THE SCREWS (2) AND THE PATCH GENERATOR

RIGHT SIDE VIEW

DISCONNECT THE CONNECTOR

Figure 1 Removing the Patch Generator

Replacement

CAUTION Handle the ESV carefully; it is easily damaged. Do not break off the alignment pin on the Patch Generator.

1.

5.

2.

CAREFULLY INSTALL THE OLD ESV ON THE NEW PATCH GENERATOR.

3.

INSTALL THE PATCH GENERATOR.

CAREFULLY REMOVE ESV FROM THE PATCH GENERATOR.

Section Name

REP 9-36, REP 9-37

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CLEAN THE PATCH GENERATOR WITH A SOFT, DRY, LINT-FREE CLEANING TOWEL.

Preliminary Working Document No Product Name Assigned

4.

CHECK THAT THE ALIGNMENT BOSSES ON THE PATCH GENERATOR ARE SEATED IN THE MATING HOLES IN BRACKET.

5.

REMOVE THE PAPER FROM THE PR. CAUTION

Ensure that the Purge Tube is connected in order to prevent a process control failure.

REP 9-37 ESV Parts List on PL 1.7 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

6.

CONNECT THE INLET PURGE TUBE.

7.

CHECK/ADJUST THE ESV HEIGHT (ADJ 9-12).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

8.

INSTALL THE ROS ASSEMBLY.

2.

PROTECT PHOTORECEPTOR BELT FROM THE LIGHT SHOCK.

9.

PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

WARNING Voltage is present on the ESV when the Printer is in the operating mode. 3.

REMOVE THE PATCH GENERATOR (REP 9-36). CAUTION

Do not break off the alignment pin on the Patch Generator during the removal or replacement of the ESV. 4.

Preliminary Working Document No Product Name Assigned

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REMOVE ESV (Figure 1).

Section Name

REP 9-36, REP 9-37

c.

Perform the Xerographic Set-up (ADJ 9-3).

1 REMOVE THE ESV PURGE TUBE FROM THE Y-CONNECTOR

2 REMOVE THE SCREW

3 REMOVE THE ESV

BOTTOM VIEW OF THE PATCH GENERATOR

Figure 1 Removing the ESV

WARNING Do not touch the ESV if the Printer is switched on. High voltage is present on the ESV when the Printer is in the operating mode. 5.

CLEAN THE ESV WITH A CLEAN, DRY, LINT FREE CLOTH.

Replacement 1.

REPLACE THE ESV, AND REPLACE THE ESV ASSEMBLY AS A MATCHED SET.

2.

IF A NEW ESV WAS INSTALLED, PERFORM THE FOLLOWING: a.

Check/Adjust ESV Height (ADJ 9-12).

b.

Install the ROS Assembly (REP 6-1).

Section Name

REP 9-37

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Preliminary Working Document No Product Name Assigned

REP 9-38 DSS Parts List on PL 9.7 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

2

3

REMOVE THE SCREW

REMOVE THE DSS

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE XEROGRAPHIC DRAWER AND RAISE THE PR MODULE FULLY.

3.

PROTECT THE PHOTORECEPTOR BELT AS SHOWN IN THE REMOVAL PROCEDURE OF THE PHOTORECEPTOR BELT (REP 9-35). CAUTION

Follow all ESD procedures. Handle the DSS carefully. 4.

REMOVE THE DSS (Figure 1).

1 DISCONNECT THE CONNECTOR

Figure 1 Removing the DSS

Replacement CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. Switch off the Printer power before cleaning the DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the DSS calibrations are performed with the components clean.

Preliminary Working Document No Product Name Assigned

1.

CLEAN THE DSS USING ANTI-STATIC SOLUTION AND A CLEAN, SOFT, LINT FREE CLOTH.

2.

CHECK THAT THE DSS IS SEATED CORRECTLY BEFORE TIGHTENING THE SCREW.

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Section Name

REP 9-38

3.

IF THE DSS IS NEW, PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

REP 9-39 Dicorotron and Shield Parts List on PL 9.10 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER RIGHT AND LEFT DOORS.

3.

REMOVE PHOTORECEPTOR INNER PANEL.

4.

REMOVE THE TRANSFER DICOROTRON (REP 9-49).

WARNING Always wear safety glasses when handling the dicorotrons. Do not touch the wire. Eye injury could result if glass breaks. Wash your hands after handling the dicorotrons. NOTE: Do not use this procedure for the Transfer Dicorotron. Use the following procedure for all other dicorotrons. 5.

REMOVE DICOROTRON AND SHIELD (Figure 1).

WARNING DO NOT TOUCH THE WIRE BOTTOM VIEW

1 2

PUSH AND HOLD

BIAS TAB TO UNLATCH THEN PULL OUT THE DICOROTRON ASSEMBLY (CORONODE AND SHIELD)

Figure 1 Removing a Dicorotron

Section Name

REP 9-38, REP 9-39

0/0/00 ?-272

Preliminary Working Document No Product Name Assigned

6.

CHECK THE DICOROTRON CONNECTORS FOR CORROSION. REPLACE THE DICOROTRONS, DICOROTRON CONNECTORS (REP 9-40), AND THE HVAC OUTPUT MODULE (REP 1-4), AS REQUIRED. CAUTION

Do not put grease from the insulator onto housing. 7.

CLEAN THE SHIELD (Figure 2).

1 REMOVE THE BIAS SHIELD

CLEAN THE OUTSIDE WITH A DRY TOWEL

3 CLEAN THE INSIDE WITH A DRY TOWEL

Figure 3 Cleaning the Housing

2 CLEAN THE OUTSIDE WITH A DRY CLEANING TOWEL

9.

ENTER [SCP], [HFSI], SELECT [P09-815 Dicorotron Shields], AND PRESS [Reset Count].

Replacement 1.

INSTALL THE DICOROTRON WITHOUT THE SHIELD, THEN INSTALL THE SHIELD IN THE DICOROTRON.

2.

IF A NEW DICOROTRON WAS INSTALLED, ENTER [SCP], [HFSI], [Dicorotrons], AND SELECT THE APPROPRIATE:

Figure 2 Cleaning a Shield

a.

[09-820 R Charge 1], [Reset Count].

b.

[09-822 R Preclean], [Reset Count].

CAUTION

c.

[09-823 R Transfer], [Reset Count].

Use only a dry cleaning towel. Water or solvents damage the coating and cause the print quality defects.

d.

[09-824 R Detack], [Reset Count].

8.

3.

CLEAN THE HOUSING (Figure 3).

Preliminary Working Document No Product Name Assigned

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IF A NEW CHARGE DICOROTRON IS INSTALLED, PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

Section Name

REP 9-39

REP 9-40 Dicorotron Connectors W- P287 Parts List on PL 9.8 Removal 1.

3 DEPRESS THE LATCH, AND PULL OUT CONNECTOR

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: Use the following procedure in order to remove connectors of the OZAC Dicorotrons. 2.

REMOVE DICOROTRON AND SHIELD (REP 9-39).

3.

IF REMOVING THE CHARGE DICOROTRON CONNECTOR, REMOVE THE HVAC OUTPUT MODULE (REP 1-4). THE HVAC OUTPUT MODULE DOES NOT NEED TO BE REMOVED TO REMOVE ANY OF THE OTHER DICOROTRON CONNECTORS.

4.

DISCONNECT THE OZAC DUCT FROM THE DICOROTRON CONNECTORS (Figure 1).

2 DISCONNECT THE DC LEAD

1 SEPARATE THE DUCT FROM THE CONNECTOR

DISCONNECT THE DUCT

Figure 2 Removing the Connector (Charge Dicorotron shown)

Replacement

Figure 1 Disconnecting the OZAC Duct

1.

REPLACE THE DICOROTRON CONNECTOR.

2.

CONNECT THE OZAC DUCT.

3.

INSTALL THE HVAC OUTPUT MODULE, IF IT WAS REMOVED.

4.

INSTALL THE DICOROTRON AND SHIELD.

NOTE: Pull the duct up in order to separate it from the Charge Dicorotron Connectors, all other ducts are pulled toward rear. 5.

REMOVE CONNECTOR (Figure 2).

Section Name

REP 9-40

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Preliminary Working Document No Product Name Assigned

REP 9-41 OZAC Duct

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assembly. Toner will fall from assembly connection.

Parts List on PL 9.8 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT REAR COVER AND THE ELECTRICAL MODULE REAR COVER (REP 4-1).

3.

OPEN THE TONER FILTER HOUSING.

4.

OPEN THE XEROGRAPHIC CARD CAGE, AND PREPARE TO REMOVE OZAC DUCT (Figure 1).

2 DISCONNECT THE AC CONNECTOR

1 CUT THE CABLE TIES (4)

Figure 1 Preparing to Remove the Ozac Duct 5.

LOCATE THE VERTICALLY ROUTED WIRE HARNESS BELOW THE CHARGE DICOROTRONS. TEMPORARILY DISCONNECT THE WIRE HARNESS FROM THE CABLE CLAMP.

6.

DISCONNECT THE CHARGE DICOROTRON CONNECTORS FROM THE CHARGE DICOROTRONS.

NOTE: Do not discard the clamps. 7.

REMOVE OZAC DUCT (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-41

4 LOOSEN THE CLAMPS (2), AND REMOVE THE OZAC DUCT

1

3 SEPARATE THE DUCT FROM THE DETACK AND TRANSFER DICOROTRONS

2 SEPARATE THE DUCT FROM THE PRECLEAN DICOROTRON

SEPARATE THE DUCT FROM THE CHARGE DICOROTRON CONNECTORS (2)

Figure 2 Removing the Ozac Duct

Replacement CAUTION Ensure that the red wires for the Charge Dicorotron Connectors are connected to the appropriate Dicorotron Connector, and ensure that the Dicorotron Connectors are reinstalled in the correct location. Failure to do this will result in improper charging of the Photoreceptor Belt. NOTE: Connect the Charge 1 Dicorotron Connector and the Charge 2 Dicorotron Connector to the Ozac Duct at the same time. 1.

REPLACE THE OZAC DUCT (Figure 3).

Section Name

REP 9-41

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Preliminary Working Document No Product Name Assigned

5 CONNECT THE DUCTS, AND TIGHTEN THE CLAMPS (2)

1 CONNECT THE DUCT CONNECTORS TO THE CHARGE DICOROTRON CONNECTORS (2)

4 CONNECT DUCT TO THE PRECLEAN, DETACK, AND TRANSFER DICOROTRON CONNECTORS

3 CONNECT THE AC CONNECTOR

2 PUSH IN THE DICOROTRON CONNECTORS (2)

Figure 3 Replacing the Ozac Duct 2.

REPLACE THE CABLE TIES (Figure 4).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-277

Section Name

REP 9-41

INSTALL THE CABLE TIES (4)

Figure 4 Installing the Cable Ties 3.

CONNECT THE VERTICAL WIRE HARNESS TO THE CABLE CLAMP.

REP 9-42 Ozone Filter Assembly

4.

CLOSE THE XEROGRAPHIC CARD CAGE.

5.

CLOSE THE TONER FILTER ASSEMBLY.

Parts List on PL 9.9 Removal

Section Name

REP 9-41

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT REAR COVER AND THE ELECTRICAL MODULE REAR COVER (REP 4-1).

3.

OPEN THE TONER FILTER HOUSING.

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Preliminary Working Document No Product Name Assigned

NOTE: Cut cable ties as required. 4.

5.

REMOVE THE OZONE FILTER ASSEMBLY (Figure 1).

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

2 1 CUT CABLE TIE

DISCONNECT THE VACUUM SWITCH CONNECTOR

3 REMOVE NUTS (2), WASHERS (4), AND BRACKET

4 DISCONNECT THE BLOWER CONNECTOR

5 DISCONNECT THE DUCT AND REMOVE FILTER ASSEMBLY

Figure 1 Removing the Filter Assembly 6.

REMOVE THE OZONE BLOWER (MOT904) (REP 9-43).

Replacement 1.

CONNECT THE OZONE BLOWER (MOT904) TO THE NEW FILTER.

2.

INSTALL THE FILTER ASSEMBLY.

NOTE: Check that the wiring is not pinched between Blower Motor and Accumulator Bottle. 3.

PUSH THE ASSEMBLY COMPLETELY TO THE RIGHT BEFORE TIGHTENING THE MOUNTING NUTS.

4.

INSTALL THE HVAC OUTPUT MODULE.

5.

REPLACE CABLE TIES.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-279

Section Name

REP 9-42

REP 9-43 Ozone Blower (MOT904)

2.

REMOVE THE OZONE FILTER ASSEMBLY (REP 9-42).

Parts List on PL 9.9 Removal

3.

REMOVE THE OZONE BLOWER (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3

4

REMOVE NUTS (2)

REMOVE THE OZONE BLOWER

1 REMOVE THE SCREWS (2) AND THE VACUUM SWITCH

2 REMOVE NUT AND WASHERS (2)

Figure 1 Removing the Ozone Blower

Replacement

REP 9-44 Cavity Cooling Fan (MOT105)

1.

INSTALL THE OZONE VACUUM SWITCH (S902).

2.

CONNECT THE OZONE FILTER TO THE NEW OZONE BLOWER.

Parts List on PL 9.8 Removal

NOTE: Check that the gasket is positioned between the blower and the filter.

1.

3.

INSTALL THE FILTER ASSEMBLY.

4.

INSTALL THE OZONE FILTER ASSEMBLY (REP 9-42).

NOTE: Positioning of the foam gasket that surrounds the fan will be easier if the printer left top cover is removed.

5.

INSTALL THE HVAC OUTPUT MODULE.

2.

REMOVE THE PRINTER LEFT TOP COVER.

6.

REPLACE CABLE TIES.

3.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

4.

REMOVE THE CAVITY COOLING FAN (Figure 1).

Section Name

REP 9-43

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SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Preliminary Working Document No Product Name Assigned

REP 9-45 PR Edge Guides or Tension Roll Parts List on PL 9.5 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3

3.

PULL THE FAN OFF THE LOCATING PINS

COVER THE DEVELOPER CAVITY IN ORDER TO PREVENT CONTAMINATION OF THE DEVELOPER MATERIAL.

4.

REMOVE THE LEFT DEVELOPER ZONE ROLL.

5.

6.

IF ONLY THE TENSION ROLL MUST BE REMOVED, PERFORM THE FOLLOWING: a.

Remove the nut securing the rear cable to the tensioning arm.

b.

Pull the rear PR Edge Guide to the left in order to remove the Tension Roll.

REMOVE PR EDGE GUIDES (Figure 1).

1 RELEASE THE CABLE TENSION

2 REMOVE THE SCREWS (2)

1 CUT THE CABLE TIES AND DISCONNECT CONNECTOR

2 REMOVE THE NUTS (4) Figure 1 Removing the Fan (MOT105)

Replacement 1.

ENSURE THAT THE WIRING IS SECURED AWAY FROM THE MOVING COMPONENTS AND THE FOAM GASKET IS REPISITIONED AROUND THE FAN.

2.

REINSTALL THE PRINTER LEFT REAR AND LEFT TOP COVER.

3 REMOVE THE TENSION ROLL AND THE EDGE GUIDES

Figure 1 Removing the Edge Guides 7.

CLEAN ANY FUSED TONER FROM THE PHOTORECEPTOR SUPPORTING SURFACES OF THE EDGE GUIDES.

Replacement 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-281

INSTALL THE EDGE GUIDE (Figure 2).

Section Name

REP 9-44, REP 9-45

REP 9-46 PR Module Parts List on PL 9.1 Removal

BEARING

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. NUTS

PULLEY 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: Ensure that PR Module Alignment Tool is available before removing the Module.

BUSHING

2.

REMOVE PHOTORECEPTOR INNER PANEL.

3.

COVER THE DEVELOPER CAVITY, AND REMOVE PHOTORECEPTOR BELT (REP 935).

4.

RAISE THE PR MODULE, AND DISCONNECT THE HARNESS FROM REAR OF MODULE.

WARNING

SPRING

For Machines with Hydraulic Lift Assemblies. Support the raised PR Module whenever the Hydraulic Lift Assembly is disconnected from Xerographic Drawer. The Module can fall freely, and can cause an injury. 5.

PREPARE PR MODULE FOR REMOVAL (Figure 1).

2

1 POSITION THE CABLE

INSTALL THE EDGE GUIDE

Figure 2 Installing the Edge Guide 2.

ADJUST THE PHOTORECEPTOR TENSION (ADJ 9-11).

3.

INSTALL THE LEFT DEVELOPER ZONE ROLL AND PHOTORECEPTOR BELT.

Section Name

REP 9-45, REP 9-46

0/0/00 ?-282

Preliminary Working Document No Product Name Assigned

2

1

RELEASE THE VALVE DURING STEP 3

REMOVE THE BOLT AND THE HINGE PIN

3 1 WARNING

PUSH BRACKET FLUSH WITH THE FRAME

PR MODULE REAR FRAME

SUPPORT THE MODULE AND REMOVE SCREWS (2)

Figure 1 Preparing the Module for Removal

2 REMOVE THE MODULE

Figure 2 Removing the Module

NOTE: Grasp the PR Module only near the center of the front and rear frame.

Replacement

6.

NOTE: Grasp the PR Module only near the center of the front and rear frame.

REMOVE PR MODULE (Figure 2).

Preliminary Working Document No Product Name Assigned

1.

SEAT THE PR MODULE ON THE RIGHT HINGE PIN.

2.

INSTALL THE OTHER HINGE PIN.

3.

RAISE PR MODULE, AND PULL BRACKET OF THE HYDRAULIC LIFT ASSEMBLY INTO ALIGNMENT WITH THE MOUNTING HOLES. SUPPORT THE PR MODULE, AND INSTALL SCREWS.

4.

CONNECT HARNESS.

5.

PERFORM PR MODULE ALIGNMENT (ADJ 9-10).

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Section Name

REP 9-46

REP 9-47 Xerographic Drawer Slides Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1

2.

REMOVE PR MODULE (REP 9-46).

3.

REMOVE DEVELOPER ASSEMBLY (REP 9-5).

4.

DISCONNECT CONNECTORS OF RIBBON CABLE FROM XEROGRAPHIC DRAWER, AND HOLD THEM TOGETHER WHILE ALLOWING THEM TO RETRACT SLOWLY TOWARD THE REAR.

CAUTION REMOVE THE BOLTS (4 ON THE LEFT OR 3 ON THE RIGHT)

5.

ENSURE THAT THE DRAWER IS EXTENDED AND LATCHED. CAUTION

Do not loosen the bolts. Loosening the bolts could require replacement of the Printer. 6.

REMOVE XEROGRAPHIC DRAWER FRAME (Figure 1).

1 CAUTION REMOVE THE NUTS (4)

2 REMOVE THE SLIDE

Figure 2 Removing a Slide

Replacement

2

1.

INSTALL THE NEW SLIDES ON BASE PLATE OF PRINTER. ENSURE THAT THE SEMIPERFS ARE SEATED IN THE ALIGNMENT HOLES IN THE BASE PLATE OF PRINTER.

2.

EXTEND THE SLIDES AND THE DRAWER LATCH LINKAGE COMPLETELY.

3.

POSITION THE DRAWER ON THE SLIDE BRACKETS, AND SEAT THE LATCH LINKAGE IN THE DETENT OF THE STOP BRACKET ON BASE PLATE.

REMOVE THE FRAME

CAUTION Do not loosen any of the other hardware. The Slides are aligned at the factory.

Figure 1 Removing the Drawer Frame 7.

REMOVE THE LEFT SLIDE AND/OR THE RIGHT SLIDE (Figure 2).

Section Name

REP 9-47

4.

TIGHTEN THE FOUR NUTS.

5.

CONNECT THE RIBBON CABLE TO THE XEROGRAPHIC DRAWER.

6.

INSTALL DEVELOPER ASSEMBLY.

7.

INSTALL PR MODULE.

8.

PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

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Preliminary Working Document No Product Name Assigned

REP 9-48 Transfer Blade

Replacement WARNING

Parts List on PL 9.11 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

Always wear safety glasses when handling a Dicorotron. Do not touch a Dicorotron wire. 1.

INSTALL THE TRANSFER DICOROTRON (REP 9-49).

2.

INSTALL THE TOOL (Figure 2).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE FRONT DOORS.

3.

REMOVE THE TRANSFER BLADE (Figure 1).

NOTE: TOOL IS SEATED WHEN THE NOTCH IS AT FRONT END OF PREFUSER RELEASE BRACKET

THE TRANSFER DICOROTRON

1 PUSH THE TOOL BETWEEN TOP OF THE BLADE ACTUATOR LEVER AND BOTTOM OF THE DICOROTRON

1 DEPRESS THE BLADE HANDLE IN ORDER TO REMOVE BLADE

Figure 2 Installing the Tool CAUTION Do not install the Transfer Blade and the Transfer Dicorotron as a pair. Damage to the Photoreceptor Belt may occur.

Figure 1 Removing the Transfer Blade

3.

CAUTION

INSTALL THE TRANSFER BLADE (Figure 3).

Ensure that the edge of the Transfer Blade is not damaged. A damaged edge will scratch the Photoreceptor Belt, and/or cause a copy quality defect. 4.

CLEAN THE EDGE OF THE TRANSFER BLADE WITH A DRY, SOFT CLOTH.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-285

Section Name

REP 9-48

REP 9-49 Transfer Dicorotron Parts List on PL 25.1 PL 9.11 Removal To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE PHOTORECEPTOR INNER PANEL.

1

WARNING

SEAT THE BLADE ON THE EDGE OF THE DICOROTRON CAREFULLY

Always wear safety glasses when handling a Dicorotron. Do not touch a Dicorotron wire. CAUTION Do not actuate the Transfer Blade Solenoid while removing the Transfer Dicorotron Assembly. The Transfer Blade will be damaged if the Solenoid is actuated during removal. 3.

2

REMOVE THE TRANSFER DICOROTRON (Figure 1).

PUSH THE TRANSFER BLADE IN COMPLETELY

3 HOLD THE BLADE IN POSITION WHILE REMOVING THE TOOL

Figure 3 Installing the Transfer Blade 4.

IF A NEW TRANSFER BLADE WAS INSTALLED, ENTER [SCP], [HFSI], [Belt Module], SELECT [P09-803 R, Transfer Assist Blade] AND PRESS [Reset Count].

1 2 WARNING

CAUTION PUSH UP, AND HOLD

PULL OUT THE DICOROTRON ASSEMBLY

Figure 1 Removing the Transfer Dicorotron 4.

Section Name

REP 9-48, REP 9-49

0/0/00 ?-286

PULL THE TRANSFER BLADE OUT OF ITS CHANNEL IN THE TRANSFER DICOROTRON (Figure 2). Preliminary Working Document No Product Name Assigned

1 REMOVE THE BIAS SHIELD

3 CLEAN THE INSIDE OF END WITH A DRY, CLEAN, LINT FREE TOWEL

2 2 CAREFULLY PULL THE BLADE OUT OF THE CHANNEL

CLEAN THE OUTSIDE WITH A DRY, CLEAN, LINT FREE TOWEL

1 PUSH AND HOLD

Figure 2 Removing the Transfer Blade 5.

6.

Figure 3 Cleaning the Shield

CHECK THE DICOROTRON CONNECTORS FOR CORROSION. REPLACE THE DICOROTRONS, DICOROTRON CONNECTORS, AND THE HVAC OUTPUT MODULE (REP 1-4).

CAUTION Do not put grease from insulator onto the housing. 7.

CLEAN THE HOUSING (Figure 4).

CLEAN THE SHIELD (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-287

Section Name

REP 9-49

CLEAN THE OUTSIDE WITH A DRY TOWEL

Figure 4 Cleaning the Housing

Replacement CAUTION Handle the Transfer Blade with care in order to prevent the damage. Do not bend the clear plastic strip. 1.

INSTALL THE TRANSFER DICOROTRON.

2.

INSTALL THE TRANSFER BLADE (REP 9-48).

3.

IF A NEW TRANSFER DICOROTRON WAS INSTALLED, ENTER [SCP], [HFSI], SELECT [Dicorotrons], [09-823 R Transfer] AND PRESS [Reset Count].

Section Name

REP 9-49

0/0/00 ?-288

Preliminary Working Document No Product Name Assigned

REP 9-50 Transfer Assist Device

d.

Parts List on PL 9.11 Removal

Prefuser Transport Assembly (REP 10-12).

NOTE: Before removing the Pretransfer Baffle record the positions of the upper and lower cam in order to avoid the adjustment.

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 4. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS, AND REMOVE THE PHOTORECEPTOR INNER PANEL.

3.

REMOVE THE FOLLOWING: a.

Detack Dicorotron (REP 9-39).

b.

Transfer Dicorotron (REP 9-49).

c.

Photoreceptor Belt (REP 9-35).

e.

Pretransfer Baffle (REP 8-5).

f.

Registration Transport Assembly (REP 8-3).

SECURE THE DICOROTRON SPRINGS OF THE TRANSFER DICOROTRON. USE THE ADHESIVE TAPE ON THE DICOROTRON SIDE OF THE RAIL IN ORDER TO KEEP THE SPRINGS IN THE POSITION. CAUTION

Handle the Transfer Assist Device carefully. Do not touch the Actuator Segments of the Transfer Assist Device because the Actuator Segments may be deformed. Loosen the Locking Knobs just enough so that the Assist Device can be carefully pushed down, and then removed to the right. 5.

REMOVE THE TRANSFER ASSIST DEVICE (Figure 1).

3

4

DISCONNECT L2

DISCONNECT L3

5 DISCONNECT L4

2 DISCONNECT L1

1 DISCONNECT THE SENSOR CONNECTOR

6 CAUTION LOOSEN THE KNOBS (1/2 REVOLUTION)

Figure 1 Removing the Transfer Assist Device

Preliminary Working Document No Product Name Assigned

0/0/00 ?-289

Section Name

REP 9-50

Replacement NOTE: If the plastic clips for the Actuator Segments and the plastic Actuator Blocks for the Transfer Solenoids are not correctly assembled the device may bind, cause erratic Transfer Blade Timing, and cause deletions on the lead and trail edge of the prints. 1.

CHECK THE TRANSFER ASSIST DEVICE (Figure 2).

SOLENOID BLOCK

2

3 CHECK THAT THE RETAINING CLIPS (2) ARE SEATED

CHECK: GAP OF 5.0 MM MINIMUM WHEN THE SOLENOID BLOCKS (4) ARE FULLY SEATED

1 CHECK THAT THE BEARING CLIPS (10) ARE SEATED

Figure 2 Checking the Transfer Assist Device NOTE: Ensure that the mounting brackets of the device are seated flat against the dicorotron rail, between the upper and the lower rib on the rail. Check that the dicorotron springs are positioned correctly, and check the wires for the solenoids are not pinched between the device and the frame. Section Name

REP 9-50

2.

0/0/00 ?-290

INSTALL THE TRANSFER ASSIST DEVICE (Figure 3).

Preliminary Working Document No Product Name Assigned

4

3

2

CONNECT L2

CONNECT L3

CONNECT L4

5 CONNECT L1

6 CONNECT SENSOR CONNECTOR

1 CAUTION SEAT THE MOUNTING BRACKETS BETWEEN THE RIBS ON RAIL, AND TIGHTEN THE LOCKING KNOBS

Figure 3 Installing the Transfer Assist Device 3.

CHECK THAT THE TRANSFER ASSIST DEVICE IS FULLY SEATED AGAINST THE FRAME.

4.

MANUALLY ACTUATE THE FOUR TRANSFER SOLENOIDS TO CHECK THE PROPER OPERATION.

5.

INSTALL THE FOLLOWING: a.

Registration Transport Assembly (REP 8-5).

NOTE: Move the upper and lower cam to the positions recorded during the removal. b.

6.

Pretransfer Baffle (REP 10-7).

c.

Prefuser Transport Assembly (REP 10-0).

d.

Transfer Dicorotron (REP 9-49).

e.

Detack Dicorotron (REP 9-39).

f.

Photoreceptor Belt (REP 9-35).

CHECK/ADJUST THE TRANSFER BLADE TIMING (ADJ 9-9).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-291

Section Name

REP 9-50

REP 9-51 Transfer Solenoids 1-4 (SOL903/904/905/906)

2.

Parts List on PL 9.12 Removal

NOTE: The following method of removal applies to all four Solenoids. All Solenoid Bodies must be removed in order to access any of the Solenoid Plungers. Electrically disconnect only the Solenoid that has to be replaced.

1.

REMOVE THE TRANSFER ASSIST DEVICE (REP 9-50).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. 3.

REMOVE THE SOLENOID BODY (Figure 1).

2 REMOVE THE CLIPS

3 REMOVE SOLENOID BODY (4)

1 CUT THE CABLE TIE AND DISCONNECT THE SOLENOID

RIGHT SIDE VIEW

Figure 1 Removing the Solenoid Body 4.

REMOVE THE SUPPORT BRACKET (Figure 2).

Section Name

REP 9-51

0/0/00 ?-292

Preliminary Working Document No Product Name Assigned

1 TOP RIGHT VIEW

REMOVE THE SCREWS (2) AND THE GROUND WIRES (4)

2 HOLD THE BOTTOM OF THE ASSEMBLY TOGETHER

3 REMOVE THE SUPPORT BRACKET

Figure 2 Removing the Support Bracket NOTE: The spring of Solenoid 1 (SOL903) is larger than the other three Solenoid springs. Save the Springs and Washers so that they can be installed on new Solenoids. 5.

REMOVE THE SOLENOID PLUNGER (Figure 3).

RIGHT SIDE VIEW

LARGER SPRING

1 NOTE: REMOVE THE SPRING, WASHER, AND PLUNGER Figure 3 Removing the Solenoid Plunger

Replacement 1.

CHECK THE ROUTING OF THE WIRES (Figure 4).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-293

Section Name

REP 9-51

3 CHECK THE CABLE TIES

2 CHECK THE SOLENOID WIRES (4)

1 CHECK THE GROUND WIRES (4)

Figure 4 Checking the Routing of the Wires 2.

INSTALL THE TRANSFER ASSIST DEVICE (REP 9-50).

REP 9-52 Xerographic Drawer Latch Cable

3.

CHECK/ADJUST THE TRANSFER BLADE TIMING (ADJ 9-9).

Parts List on PL 9.6 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE XEROGRAPHIC DRAWER (REP 9-34).

3.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

4.

REMOVE NUT SECURING THE LATCH CABLE, AND REMOVE CABLE.

Replacement 1.

Section Name

REP 9-51

0/0/00 ?-294

INSTALL THE CABLE (Figure 1).

Preliminary Working Document No Product Name Assigned

4 ATTACH THE CABLE

3 ONE COMPLETE WRAP

1 ROUTE THE CABLE

2 ONE COMPLETE WRAP AROUND THE PULLEY

Figure 1 Installing the Cable 2.

ADJUST THE CABLE TENSION (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-295

Section Name

REP 9-52

REAR VIEW

2 SPECIFICATION: THE LEFT EDGE OF LATCH TOUCHES RIGHT EDGE OF BRACKET 0.0 TO 0.5 mm

1 PREVENT CABLE FROM TURNING, AND TIGHTEN THE ADJUSTING NUT TO SPECIFICATION OF STEP 2

3 TIGHTEN THE LOCK NUT

Figure 2 Adjusting the Cable Tension

Section Name

REP 9-52

0/0/00 ?-296

Preliminary Working Document No Product Name Assigned

REP 9-53 Discharge Lamps PWB (PS902)

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

Parts List on PL 9.4 Removal

3.

REMOVE THE DISCHARGE LAMPS POWER SUPPLY PWB (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1 HOLD OPEN THE PR MODULE

2 REMOVE THE PWB

Figure 1 Removing the PWB

Preliminary Working Document No Product Name Assigned

0/0/00 ?-297

Section Name

REP 9-53

REP 9-54 Hydraulic Lift Assembly

NOTE: Prepare a stack of paper in order to hold the PR Module open while removing the Cylinder.

Parts List on PL 9.4 Removal 1.

6.

RAISE THE PR MODULE, AND REMOVE THE HYDRAULIC CYLINDER (Figure 2).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR INNER PANEL.

3.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3

4.

REMOVE THE LOWER SAFETY SHIELD OF THE PR MODULE.

REMOVE THE NUT

5.

LOWER THE PR MODULE, AND REMOVE THE RIGHT LIGHT SHIELD (Figure 1).

4 REMOVE THE LIGHT SHIELD

3 REMOVE THE SCREWS (FRONT 1 AND REAR 1)

4 PUSH IN PISTON, REMOVE THE RETAINING RING AND CYLINDER

1 SUPPORT THE PR MODULE WITH A STACK OF PAPER

2

2

1 LOOSEN THE SCREWS (FRONT 1 AND REAR 1)

REMOVE THE RETAINING RING AND THE CLEVIS PIN

REMOVE THE DUMP BUTTON COVER

Figure 2 Removing the Hydraulic Cylinder 7.

REMOVE THE CLEVIS PIN RECEIVER FROM THE OLD PISTON ROD, AND THREAD IT ONTO THE NEW PISTON ROD.

Replacement 1.

INSTALL THE CYLINDER (Figure 3).

Figure 1 Removing the Light Shield

Section Name

REP 9-54

0/0/00 ?-298

Preliminary Working Document No Product Name Assigned

3

1

INSTALL THE DUMP BUTTON, AND TIGHTEN THE NUT

0.25 mm to 0.75 mm GAP

HYDRAULIC DUMP BUTTON

1 INSTALL THE CYLINDER AND SECURE WITH THE RETAINING RING

2 MOVE ACTUATOR UNTIL BUTTON JUST HOLDS THE SHIM, THEN TIGHTEN THE SCREWS (2)

XEROGRAPHIC DRAWER FRAME PR MODULE FRAME

2 VIEW FROM THE LEFT

INSTALL THE CLEVIS PIN AND RETAINING RING

Figure 3 Installing the Cylinder

Figure 4 Adjusting the Dump Actuator

2.

HOLD THE PR MODULE, AND REMOVE THE STACK OF PAPER.

4.

3.

LOWER THE PR MODULE, AND ADJUST THE HYDRAULIC DUMP ACTUATOR (Figure 4).

INSTALL THE RIGHT LIGHT SHIELD, AND TIGHTEN THE FOUR SCREWS ON THE TWO LIGHT SHIELDS.

5.

INSTALL THE DUMP BUTTON COVER.

6.

CHECK THAT THE NEW CYLINDER SUPPORTS THE PR MODULE BY CAREFULLY OPENING AND CLOSING THE MODULE A FEW TIMES.

Preliminary Working Document No Product Name Assigned

7.

OPEN THE PR MODULE, AND INSTALL THE LOWER SAFETY SHIELD.

8.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

9.

INSTALL THE PHOTORECEPTOR INNER PANEL.

0/0/00 ?-299

Section Name

REP 9-54

REP 9-55 Photoreceptor Spot Cleaning

CAUTION Work as quickly as possible to keep the light shock to a minimum. Replace the Photoreceptor Belt if it is exposed to the room light for more than 10 minutes.

Parts List on PL 9.26 Clean

2.

NOTE: Before performing this procedure, ensure that all other causes of spots, streaks, or horizontal lines have been eliminated. (Refer to the Print Quality RAPs.) The following materials are required to clean the spots: Film Remover (43P45), Cotton Swabs (35P2162), and Foam Pads (600S4653). 1.

CUT THE FOAM PAD INTO FOUR EQUAL SIZE SQUARES.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS, AND OPEN THE XEROGRAPHIC DRAWER. CAUTION

Ensure that the PR Module is securely blocked in the upward position, and ensure the Photoreceptor Belt does not touch the Developer Housing. This will prevent the damage to the Photoreceptor Belt. 3.

PREPARE THE PR MODULE (Figure 1).

3 CAREFULLY LOWER THE PR MODULE ONTO THE PLIERS

1 UNLATCH AND RAISE THE PR MODULE

2 POSITION THE PLIERS

Figure 1 Preparing the PR Module

Clean any Transfer Blade Timing Ink marks only with a Cotton Swab moistened with water. The ink must be removed with water. Film remover will make the marks permanent.

NOTE: The interdocument gap in the 7 pitch mode is 30 mm. The distance between the PR Belt seam and the lead edge of print #1 is 8 mm. The distance between the trail edge of print #7 and the PR Belt seam is 22 mm.

4.

ROTATE THE PR BELT IN A COUNTERCLOCKWISE DIRECTION ONE COMPLETE REVOLUTION, AND CHECK FOR CONTAMINATION BY THE TRANSFER BLADE TIMING INK. USE ONLY WATER TO CLEAN THE TIMING INK.

6.

5.

ROTATE THE PR BELT UNTIL THE PR BELT SEAM IS CENTERED ON TOP OF THE PHOTORECEPTOR MODULE.

CAUTION

Section Name

REP 9-55

0/0/00 ?-300

ALIGN THE PRINTS THAT WERE GENERATED IN THE BLACK SPOTS RAP ON THE PR BELT, WITH THE PRINT ORIENTED FACE DOWN AND THE LEAD EDGE ARROW POINTING TOWARDS THE LEFT, TO LOCATE THE IMAGE FRAME WITH A SPOT(S) (Figure 2).

Preliminary Working Document No Product Name Assigned

FRONT EDGE OF THE PR BELT

PR BELT SEAM

1 NOTE: POSITION THE PRINTS WITH THE LEAD EDGE ARROW FACING THE PR BELT

Figure 2 Aligning the Prints on the PR Belt NOTE: The visibility of the spot(s) will be enhanced if the surface of the PR Belt is viewed at an angle. 7.

CAREFULLY LIFT THE EDGE OF THE PRINT, AND LOCATE THE SPOT(S) ON THE PR BELT THAT CORRESPOND(S) TO THE SPOT(S) ON THE PRINT.

8.

ROTATE THE PHOTORECEPTOR BELT UNTIL THE SPOT(S) IS POSITIONED DIRECTLY ON TOP OF THE CARPET IN ORDER TO PROVIDE MORE SUPPORT WHILE CLEANING THE PR BELT.

Preliminary Working Document No Product Name Assigned

CAUTION Wipe away all background Toner from the surrounding area of a spot before applying the Film Remover, otherwise blotches of the image will result. Do not use excessive pressure when cleaning spots from the PR Belt. The belt may be scratched or permanently deformed. 9.

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POUR A SMALL AMOUNT OF THE FILM REMOVER INTO THE BOTTLE CAP, AND CLEAN THE SPOT(S): a.

Wipe any loose Toner off the Photoreceptor Belt with the edge of one of the sponges. Use a clean edge for each spot area.

Section Name

REP 9-55

b.

Touch the spot(s) with the Cotton Swab that has been lightly soaked with Film Remover. After the spot(s) is wetted, gently rub it with the wet swab in a circular motion until the spot(s) disappear. When the spot disappears, wipe the area dry with a clean edge of a sponge.

12. ENTER dC106, SELECT [Printer Options], [Test Patterns and PQ], Dimensional], AND [Lighter 2]. 13. MAKE 100 PRINTS, AND VERIFY THAT THE SPOTS HAVE BEEN REMOVED. 14. IF SPOTS REMAIN, PERFORM THE FOLLOWING:

NOTE: Wetting the spot prior to the cleaning will allow some Film Remover to penetrate between the dirt and the Photoreceptor Belt, and assist in loosening the dirt. c.

Repeat Steps 6-9 until all circled spots, on each print, of the Set are cleaned. Work as quickly as possible to reduce the amount of light shock.

a.

Replace the Photoreceptor Belt (REP 9-35).

b.

Perform the Xerographic Set-up (ADJ 9-3).

REP 9-56 Transfer Blade Sensor (Q907)

10. REMOVE THE PLIERS, LATCH THE PR MODULE, AND CLOSE THE XEROGRAPHIC DRAWER.

Parts List on PL 9.12 Removal

11. RESTORE THE PRINTER TO THE OPERATING CONDITION.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1 REMOVE THE SCREWS (2) AND THE GROUND WIRES (4) TRANSFER BLADE SENSOR (Q907)

2 3

HOLD THE ASSEMBLY TOGETHER

MOVE THE SUPPORT BRACKET

Figure 1 Moving the Support Bracket 4.

REMOVE THE TRANSFER BLADE SENSOR (Figure 2).

Section Name

REP 9-55

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Preliminary Working Document No Product Name Assigned

1

THE LOCATING PIN

REMOVE THE SCREW AND THE SENSOR

THE SUPPORT BRACKET

Figure 2 Removing the Transfer Blade Sensor

Replacement 1.

REPLACE THE TRANSFER BLADE SENSOR.

2.

CHECK THE ROUTING OF THE WIRES (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-56

3 CHECK THE CABLE TIES

2 CHECK SOLENOID WIRES (4)

1 CHECK THE GROUND WIRES (4)

Figure 3 Checking the Routing of the Wires 3.

INSTALL THE TRANSFER ASSIST DEVICE (REP 9-50).

REP 9-57 Spots Blade

4.

RESTORE THE PRINTER POWER.

5.

CHECK THE TRANSFER BLADE SENSOR (Q907):

Parts List on PL 9.26 Removal

6.

a.

Enter dC330, [9], and [Xfer Blade Sol 1].

b.

Press the Continue button, and check that the Transfer Blade Position Sensor display changes from [L] to [H].

CHECK/ADJUST THE TRANSFER BLADE TIMING (ADJ 9-9).

Section Name

REP 9-56

NOTE: The DP180MX has a unique Spots Blade and it is not compatible with the DP180. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE FUSER DRIP PAN (Figure 1).

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Preliminary Working Document No Product Name Assigned

2 OPEN THE FUSER

1 LOOSEN THE SCREW

3 REMOVE THE DRIP PAN

Figure 1 Removing the Drip Pan 3.

REMOVE THE BLADE BRACKET (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-57

BLADE GUIDES

LEFT SIDE VIEW

1 REMOVE THE BLADE BRACKET

CLEANER MODULE

Figure 2 Removing the Blade Bracket 4.

REMOVE THE SPOTS BLADE (Figure 3).

Section Name

REP 9-57

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Preliminary Working Document No Product Name Assigned

LEFT SIDE VIEW

BLADE BRACKET

2 REMOVE THE BLADE

1 REMOVE THE NUTS (2)

Figure 3 Removing the Spots Blade

Replacement CAUTION Do not install a new spots blade and a new PR belt simultaneously. Perform the Xerographic Setup (ADJ 9-3) with the new PR belt, then install the new spots blade. 1.

INSTALL THE NEW BLADE ONTO THE BLADE BRACKET. CAUTION

Toner must be applied to the edge of the Spots Blade along its entire length. The toner will protect the Photoreceptor Belt by acting as a lubricant between the new Spots Blade and the Belt. 2.

USE THE TONER PAD SUPPLIED, AND APPLY THE TONER TO THE ENTIRE LENGTH OF THE SPOTS BLADE.

3.

INSTALL THE BLADE BRACKET INTO THE FRONT AND THE REAR BLADE GUIDES.

4.

ENSURE THAT THE BLADE BRACKET MOVES FREELY.

5.

IF INSTALLING A NEW SPOTS BLADE, SELECT [SCP], [HFSI], [Cleaner/Developer], [09-805 R Post-Cleaner Blade], AND PRESS [Reset Count].

6.

Inspect old spots blade to insure contact area (brown) is 0.5mm to 0.3mm adjust spots blade contact (ADJ 9-16) if required.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-307

Section Name

REP 9-57

REP 9-58 Spots Blade Guide

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 9.26 Removal

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

3.

REMOVE THE FUSER DRIP PAN (Figure 1).

4.

REMOVE THE BLADE BRACKET (Figure 2).

5.

REMOVE THE BLADE GUIDES (Figure 1).

1 REMOVE THE E-RINGS (2)

3 2 MOVE THE SHAFT AND REMOVE THE REAR GUIDE

REMOVE THE SHAFT AND THE FRONT GUIDE

Figure 1 Removing the Guides 6.

REMOVE THE SPOTS BLADE (Figure 2).

LEFT SIDE VIEW

BLADE BRACKET

2 REMOVE THE BLADE

1 REMOVE THE NUTS (2)

Figure 2 Removing the Spots Blade

Replacement Section Name

REP 9-58

1.

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CHECK/ADJUST THE SPOTS BLADE CONTACT (ADJ 9-16).

Preliminary Working Document No Product Name Assigned

REP 9-59 PR Mini-rug

3.

Removal

NOTE: Save the Screws (4) and the Spring Washers (4).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

CLOSE THE PR MODULE.

DISCARD THE PR MINI-RUG (Figure 1).

1 REMOVE THE SCREWS (4) AND THE SPRING WASHERS (4)

2 REMOVE THE MINI-RUG

Figure 1 Removing the PR Mini-Rug

Replacement CAUTION Do not tighten the screws. The spring washers can be flattened, and will not support the MiniRug correctly. 1.

POSITION THE MINI-RUG (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-309

Section Name

REP 9-59

REP 9-60 POP Sensor (Q904) Cleaning 3 CAUTION VERY LOOSELY INSTALL THE SCREWS (4)

Parts List on PL 9.3 Clean 1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE XEROGRAPHIC DRAWER.

3.

CLEAN THE POP SENSOR.

4.

ENTER [SCP], [HFSI], [Belt Module], SELECT [09-809 C POP Sensor], AND PRESS [Reset Count].

2 ALIGN HOLES OF MINI-RUG WITH THE WASHERS (4)

1 CENTER THE SPRING WASHERS TO THE MOUNTING HOLES (4)

Figure 2 Positioning the PR Mini-Rug 2.

ADJUST THE PR MINI-RUG HEIGHT (ADJ 9-17).

Section Name

REP 9-59, REP 9-60

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Preliminary Working Document No Product Name Assigned

REP 9-61 Cleaner Detoning Rolls or Bearing Plates Parts List on PL 9.25 Removal 1.

Switch off the Printer Circuit Breakers.

NOTE: Replace a bound up cleaner module. Do not attempt to clean it. 2.

Remove Photoreceptor (REP 9-35) and cover the PR Module under the cleaner module with paper.

3.

Remove the Cleaner Brush (REP 9-23).

4.

Remove the ROS lower inner panel.

5.

Remove the Cleaner Manifold (REP 9-24).

6.

Place a stack of paper (approx. 13mm thick) between the PR Module and the Cleaner Housing to support the Cleaner Module.

7.

Remove the Preclean Dicorotron (REP 9-39).

8.

Remove the Front Spots Blade Guide (REP 9-58).

9.

Remove the Cleaner Augers and Blades (REP 9-25). Discard the Cleaner Blades.

10. Clean the Augers. 11. Remove the nuts securing the Front Detoning Roll Gears and remove the gears. 12. Remove Dicorotron Connectors (OZAC) of the Preclean Dicorotron (REP 9-40). 13. Remove the upper waste toner duct (REP 9-17). Remove the Auger Tube Support located behind the upper Waste Toner Duct. 14. Remove the Cleaner Drive Gears (REP 9-27). 15. Visually check the gears for excessive wear. 16. Check the bearings of the Detoning Rolls. If the ball bearings have fallen out or the bearing races rotate in the plastic housing, the plates or the cleaner module must be replaced. To replace the rear plate, the cleaner module must be removed (REP 9-26). 17. Remove the cleaner front support. CAUTION Avoid damaging the plate while separating it from the housing by gently prying all along the interface. Do not lose the Spring for the manifold latch. 18. Remove the front plate (Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 9-61

NOTE: MANIFOLD LATCH SPRING IS BEHIND THIS SCREW

1 DETACH THE FRONT DICOROTRON RAIL, SAVE THE SHIM(S)

2 REMOVE SCREWS (6), THEN REMOVE THE FRONT PLATE

Figure 1 Removing the Front Plate 19. Remove the detoning rolls. Clean the inside housing with the vacuum adapter tube. Clean the bearing areas of the plates.

6.

Replacement

7.

Reinstall the upper waste toner duct.

CAUTION

8.

Reinstall Dicorotron Connectors (OZAC) of the Preclean Dicorotron (REP 9-40).

Wrap the roll in paper during the handling or installation to prevent scratches which will lead to premature roll failure.

9.

Install the Front Detoning Roll Gears so that the gear teeth are toward the front.

1.

Install the new detoning rolls with the slotted end of the shaft in the rear plate. Protect the coated surface of the roll during installation.

11. Reinstall the Augers (REP 9-25).

2.

Ensure that the manifold latch spring is seated in the housing and install the front plates.

3.

Reinstall the Preclean Dicorotron Rail and shim(s) on the front plate.

13. Guide the alignment pin on the brush door into the locating hole in the xerographic drawer and latch the drawer.

4.

Check/Adjust the Preclean Dicorotron Height (ADJ 9-18).

14. Tighten the screws of the cleaner front support.

5.

Loosely reinstall the front support bracket of the cleaner. Remove the paper support for the Cleaner Module.

15. Reinstall and check adjust the Spots Blade Guide (REP 9-58).

Section Name

REP 9-61

Reinstall the cleaner drive gears with the part numbers toward the front (REP 9-27). Ensure that new gears are installed if required.

10. Install new Cleaner Blades. 12. Install a new Cleaner Brush.

16. Reinstall the Photoreceptor (REP 9-35).

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Preliminary Working Document No Product Name Assigned

17. Reinstall the Fuser Drip Tray and inner panels. 18. Switch on the printer power. Run a print job while visually verifying from the back side of the printer that the Cleaner Augers and the waste compactor motor are operating. 19. Reinstall all panels, doors, and covers. Restore the printer to an operational condition.

REP 9-62 Transfer Solenoids (SOL903/SOL904/SOL905/ SOL906) Parts List on PL 9.12 Removal 1.

SWITCH OFF THE PRINTER AND DISCONNECT ALL PRINTER POWER CORDS. CAUTION

Handle the Transfer Assist Device carefully. Do not touch the actuator segments of the Transfer Assist Device because the actuator segments may be deformed. 2.

REMOVE THE TRANSFER ASSIST DEVICE (REP 9-50). NOTE: The body of each of the four Solenoids must be removed to access the solenoid plungers.

3.

Preliminary Working Document No Product Name Assigned

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REMOVE THE BODY OF EACH SOLENOID (Figure 1).

Section Name

REP 9-61, REP 9-62

2

3

REMOVE THE CLIPS (4)

REMOVE AND DISCARD THE BODY OF THE DEFECTIVE SOLENOID

RIGHT SIDE VIEW

4 NOTE: TEMPORARILY REMOVE THE BODIES OF THE THREE REMAINING SOLENOIDS

TRANSFER 4 SOLENOID (SOL904)

1 TRANSFER 1 SOLENOID (SOL903)

CUT CABLE TIE OF THE DEFECTIVE SOLENOID

TRANSFER 2 SOLENOID (SOL905)

TRANSFER 3 SOLENOID (SOL906)

Figure 1 Removing the Body of Each Transfer Solenoid 4.

DISCONNECT THE GROUND WIRES AND REMOVE THE SUPPORT BRACKET (Figure 2).

Section Name

REP 9-62

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Preliminary Working Document No Product Name Assigned

TOP RIGHT VIEW

1 REMOVE THE SCREWS (2) AND DISCONNECT THE GROUND WIRES (4)

2 SQUEEZE THE ASSEMBLY TOGETHER

3. REMOVE THE SUPPORT BRACKET

Figure 2 Disconnecting the Ground Wires and Removing the Support Bracket 5.

REMOVE AND DISCARD THE DEFECTIVE SOLENOID PLUNGER (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-315

Section Name

REP 9-62

RIGHT SIDE VIEW

NOTE: LARGEST SPRING

NYLON WASHER

1 SOLENOID #1: REMOVE PLUNGER AND TRANSFER THE SPRING, WASHERS AND GRIP RING TO THE NEW PLUNGER

METAL WASHER

2 SOLENOIDS #2, 3 AND 4: REMOVE PLUNGER AND TRANSFER THE SPRING, WASHER, E-RING AND NYLON SPRING HOLDER TO THE NEW PLUNGER

Figure 3 Removing the Defective Solenoid Plunger NOTE: The spring on the plunger of the Transfer 1 Solenoid is the largest and strongest spring. 6.

REMOVE AND RETAIN THE SPRING AND MOUNTING HARDWARE FROM THE OLD PLUNGER.

Replacement 1.

b.

Install the new plunger. NOTE: Ensure that the four ground wires and the solenoid wires are routed correctly. This will prevent the wires from catching on internal Printer components.

c.

Reinstall the Support Bracket and ensure that the ground wires are reconnected (Figure 4).

INSTALL THE SOLENOID. a.

Install the retaining ring(s), washer(s) and spring onto the new plunger.

Section Name

REP 9-62

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Preliminary Working Document No Product Name Assigned

RIGHT SIDE VIEW

2 CHECK: ENSURE THAT THE SOLENOID WIRES ARE ROUTED CORRECTLY

1 CHECK: ENSURE THAT THE GROUND WIRES (4) ARE ROUTED CORRECTLY

Figure 4 Ensuring that the Ground Wires and Solenoid Wires are Routed Correctly d.

Install the body of the new solenoid and reinstall the bodies of the remaining solenoids.

e.

Reinstall the clips (4). Ensure that the clip is seated in the notches on Solenoid #1.

f.

Replace the cable tie for the new solenoid connector (Figure 1).

2.

REINSTALL THE TRANSFER ASSIST DEVICE (REP 9-50).

3.

CHECK/ADJUST THE TRANSFER BLADE TIMING (ADJ 9-9).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-317

Section Name

REP 9-62

Section Name

REP 9-62

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Preliminary Working Document No Product Name Assigned

REP 10-0 Camshaft

Parts List on PL 10.2 Removal CAUTION If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE CAMSHAFT (Figure 1).

2

1 REMOVE COVER

3

MOVE

PUSH DOWN, AND DISENGAGE (FRONT AND REAR)

6 REMOVE THE CAMSHAFT

5 REMOVE SENSOR ASSEMBLY

4 MOVE

THE COVER SCREWS

Figure 1 Removing the Camshaft

Replacement

REP 10-1 Fuser Roll and Heat Rod (HTR1001)

NOTE: The coupling slider may drop into motor mount. Position the slider on motor coupling hub before installing the camshaft.

Parts List on PL 10.6 Removal

1.

IF INSTALLING A NEW CAMSHAFT, USE THE COUPLING HUB FROM OLD CAMSHAFT.

To see additional information go to Fuser in the DocuPrint 180 Unique Components and Functions section.

2.

INSTALL CAM WITH THE LOW POINT AT THE BOTTOM POSITION.

3.

CHECK/ADJUST THE PRESSURE ROLL CONTACT ARC (ADJ 10-2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-319

Section Name

REP 10-0

WARNING Fuser is hot. Keep Fuser Agent away from eyes.

2.

OPEN THE PRINTER FRONT DOORS.

3.

PULL OUT THE FUSER.

CAUTION

4.

REMOVE THE FUSER INNER PANEL.

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR and possible blurred image problems.

5.

REMOVE FUSER ROLL (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

6

1

REMOVE THE FUSER ROLL

RAISE STRIPPER ASSEMBLY

2 PUSH DOWN, AND DISENGAGE (FRONT AND REAR)

5

3

DISCONNECT (FRONT (1) AND REAR (2))

RAISE PRESSURE ROLL

4 LOOSEN AND REMOVE CLAMPS (2) (FRONT AND REAR)

Figure 1 Removing the Fuser Roll 6.

REMOVE HEAT ROD (Figure 2).

Section Name

REP 10-1

0/0/00 ?-320

Preliminary Working Document No Product Name Assigned

1 REMOVE

2 REMOVE THE HEAT ROD

Figure 2 Removing the Heat Rod

Replacement

REP 10-2 Metering Assembly

1.

INSTALL HEAT ROD WITH TWO CONNECTORS TOWARDS THE REAR.

2.

CLEAN THE THERMISTORS BEFORE INSTALLING FUSER ROLL.

Parts List on PL 10.4 Removal

NOTE: Push down on the Clamps while tightening. 3.

INSTALL THE CLAMPS WITH THE SCREW FACING OUT.

4.

RESTORE THE PRINTER POWER.

5.

LUBRICATE THE NEW FUSER ROLL, AND RESET THE COUNTERS:

WARNING Fuser is hot. Keep Fuser Agent away from eyes. CAUTION If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems.

a.

Enter dC701, [Fuser Setups].

b.

Select [Fuser Roll Prep], and press the Continue button.

c.

Enter dC107, select [Fuser], [Fuser Roll], and press [Reset counter to zero and update History.].

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS.

6.

CHECK/ADJUST THE FUSER ROLL TEMPERATURE (ADJ 10-6).

3.

PULL OUT THE FUSER.

7.

CHECK/ADJUST THE PRESSURE ROLL CONTACT ARC (ADJ 10-2).

4.

REMOVE METERING ASSEMBLY (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-321

Section Name

REP 10-1

4 DISCONNECT (2)

3

5

MOVE UP

RELEASE (2)

2 UNLATCH

1

6

REMOVE CAP, AND PLACE IN NOTCH ABOVE

REMOVE METERING ASSEMBLY

Figure 1 Removing Metering Assembly

Replacement

REP 10-3 Metering Assembly Cleaning

NOTE: Ensure latch pins are fully engaged with side frame holes. Rotate pin handles up into frame notches.

Parts List on PL 10.7 PL 10.8 Clean WARNING

1.

REPLACE METERING ASSEMBLY.

2.

FILL THE METERING ASSEMBLY WITH FUSER AGENT TO THE OVERFLOW LEVEL INDICATOR.

3.

IF A NEW DONOR ROLL WAS INSTALLED, ENTER [SCP], [HFSI], SELECT [Fuser Module], [10-803 R Donor Roll], AND PRESS [Reset Count].

Fuser is hot. Keep Fuser Agent away from eyes. 1.

CAUTION If a long print run was just completed (15 minutes or longer), remove the Preclean Dicorotron in order to avoid contamination of the Photoreceptor Belt, and to avoid possible blurred image problems. 2.

Section Name

REP 10-3

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

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PULL OUT THE FUSER, AND REMOVE THE FOLLOWING: a.

Metering Assembly (REP 10-2).

b.

Metering Roll (REP 10-4).

c.

Metering Blade (REP 10-5).

d.

Fuser Wick and Fuser Agent Filter (REP 10-7).

Preliminary Working Document No Product Name Assigned

3.

4.

WIPE AWAY ALL FUSER AGENT AND CONTAMINANTS FROM THE FOLLOWING COMPONENTS: a.

Housing of the Metering Assembly

b.

Metering Blade

c.

Metering Roll Thermistor (RT1002)

c.

[10-814 C Metering Assembly] AND PRESS [Reset Count]

REP 10-4 Metering Roll Parts List on PL 10.7 Removal CAUTION

INSTALL THE FOLLOWING: a.

Fuser Wick and Fuser Agent Filter (REP 10-7).

b.

Metering Blade (REP 10-5).

c.

Metering Roll (REP 10-4).

d.

Metering Assembly (REP 10-2).

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems.

5.

FILL THE HOUSING WITH FUSER AGENT TO THE OVERFLOW LEVEL.

6.

RESTORE THE PRINTER POWER, AND ENTER [SCP], [HFSI], AND [Fuser Module] TO RESET THE FOLLOWING SELECT:

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

OPEN THE PRINTER FRONT DOORS.

3.

PULL OUT THE FUSER.

4.

REMOVE METERING ASSEMBLY (REP 10-2).

NOTE: Cut and replace cable ties as required.

a.

[10-801 Ro/R Metering Blade] AND PRESS [Reset Count]

b.

[10-802 R Wick and Fuser Agent Filter] AND PRESS [Reset Count]

3 REMOVE THE METERING ROLL

1 MOVE

2 PUSH DOWN (2)

Figure 1 Removing Metering Roll

Replacement 1.

AGENT TO ROLL TO AVOID DAMAGE TO METERING BLADE.

IF INSTALLING A NEW METERING ROLL, APPLY A LIGHT COATING OF FUSER

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-4

REP 10-5 Metering Blade

CAUTION Ensure Metering Blade is in the down position and the Metering Roll is installed on top of blade. Damage to the Donor Roll will occur if blade is not under the Metering Roll. 2.

PUSH METERING ROLL BEARINGS DOWN UNTIL THE LATCHES ARE SECURE.

3.

CHECK/ADJUST THE METERING ROLL OVERHEAT THERMOSTAT (THS1001) (ADJ 10-1).

4.

IF A NEW METERING ROLL WAS INSTALLED, ENTER [SCP], [HFSI], [Fuser Module], SELECT [10-812 R Metering Roll], AND PRESS [Reset Count].

Parts List on PL 10.7 Removal CAUTION If the Printer just completed a long print run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE METERING ROLL (REP 10-4).

3.

REMOVE METERING BLADE (Figure 1).

WICK

1 REMOVE THE METERING BLADE

Figure 1 Removing the Metering Blade

Replacement

1. CAUTION

Ensure Metering Blade is in the down position, and the Metering Roll is installed on top of blade. Damage to the Donor Roll will occur if blade is not under the Metering Roll.

NOTE: If 4 corners are cut, install a new blade. 2.

NOTE: To avoid stretching the blade, insert blade into holder and work from the ends toward the center. Section Name

REP 10-5

IF INSTALLING A NEW BLADE, APPLY A LIGHT COATING OF FUSER AGENT TO BLADE, AND INSTALL EDGE NUMBER "1".

0/0/00 ?-324

IF EXISTING METERING BLADE IS BEING ROTATED TO A NEW EDGE, CUT THE CORNER OF THE USED EDGE (Figure 2), AND INSTALL NEXT HIGHER NUMBER EDGE. Preliminary Working Document No Product Name Assigned

METERING BLADE

USED EDGE

CUT CORNER

Figure 2 Cutting the Corner 3.

INSTALL THE FOLLOWING: a.

Metering Roll (REP 10-4).

NOTE: After the metering roll is installed, check for a gap of at least 2.0 mm between each end of the metering blade and metering roll bearings. If required, trim the metering blade to achieve the required gap. b. 4.

Metering Assembly (REP 10-2).

CLOSE AND LATCH THE FUSER.

5.

RESTORE THE PRINTER POWER.

6.

IF A NEW METERING BLADE WAS INSTALLED OR THE EXISTING BLADE WAS ROTATED, ENTER [SCP], [HFSI], [Fuser Module], SELECT [10-801 Ro/R Metering Blade], AND SELECT [Reset Count].

Preliminary Working Document No Product Name Assigned

0/0/00 ?-325

Section Name

REP 10-5

REP 10-6 Air Knife Manifold Cleaning

2.

REMOVE THE PRINT TRANSPORT INNER PANEL.

Parts List on PL 10.6 Clean

3.

INSTALL A CHEATER IN THE PRINTER INTERLOCK BYPASS SWITCH (S103).

NOTE: The purpose of this procedure is to prevent dirt from being pushed into the holes, and clog the holes. 1.

OPEN THE PRINTER FRONT DOORS.

4.

ENTER dC330, SELECT [10], [Compressor], AND PRESS THE Continue BUTTON.

5.

SELECT [Cycle Mode], [Air Knife], AND PRESS THE Continue BUTTON.

6.

PULL OUT THE FUSER.

NOTE: Ensure that the Air Knife Manifold holes are free of any obstructions 7.

CLEAN THE AIR KNIFE MANIFOLD WITH FORMULA "A" (Figure 1).

1 RAISE THE STRIPPER ASSEMBLY

2 CLEAN THE MANIFOLD RIGHT FRONT VIEW

Figure 1 Cleaning the Air Knife Manifold 8.

CLOSE THE FUSER.

REP 10-7 Fuser Wick and Fuser Agent Filter Parts List on PL 10.7 PL 10.8 Removal 1.

Section Name

REP 10-6

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SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Preliminary Working Document No Product Name Assigned

CAUTION

3.

REMOVE THE FUSER WICK (Figure 1).

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and, to avoid possible blurred image problems. 2.

REMOVE THE METERING ROLL (REP 10-4).

1 REMOVE THE FUSER WICK

METERING BLADE

Figure 1 Removing the Fuser Wick 4.

REMOVE THE FUSER AGENT FILTER (Figure 2).

LEFT SIDE VIEW

1 LOOSEN AND DISCONNECT THE HOSE (2)

3 LOOSEN AND DISCONNECT THE HOSE

2 REMOVE THE FILTER AND THE SPRING Figure 2 Removing the Fuser Agent Filter 5.

WIPE AWAY ALL FUSER AGENT AND CONTAMINANTS FROM THE FOLLOWING COMPONENTS:

Preliminary Working Document No Product Name Assigned

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a.

Housing of the Metering Assembly

b.

Metering Blade

Section Name

REP 10-7, REP 10-8

c.

REP 10-8 Fuser Sensor (Q1010) CLEANING

Metering Roll Thermistor (RT1002)

Replacement CAUTION Ensure that the new filter is installed with the end marked OUT towards the Fuser Agent Pump. 1.

INSTALL A NEW FUSER AGENT FILTER.

2.

INSTALL A NEW FUSER WICK, AND APPLY ENOUGH FUSER AGENT TO SATURATE IT.

Parts List on PL 10.6 Clean 1.

CLEAN THE SENSOR AND REFLECTIVE TAPE ON AIR KNIFE USING 43P81 LENS AND MIRROR CLEANER: USE COTTON SWAB 35P2162, AND INSERT THE SWAB FROM THE TOP OF THE STRIPPER MANIFOLD.

CAUTION Ensure that the Metering Blade is centered and seated in the Blade Support. Also ensure that the Metering Roll is installed on top of the blade. Damage to the Donor Roll will occur if blade is not under the Metering Roll. 3.

INSTALL THE METERING ROLL (REP 10-4).

4.

FILL THE METERING ASSEMBLY WITH FUSER AGENT TO THE OVERFLOW LEVEL INDICATOR.

5.

INSTALL THE METERING ASSEMBLY (REP 10-2).

6.

CLOSE AND LATCH THE FUSER.

7.

RESTORE THE PRINTER POWER.

8.

ENTER [SCP], [HFSI], [Fuser Module], SELECT [10-802 R Wick and Agent Filter], AND SELECT [Reset Count].

Section Name

REP 10-7, REP 10-8

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Preliminary Working Document No Product Name Assigned

REP 10-9 Left and Right Drawer Slide

2.

Parts List on PL 10.2 Removal 1.

PLACE THE SUPPORT UNDER THE FUSER ASSEMBLY, AND REMOVE THE RIGHT SLIDE (Figure 1).

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1 SCRIBE THE POSITIONS OF THE SLIDE BRACKETS (2)

5 REMOVE THE RIGHT SLIDE

4 REMOVE THE SCREWS (2)

2

3

PLACE THE BOX OF PAPER UNDER THE FUSER ASSEMBLY, AND ADD PAPER TO FIRMLY SUPPORT THE FUSER ASSEMBLY

REMOVE THE SCREWS (2 EACH SIDE)

NOTE: ACCESS THE REAR SCREWS THROUGH HOLE IN THE SLIDE

Figure 1 Removing the Right Slide 3.

DISENGAGE THE HARNESS, AND REMOVE THE LEFT SLIDE (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-9

2 PULL THE BRACKET OUT

1 REMOVE THE SCREWS (2)

5 REMOVE THE LEFT SLIDE

3 REMOVE THE CLAMP

4 MOVE HARNESS THE OUT OF THE CLAMP BRACKET

Figure 2 Disengaging the Harness and Removing the Left Slide

Replacement 1.

REMOVE THE HARNESS CLAMP BRACKET FROM THE OLD SLIDE, AND INSTALL IT ON NEW THE SLIDE.

2.

INSTALL THE SLIDES FROM THE FRONT. ENSURE THAT THE PINS AT THE REAR END OF THE SLIDE ENGAGE WITH THE SLOTS IN THE REAR BRACKETS.

NOTE: The scribe marks are used only for the rough positioning of the slides. The brackets will not necessarily align to the scribe marks after the final adjustment. 3.

ALIGN THE FRONT BRACKETS TO THE SCRIBE MARKS, AND INSTALL THE SCREWS (4).

4.

INSTALL THE SCREWS (4) TO FUSER ASSEMBLY.

5.

ADJUST THE LEFT AND THE RIGHT DRAWER SLIDES (ADJ 10-11).

Section Name

REP 10-9

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Preliminary Working Document No Product Name Assigned

REP 10-10 MIM Compressor (MOT1002)

2.

REMOVE THE ELECTRICAL MODULE REAR COVER.

Parts List on PL 10.9 Removal

3.

REMOVE THE TONER FILTER ASSEMBLY (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

1

REAR VIEW

DISCONNECT THE CONNECTOR

2 OPEN AND REMOVE THE TONER FILTER ASSEMBLY

3 DISCONNECT P209

Figure 1 Removing the Filter Assembly 4.

REMOVE THE COMPRESSOR (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-10

3 DISCONNECT THE FASTON CONNECTORS (2)

2 DISCONNECT P270

1

4

DISCONNECT THE AIR LINE

LOOSEN THE 10MM SCREW

7 REMOVE THE MIM COMPRESSOR

5 REMOVE THE 10MM SCREW

6 LOOSEN THE 10MM SCREW

Figure 2 Removing the MIM Compressor

Replacement

REP 10-11 Top Transport Assembly

1.

CHECK/ADJUST THE AIR KNIFE PRESSURE, PRESSURE REGULATOR, COMPRESSOR (MOT 1002) (ADJ 10-5).

2.

IF A NEW COMPRESSOR WAS INSTALLED, ENTER dC107, SELECT [Fuser], [Compressor Motor], AND PRESS [Reset counter to zero and update History].

Parts List on PL 10.13 Removal

Section Name

REP 10-10

To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

3.

REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0).

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Preliminary Working Document No Product Name Assigned

4.

REMOVE THE LATCH SUPPORT PLATE FOR THE PRINTER RIGHT TOP COVER.

5.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

6.

OPEN THE PHN PANEL DOOR, AND PREPARE TO REMOVE THE TOP TRANSPORT ASSEMBLY (Figure 1).

REAR VIEW

1 DISCONNECT P/J393

Figure 1 Preparing to Remove the Top Transport Assembly 7.

REMOVE THE TOP TRANSPORT ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-11

4

1

REMOVE THE TRANSPORT

LOOSEN IDLER AND REMOVE THE BELT

2 3

LOOSEN IDLER AND REMOVE THE BELT

REMOVE THE SCREWS (4)

Figure 2 Removing the Transport

Section Name

REP 10-11

0/0/00 ?-334

Preliminary Working Document No Product Name Assigned

REP 10-12 Prefuser Transport Assembly Parts List on PL 8.12 Removal 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

NOTE: Cut the cable tie for the blower wire harness. 2.

REMOVE THE TRANSPORT ASSEMBLY (Figure 1).

3 PULL THE FUSER OUT

2 REMOVE SCREW AND BRACKET

1 4 PULL TRANSPORT OUT AND REMOVE

DISCONNECT CONNECTORS (2) AND AIR HOSE

Figure 1 Removing the Transport Assembly

Replacement 1.

WHEN INSTALLING NEW TRANSPORT BELTS OR A NEW PREFUSER VACUUM TRANSPORT, RESET THE FOLLOWING: a.

Enter [SCP], [HSFI], [Print Transport], [10-811 R Prefuser Transport Belts], and [Reset Count].

b.

Enter [SCP], [HSFI], [Print Transport], [10-815 C Prefuser Transport vacuum holes], and press [Reset Count].

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-12

REP 10-13 Exit Transport Assembly

2.

Parts List on PL 10.13 Removal

OPEN THE PRINTER RIGHT FRONT DOOR, AND REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0). REMOVR THE PRINTER TRANSPORT INNER PANEL. REMOVE THE PRINTER LATCH SUPPORT PLATE.

3.

REMOVE THE EXIT TRANSPORT ASSEMBLY (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3 REMOVE THE TRANSPORT

2 REMOVE THE SCREWS (4)

1 LOOSEN IDLER AND REMOVE THE BELT

Figure 1 Removing the Exit Transport

Section Name

REP 10-13

0/0/00 ?-336

Preliminary Working Document No Product Name Assigned

REP 10-14 Decurler Assembly

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Parts List on PL 10.11 Removal

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-0). CAUTION

Remove and protect the Photoreceptor from the light.

To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section.

3.

REMOVE THE ROS UPPER INNER PANEL AND THE PRINT TRANSPORT INNER PANEL.

4.

PREPARE TO REMOVE THE DECURLER ASSEMBLY (Figure 1).

TOP FRONT VIEW

4 LIFT AND MOVE THE BRACKET

3 LOOSEN CLAMP AND REMOVE HOSE

2 REMOVE NUT (1)

1 REMOVE SCREWS (2)

Figure 1 Preparing to Remove the Decurler Assembly 5.

REMOVE THE DECURLER ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-14

3 REMOVE THE DRIVE BELT

4 REMOVE THE DECURLER ASSEMBLY

2 MOVE OFF THE MOUNTING PINS

1 REMOVE SCREW

Figure 2 Removing the Decurler Assembly

Replacement

REP 10-15 Decurler Belts

1.

ADJUST THE DECURLER DRIVE BELT (ADJ 4-11).

2.

CHECK/ADJUST THE DECURLER JAM SENSOR (ADJ 10-10).

Parts List on PL 10.12 Removal To see additional information go to Processor Paper Path in the DocuPrint 180 Unique Components and Functions section.

Section Name

REP 10-14

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE DECURLER ASSEMBLY (REP 10-14).

3.

REMOVE DECURLER BELTS (Figure 1).

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Preliminary Working Document No Product Name Assigned

2 REMOVE THE BELTS

1 PULL THE LOWER ROLL OUT OF THE FRAME

Figure 1 Removing the Decurler Belts

Replacement

REP 10-16 Flexible Coupling

1.

Parts List on PL 10.1 PL 10.2 PL 10.3 PL 10.4 PL 10.5 PL 10.6 PL 10.7 PL 10.8 PL 10.9 PL 10.10 PL 10.11 PL 10.12 PL 10.13 PL 10.14 PL 10.15 PL 10.16 PL 10.17 PL 10.18 PL 10.19 PL 10.20 PL 10.21 PL 10.22 Replacement

ENTER [SCP], [HSFI], [Print Transport], [10-813 R Decurler Belts], and press [Reset Count].

1.

REMOVE THE VERTICAL TRANSPORT ASSEMBLY (REP 8-0). CAUTION

The flexible pivot of the coupling must be located as far towards the front of the transport as possible, to avoid premature wear. 2.

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INSTALL COUPLING COMPLETELY TOWARDS FRONT OF TRANSPORT (Figure 1).

Section Name

REP 10-16

PUSH THE COUPLING COMPLETELY TOWARDS THE FRONT

Figure 1 Replacing the Flexible Coupling

Section Name

REP 10-16

0/0/00 ?-340

Preliminary Working Document No Product Name Assigned

REP 10-17 Duplex Inverter Assembly

2.

REMOVE THE TOP TRANSPORT ASSEMBLY (REP 10-11).

Parts List on PL 10.13 Removal

3.

REMOVE OR COVER THE PHOTORECEPTOR BELT TO PREVENT LIGHT SHOCK (REP 9-35).

4.

DISCONNECT THE ELECTRICAL CONNECTOR OF THE INVERTER ASSEMBLY (Figure 1).

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

REAR VIEW

1 DISCONNECT THE CONNECTOR P/J363 THE INVERTER ASSEMBLY

Figure 1 Disconnecting the Electrical Connector for the Inverter CAUTION Hold the Inverter handle while releasing the latches. The left side of the Inverter will fall downwards. 5.

REMOVE THE INVERTER ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-17

FRONT TOP VIEW

4 LIFT THE INVERTER OUT OF THE PRINTER

3 CAUTION RELEASE THE LATCHES (2)

1 REMOVE BOLTS (2)

2 GRASP AND HOLD THE HANDLE

Figure 2 Removing the Inverter Assembly

Replacement 1.

CHECK/ADJUST THE DUPLEX TIMING (ADJ 10-14).

REP 10-18 Inverter Gear Box Drive Belt and Inverter Reversing Roll Drive Belt Parts List on PL 10.22 Removal

Section Name

REP 10-17

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

3.

OPEN THE PHN PANEL DOOR.

4.

REMOVE THE INVERTER COUPLER ASSEMBLY (Figure 1).

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Preliminary Working Document No Product Name Assigned

1

REAR VIEW

LOOSEN THE SCREW AND MOVE THE IDLER

4 REMOVE THE INVERTER COUPLER ASSEMBLY

2 REMOVE THE INVERTER DRIVE BELT

3 REMOVE BOLTS (3)

Figure 1 Removing the Inverter Coupler Assembly 5.

REMOVE THE INVERTER GEAR BOX DRIVE BELT AND THE INVERTER REVERSING ROLL DRIVE BELT (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 10-18

REAR VIEW

1 LOOSEN NUT AND MOVE THE IDLER

6

5

3 2 TIGHTEN NUT

REMOVE THE GEAR BOX DRIVE BELT

REMOVE THE REVERSING ROLL DRIVE BELT

TIGHTEN THE NUT

4 LOOSEN NUT AND THE MOVE THE IDLER

Figure 2 Removing the Inverter Gear Box Drive Belt and the Reversing Roll Drive Belt

Replacement

REP 10-19 Inverter Gear Box Assembly

1.

Parts List on PL 10.22 Removal

TIGHTEN THE GEAR BOX DRIVE BELT, THE REVERSING ROLL DRIVE BELT, AND THE INVERTER DRIVE BELT.

Section Name

REP 10-18

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE INVERTER GEAR BOX DRIVE BELT AND THE INVERTER REVERSING ROLL DRIVE BELT (REP 10-18).

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Preliminary Working Document No Product Name Assigned

CAUTION Gently remove the Inverter Gear Box from the Inverter Frame. The electrical connector for the Gear Box must be disconnected before the Gear Box is completely removed from the Printer. 3.

REMOVE THE INVERTER GEAR BOX ASSEMBLY (Figure 1).

REAR VIEW

3 DISCONNECT THE ELECTRICAL CONNECTOR

2 CAUTION GENTLY PULL THE GEAR BOX AWAY FROM THE INVERTER

1 REMOVE NUTS (3)

Figure 1 Removing the Inverter Gear Box Assembly

Replacement 1.

CHECK/ADJUST THE DUPLEX TIMING (ADJ 10-14).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-345

Section Name

REP 10-19

Section Name

REP 10-19

0/0/00 ?-346

Preliminary Working Document No Product Name Assigned

REP 11-1 Inverter Transport Parts List on PL 11.22 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER LEFT SIDE COVER (REP 4-54).

2 DISCONNECT

3.

REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0).

4.

REMOVE THE INVERTER REAR COVER.

5.

REMOVE THE TRIM STRIP LOCATED BETWEEN THE PRINTER RIGHT TOP COVER AND THE INVERTER LEFT SIDE COVER.

6.

DISCONNECT THE INVERTER CONNECTORS (Figure 1).

1 DISCONNECT

Figure 1 Disconnecting the Connectors 7.

REMOVE THE INVERTER DOOR INTERLOCK SWITCH AND BRACKET FROM THE FRAME.

NOTE: After the mounting bolts have been removed, lower the front of the Inverter Transport until it is positioned on the inner panel located below the Inverter. 8.

Preliminary Working Document No Product Name Assigned

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REMOVE THE INVERTER MOUNTING BOLTS (Figure 2).

Section Name

REP 11-1

1 REMOVE

2 REMOVE

Figure 2 Removing the Mounting Bolts 9.

REMOVE THE DRIVE BELT FROM THE REAR OF THE INVERTER TRANSPORT (Figure 3).

Section Name

REP 11-1

0/0/00 ?-348

Preliminary Working Document No Product Name Assigned

1 MOVE THE INVERTER FORWARD UNTIL THE TAB IS REMOVED FROM THE SLOT

2 MOVE THE INVERTER TOWARD THE LEFT SLIGHTLY

3 REMOVE THE BELT FROM THE INVERTER PULLEY

Figure 3 Removing the Belt CAUTION Do not damage any existing harnesses when removing or installing the Inverter Transport. NOTE: It may be necessary to remove the hinge pins and the Inverter Door. 10. REMOVE THE INVERTER TRANSPORT.

Replacement NOTE: If a new Inverter Transport is being installed, ensure that the Inverter Guard Bracket is removed and discarded. Disconnect the Inverter Entrance Sensor (Q1155) and the Inverter Gate Solenoid from the auxiliary harness and discard the harness. 1.

PARTIALLY INSTALL THE INVERTER TRANSPORT AND REINSTALL THE DRIVE BELT.

2.

INSTALL THE INVERTER (Figure 4).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 11-1

REP 11-2 Inverter Gate Solenoid (SOL1108) Parts List on PL 11.24 Removal 2

1.

REINSTALL THE INVERTER MOUNTING BOLTS

NOTE: The solenoid removal is possible without removing the Inverter. However, replacement is easier with the Inverter removed.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

3.

REMOVE THE INVERTER GATE SOLENOID (Figure 1).

5 REMOVE THE SOLENOID

4 REMOVE THE SCREWS (2)

3 DISCONNECT THE PLUNGER LINKAGE

1 ENSURE TAB ON INVERTER IS LOCATED IN SLOT ON POST INVERTER

3 RECONNECT CONNECTORS (3)

2 1

REMOVE SPRING

DISCONNECT THE CONNECTOR Figure 4 Installing the Inverter Figure 1 Removing the Inverter Gate Solenoid

Replacement 1.

Section Name

REP 11-1, REP 11-2

REPLACE THE INVERTER GATE SOLENOID.

2.

CHECK/ADJUST THE INVERTER GATE SOLENOID (ADJ 11-1).

3.

REINSTALL THE INVERTER TRANSPORT.

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Preliminary Working Document No Product Name Assigned

REP 11-3 Inverter Drive Motor (MOT1111) Parts List on PL 11.24 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

NOTE: Ensure that the motor is supported from underneath when removing the mounting hardware. 3.

REMOVE THE INVERTER DRIVE MOTOR (Figure 1).

2 REMOVE THE MOTOR

1 REMOVE THE SCREWS (4)

REAR VIEW

Figure 1 Removing the Inverter Motor

Replacement 1.

REPLACE THE INVERTER DRIVE MOTOR.

2.

PERFORM THE INVERTER MOTOR BELT TENSION ADJUSTMENT (ADJ 11-14).

3.

REINSTALL THE INVERTER TRANSPORT.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-351

Section Name

REP 11-3

REP 11-4 Inverter Latch Assembly

2.

OPEN THE INVERTER FRONT DOOR.

Parts List on PL 11.25 Removal

3.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

4.

REMOVE THE INVERTER LATCH ASSEMBLY (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

INVERTER OUTPUT BAFFLE

2 REMOVE THE LATCH ASSEMBLY

1 REMOVE THE SCREWS (2)

RIGHT SIDE VIEW

FRONT VIEW

Figure 1 Removing the Latch Assembly

Replacement

REP 11-5 Inverter Top and Bottom Hinges

1.

REPLACE THE INVERTER LATCH ASSEMBLY.

2.

CHECK/ADJUST THE INVERTER OUTPUT BAFFLE (ADJ 11-3).

3.

REINSTALL THE INVERTER TRANSPORT.

Parts List on PL 11.24 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1). CAUTION

Do not allow the Pivoting Assembly to fall when the hinges are removed. 3.

Section Name

REP 11-4

0/0/00 ?-352

REMOVE THE HINGES (Figure 1).

Preliminary Working Document No Product Name Assigned

REP 11-6 Inverter Pivoting Assembly Parts List on PL 11.23 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

3.

PREPARE TO REMOVE THE PIVOTING ASSEMBLY (Figure 1).

1 REMOVE THE SCREWS (2) AND THE TOP HINGE

2

2

REMOVE THE SCREWS (2) AND BOTTOM HINGE

REMOVE THE SCREWS (2) AND THE TOP HINGE

1 REMOVE THE SCREW AND GROUND STRAP FROM PIVOTING ASSEMBLY Figure 1 Removing the Hinges

Replacement NOTE: The Top and Bottom Hinges are not interchangeable. 1.

REPLACE THE HINGES.

2.

CHECK/ADJUST THE TOP AND BOTTOM HINGES (ADJ 11-4).

3.

CHECK/ADJUST THE INVERTER PIVOTING ASSEMBLY ALIGNMENT (ADJ 11-8).

4.

REINSTALL THE INVERTER TRANSPORT.

Figure 1 Preparing to Remove the Pivoting Assembly 4.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-353

UNLATCH THE PIVOTING ASSEMBLY AND LIFT IT OFF OF THE BOTTOM HINGE.

Section Name

REP 11-6

Replacement

REP 11-7 Inverter Passive Gate

1.

REPLACE THE PIVOTING ASSEMBLY.

2.

CHECK/ADJUST THE TOP AND BOTTOM HINGES (ADJ 11-4).

3.

CHECK/ADJUST THE PIVOTING ASSEMBLY ALIGNMENT (ADJ 11-8).

Parts List on PL 11.25 Removal

4.

CHECK/ADJUST THE INVERTER OUTPUT BAFFLE (ADJ 11-3).

5.

REINSTALL THE INVERTER TRANSPORT.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

3.

DISCONNECT THE PASSIVE GATE SPRING (Figure 1).

2 DISCONNECT GATE SPRING

3 CLOSE THE ASSEMBLY

1 OPEN THE PIVOTING ASSEMBLY

Figure 1 Disconnecting the Passive Gate Spring NOTE: The illustration depicts only the rear hardware, because the front and rear hardware are identical. 4.

REMOVE THE INVERTER OUTPUT BAFFLE (Figure 2).

Section Name

REP 11-7

0/0/00 ?-354

Preliminary Working Document No Product Name Assigned

1

2

REMOVE E-RING

REMOVE BEARING

2 MOVE THE SPRING AWAY

1 LOOSEN THE NUTS (4)

3 REMOVE THE SCREWS (4)

4

3

REMOVE THE BAFFLE

REMOVE GATE

Figure 2 Removing the Inverter Output Baffle 5.

REMOVE THE PASSIVE GATE (Figure 3).

Figure 3 Removing the Passive Gate

Replacement 1.

REPLACE THE PASSIVE GATE.

2.

RECONNECT THE PASSIVE GATE SPRING.

3.

REINSTALL THE INVERTER OUTPUT BAFFLE.

4.

CHECK/ADJUST THE GATE FLAT SPRINGS (ADJ 11-2).

5.

CHECK/ADJUST THE INVERTER OUTPUT BAFFLE (ADJ 11-3).

NOTE: Ensure that the passive gate spring is reinstalled. 6.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-355

REINSTALL THE INVERTER TRANSPORT.

Section Name

REP 11-7

REP 11-8 Inverter Bottom Drive Shaft

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

Parts List on PL 11.24 Removal

3.

REMOVE THE BOTTOM DRIVE SHAFT (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

5 PUSH THE SHAFT TOWARD THE REAR

6 REMOVE BELT

7 REMOVE SHAFT

4 REMOVE BEARING RETAINER

2 REMOVE THE REAR BEARING RETAINER

3 REMOVE SCREW

1 REMOVE SCREW

Figure 1 Removing the Bottom Drive Shaft

Replacement

REP 11-9 Inverter Top and Middle Shafts

NOTE: Ensure that the front and rear retainers are seated firmly against the bearings. 1.

REPLACE THE BOTTOM DRIVE SHAFT.

Parts List on PL 11.25 Removal

2.

PERFORM THE INVERTER MOTOR BELT TENSION ADJUSTMENT (ADJ 11-14).

1.

SWITCH OFF THE PRINTER POWER.

REINSTALL THE INVERTER TRANSPORT.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

3.

REMOVE THE INVERTER LATCH ASSEMBLY (Figure 1).

3.

Section Name

REP 11-8

0/0/00 ?-356

Preliminary Working Document No Product Name Assigned

3

2

REMOVE SCREW

REMOVE LATCH

1 REMOVE THE SCREWS (2)

4 REMOVE BEARING RETAINER AND GROUND TAB

FRONT VIEW

Figure 1 Removing the Inverter Latch Assembly 4.

REMOVE THE INVERTER OUTPUT BAFFLE (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-357

Section Name

REP 11-9

2 REMOVE SCREWS (4)

1 LOOSEN NUTS (4) AND MOVE THE SPRINGS AWAY

3 REMOVE THE BAFFLE

Figure 2 Removing the Inverter Output Baffle 5.

REMOVE THE TOP AND MIDDLE SHAFTS (Figure 3).

Section Name

REP 11-9

0/0/00 ?-358

Preliminary Working Document No Product Name Assigned

2 REMOVE BEARING RETAINER

3 REMOVE TOP SHAFT

4 REMOVE MIDDLE SHAFT

1 REMOVE SCREW

REAR VIEW

Figure 3 Removing the Top And Middle Shafts

Replacement NOTE: Ensure that the bearing retainers are seated firmly against the bearings. 1.

REPLACE THE TOP AND MIDDLE SHAFTS.

2.

REINSTALL THE INVERTER OUTPUT BAFFLE.

3.

REINSTALL THE INVERTER LATCH ASSEMBLY.

4.

ADJUST THE GATE FLAT SPRINGS (ADJ 11-2).

5.

CHECK/ADJUST THE INVERTER OUTPUT BAFFLE (ADJ 11-3).

6.

REINSTALL THE INVERTER TRANSPORT.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-359

Section Name

REP 11-9

REP 11-10 Stacker Main Drive Motor (MOT1110)

2.

REMOVE THE INVERTER TOP COVER (REP 4-52).

Parts List on PL 11.1 Removal

3.

REMOVE THE INVERTER LEFT SIDE COVER (REP 4-54).

4.

REMOVE THE INVERTER REAR COVER.

5.

REMOVE THE STACKER MAIN DRIVE MOTOR (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

5 REMOVE THE MOTOR

4 REMOVE NUTS (4) AND BOLTS (4)

1 LOOSEN THE IDLER MOUNTING SCREW

2

3

REMOVE BELT

DISCONNECT

Figure 1 Removing the Drive Motor

Section Name

REP 11-10

0/0/00 ?-360

Preliminary Working Document No Product Name Assigned

REP 11-11 Post Inverter Transport

2.

REMOVE THE STACKER PRE-REGISTRATION TRANSPORT (REP 11-20).

Parts List on PL 11.22 Removal

3.

REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0).

4.

REMOVE THE TRIM STRIP LOCATED BETWEEN THE PRINTER RIGHT TOP COVER AND THE INVERTER LEFT SIDE COVER.

1.

5.

PREPARE TO REMOVE THE POST INVERTER TRANSPORT (Figure 1).

SWITCH OFF THE PRINTER POWER.

1

3

DISCONNECT

LOOSEN THE IDLER MOUNTING SCREW AND REMOVE THE DRIVE BELT

2 DISCONNECT

Figure 1 Preparing to Remove the Transport 6.

REMOVE THE POST INVERTER TRANSPORT MOUNTING HARDWARE (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-361

Section Name

REP 11-11

1 REMOVE THE UPPER BOLTS (2)

3 REMOVE THE SAMPLE TRAY STATIC BRUSH

2 REMOVE BOLT

Figure 2 Removing the Hardware CAUTION Do not damage any existing harnesses when removing or installing the transport. NOTE: Remove the sample tray static brush, set aside to be reinstalled. 7.

REMOVE THE POST INVERTER TRANSPORT (Figure 3).

Section Name

REP 11-11

0/0/00 ?-362

Preliminary Working Document No Product Name Assigned

1 REMOVE THE TRANSPORT FROM THE ALIGNMENT PINS

2 MOVE THE TRANSPORT TOWARDS THE REAR

3

4

REMOVE THE BELT FROM LOWER PULLEY

CAUTION REMOVE THE TRANSPORT

Figure 3 Removing the Transport

Replacement NOTE: Reinstall the sample tray static brush. 1.

INSTALL THE POST INVERTER TRANSPORT (Figure 4).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-363

Section Name

REP 11-11

2 INSTALL BOLTS (3)

1 ENSURE THAT THE TAB IS POSITIONED IN THE SLOT

Figure 4 Installing the Transport 2.

REINSTALL THE STACKER PREREGISTRATION TRANSPORT.

REP 11-12 Post Inverter Transport Gear Bracket/Main Drive Belt/Lower Shaft Parts List on PL 11.26 Removal 1.

Section Name

REP 11-11

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE POST INVERTER TRANSPORT (REP 11-11).

4.

REMOVE THE SAMPLE TRAY GATE SOLENOID (REP 11-15).

5.

PREPARE TO REMOVE THE GEAR BRACKET (Figure 1).

0/0/00 ?-364

Preliminary Working Document No Product Name Assigned

3 REMOVE SPRING

4 LOOSEN IDLER MOUNTING SCREW AND REMOVE THE BELT FROM UPPER GEARS

1 LOOSEN SCREW AND REMOVE THE BEARING RETAINER

2 REMOVE SHAFT AND BELT

Figure 1 Preparing to Remove the Gear Bracket 1 NOTE: Scribe a line along the top of the Gear Bracket before removing the mounting hardware to ensure that it is reinstalled in the same position. 6.

REMOVE THE GEAR BRACKET (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-365

Section Name

REP 11-12

1 NOTE: REMOVE THE NUTS (2)

2 LOOSEN SCREW AND REMOVE THE BEARING RETAINER

3 MOVE SHAFT SLIGHTLY

4 REMOVE THE GEAR BRACKET

Figure 2 Removing the Gear Bracket 7.

REMOVE THE MAIN DRIVE BELT.

8.

IF NECESSARY, REMOVE THE LOWER SHAFT.

Replacement 1.

BEGIN TO REINSTALL THE GEAR BRACKET AND MAIN DRIVE BELT (Figure 3).

Section Name

REP 11-12

0/0/00 ?-366

Preliminary Working Document No Product Name Assigned

4 REINSTALL NUTS (2) BUT DO NOT TIGHTEN

5 REINSTALL THE BEARING RETAINER AND TIGHTEN THE SCREW

3 MOVE THE SHAFT AND THE BRACKET INTO MOUNTING POSITION

2 POSITION BRACKET ON THE SHAFT

1 ENSURE BELT IS ON THE PULLEY

Figure 3 Beginning to reinstall the Gear Bracket 2.

REINSTALL THE GEAR BRACKET (Figure 4).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-367

Section Name

REP 11-12

5 TIGHTEN NUTS (2)

4 REINSTALL SPRING

1 REINSTALL BELT ON UPPER GEARS AND TIGHTEN THE IDLER MOUNTING SCREW

3

2

REINSTALL RETAINER AND TIGHTEN SCREW

REINSTALL THE SHAFT AND BELT

Figure 4 Reinstalling the Gear Bracket 3.

REINSTALL THE SAMPLE TRAY GATE SOLENOID.

4.

REINSTALL THE POST INVERTER TRANSPORT.

5.

REINSTALL THE STACKER PREREGISTRATION TRANSPORT.

6.

CHECK/ADJUST THE SAMPLE TRAY GATE SOLENOID (ADJ 11-8).

REP 11-13 Post Inverter Upper Drive Shaft/Sample Tray Drive Shaft Parts List on PL 11.26 Removal 1.

Section Name

REP 11-12

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE POST INVERTER TRANSPORT (REP 11-11).

4.

REMOVE THE MAIN DRIVE BELT (REP 11-12).

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Preliminary Working Document No Product Name Assigned

5.

REMOVE THE RETAINER AND THE UPPER DRIVE SHAFT.

REP 11-14 Inverter Drive Belt/Short Shaft

6.

REMOVE THE RETAINER AND THE SAMPLE TRAY DRIVE SHAFT.

Parts List on PL 11.26 Removal

Replacement 1.

REINSTALL THE MAIN DRIVE BELT.

2.

REINSTALL THE POST INVERTER.

3.

REINSTALL THE STACKER PREREGISTRATION TRANSPORT.

4.

CHECK/ADJUST THE SAMPLE TRAY GATE SOLENOID (ADJ 11-8).

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE POST INVERTER TRANSPORT (REP 11-11).

4.

REMOVE THE INVERTER DRIVE BELT/SHORT SHAFT (Figure 1).

1 LOOSEN

2 REMOVE BEARING RETAINER

4 REMOVE BELT

3 REMOVE SHAFT

Figure 1 Removing the Drive Belt

Preliminary Working Document No Product Name Assigned

0/0/00 ?-369

Section Name

REP 11-13, REP 11-14

REP 11-15 Sample Tray Gate Solenoid (SOL1110)/Actuator Arm Assembly

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE POST INVERTER TRANSPORT (REP 11-11).

Parts List on PL 11.27 Removal

NOTE: It is necessary to remove just the mounting screws (2) when removing the solenoid only.

1.

4.

SWITCH OFF THE PRINTER POWER.

REMOVE THE SAMPLE TRAY GATE SOLENOID/ACTUATOR ARM ASSEMBLY (Figure 1).

1 REMOVE SPRING FROM THE POST

2 REMOVE SCREWS (2)

3 REMOVE THE SOLENOID AND ACTUATOR ARM ASSEMBLY

Figure 1 Removing the Solenoid

Replacement

REP 11-16 Sample Tray Gate/Sample Tray Gate Actuator

1.

REINSTALL THE SAMPLE TRAY GATE SOLENOID.

2.

REINSTALL THE POST INVERTER TRANSPORT.

Parts List on PL 11.27 Removal

3.

REINSTALL THE STACKER PREREGISTRATION TRANSPORT.

4.

CHECK/ADJUST THE SAMPLE TRAY GATE SOLENOID (ADJ 11-8).

Section Name

REP 11-15

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE POST INVERTER TRANSPORT (REP 11-11).

4.

POSITION THE POST INVERTER ON A FLAT SURFACE SO THAT THE PIVOTING ASSEMBLY IS FACING UPWARDS.

5.

REMOVE THE PIVOTING ASSEMBLY HINGE PIN AND PIVOTING ASSEMBLY.

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Preliminary Working Document No Product Name Assigned

6.

REMOVE THE SAMPLE TRAY GATE SOLENOID AND ACTUATOR ARM ASSEMBLY (REP 11-15).

7.

REMOVE THE SAMPLE TRAY GATE/SAMPLE TRAY GATE ACTUATOR (Figure 1).

2

3

REMOVE E-RING

REMOVE THE GATE ACTUATOR FROM THE GATE SHAFT

1 REMOVE CLIP

4 REMOVE GATE

Figure 1 Removing the Sample Tray Gate

Replacement

REP 11-20 Stacker Preregistration Transport

1.

REINSTALL THE SAMPLE TRAY GATE/SAMPLE TRAY GATE ACTUATOR.

2.

REINSTALL THE POST INVERTER TRANSPORT.

Parts List on PL 11.2 Removal

3.

REINSTALL THE STACKER PREREGISTRATION TRANSPORT.

4.

CHECK/ADJUST THE SAMPLE TRAY GATE SOLENOID (ADJ 11-8).

Preliminary Working Document No Product Name Assigned

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TOP COVER (REP 4-52).

3.

REMOVE THE INVERTER LEFT SIDE COVER (REP 4-54).

0/0/00 ?-371

Section Name

REP 11-16, REP 11-20

4.

REMOVE THE INVERTER REAR COVER.

5.

DISCONNECT THE STACKER PRE-REGISTRATION TRANSPORT CONNECTORS (Figure 1).

1 DISCONNECT

2 DISCONNECT

Figure 1 Disconnecting the Connectors 6.

REMOVE THE STACKER PRE-REGISTRATION TRANSPORT DRIVE BELT (Figure 2).

Section Name

REP 11-20

0/0/00 ?-372

Preliminary Working Document No Product Name Assigned

2 REMOVE THE BELT

1 LOOSEN THE IDLER MOUNTING SCREW

Figure 2 Removing the Drive Belt CAUTION Do not damage any existing harnesses when removing or installing the transport. 7.

REMOVE THE STACKER PRE-REGISTRATION TRANSPORT (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-373

Section Name

REP 11-20

1 REMOVE THE UPPER BOLTS (2)

2 LOOSEN THE LOWER BOLTS (2)

3 CAUTION REMOVE THE TRANSPORT

Figure 3 Removing the Transport

Section Name

REP 11-20

0/0/00 ?-374

Preliminary Working Document No Product Name Assigned

REP 11-21 Stacker Preregistration Transport Drive Pulley Assembly Parts List on PL 11.2 Removal 1.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE STACKER PREREGISTRATION TRANSPORT DRIVE BELT.

4.

POSITION THE STACKER PREREGISTRATION TRANSPORT ON A FLAT SURFACE WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.

5.

REMOVE THE DRIVE PULLEY ASSEMBLY (Figure 1).

SWITCH OFF THE PRINTER POWER.

2 REMOVE SCREWS (2)

1 LOOSEN SETSCREW

2 REMOVE SCREWS (2)

3 REMOVE PULLEY ASSEMBLY

Figure 1 Removing the Drive Pulley Assembly

Preliminary Working Document No Product Name Assigned

0/0/00 ?-375

Section Name

REP 11-21

REP 11-22 Prestacker Drive Roll Shaft Parts List on PL 11.2 Removal

REP 11-23 Stacker Preregistration Transport Flexible Drive Shaft

1.

SWITCH OFF THE PRINTER POWER.

Parts List on PL 11.2 Removal

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

1.

3.

REMOVE THE STACKER PREREGISTRATION TRANSPORT DRIVE BELT.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

4.

LOOSEN THE SCREW AND REMOVE THE DRIVE ROLL SHAFT RETAINER.

3.

5.

REMOVE THE PRESTACKER DRIVE ROLL SHAFT.

POSITION THE STACKER PREREGISTRATION TRANSPORT ON A FLAT SURFACE WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.

4.

LOOSEN THE SETSCREW LOCATED AT EACH END OF THE FLEXIBLE DRIVE SHAFT.

5.

REMOVE THE FLEXIBLE DRIVE SHAFT.

Section Name

REP 11-22, REP 11-23

0/0/00 ?-376

SWITCH OFF THE PRINTER POWER.

Preliminary Working Document No Product Name Assigned

REP 11-25 Post Inverter Sensor (Q1156) Parts List on PL 11.2 Removal

3 INSTALL SENSOR ON BRACKET

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

POSITION THE STACKER PREREGISTRATION TRANSPORT ON A FLAT SURFACE WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.

4.

REMOVE THE POST INVERTER SENSOR (Figure 1).

1 REMOVE NUTS (2)

1 CAUTION INSTALL ACTUATOR IN SLOT OF SHAFT

2

2

INSTALL CLIP ON SHAFT

REMOVE SENSOR AND MOUNTING BRACKET

Figure 2 Installing the Actuator Figure 1 Removing the Sensor

Replacement

2.

REINSTALL THE POST INVERTER SENSOR.

3.

REINSTALL THE STACKER PREREGISTRATION TRANSPORT.

CAUTION Ensure that the Actuator is positioned on the Sensor exactly as shown in Figure 2. 1.

IF A NEW SENSOR IS BEING INSTALLED, INSTALL THE ACTUATOR ON THE SENSOR (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-377

Section Name

REP 11-25

REP 11-26 Registration Assembly

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

Parts List on PL 11.2 Removal

3.

POSITION THE STACKER PREREGISTRATION TRANSPORT ON A FLAT SURFACE WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.

4.

REMOVE THE REGISTRATION ASSEMBLY (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

1 LOOSEN THE SETSCREW

3

2

REMOVE THE REGISTRATION ASSEMBLY

REMOVE NUTS (2)

Figure 1 Removing the Registration Assembly

Section Name

REP 11-26

0/0/00 ?-378

Preliminary Working Document No Product Name Assigned

REP 11-27 Stacker Preregistration Transport Corrugator Rolls Parts List on PL 11.3 Removal

Replacement NOTE: Replace the Corrugator Roll by pushing it on the drive shaft as far as it will go, then tighten the setscrew. 1.

REINSTALL THE CORRUGATOR ROLL.

1.

SWITCH OFF THE PRINTER POWER.

REP 11-28 Corrugator Roll Drive Shafts and Belts

2.

REMOVE THE STACKER PREREGISTRATION TRANSPORT (REP 11-20).

3.

REMOVE THE REGISTRATION ASSEMBLY (REP 11-26).

4.

LOSEN THE SETSCREW AND REMOVE THE CORRUGATOR ROLL.

Parts List on PL 11.3 Removal

3 LOOSEN THE RETAINER MOUNTING SCREW (3 PLACES)

4 REMOVE THE DRIVE SHAFTS AND BELTS

2

1

REMOVE THE SCREW AND SPRING RETAINER (2 PLACES)

NOTE: REMOVE THE CORRUGATOR ROLLS (3)

Figure 1 Removing the Shafts and Belts

Preliminary Working Document No Product Name Assigned

0/0/00 ?-379

Section Name

REP 11-27

Replacement NOTE: Replace the Corrugator Rolls by pushing it on the drive shaft as far as it will go, then tighten the setscrew. 1.

REP 11-29 Stacker Lead in Baffle/Trail Edge Assist Idler Roll/Disk Sheet Sensor (Q1106) (Purge and Bypass Transport) Parts List on PL 11.14 Removal

REINSTALL THE CORRUGATOR ROLLS.

1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

3.

REMOVE THE BYPASS GATE (REP 11-35).

4.

REMOVE THE BYPASS LEAD IN BAFFLE (REP 11-34) OR THE PURGE LEAD IN BAFFLE (REP 11-45).

5.

REMOVE THE STACKER LEAD IN BAFFLE AND THE TRAIL EDGE ASSIST IDLER ROLL (Figure 1).

4 REMOVE THE IDLER ROLL

2 REMOVE NUTS (3)

3 REMOVE BAFFLE

1 DISCONNECT SPRINGS (2)

Figure 1 Removing the Baffle and Idler Roll 6.

DISCONNECT AND REMOVE THE DISK SHEET SENSOR.

Section Name

REP 11-29

REP 11-30 Chute Baffle (IFS/FS)

0/0/00 ?-380

Preliminary Working Document No Product Name Assigned

Parts List on PL 11.16 Removal 3.

1.

SWITCH OFF THE PRINTER POWER.

2.

IF REMOVING THE IFS CHUTE BAFFLE, PERFORM THE FOLLOWING: a.

Open the Stacker Top Cover.

b.

Remove the IFS Front Cover (REP 4-49).

c.

Remove the Inverter Top Cover (REP 4-52).

d.

Remove the Inverter Rear Cover and the Stacker Upper Rear Cover. 4.

e.

Remove the Top Trim Strip.

f.

Continue with Step 4.

IF REMOVING THE FS CHUTE BAFFLE, PERFORM THE FOLLOWING: a.

Open both Stacker Top Covers.

b.

Remove the FS Front Cover (REP 4-49).

c.

Remove both Stacker Upper Rear Covers.

d.

Remove the Top Trim Strip.

e.

Continue with Step 4.

REMOVE THE CHUTE BAFFLE (Figure 1).

4

2

REMOVE THE CHUTE BAFFLE

REMOVE SCREW

1 REMOVE SCREWS (2)

3 REMOVE THE GROUND WIRE

Figure 1 Removing the Chute Baffle

Preliminary Working Document No Product Name Assigned

0/0/00 ?-381

Section Name

REP 11-30

REP 11-31 Bypass Transport Top Baffle Parts List on PL 11.14 Removal 1.

OPEN THE STACKER TOP COVER. CAUTION

Do not allow the Bypass Transport Top Baffle to drop after unlatching it from the Stacker Top Cover. 2.

UNLATCH AND LOWER THE BYPASS TRANSPORT TOP BAFFLE (Figure 1).

1 UNLATCH BYPASS TRANSPORT TOP BAFFLE

2 CAUTION LOWER THE BAFFLE

Figure 1 Unlatching the Baffle 3.

REMOVE THE BYPASS TRANSPORT TOP BAFFLE (Figure 2).

Section Name

REP 11-31

0/0/00 ?-382

Preliminary Working Document No Product Name Assigned

1

2 REMOVE SCREWS (4)

REMOVE THE GROUND WIRE

3 REMOVE THE BYPASS TRANSPORT TOP BAFFLE

Figure 2 Removing the Baffle

Replacement CAUTION Do not damage the Bypass Transport Sensor when reinstalling the Bypass Transport Top Baffle. 1.

REINSTALL THE BYPASS TRANSPORT TOP BAFFLE (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-383

Section Name

REP 11-31

1

2

CAUTION INSTALL THE BAFFLE

7

INSTALL SCREWS (4) AND SNUG

TIGHTEN THE SCREWS (4)

6 RAISE AND LOWER THE BAFFLE TO ENSURE THAT THERE IS NO INTERFERENCE

3 INSTALL THE GROUND WIRE AND NUT

5

4

ENSURE THAT THE BAFFLE TABS (2) ARE POSITIONED IN THE SLOTS ON THE TRANSPORT FRAME

RAISE AND LOWER THE BAFFLE TO ENSURE THAT IT CLEARS THE SENSOR

Figure 3 Reinstalling the Baffle

Section Name

REP 11-31

0/0/00 ?-384

Preliminary Working Document No Product Name Assigned

REP 11-32 Purge Transport Top Baffle

Replacement

Parts List on PL 11.15 Removal

1.

REINSTALL THE PURGE TRANSPORT TOP BAFFLE.

NOTE: Ensure that the Cable that secures the Baffle to the Top Cover is reinstalled exactly as shown in Figure 2.

1.

OPEN THE PURGE TRAY TOP COVER.

2.

REMOVE THE NUT AND DISCONNECT THE CABLE THAT SECURES THE PURGE TRANSPORT TOP BAFFLE TO THE PURGE TRAY TOP COVER.

3.

LOWER THE BAFFLE.

4.

REMOVE THE PURGE TRANSPORT TOP BAFFLE (Figure 1).

1

2

DISCONNECT THE GROUND WIRE

REMOVE THE SCREWS (2)

2.

RECONNECT THE BAFFLE TO THE TOP COVER (Figure 2).

1 NOTE: REINSTALL CABLE ON STUD

2 REINSTALL THE NUT AND TIGHTEN

Figure 2 Reinstalling the Cable

3 REMOVE THE PURGE TRANSPORT TOP BAFFLE

Figure 1 Removing the Baffle

Preliminary Working Document No Product Name Assigned

0/0/00 ?-385

Section Name

REP 11-32

REP 11-33 Bypass Transport/Purge Transport Parts List on PL 11.10 PL 11.12 Removal

2

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51).

3.

REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 1132).

REMOVE THE HARNESS FROM THE CLIP

NOTE: The Bypass Transport and Purge Transport are removed in the same manner. The transport shown in the following figures is the Bypass Transport. 4.

PREPARE TO REMOVE THE TRANSPORT (Figure 1).

1 3 ROTATE THE NUT UNTIL IT TOUCHES THE COUNTERBALANCE (2 PLACES)

DISCONNECT (P473) AND PULL THE HARNESS THROUGH FRAME

Figure 1 Preparing to Remove the Transport

Section Name

REP 11-33

0/0/00 ?-386

Preliminary Working Document No Product Name Assigned

CAUTION Do not damage the loose harness when removing the Transport. 5.

REMOVE THE TRANSPORT (Figure 2).

4 REMOVE NUTS (4)

5 DISCONNECT THE GROUND WIRE

6 CAUTION REMOVE THE TRANSPORT

3 CLOSE THE TRANSPORT

2

1

OPEN THE BYPASS TRANSPORT AND DISENGAGE THE DRIVE SHAFT

LOOSEN SETSCREW ON THE COUPLING

Figure 2 Removing the Transport

Replacement

REP 11-34 BYPASS LEAD IN BAFFLE

NOTE: Ensure that the tab located on the left rear corner of the Bypass Transport, is positioned in the slot on the weldment frame before tightening the four nuts.

Parts List on PL 11.11 Removal

1.

REINSTALL THE TRANSPORT.

1.

SWITCH OFF THE PRINTER POWER.

2.

CHECK/ADJUST THE TRANSPORT (ADJ 11-10).

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-387

Section Name

REP 11-33

3.

REMOVE THE BYPASS GATE (REP 11-35).

4.

RAISE THE BYPASS TRANSPORT.

5.

LOOSEN THE NUT SECURING THE A3 ROLLOVER SHAFT AND REMOVE THE SHAFT.

6.

REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLER ROLLS AND PARTIALLY REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.

7.

REMOVE THE BYPASS LEAD IN BAFFLE (Figure 1).

2 REMOVE THE NUTS (4)

3 LOWER THE TRANSPORT

1 REMOVE THE NUTS (2) AND THE BRACKET

4 REMOVE THE BAFFLE

Figure 1 Removing the Baffle

Section Name

REP 11-34

0/0/00 ?-388

Preliminary Working Document No Product Name Assigned

REP 11-35 Bypass/Purge Transport Gate

2.

RAISE THE APPROPRIATE STACKER TOP COVER.

Parts List on PL 11.14 PL 11.11 Removal

3.

PARTIALLY RAISE THE BYPASS OR PURGE TRANSPORT.

4.

REMOVE THE TRANSPORT GATE (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

3 SQUEEZE TABS AND PULL OUT THE GATE

2 UNWIND THE CABLE FROM THE GATE SHAFT (1 1/4 TURNS)

1 REMOVE SPRING END FROM POST

Figure 1 Removing the Bypass Gate

Replacement

REP 11-36 Disk Gate

NOTE: Ensure that the routing of the cable is started over the top of the Bypass Transport Gate Shaft and that the ball on the cable is positioned in the indent.

Parts List on PL 11.14 Removal

1.

1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

3.

REMOVE THE BYPASS GATE (REP 11-35).

4.

REMOVE THE BYPASS LEAD IN BAFFLE (REP 11-34) OR THE PURGE LEAD IN BAFFLE (REP 11-45).

5.

REMOVE THE DISK GATE (Figure 1).

REINSTALL THE TRANSPORT GATE.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-389

Section Name

REP 11-35

3 REMOVE THE DISK GATE

2 RAISE THE TRANSPORT

1 REMOVE SCREWS (2)

Figure 1 Removing the Disk Gate

Section Name

REP 11-36

0/0/00 ?-390

Preliminary Working Document No Product Name Assigned

REP 11-37 Bypass/Purge Transport Gate Solenoid (SOL1104) Parts List on PL 11.13 PL 11.11 Removal 1.

2.

RAISE THE APPROPRIATE STACKER TOP COVER.

3.

PARTIALLY RAISE THE BYPASS OR PURGE TRANSPORT.

4.

REMOVE THE LEFT DRIVES COVER AND MOUNTING BRACKET.

5.

REMOVE THE TRANSPORT GATE SOLENOID (Figure 1).

SWITCH OFF THE PRINTER POWER.

3 REMOVE SCREW

4 DISCONECT AND REMOVE THE SOLENOID

2 UNWIND THE CABLE FROM GATE SHAFT (1 1/4 TURNS)

1 REMOVE SPRING END FROM POST

Figure 1 Removing the Solenoid

Replacement NOTE: Ensure that the routing of the cable is started over the top of the Bypass Transport Gate Shaft and that the ball on the cable is positioned in the indent. 1.

REINSTALL THE TRANSPORT GATE SOLENOID.

REP 11-38 Trail Edge Assist Drive Shaft (Bypass or Purge Transport) Parts List on PL 11.11 PL 11.13 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.

NOTE: Scribe a line along the Rear Cover Mounting Bracket to ensure that it is positioned correctly when reinstalled. 3.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-391

PREPARE TO REMOVE THE TRAIL EDGE ASSIST DRIVE SHAFT (Figure 1).

Section Name

REP 11-37

1 REMOVE NUTS (4)

2 REMOVE THE COVER

3 NOTE: REMOVE THE SCREWS (2) AND THE REAR COVER MOUNTING BRACKET

Figure 1 Preparing to Remove the Shaft 4.

OPEN THE APPROPRIATE STACKER TOP COVER.

5.

REMOVE THE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET.

10. PUSH THE TRAIL EDGE ASSIST SHAFT TOWARDS THE REAR OF THE FS UNTIL IT IS REMOVED FROM THE FRONT FRAME OF THE TRANSPORT.

6.

RAISE THE TRANSPORT.

11. REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.

7.

REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.

CAUTION

8.

REMOVE THE SCREW THAT SECURES THE TRAIL EDGE ASSIST SHAFT RETAINER.

9.

PULL THE TRAIL EDGE ASSIST SHAFT FORWARD SLIGHTLY AND REMOVE THE RETAINER.

Section Name

REP 11-38, REP 11-39

Do not damage the Transport Drive Belt when removing the Trail Edge Assist Shaft. 12. REMOVE THE TRAIL EDGE ASSIST SHAFT THROUGH THE REAR OF THE FS.

0/0/00 ?-392

Preliminary Working Document No Product Name Assigned

REP 11-39 Trail Edge Assist Belts (Bypass or Purge Transport)

REP 11-40 Telescopic Drive Shaft Parts List on PL 11.11 PL 11.12 Removal

Parts List on PL 11.14 Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

1.

OPEN THE APPROPRIATE STACKER TOP COVER.

2.

RAISE THE BYPASS TRANSPORT OR THE PURGE TRANSPORT. CAUTION

3.

REMOVE THE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET.

Do not bend the Telescopic Drive Shaft during removal or installation.

4.

RAISE THE TRANSPORT.

3.

5.

REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.

6.

REMOVE THE SCREW THAT SECURES THE TRAIL EDGE ASSIST SHAFT RETAINER.

7.

PULL THE TRAIL EDGE ASSIST SHAFT FORWARD SLIGHTLY AND REMOVE THE RETAINER.

8.

PUSH THE TRAIL EDGE ASSIST SHAFT TOWARDS THE REAR OF THE FS UNTIL IT IS REMOVED FROM THE FRONT FRAME OF THE TRANSPORT.

9.

REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.

REMOVE THE TELESCOPIC DRIVE SHAFT (Figure 1).

3 CAUTION REMOVE DRIVE SHAFT

2 LOOSEN THE SETSCREWS

1 ROTATE BELT TO ACCESS THE SETSCREWS

Figure 1 Removing the Drive Shaft

Preliminary Working Document No Product Name Assigned

0/0/00 ?-393

Section Name

REP 11-40

REP 11-41 Middle Drive Shaft (Bypass or Purge Transport)

4.

Parts List on PL 11.11 PL 11.13 Removal

REMOVE THE APPROPRIATE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET.

5.

REMOVE THE APPROPRIATE TRANSPORT (REP 11-33).

NOTE: Place the Transport on a flat surface with the Trail Edge Assist Belts facing upwards.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51).

6.

REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.

3.

REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 1132).

7.

REMOVE THE MIDDLE DRIVE SHAFT (Figure 1).

6 REMOVE THE RETAINER

5 LOOSEN IDLER AND REMOVE BELT FROM REAR OF SHAFT

7 REMOVE SHAFT

4 REMOVE NUTS (2) AND BRACKET

3 REMOVE NUTS (2) AND BRACKET

1 LOOSEN IDLER

2 REMOVE BELT

Figure 1 Removing the Drive Shaft

Section Name

REP 11-41

0/0/00 ?-394

Preliminary Working Document No Product Name Assigned

REP 11-42 Right Drive Shaft (Bypass or Purge Transport)

3.

Parts List on PL 11.11 PL 11.13 Removal

4.

REMOVE THE APPROPRIATE TRANSPORT'S RIGHT DRIVES COVER.

5.

REMOVE THE APPROPRIATE TRANSPORT (REP 11-33).

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51).

REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 1132).

NOTE: Place the Transport on a flat surface with the Trail Edge Assist Belts facing upwards. 6.

REMOVE THE RIGHT DRIVE SHAFT (Figure 1).

3 LOOSEN IDLER AND REMOVE BELT FROM REAR OF SHAFT

4 REMOVE THE RETAINER

5 REMOVE SHAFT

1 LOOSEN IDLER

2 REMOVE BELT VIEW SHOWN WITH TRAIL EDGE ASSIST BELTS REMOVED

Figure 1 Removing the Drive Shaft

Preliminary Working Document No Product Name Assigned

0/0/00 ?-395

Section Name

REP 11-42

REP 11-43 Left Drive Shaft (Bypass or Purge Transport)

4.

Parts List on PL 11.11 PL 11.13 Removal

REMOVE THE APPROPRIATE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET.

5.

REMOVE THE APPROPRIATE TRANSPORT (REP 11-33).

NOTE: Place the Transport on a flat surface with the Trail Edge Assist Belts facing upwards.

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER TOP COVER (REP 4-50) OR (REP 4-51).

6.

REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLERS.

3.

REMOVE THE APPROPRIATE TRANSPORT TOP BAFFLE (REP 11-31) OR (REP 1132).

7.

REMOVE THE LEFT DRIVE SHAFT (Figure 1).

2

3

REMOVE BELT

REMOVE CLIP AND GEAR

4 REMOVE NUTS (2) AND BRACKET

5 REMOVE THE RETAINER

1 LOOSEN IDLER

6 REMOVE SHAFT

Figure 1 Removing the Drive Shaft

Section Name

REP 11-43

0/0/00 ?-396

Preliminary Working Document No Product Name Assigned

REP 11-44 Purge Output Drive Shaft

3.

REMOVE THE PURGE TRANSPORT TOP BAFFLE (REP 11-31).

Parts List on PL 11.12 Removal

4.

REMOVE THE PURGE TRANSPORT'S LEFT DRIVES COVER AND MOUNTING BRACKET.

5.

REMOVE THE PURGE LEAD IN BAFFLE (REP 11-45).

1.

SWITCH OFF THE PRINTER POWER.

6.

REMOVE THE PURGE OUTPUT DRIVE SHAFT (Figure 1).

2.

REMOVE THE STACKER REAR TOP COVER (REP 4-51).

3 LOOSEN SCREW AND REMOVE THE RETAINER

4 REMOVE SHAFT

1 LOOSEN IDLER

2 REMOVE BELT

Figure 1 Removing the Shaft 7.

(Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-397

Section Name

REP 11-44

3 LOOSEN SCREW AND REMOVE THE RETAINER

4 REMOVE SHAFT

1 LOOSEN IDLER

2 REMOVE BELT

Figure 2 Removing the Shaft

Section Name

REP 11-44

0/0/00 ?-398

Preliminary Working Document No Product Name Assigned

REP 11-45 Purge Lead in Baffle

4.

Parts List on PL 11.12 Removal

LOOSEN THE MOUNTING SCREW THAT SECURES THE PURGE TRANSPORT SENSOR (Q1164).

5.

RAISE THE PURGE TRANSPORT.

6.

LOOSEN THE NUT SECURING THE A3 ROLLOVER SHAFT AND REMOVE THE SHAFT.

7.

REMOVE THE FOUR TRAIL EDGE ASSIST BELT IDLER ROLLS AND PARTIALLY REMOVE THE FOUR TRAIL EDGE ASSIST BELTS.

8.

REMOVE THE PURGE LEAD IN BAFFLE (Figure 1).

1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE STACKER PURGE TRAY TOP COVER.

3.

REMOVE THE PURGE TRANSPORT'S LEFT DRIVES COVER.

1 REMOVE NUTS

3 LOWER THE TRANSPORT

2 REMOVE THE BAFFLE

Figure 1 Removing the Purge Lead In Baffle

Replacement

REP 11-46 Inverter Transport Motor Fan

1.

REINSTALL THE PURGE LEAD IN BAFFLE.

2.

BIAS THE PURGE TRANSPORT SENSOR UPWARD AGAINST THE BOTTOM OF THE PURGE TRANSPORT LEAD IN BAFFLE AND TIGHTEN THE MOUNTING SCREW.

Parts List on PL 11.22 Removal

Preliminary Working Document No Product Name Assigned

1.

SWITCH OFF THE PRINTER POWER, THE CIRCUIT BREAKERS AND DISCONNECT ALL POWER CORDS.

2.

OPEN THE INVERTER DOOR.

3.

REMOVE THE INVERTER LEFT SIDE COVER (REP 11-11).

0/0/00 ?-399

Section Name

REP 11-45

4.

DISCONNECT THE INVERTER MOTOR FAN POWER CONNECTOR.

REP 11-47 Blower Assembly

5.

LOOSEN THE SCREWS (2) WHICH SECURE THE FAN BRACKET ASSEMBLY AND SLIDE THE BRACKET ASSEMBLY OFF THE MOTOR (PL 11.22).

Removal 1.

CAUTION Before removing the Fan from the mounting Bracket, note the orientation of the Fan and the direction of the air flow. 6.

REMOVE THE FAN MOUNTING SCREWS (4) AND THE FAN FROM THE BRACKET.

Replacement 1.

ENSURE THE NEW FAN IS INSTALLED ONTO THE MOUNTING BRACKET WITH THE AIR FLOW IN THE PROPER DIRECTION.

2.

REINSTALL THE MOUNTING BRACKET ASSEMBLY ONTO THE INVERTER TRANSPORT MOTOR AND RECONNECT THE FAN POWER CONNECTOR.

3.

REAPPLY POWER AND CHECK THE PRINTER FOR PROPER OPERATION.

SWITCH OFF THE PRINTER POWER, THE CIRCUIT BREAKERS AND DISCONNECT ALL POWER CORDS.

2.

OPEN THE INVERTER DOOR.

3.

REMOVE THE AIR HOSE CLAMP AND AIR HOSE AT THE BLOWER ASSEMBLY.

4.

DISCONNECT BLOWER ASSEMBLY FROM WIRING HARNESS.

5.

REMOVE THE BLOWER ASSEMBLY, FIGURE 1.

2. LIFT BLOWER ASSEMBLY UP AND OUT OF MACHINE

1. REMOVE NUTS (2)

INBOARD PULLEY (50 HZ)

OUTBOARD PULLEY (60 HZ)

Figure 1 REMOVING BLOWER ASSEMBLY.

Section Name

REP 11-46, REP 11-47

6.

REMOVE O-RING BELT FROM BLOWER ASSEMBLY

7.

SEPERATE BLOWER FROM BRACKET.

0/0/00 ?-400

Preliminary Working Document No Product Name Assigned

Replacement 1.

INSTALL BLOWER ASSEMBLY USING REVERSE ORDER OF THE REMOVAL PROCEDURE. NOTE: See Figure 1 for correct O-Ring position.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-401

Section Name

REP 11-47

Section Name

REP 11-47

0/0/00 ?-402

Preliminary Working Document No Product Name Assigned

REP 11-58 Pallet Lift Frame

2.

Parts List on PL 11.17 Removal

3.

SWITCH OFF THE PRINTER POWER.

4.

REMOVE THE STACKER FRONT COVER (REP 4-49).

NOTE: Be prepared to press the Stop button when the Elevator is just below the halfway down position. 1.

PRESS THE Stop BUTTON WHEN THE ELEVATOR IS JUST BELOW THE HALFWAY DOWN POSITION.

5.

REMOVE THE MAIN PALLET.

6.

REMOVE THE PALLET LIFT FRAME (Figure 1).

ENTER dC330. SELECT [11X2], [Elevator DN] AND PRESS THE Continue BUTTON.

1

3

2

REMOVE THE LIFT FRAME

REMOVE SCREW AND BRACKET (4 PLACES)

REMOVE SCREWS (2) AND THE RETAINER

Figure 1 Removing the Lift Frame

Replacement

REP 11-59 Stacker Elevator Motor (MOT1106)

1.

REINSTALL THE PALLET LIFT FRAME.

2.

CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31).

Parts List on PL 11.19 Removal 1.

Preliminary Working Document No Product Name Assigned

ENSURE THAT THE STACKER ELEVATOR IS IN THE RAISED POSITION.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE STACKER FRONT COVER (REP 4-49).

4.

PULL OUT THE PALLET BASE.

5.

REMOVE THE ELEVATOR BASE COVER.

6.

REMOVE THE STACKER ELEVATOR MOTOR (Figure 1).

0/0/00 ?-403

Section Name

REP 11-58

6 DISCONNECT AND REMOVE MOTOR

1 LOOSEN IDLER

5 REMOVE SCREWS (4)

2 DISCONNECT ONE END OF IDLER SPRING

4 DISCONNECT

3 REMOVE THE DRIVE BELT FROM MOTOR AND IDLER

Figure 1 Removing the Motor

Replacement

REP 11-60 Stacker Elevator Drive Belt

NOTE: Ensure that the Drive Belt is positioned around all of the pulleys and idlers. 1.

REINSTALL THE STACKER ELEVATOR DRIVE BELT.

Parts List on PL 11.18 Removal

2.

CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31).

NOTE: The HCT is pulled out to aid in accessing the Stacker Elevator Drive Belt.

Section Name

REP 11-60

1.

UNLATCH THE APPROPRIATE HCT.

2.

ENSURE THAT THE STACKER ELEVATOR IS IN THE RAISED POSITION.

3.

SWITCH OFF THE PRINTER POWER.

4.

REMOVE THE STACKER FRONT COVER (REP 4-49).

5.

PULL OUT THE PALLET BASE.

6.

REMOVE THE ELEVATOR BASE COVER.

7.

REMOVE THE STACKER ELEVATOR DRIVE BELT (Figure 1).

0/0/00 ?-404

Preliminary Working Document No Product Name Assigned

5

1

REMOVE THE BELT

LOOSEN IDLER

4

3

2

REMOVE RETAINER

REMOVE RETAINER

DISCONNECT ONE END OF IDLER SPRING

Figure 1 Removing the Drive Belt

Replacement

REP 11-61 Lead Screw

NOTE: Ensure that the Drive Belt is positioned around all of the pulleys and idlers. 1.

REINSTALL THE STACKER ELEVATOR DRIVE BELT.

Parts List on PL 11.18 Removal

2.

CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31).

1.

REMOVE THE MAIN PALLET.

2.

REMOVE THE PALLET LIFT FRAME (REP 11-58).

Preliminary Working Document No Product Name Assigned

3.

PULL OUT THE PALLET BASE.

4.

IF REMOVING EITHER OF THE RIGHT LEAD SCREWS, REMOVE THE ELEVATOR BASE COVER.

0/0/00 ?-405

Section Name

REP 11-61

5.

IF REMOVING THE LEFT REAR LEAD SCREW, REMOVE THE CONTAINER SIZE SENSORS BRACKET FROM THE FRAME.

NOTE: Although some of the lower retainers are different, all of the Lead Screws are removed in the same manner. 6.

REMOVE THE LEAD SCREW (Figure 1).

3 REMOVE THE UPPER MOUNTING SCREW

4 LIFT UP THE LEAD SCREW UNTIL THE LOWER BEARING CLEARS THE FRAME

5 REMOVE THE LEAD SCREW

2 NOTE: REMOVE THE LOWER MOUNTING SCREW AND RETAINER

1 LOOSEN IDLER

Figure 1 Removing the Lead Screw

Replacement 1.

REINSTALL THE LEAD SCREW.

2.

REINSTALL THE LIFT FRAME.

3.

CHECK/ADJUST THE PALLET LIFT FRAME PARALLELISM (ADJ 11-31).

REP 11-62 Stacker Overtravel Down Switch (S1141)/ Stacker Elevator Down Sensor (Q1125) Parts List on PL 11.18 Removal 1.

Section Name

REP 11-62, REP 11-63

0/0/00 ?-406

SWITCH OFF THE PRINTER POWER. Preliminary Working Document No Product Name Assigned

2.

OPEN THE APPROPRIATE STACKER DOORS.

REP 11-63 Stacker Overtravel up Switch (S1140)

3.

REMOVE THE STACKER REAR DRIVES INNER COVER (PL 11.21

4.

LOOSEN THE TWO SCREW SECURING THE LEFT SIDE OF THE STACKER REAR INNER COVER (PL 11.21

Parts List on PL 11.18 Removal

5.

REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.

1.

SWITCH OFF THE PRINTER POWER.

SWING OUT THE APPROPRIATE STACKER PWB PANEL.

2.

OPEN THE APPROPRIATE STACKER DOORS.

6.

CAUTION Do not damage any harnesses when removing the Stacker Rear Inner Cover. 7.

LOOSEN THE TWO SCREWS SECURING THE RIGHT SIDE OF THE STACKER REAR INNER COVER AND REMOVE THE COVER.

NOTE: The following step is performed to ensure that the sensor is not damaged when removing the Stacker Overtravel Down Switch. If the sensor is being replaced, disconnect and remove it at this time. 8.

REMOVE THE STACKER ELEVATOR DOWN SENSOR (Q1125) FROM THE MOUNTING BRACKET. CAUTION

3.

REMOVE THE STACKER REAR DRIVES INNER COVER (PL 11.21

4.

LOOSEN THE TWO SCREW SECURING THE LEFT SIDE OF THE STACKER REAR INNER COVER (PL 11.21

5.

REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.

6.

SWING OUT THE APPROPRIATE STACKER PWB PANEL. CAUTION

Do not damage any harnesses when removing the Stacker Rear Inner Cover. 7.

LOOSEN THE TWO SCREWS SECURING THE RIGHT SIDE OF THE STACKER REAR INNER COVER AND REMOVE THE COVER.

8.

DISCONNECT AND REMOVE THE STACKER OVERTRAVEL UP SWITCH.

Do not allow the left mounting screw to drop into the lower transports. NOTE: Reference to the mounting screws and mounting bracket are made from the rear of the FS. 9.

REMOVE THE LEFT MOUNTING SCREW SECURING THE SWITCH MOUNTING BRACKET.

10. LOOSEN THE RIGHT MOUNTING SCREW AND ROTATE THE MOUNTING BRACKET CLOCKWISE UNTIL BOTH SWITCH MOUNTING SCREWS CAN BE ACCESSED. 11. DISCONNECT AND REMOVE THE STACKER OVERTRAVEL DOWN SWITCH.

Replacement NOTE: Align the mounting brackets left mounting hole and tighten the right mounting screw before reinstalling the left mounting screw. 1.

REINSTALL THE STACKER OVERTRAVEL DOWN SWITCH.

2.

REINSTALL THE ELEVATOR DOWN SENSOR ON THE MOUNTING BRACKET.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-407

Section Name

REP 11-62, REP 11-63

REP 11-64 Container Size Sensors (Q1126, Q1127, Q1128) Parts List on PL 11.18 Removal

3 INSTALL THE SHORT SCREW

1.

ENTER dC330. SELECT [11x2], [Elevator DN] AND PRESS Continue.

2.

WHEN THE ELEVATOR IS IN THE DOWN POSITION, OPEN THE STACKER DOORS AND REMOVE THE MAIN PALLET.

3.

CLOSE THE STACKER DOORS.

4.

SELECT [Elevator UP], AND PRESS Start.

5.

WHEN THE PALLET LIFT FRAME IS IN THE UP POSITION, SWITCH OFF THE PRINTER POWER.

6.

OPEN THE STACKER DOORS.

7.

DISCONNECT THE CONTAINER SIZE SENSOR AND REMOVE THE SENSOR AND MOUNTING BRACKET ASSEMBLY.

1 INSTALL SENSOR AND ALIGNMENT BLOCK

NOTE: Retain one Sensor mounting screw for future use. 8.

REMOVE THE CONTAINER SIZE SENSOR FROM THE OLD MOUNTING BRACKET AND DISCARD THE BRACKET (Figure 1).

2 INSTALL THE LONG SCREW

SENSOR ALIGNMENT BLOCK

Figure 1 Removing the Container Size Sensor

Replacement NOTE: Ensure that the top surface of the Sensor is flush with the top surface of the Sensor Alignment Block. Ensure that the top surface of the Sensor is parallel with the top edge of the new Mounting Bracket.

Section Name

REP 11-64

1.

INSTALL THE CONTAINER SIZE SENSOR, ALIGNMENT BLOCK AND HARNESS CLIP ONTO THE NEW MOUNTING BRACKET.

2.

REINSTALL THE SENSOR AND THE NEW MOUNTING ASSEMBLY INTO THE FEEDER STACKER. DO NOT TIGHTEN THE BRACKET MOUNTING SCREWS AT THIS TIME.

0/0/00 ?-408

Preliminary Working Document No Product Name Assigned

3.

INSTALL THE MAIN PALLET ONTO THE PALLET BASE.

REP 11-68 Stack Height Sensor (Q1122)

4.

CHECK/ADJUST THE CONTAINER SIZE SENSORS (ADJ 11-32).

Parts List on PL 11.29 Removal 1.

ENTER dC330. SELECT [11X2], [Elevator DN], AND PRESS THE Continue BUTTON.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE STACKER FRONT COVER (REP 4-49).

4.

REMOVE THE STACK HEIGHT SENSOR (Figure 1).

2 1

DISCONNECT

REMOVE SCREW

3 REMOVE NUTS (2)

5 REMOVE THE STACK HEIGHT SENSOR

4 DISCONNECT

Figure 1 Removing the Stack Height Sensor

Replacement Preliminary Working Document No Product Name Assigned

1.

0/0/00 ?-409

INSTALL THE STACK HEIGHT SENSOR.

Section Name

REP 11-64, REP 11-68

2.

CHECK/ADJUST THE STACK HEIGHT (ADJ 11-27).

REP 11-70 Back Guide Parts List on PL 11.6 PL 11.7 Removal 1.

OPEN THE STACKER TOP COVER.

2.

RAISE THE BYPASS TRANSPORT OR THE PURGE TRANSPORT.

3.

PLACE A CHEATER IN THE STACKER TOP COVER INTERLOCK SWITCH. CAUTION

Do not manually extend the Back Guide. 4.

ENTER dC203. SELECT [Edge Guides], [Stacker X], AND [Back Guide].

5.

PRESS THE Continue BUTTON. WHEN THE BACK GUIDE IS FULLY EXTENDED, PRESS THE Stop BUTTON.

6.

SWITCH OFF THE PRINTER POWER.

7.

REMOVE THE STACKER TOP COVER (REP 4-50) OR (REP 4-51).

8.

IF REMOVING THE BACK GUIDE FROM THE IFS, REMOVE THE BYPASS TRANSPORT TOP BAFFLE (REP 11-31).

9.

RAISE THE BYPASS/PURGE TRANSPORT.

10. PREPARE THE REAR OF THE BACK GUIDE FOR REMOVAL (Figure 1).

2

1

DISCONNECT

DISCONNECT

Figure 1 Preparing the Back Guide Section Name

REP 11-68, REP 11-70

0/0/00 ?-410

Preliminary Working Document No Product Name Assigned

CAUTION Do not damage the Back Guide or any stacking components when removing the Back Guide. The Back Guide is very delicate when it is fully extended. NOTE: The Back Guide will have to be removed through the Stacker Doors. 11. REMOVE THE BACK GUIDE (Figure 2).

1 REMOVE SCREWS (2)

NOTE: ON THE NEW STYLE REAR GUIDES, THE SCREWS ARE REMOVED FROM UNDER THE GUIDE.

BYPASS TRANSPORT SHOWN REMOVED FOR CLARITY

2 CAUTION REMOVE THE GUIDE

Figure 2 Removing the Back Guide

REP 11-71 Front Guide Parts List on PL 11.8 Removal 1.

SWITCH OFF PRINTER POWER.

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

3.

RAISE THE BYPASS TRANSPORT OR THE PURGE TRANSPORT.

4.

REMOVE THE STACKER FRONT COVER (REP 4-49).

5.

REMOVE THE FRONT GUIDE (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-411

Section Name

REP 11-70

4

1

REMOVE THE FRONT GUIDE

LOOSEN SETSCREWS (2) AND DISENGAGE COUPLING FROM THE MOTOR DRIVE SHAFT

3

2

REMOVE SCREWS (2)

DISCONNECT

Figure 1 Removing the Front Guide

Replacement

REP 11-72 Right Guide

NOTE: Ensure that the coupling is equally engaged on both shafts.

Parts List on PL 11.9 Removal

1.

REINSTALL THE FRONT GUIDE.

Section Name

REP 11-72

1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

3.

RAISE THE BYPASS TRANSPORT OR THE PURGE TRANSPORT.

4.

REMOVE THE APPROPRIATE STACKER FRONT COVER (REP 4-49).

5.

REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.

6.

IF REMOVING THE RIGHT GUIDE FROM STACKER B, REMOVE THE STACKER UPPER RIGHT SIDE COVER.

7.

PREPARE TO REMOVE THE RIGHT GUIDE (Figure 1).

0/0/00 ?-412

Preliminary Working Document No Product Name Assigned

1 LOOSEN SCREW FRONT AND REAR

2 REMOVE SCREWS (2)

Figure 1 Preparing the Right Guide NOTE: If removing the Right Guide from Stacker A, the Stacker Right Inner Cover must be removed to access the connectors. 8.

DISCONNECT THE CONNECTORS AND REMOVE THE GUIDE (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-413

Section Name

REP 11-72

2 REMOVE THE GUIDE

1 NOTE: DISCONNECT (3)

Figure 2 Disconnecting the Connectors

Replacement CAUTION Do not damage the Right Guide Connectors during the reinstallation. NOTE: Ensure that the Right Guide is properly positioned under the Spring Loaded Bracket. 1.

REINSTALL THE RIGHT GUIDE (Figure 3).

Section Name

REP 11-72

0/0/00 ?-414

Preliminary Working Document No Product Name Assigned

1 RECONNECT THE CONNECTORS

2 NOTE: POSITION THE RIGHT GUIDE UNDER SPRING LOADED BRACKET

4 PUSH DOWN AND TIGHTEN SCREW FRONT AND REAR

3 INSTALL SCREWS (2)

Figure 3 Reinstalling the Right Guide 2.

CHECK/ADJUST THE RIGHT GUIDE (ADJ 11-28).

REP 11-73 Disk Stepper Motor Removal 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER REAR TOP COVER (REP 4-53). CAUTION

Do not allow the screws to drop into the machine during removal. 3.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-415

REMOVE THE DISK STEPPER MOTOR (Figure 1).

Section Name

REP 11-72

2 CAUTION REMOVE SCREWS (4)

3 REMOVE THE STEPPER MOTOR

1 DISCONNECT (P497)

Figure 1 Removing the Stepper Motor

Replacement NOTE: Ensure that the coupling on the Stepper Motor Shaft aligns with the spacer and the coupling on the Disk Shaft. 1.

REPLACE THE DISK STEPPER MOTOR.

Section Name

REP 11-73

0/0/00 ?-416

Preliminary Working Document No Product Name Assigned

REP 11-74 Right Guide Tamper Motor (MOT1113)

2.

REMOVE THE APPROPRIATE RIGHT GUIDE (REP 11-72).

Parts List on PL 11.9 Removal

3.

ROTATE THE BELT PULLEYS AND FULLY EXTEND THE RIGHT GUIDE.

1.

4.

NOTE: Ensure that the Link is not lost when removing the Moving Wall Assembly.

SWITCH OFF THE PRINTER POWER.

REMOVE THE MOVING WALL ASSEMBLY (Figure 1).

2 NOTE: REMOVE THE MOVING WALL ASSEMBLY

1 LOOSEN NUTS (4)

Figure 1 Removing the Moving Wall Assembly 5.

REMOVE THE THREE SCREWS SECURING THE TAMPER MOTOR.

6.

CUT THE CABLE TIE SECURING THE TAMPER MOTOR HARNESS AND DISCONNECT THE CONNECTOR.

7.

REMOVE THE RIGHT GUIDE TAMPER MOTOR.

Replacement CAUTION Route the harnesses exactly as shown in the following Figures. Damage to the harnesses will occur if the harnesses are not routed exactly as shown. NOTE: It will be necessary to route the Coil Cord Harness under the tab and behind the Tamper Motor before the motor can be positioned in the housing. 1.

INSTALL THE RIGHT GUIDE TAMPER MOTOR (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-417

Section Name

REP 11-74

1 NOTE: ROUTE THE COIL CORD HARNESS BEHIND THE MOTOR AND UNDER THE TAB

2 POSITION THE MOTOR IN THE HOUSING AND REINSTALL SCREWS (3)

Figure 2 Installing the Motor CAUTION Do not allow the harness to interfere with any portion of the Right Guide during movement. Extend and retract the Right Guide after securing the harnesses to ensure that there is not any interference. NOTE: Ensure that the Tamper Motor Harness is routed through the push in cable tie. 2.

SECURE THE HARNESS (Figure 3).

Section Name

REP 11-74

0/0/00 ?-418

Preliminary Working Document No Product Name Assigned

REP 11-75 Right Guide Drive Belt 1

2 CONNECT

NOTE: ROUTE TAMPER MOTOR HARNESS THROUGH PUSH IN CABLE TIE

Parts List on PL 11.9 Removal 1.

SWITCH OFF THE PRINTER POWER.

NOTE: It is necessary to remove the Right Guide to ensure that the Housings are square after the Drive Belt is reinstalled. 2.

REMOVE THE RIGHT GUIDE (REP 11-72).

NOTE: It is necessary to scribe a line along the Drive Belt Idler to ensure that it is repositioned in the same location. 3.

SCRIBE A LINE ALONG THE DRIVE BELT IDLER.

4.

LOOSEN THE IDLER.

5.

REMOVE THE DRIVE BELT.

Replacement NOTE: Do not allow one Drive Belt Pulley to rotate more than the other when installing the Drive Belt. 1.

REINSTALL THE DRIVE BELT.

2.

TENSION THE DRIVE BELT AND TIGHTEN THE IDLER.

3.

CHECK THAT THE RIGHT GUIDE HOUSINGS ARE SQUARE (Figure 1).

3 CAUTION INSTALL CABLE TIE TO SECURE HARNESS

Figure 3 Securing the Harness NOTE: Ensure that the Link is engaged with the motor. 3.

REINSTALL THE RIGHT GUIDE MOVING WALL ASSEMBLY.

4.

REINSTALL THE RIGHT GUIDE.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-419

Section Name

REP 11-74, REP 11-75

REP 11-85 Disk Module Weldment (IFS) Parts List on PL 11.30 Removal

CHECK: THAT THE SMALL HOUSING IS SQUARE WITH THE MAIN HOUSING +/-1mm

NOTE: Two CSE's will be required to perform this removal. 1.

EXTEND THE BACK GUIDE BY PERFORMING THE FOLLOWING:

NOTE: The following step is performed to ensure that the Back Guide is not manually extended. The Back Guide can be damaged if it is manually extended.

MAIN HOUSING

SMALL HOUSING

a.

Open the Stacker Top Cover.

b.

Raise the Bypass Transport.

c.

Place a Cheater in the Stacker Top Cover Interlock Switch.

d.

Enter dC203. Select [Edge Guides], [Stacker X], and [Back Guide].

e.

Press the Continue button. When the Back Guide is fully extended, press the Stop button.

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE STACKER TOP COVER (REP 4-50).

4.

REMOVE BOTH OF THE STACKER FRONT COVERS (REP 4-49).

5.

REMOVE THE INVERTER TOP COVER (REP 4-52).

6.

OPEN THE STACKER PURGE TRAY TOP COVER.

7.

REMOVE THE BYPASS TRANSPORT TOP BAFFLE (REP 11-31).

8.

REMOVE THE TELESCOPIC DRIVE SHAFT (REP 11-40).

9.

REMOVE THE BYPASS TRANSPORT (REP 11-33).

10. REMOVE THE IFS AND FS CHUTE BAFFLE (REP 11-30). 11. REMOVE THE IFS UPPER TRANSPORTS DRIVE BELTS (PL 11.29 12. DISCONNECT THE IFS DISK STEPPER MOTOR (REP 11-73).

Figure 1 Checking the Right Guide Squareness

CAUTION 4.

IF NECESSARY, SQUARE THE HOUSINGS BY ROTATING THE APPROPRIATE DRIVE BELT PULLEY.

Do not remove the Bypass Transport Left Counterbalance. Ensure that it is the Stacker Top Cover Left Counterbalance that is removed. 13. REMOVE THE STACKER TOP COVER LEFT COUNTERBALANCE (PL 4.14 14. REMOVE THE BACK GUIDE (REP 11-70). 15. REMOVE THE FRONT GUIDE (REP 11-71). 16. REMOVE THE RIGHT GUIDE (REP 11-72). 17. REMOVE THE STACK HEIGHT SENSOR (Q1122) (REP 11-68). 18. REMOVE THE DISK MODULE WELDMENT (Figure 1).

Section Name

REP 11-75, REP 11-85

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Preliminary Working Document No Product Name Assigned

6

7

1

DISCONNECT SENSOR HARNESS (P460)

REMOVE PUSH IN CABLE TIE

DISCONNECT (2)

8 REMOVE SCREWS (4)

2 DISCONNECT

9 REMOVE WELDMENT

4 DISCONNECT THE INTERLOCK AND REMOVE BRACKET

5 REMOVE SHAFT

3 REMOVE LATCH BRACKET

Figure 1 Removing the Disk Module Weldment

Replacement

e.

1.

f.

Back Guide (ADJ 11-29).

g.

Right Guide (ADJ 11-28).

2. 3.

REMOVE THE FRONT TAMPER MOTOR AND CAPACITOR (C1106) FROM THE OLD DISK MODULE WELDMENT AND INSTALL THEM ON THE NEW WELDMENT.

Stack Height (ADJ 11-27).

REINSTALL THE DISK MODULE WELDMENT AND COMPONENTS. CHECK/ADJUST THE FOLLOWING: a.

Bypass Transport (ADJ 11-10).

b.

Upper Transports Drive Belts.

c.

Disk Home Position (ADJ 11-25).

d.

Disk Gate Height (ADJ 11-26).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 11-85

REP 11-86 Disk Module Weldment (FS) Parts List on PL 11.31 Removal NOTE: Two CSE's will be required to perform this removal. 1.

EXTEND THE BACK GUIDE BY PERFORMING THE FOLLOWING:

NOTE: The following step is performed to ensure that the Back Guide is not manually extended. The Back Guide can be damaged if it is manually extended.

2.

a.

Open the Stacker Top Cover.

b.

Raise the Bypass Transport.

c.

Place a Cheater in the Stacker Top Cover Interlock Switch.

d.

Enter dC203. Select [Edge Guides], [Stacker X], and [Back Guide].

e.

Press the Continue button. When the Back Guide is fully extended, press the Stop button.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE STACKER PURGE TRAY TOP COVER (REP 4-51).

4.

REMOVE BOTH OF THE STACKER FRONT COVERS (REP 4-49).

5.

REMOVE THE PURGE TRANSPORT TOP BAFFLE (REP 11-32).

6.

REMOVE THE TELESCOPIC DRIVE SHAFT (REP 11-40).

7.

REMOVE THE PURGE TRANSPORT (REP 11-33).

8.

REMOVE THE FS CHUTE BAFFLE (REP 11-30).

9.

REMOVE THE FS UPPER TRANSPORTS DRIVE BELTS (PL 11.29

10. DISCONNECT THE FS DISK STEPPER MOTOR (REP 11-73). CAUTION Do not remove the Purge Transport Left Counterbalance. Ensure that it is the Stacker Purge Tray Top Cover Left Counterbalance that is removed. 11. REMOVE THE STACKER PURGE TRAY TOP COVER LEFT COUNTERBALANCE (PL 4.14 12. REMOVE THE BACK GUIDE (REP 11-70). 13. REMOVE THE FRONT GUIDE (REP 11-71). 14. REMOVE THE RIGHT GUIDE (REP 11-72). 15. REMOVE THE STACK HEIGHT SENSOR (REP 11-68). 16. REMOVE THE DISK MODULE WELDMENT (Figure 1).

Section Name

REP 11-86

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Preliminary Working Document No Product Name Assigned

6

7

DISCONNECT SENSOR HARNESS (P460)

REMOVE PUSH IN CABLE TIE

1 DISCONNECT (2)

8 REMOVE SCREWS (4)

2 DISCONNECT

9 REMOVE WELDMENT

4 5

DISCONNECT THE INTERLOCK AND REMOVE BRACKET

REMOVE SHAFT

3 REMOVE LATCH BRACKET

Figure 1 Removing the Disk Module Weldment

Replacement

e.

1.

f.

Back Guide (ADJ 11-29).

g.

Right Guide (ADJ 11-28).

2. 3.

REMOVE THE FRONT TAMPER MOTOR AND CAPACITOR (C1106) FROM THE OLD DISK MODULE WELDMENT AND INSTALL THEM ON THE NEW WELDMENT.

Stack Height (ADJ 11-27).

REINSTALL THE DISK MODULE WELDMENT AND COMPONENTS. CHECK/ADJUST THE FOLLOWING: a.

Purge Transport (ADJ 11-10).

b.

Upper Transports Drive Belts.

c.

Disk Home Position (ADJ 11-25).

d.

Disk Gate Height (ADJ 11-26).

Preliminary Working Document No Product Name Assigned

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Section Name

REP 11-86

Section Name

REP 11-86

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Preliminary Working Document No Product Name Assigned

ADJ 2-0 Printer UI Tilt Purpose The purpose is to tighten the Printer UI Shoulder Bolt so that the UI can be tilted up or down freely and still hold any tilted position after adjustment.

Check 1.

CHECK THAT THE UI WILL STAY IN THE LOWER TILTED POSITION.

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE UI HOUSING COVER.

NOTE: An additional wrench will be needed to hold the bolt when tightening the nut. 3.

TIGHTEN THE UI SHOULDER BOLT (Figure 1).

TIGHTEN THE SHOULDER BOLT

Figure 1 Tightening the Shoulder Bolt

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 2-0

Section Name

ADJ 2-0

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Preliminary Working Document No Product Name Assigned

ADJ 4-0 Printer Right Top Cover

Adjustment

Purpose

1.

OPEN THE PRINTER RIGHT DOOR.

The purpose is to ensure that the Right Top Cover is flush with the Printer Left Top Cover and the top edge of the Printer Right Door.

2.

ADJUST THE RIGHT TOP COVER (Figure 1).

3

4

MOVE THE BUMPERS (2) UNTIL THE COVER IS FLUSH WITHIN +/-1.0 mm OF THE LEFT TOP COVER AND THE TOP EDGE OF THE RIGHT DOOR

PUSH DOWN THE COVER AND TIGHTEN THE SCREWS (2)

5 TIGHTEN THE LOCK NUTS (2)

2 LOOSEN THE LOCK NUTS (2)

1 LOOSEN THE SCREWS (2)

Figure 1 Adjusting the Right Top Cover

ADJ 4-1 Printer Right Door Latch

Check

Purpose

1.

CHECK THE RIGHT DOOR (Figure 1).

The purpose is to ensure that the right door does not bind and that the left door is flush against the Printer Left Top Cover.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-427

Section Name

ADJ 4-0

2 MEASURE THE GAP: 4.0 +/-1.0 mm

1 CHECK THAT THE DOOR CLOSES CORRECTLY

Figure 1 Checking the Door

Adjustment 1.

REMOVE THE ROS UPPER INNER PANEL.

2.

ADJUST THE LATCH (Figure 2).

Section Name

ADJ 4-1

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Preliminary Working Document No Product Name Assigned

3 MOVE THE BRACKET

4 2

TIGHTEN THE SCREWS (2)

LOOSEN THE SCREWS (2)

1 CLOSE THE RIGHT DOOR

Figure 2 Adjusting the Latch 3.

ADJUST THE DOOR (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 4-1

TOP COVER

GAP: 4.0 +/- 1.0

4 TIGHTEN THE SCREW

DOOR

2 LOOSEN THE SCREW

3 MOVE THE LATCH FOR THE GAP OF 4.0 +/- 1.0 mm

1 CLOSE THE RIGHT DOOR

Figure 3 Adjusting the Door

Section Name

ADJ 4-1

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Preliminary Working Document No Product Name Assigned

ADJ 4-2 Printer Rear Covers

Adjustment

Purpose

NOTE: If the top corner dimension of +/-1.0 mm cannot be set, the side cover must be removed and the bumper studs (2) turned in or out so that the cover is within specification.

The purpose is to ensure that the rear covers are installed with the proper clearances.

1.

ADJUST THE PRINTER REAR COVERS (Figure 1).

7 TIGHTEN THE PIN

6 ADJUST: MOVE FOR A GAP OF 3 +/-1.0 mm

1 LOOSEN THE PIN

5 LOOSEN THE PIN

2 3 TIGHTEN THE PIN

MOVE THE COVER UNTIL THE BOTTOM IS FLUSH WITH THE SIDE COVER

4 MEASURE THE GAP: 3 +/-1.0 mm

Figure 1 Adjusting the Rear Covers

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 4-2

ADJ 4-3 Interlock Actuator

•

Printer Right Door

Purpose

•

Printer Right Top Cover

The purpose of this adjustment is to ensure that the Interlock Actuator is centered within the Interlock Switch. This adjustment procedure includes the following covers and doors: •

Adjustment NOTE: There are two different types of Interlock Actuators. When adjusting the Interlock Actuator, refer to the correct configuration shown on Figure 1.

Printer Left Door 1.

ADJUST THE INTERLOCK ACTUATOR (Figure 1).

VERTICAL ACTUATOR

2

1

MOVE THE ACTUATOR

3

LOOSEN THE SCREWS

HORIZONTAL ACTUATOR

TIGHTEN THE SCREWS

Figure 1 Adjusting the Interlock Actuator

Section Name

ADJ 4-3

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Preliminary Working Document No Product Name Assigned

ADJ 4-4 Stacker Top Cover Counterbalances

ADJ 4-5 Stacker Doors Interlock Switches (S1138) & (S1163)

Purpose The purpose is to adjust the Counterbalances so that the Stacker Top Cover remains stationary in any open position.

Check

Purpose The purpose is to ensure that the Stacker Doors Interlock Switches are deactuated before the doors are opened to far.

1.

OPEN THE APPROPRIATE STACKER TOP COVER APPROXIMATELY 120mm.

Check

2.

ENSURE THAT THE COVER REMAINS STATIONARY.

1.

3.

ADJUST THE COUNTERBALANCES IF THE STACKER TOP COVER CLOSES OR OPENS FURTHER.

NOTE: It will be necessary to listen for the deactuation of the interlock switch.

Adjustment 1.

2.

REMOVE THE APPROPRIATE STACKER UPPER REAR COVER.

SWITCH OFF THE PRINTER POWER.

OPEN EACH STACKER DOOR SEPARATELY AND CHECK EACH INTERLOCK SWITCH (Figure 1).

CAUTION Ensure that the Stacker Top Cover Counterbalances are adjusted. NOTE: The two Counterbalances must be adjusted at the same time and rotated the same amount. Rotating the hex head shaft clockwise will increase the spring force. 2.

ROTATE THE 8mm HEX HEAD SHAFT ON EACH COUNTERBALANCE AS REQUIRED.

3.

RECHECK THE COUNTERBALANCES.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-433

Section Name

ADJ 4-4, ADJ 4-5

1 POSITION THE SCALE AGAINST CLOSED DOOR

2 NOTE: OPEN THE DOOR BEING CHECKED SLOWLY

4

3

OPEN THE DOOR AND RECHECK DEACTUATION

TIGHTEN NUT

3 CHECK: THAT THE INTERLOCK SWITCH DEACTUATES WHEN THE INSIDE LIP OF THE DOOR BEING OPENED IS EVEN WITH THE OUTSIDE SURFACE OF THE CLOSED DOOR

2 MOVE INTERLOCK SWITCH AS REQUIRED

1 LOOSEN NUT

Figure 1 Checking the Interlock Switch Figure 2 Adjusting the Interlock Switch

Adjustment 1.

REMOVE THE STACKER FRONT COVER (REP 4-49).

2.

ADJUST THE INTERLOCK SWITCH (Figure 2).

Section Name

ADJ 4-5

3.

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REINSTALL THE STACKER FRONT COVER.

Preliminary Working Document No Product Name Assigned

ADJ 4-10 Cleaner Drive Belt

CAUTION

Purpose

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt.

The purpose is to adjust the belt tension, using a spring loaded idler, so that there is no belt slippage.

3.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

4.

REMOVE THE PRINTER LEFT AND RIGHT REAR COVERS (REP 4-1).

Adjustment

5.

OPEN THE AC DISTRIBUTION PANEL.

1. 2.

CAUTION

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. OPEN THE PRINTER FRONT DOORS.

To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor in a counterclockwise direction. 6.

ADJUST THE CLEANER DRIVE BELT (Figure 1).

1 LOOSEN BOLT

3 TIGHTEN BOLT

2 CAUTION HANDCRANK THE MAIN DRIVE MOTOR TWO REVOLUTIONS IN A CLOCKWISE DIRECTION ONLY

Figure 1 Adjusting the Cleaner Drive Belt Tension 7.

CLOSE THE XEROGRAPHIC DRAWER.

ADJ 4-11 Decurler Drive Belt Purpose The purpose is to adjust the belt tension, in order to prevent belt slippage, noise, and wear of the bearings.

Adjustment 1. Preliminary Working Document No Product Name Assigned

0/0/00 ?-435

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. Section Name

ADJ 4-10

2.

OPEN THE PRINTER FRONT DOORS. CAUTION

4.

REMOVE THE PRINTER LEFT REAR COVER.

5.

REMOVE TENSION FROM THE DECURLER INTERMEDIATE DRIVE BELT (Figure 1).

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt. 3.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

2 MOVE THE IDLER BRACKET

1 LOOSEN BOLT

3 TIGHTEN BOLT

Figure 1 Removing the Tension from Decurler Intermediate Drive Belt CAUTION Handcrank the Main Drive Motor in a clockwise direction in order to ensure that the belts run smoothly. NOTE: Always adjust the tension of the Decurler Drive Belt with the Decurler Intermediate Drive Belt loose. 6.

ADJUST THE DECURLER DRIVE BELT (Figure 2).

Section Name

ADJ 4-11

0/0/00 ?-436

Preliminary Working Document No Product Name Assigned

3 TIGHTEN BOLTS (2)

2 NOTE: ALLOW THE SPRING TO PULL THE ASSEMBLY

4 LOOSEN BOLT

1 LOOSEN BOLTS (2)

5 ALLOW THE IDLER BRACKET TO MOVE

6 TIGHTEN BOLT

Figure 2 Adjusting the Decurler Drive Belt 7.

ADJUST THE TENSION OF THE DECURLER INTERMEDIATE DRIVE BELT (Figure 2, STEPS 4-6).

ADJ 4-12 Decurler Intermediate Drive Belt Purpose The purpose is to adjust the belt tension, using a spring loaded idler, so that there is no belt slippage.

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt.

Preliminary Working Document No Product Name Assigned

2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

3.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL.

5.

ADJUST THE DECURLER INTERMEDIATE DRIVE BELT (Figure 1).

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Section Name

ADJ 4-11

2 ALLOW THE IDLER BRACKET TO MOVE

1 LOOSEN BOLT

3 TIGHTEN BOLT

Figure 1 Adjusting the Decurler Intermediate Drive Belt

ADJ 4-13 Decurler Intermediate Drive Pulley

CAUTION To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor in a counterclockwise direction.

Purpose

6.

HANDCRANK THE MAIN DRIVE MOTOR IN A CLOCKWISE DIRECTION IN ORDER TO ENSURE THAT THE BELTS RUN SMOOTHLY.

The purpose of the adjustment is to position the Decurler Intermediate Drive Pulley in order to ensure that the drive belt stays in the center of the pulley.

7.

CLOSE THE XEROGRAPHIC DRAWER.

Section Name

ADJ 4-13

Check 1.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

2.

CHECK THE PULLEY (Figure 1, STEP 1).

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Preliminary Working Document No Product Name Assigned

1 CHECK: 80 +/-0.2 mm

2 LOOSEN THE SETSCREW

3

4

ADJUST: CAUTION MOVE THE PULLEY TIGHTEN THE 80 +/-0.2 mm FROM SETSCREW THE FRAME

PREFUSER DRIVE ASSEMBLY

Figure 1 Checking/Adjusting the Pulley

ADJ 4-14 Intermediate Drive Assembly

Adjustment CAUTION To prevent damage to the pulley, ensure that the key is positioned under the setscrew. 1.

ADJUST THE PULLEY (Figure 1, STEPS 2-4).

Purpose The purpose is to adjust gear alignment and gap to ensure proper gear engagement to reduce wear.

Check 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

NOTE: The 0.13 mm MAX. GAP is between the small gear and the retaining ring. 3.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-439

CHECK THE INTERMEDIATE DRIVE ASSEMBLY (Figure 1).

Section Name

ADJ 4-14

2 CHECK: THE LARGE GEAR SURFACE FLUSH +/-0.50 mm TO THE SMALL GEAR

1 CHECK: 0.13 mm MAX

Figure 1 Checking the Intermediate Drive Assembly

Adjustment 1.

ADJUST THE INTERMEDIATE DRIVE ASSEMBLY (Figure 2).

Section Name

ADJ 4-14

0/0/00 ?-440

Preliminary Working Document No Product Name Assigned

6 TIGHTEN

5 ADJUST: FLUSH TO SMALL GEAR +/-0.50 mm

4 LOOSEN SET SCREW

1

3 TIGHTEN

2 ADJUST: THE GEAR AGAINST THE RETAINER 0.13 mm MAX. GAP

LOOSEN SET SCREW

Figure 2 Adjusting the Intermediate Drive Assembly

Preliminary Working Document No Product Name Assigned

0/0/00 ?-441

Section Name

ADJ 4-14

ADJ 4-15 Intermediate Drive Belt

Adjustment

Purpose

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

The purpose is to adjust belt tension, so that there is no belt slippage.

2.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

NOTE: Loosen bolts (2) just enough to allow the Intermediate Drive Assembly to move. 3.

ADJUST THE INTERMEDIATE DRIVE BELT (Figure 1).

2 ALLOW THE DRIVE ASSEMBLY TO MOVE

3 TIGHTEN BOLTS (2)

1 NOTE: LOOSEN THE BOLTS (2) REAR VIEW

Figure 1 Adjusting the Belt Tension

Section Name

ADJ 4-15

0/0/00 ?-442

Preliminary Working Document No Product Name Assigned

ADJ 4-16 MIM Drive Belt

6.

CLOSE THE XEROGRAPHIC DRAWER.

Purpose The purpose is to adjust belt tension, using a spring-loaded idler, so that there is no belt slippage.

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt. 2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

3.

REMOVE THE PRINTER LEFT REAR COVER (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL. CAUTION

To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor in a Counterclockwise direction. 5.

ADJUST THE TENSION OF THE MIM DRIVE BELT (Figure 1).

2 CAUTION HANDCRANK THE MAIN DRIVE MOTOR SEVEN REVOLUTIONS

3

1

TIGHTEN IDLER BOLT

LOOSEN IDLER BOLT

Figure 1 Adjusting the MIM Drive Belt Tension

Preliminary Working Document No Product Name Assigned

0/0/00 ?-443

Section Name

ADJ 4-16

ADJ 4-17 PHM Drive Belt

6.

CLOSE THE XEROGRAPHIC DRAWER.

Purpose The purpose is to adjust belt tension, using a spring loaded idler, so that there is no belt slippage.

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt. 2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

3.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL AND THE PHM PWB PANEL. CAUTION

To prevent damage to the Photoreceptor and Cleaner, do not handcrank the Main Drive Motor in a counterclockwise direction. 5.

ADJUST THE TENSION OF THE PHM DRIVE BELT (Figure 1).

3 TIGHTEN BOLT

2 1 LOOSEN BOLT

CAUTION HANDCRANK THE MAIN DRIVE MOTOR SEVEN REVOLUTIONS

Figure 1 Adjusting the PHM Drive Belt Tension

Section Name

ADJ 4-17

0/0/00 ?-444

Preliminary Working Document No Product Name Assigned

ADJ 4-18 PHM/MIM Drive Pulleys

CAUTION Do not handcrank the Main Drive Motor in a counterclockwise direction.

Purpose The purpose is to position the pulleys so that the drive belts stay seated in the center of the pulleys.

2.

ADJUST THE PULLEYS (Figure 2).

Check 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt. 2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

3.

REMOVE THE PRINTER RIGHT REAR COVER (REP 4-1).

4.

OPEN THE AC DISTRIBUTION PANEL AND THE PHM PWB PANEL.

5.

CHECK THE PULLEY DIMENSIONS (Figure 1).

0.13 mm MAX 8.0 +/-0.5 mm

2 ADJUST THE PULLEYS

3 TIGHTEN THE SETSCREWS (2)

1 LOOSEN THE SETSCREWS (2)

0.13 mm MAX

8.0 +/-0.5 mm Figure 2 Adjusting the Pulleys

Figure 1 Checking the Pulley Dimensions

Adjustment 1.

DISENGAGE THE MIM DRIVE BELT (REP 4-29).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-445

Section Name

ADJ 4-18

ADJ 4-19 Prefuser Drive Belt

CAUTION

Purpose

To prevent the damage to the Photoreceptor, pull out the Xerographic Drawer and protect the PR Belt.

The purpose is to adjust the belt tension, using a spring-loaded idler, so that there is no belt slippage.

2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

3.

REMOVE THE PRINTER LEFT AND RIGHT REAR COVERS (REP 4-1).

Adjustment

4.

OPEN THE AC DISTRIBUTION PANEL.

1.

CAUTION

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

Do not handcrank the Main Drive Motor in a counterclockwise direction. 5.

ADJUST THE PREFUSER DRIVE BELT (Figure 1).

1 LOOSEN BOLT

3 TIGHTEN BOLT

2 CAUTION HANDCRANK THE MOTOR 2 REVOLUTIONS IN A CLOCKWISE DIRECTION

Figure 1 Adjusting the Prefuser Drive Belt 6.

CLOSE THE XEROGRAPHIC DRAWER.

ADJ 4-20 Tray 1 and 2 Feeder Drives Purpose The purpose is to align the feeder drive coupling to the feed head coupling in the tube shaft. This will ensure the proper operation, without excessive wear, noise or vibration.

Check 1.

Section Name

ADJ 4-19

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OPEN THE PRINTER LEFT AND RIGHT FRONT DOORS.

Preliminary Working Document No Product Name Assigned

2.

PULL OUT TRAY.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

INSERT THE PIN (271W1852) INTO THE HOLE AT THE REAR OF THE TUBE SHAFT COUPLING (Figure 1).

NOTE: THE HOLE IS IN THE MIDDLE OF THE TUBE SHAFT COUPLING

Figure 1 Inserting the Pin 5.

SLOWLY BUT FIRMLY PUSH THE TRAY INTO THE PRINTER.

6.

IF THE TRAY MOVES INTO THE LATCH POSITION, THE ALIGNMENT IS GOOD. IF THE TRAY DOES NOT MOVE INTO THE LATCH POSITION, PERFORM THE ADJUSTMENT.

Adjustment NOTE: Loosen bolts (2) only enough to allow movement of the drives. 1.

PREPARE TO ADJUST THE FEEDER DRIVE (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 4-20

5 NOTE: LOOSEN THE BOLTS (2)

1 LOOSEN BOLT

4 REMOVE BELT FROM DRIVE

2 MOVE THE BRACKET

3 TIGHTEN BOLT

Figure 2 Preparing to Adjust the Feeder Drive NOTE: Turn the Feeder Drive Pulley by hand to ensure that the drive coupling is properly engaged (Figure 3). 2.

MOVE THE FEEDER DRIVE UNTIL THE TRAY MOVES INTO THE LATCH POSITION.

Section Name

ADJ 4-20

0/0/00 ?-448

Preliminary Working Document No Product Name Assigned

NOTE: COUPLING ENGAGEMENT

Figure 3 Ensuring Proper Coupler Engagement 3.

TIGHTEN THE TWO FEEDER DRIVE BOLTS.

4.

PULL OUT TRAY AND REPEAT STEPS 5 AND 6 OF THE CHECK.

5.

REMOVE THE PIN.

6.

ENGAGE AND ADJUST THE PHM DRIVE BELT (ADJ 4-17).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-449

Section Name

ADJ 4-20

ADJ 4-21 Fuser-Developer Drive Belt

3.

Purpose

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assembly. Toner will fall from assembly connection.

The purpose is to adjust belt tension, using a spring-loaded idler, so that there is no belt slippage.

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

PULL OUT THE XEROGRAPHIC DRAWER IN ORDER TO DISENGAGE THE DRIVES.

REMOVE THE PRINTER REAR COVERS (REP 4-1).

4.

OPEN THE TONER FILTER ASSEMBLY.

5.

OPEN THE XEROGRAPHIC CARD CAGE.

6.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

7.

ADJUST THE TENSION OF THE FUSER DEVELOPER DRIVE BELT (Figure 1).

2 ALLOW IDLER BRACKET TO MOVE AND THEN TIGHTEN THE BOLT

1 LOOSEN BOLT

3 ADJUST: HANDCRANK THE DRIVE PULLEY 7 REVOLUTIONS IN A CLOCKWISE DIRECTION

Figure 1 Adjusting the Fuser Developer Drive Belt

Section Name

ADJ 4-21

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Preliminary Working Document No Product Name Assigned

NOTE: Handcrank the Drive Pulley in a clockwise direction in order to ensure that the belt is seated.

ADJ 4-22 Fuser-Developer Drive Pulley

8.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

9.

CONNECT THE OZAC DUCT TO THE OZONE FILTER.

The purpose is to position the Drive Pulley on the Jackshaft so that the Fuser-Developer Drive Belt stays seated in the center of the Drive Pulley.

Purpose

NOTE: Replace cable ties as required and ensure that the Cleaner and Ozac hoses are away from moving parts.

Check

10. CLOSE THE XEROGRAPHIC DRAWER.

NOTE: Use a 6 inch and a 150 mm scale from the Basic Tool Kit (600T1835) and the Metric Tool Kit (600T1880). 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT REAR COVER AND THE ELECTRICAL MODULE REAR COVER (REP 4-1).

NOTE: Place a dropcloth under the rear of the Printer before opening the Toner Filter Assembly. Toner will fall from assembly connection. 3.

Preliminary Working Document No Product Name Assigned

OPEN THE TONER FILTER ASSEMBLY AND THE XEROGRAPHIC CARD CAGE.

4.

REMOVE THE HVAC OUTPUT MODULE (REP 1-4).

5.

LOOSEN THE FUSER-DEVELOPER DRIVE BELT (Figure 1).

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Section Name

ADJ 4-21, ADJ 4-22

2 MOVE THE IDLER AND TIGHTEN THE BOLT

3 DISCONNECT THE BELT FROM THE JACKSHAFT

1 LOOSEN BOLT

Figure 1 Loosening the Fuser-Developer Drive Belt 6.

CHECK/ADJUST THE DRIVE PULLEY (Figure 2).

Section Name

ADJ 4-22

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Preliminary Working Document No Product Name Assigned

RIGHT REAR VIEW

1 PLACE THE SCALE ACROSS THE CUTOUT

5 TIGHTEN THE SETSCREW

2 CHECK:GAP MUST BE 28.0 +/-0.0 mm SCALE FRAME

4

3

ADJUST: POSITION THE PULLEY AT 12.0 +/-0.0 mm

LOOSEN THE SETSCREW

Figure 2 Checking /Adjusting the Drive Pulley 7.

CONNECT AND TIGHTEN THE DRIVE BELT.

ADJ 4-23 Fuser-developer Intermediate Drive

8.

HANDCRANK THE DRIVE PULLEY IN A CLOCKWISE DIRECTION IN ORDER TO ENSURE THAT THE BELT IS SEATED.

Purpose

9.

INSTALL THE HVAC OUTPUT MODULE (REP 1-4).

The purpose is to adjust belt tension, using a spring-loaded idler, so that there is no belt slippage.

10. CONNECT THE OZAC DUCT TO THE OZONE FILTER. 11. REPLACE CABLE TIES AS REQUIRED AND ENSURE THAT THE CLEANER AND OZAC HOSES ARE AWAY FROM MOVING PARTS.

Preliminary Working Document No Product Name Assigned

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

3.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

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Section Name

ADJ 4-22

4.

REMOVE THE FUSER-DEVELOPER DRIVE DIRT SHIELD (REP 4-47).

5.

ADJUST THE FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (Figure 1).

FRONT TOP VIEW REAR VIEW

1 LOOSEN THE SCREW

3 2 ALLOW THE IDLER TO MOVE

TIGHTEN THE SCREW

Figure 1 Adjusting the Fuser-Developer Intermediate Drive Belt

Section Name

ADJ 4-23

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Preliminary Working Document No Product Name Assigned

ADJ 6-1 ROS Magnification Setup Purpose The purpose is to ensure that the Magnification parameters remain within specification after the replacement of critical ROS components.

Check NOTE: Use the 300 mm scale (600T41501) to measure the prints. 1.

TOP-TO-BOTTOM (FAST SCAN) MAGNIFICATION:

NOTE: Use A4 (8 1/2 x 11) or a larger paper size in Tray 1.

2.

a.

Enter dC603, [Printer Options], [Test Patterns and PQ], [Dimensional], [Magnification], and press the Continue button.

b.

Measure the C - D (200 mm +/- 0.4 mm) distance on the prints using the 300mm scale (600T41501).

SIDE-TO-SIDE (SLOW SCAN) MAGNIFICATION: a.

Enter dC603, [Printer Options], [Test Patterns and PQ], [Dimensional], [Magnification], and press the Continue button.

b.

Measure the A - B (200 mm +/- 0.5 mm) distance on 5 consecutive prints. Using the average of the 5 prints the distance A - B should be 200 mm +/- 0.5 mm using the 300mm scale (600T41501).

Adjustment 1.

TOP-TO-BOTTOM (FAST SCAN) MAGNIFICATION:

NOTE: Increasing the Range value increases the C - D distance. a. 2.

Correct the C - D distance by using the Up and Down Arrows.

SIDE-TO-SIDE (SLOW SCAN) MAGNIFICATION:

NOTE: Increasing the Range value increases the A - B distance. a. 3.

Correct the A - B distance by using the Left and Right Arrows.

CHECK/ADJUST THE FOLLOWING: a.

Pre Transfer Baffle (ADJ 8-1)

b.

ROS Image Squareness (ADJ 6-2)

c.

(Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 6-1

Figure 1 DIME11 (Dimensional Controller Test Pattern)

ADJ 6-2 ROS Image Squareness Section Name

ADJ 6-1

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Preliminary Working Document No Product Name Assigned

Purpose

Check

The purpose of the ROS Image Squareness Adjustment is to ensure that the scanned image on the Photoreceptor Belt is square regardless of other factors, such as out-off-square paper or paper path skew.

1.

PLACE 500 SHEETS OF 20 LB (80 GSM), 14 INCH OR B4 PAPER INTO TRAY 3.

2.

ENTER dC106, [Printer Options], [Test Patterns and PQ], [Dimensional], SELECT 50 PRINTS, AND PRESS THE Continue BUTTON.

3.

USING THE XTP #564.001 (82E4161), CHECK THE PRINTS FOR THE ROS IMAGE SQUARENESS (Figure 1).

1

2 ALIGN THE CORNER OF THE TEST PATTERN WITH THE #4 LINES ON X1 AND X3

ALIGN THE EDGE OF THE TEST PATTERN WITH THE #4 LINE ON X2

PRINT

TEST PATTERN

3 THE EDGE OF THE TEST PATTERN SHOULD BE ALIGNED WITH THE #4 LINE ON X5 WITHIN +/- 0.5 mm

Figure 1 Checking the ROS Image Squareness

Adjustment 1.

REMOVE THE ROS UPPER INNER PANEL.

2.

REMOVE THE PRINTER LEFT TOP COVER (REP 4-2).

Preliminary Working Document No Product Name Assigned

3.

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LOOSEN THE ROS ASSEMBLY REAR HOLD DOWN CLAMP.

Section Name

ADJ 6-2

CAUTION Do not drop the Clamp. 4.

REMOVE THE ROS ASSEMBLY FRONT HOLD DOWN CLAMP (Figure 2).

2 CAUTION REMOVE THE CLAMP

1 CAUTION LOOSEN THE SCREW

Figure 2 Removing the Hold Down Clamp 5.

ADJUST THE ROS IMAGE SQUARENESS (Figure 3).

Section Name

ADJ 6-2

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Preliminary Working Document No Product Name Assigned

1 LOOSEN THE FRONT SCREWS (2)

4 TIGHTEN THE SCREWS (2)

3 TURN THE SCREW CLOCKWISE IF EDGE OF PATTERN IS BETWEEN THE #4 LINE AND THE EDGE OF THE PRINT

2 TURN THE SCREW COUNTER-CLOCKWISE IF EDGE OF PATTERN IS BETWEEN #4 AND #10 LINES

Figure 3 Adjusting the ROS Image Squareness 6.

INSTALL AND TIGHTEN THE FRONT HOLD DOWN CLAMP.

ADJ 6-3 ROS Low Correction Factor

7.

TIGHTEN THE ROS ASSEMBLY REAR HOLD DOWN CLAMP.

8.

REPEAT THE CHECK IF REQUIRED.

Purpose

9.

INSTALL THE PRINTER LEFT TOP COVER (REP 4-2).

The purpose is to establish a basic ROS calibration parameter to ensure the proper charge and exposure of the Photoreceptor Belt.

Adjustment 1.

ENTER PRINTER DIAGNOSTICS, [dC951, ROS Correction]. NOTE: Do Not press [Continue] to run the Autocal.

Preliminary Working Document No Product Name Assigned

2.

Set value to 50%, or set to the Cal Tag value if there is one.

3.

Press [Enter].

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Section Name

ADJ 6-2

ADJ 6-4 ROS Power Calibration Purpose The purpose is to calibrate the ROS power.

Adjustment 1.

ENTER dC131 [MIN] LOCATION [32]. SET DATA VALUE TO [1].

2.

ENTER dC606. SELECT [TESTS], [ROS Self Test]. PRESS [CONTINUE].

3.

IF A FAULT IS DECLARED, FIX THE PROBLEM AND REPEAT STEP 2 UNTIL IT PASSES THE SELF TEST. NOTE: It is important to run prints after the Self Test is performed to ensure all the proper values are downloaded to NVM.

4.

SELECT [SETUPS], [6] PRINTS.

Section Name

ADJ 6-3, ADJ 6-4

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Preliminary Working Document No Product Name Assigned

ADJ 7-0 Feed Clutch Belt and Takeaway Drive Belt

Adjustment CAUTION

Purpose The purpose is to adjust the tension of the Feed Clutch Belt and the Takeaway Drive Belt.

Rotate the Takeaway Pulley and the Feed Clutch Pulley five times. Do not manually apply extra tension to the belt or the tension idler. NOTE: While holding the Feed Clutch Pulley the Takeaway Roll should rotate only in the counterclockwise direction. 1.

ADJUST FEED CLUTCH BELT (Figure 1, STEPS 1-4).

1

9

RAISE

TIGHTEN THE SCREW

2 LOOSEN THE SCREW

8 TIGHTEN THE SETSCREW

TAKEAWAY DRIVE BELT FEED CLUTCH BELT

7 CAUTION ROTATE THE PULLEY FIVE TIMES

3 CAUTION ROTATE THE PULLEY FIVE TIMES

4 TIGHTEN THE SCREW

5

6

LOOSEN THE SCREW

LOOSEN THE SETSCREW

Figure 1 Adjusting the Feed Clutch Belt/Takeaway Drive Belt 2.

ADJUST TAKEAWAY DRIVE BELT (Figure 1, STEPS 1, 5-9).

ADJ 7-1 Takeaway Shaft Endplay Purpose The purpose is to minimize skew by properly aligning the Feed Belt with the Takeaway Roll and to properly compress the grease seal in order to prevent leakage of grease from the Takeaway Roll.

Check

Preliminary Working Document No Product Name Assigned

1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER POWER.

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Section Name

ADJ 7-0

NOTE: Turn the roll in a counterclockwise direction while pushing in order to remove endplay (Figure 1, Step 2). NOTE: Do not interfere with the grease seal when measuring the gap between the roll and casting (Figure 1, Step 3). 3.

CHECK THE ENDPLAY (Figure 1).

FEED BELT CASTING

GREASE SEAL

FEED HEAD CASTING

3 NOTE: CHECK 1.9 +/-0.15 mm

1

2

PUSH TO REMOVE THE PLAY

NOTE: PUSH TO REMOVE THE PLAY

Figure 1 Checking the Endplay

Adjustment 1.

REMOVE THE SAFETY COVER FROM THE TUBE SHAFT.

NOTE: Do not interfere with the grease seal when inserting the shim (Figure 2, Step 3). NOTE: In the following step, it is easier to move the roll along the shaft if you simultaneously turn the roll in a counterclockwise direction, as viewed from the front (Figure 2, Step 4). 2.

ADJUST THE ENDPLAY (Figure 2).

Section Name

ADJ 7-1

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Preliminary Working Document No Product Name Assigned

FEED BELT CASTING

7

1

TIGHTEN

LOOSEN

GREASE SEAL

2 PUSH AND HOLD

3

6 PUSH THE PULLEY AGAINST THE CASTING

4

5 PUSH THE CASTING AGAINST THE ROLL

NOTE: INSERT THE 1.9 mm SHIM

NOTE: PUSH THE ROLL AGAINST THE SHIM

Figure 2 Adjusting the Endplay

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-1

ADJ 7-2 Down/Low Paper Sensor (Q714/724)

Adjustment

Purpose

1.

REMOVE ALL PAPER FROM THE TRAY.

The purpose is to ensure that a low paper condition will be detected within the normal range of expected paper weights.

2.

REMOVE THE LABEL PANEL TO ACCESS THE SETSCREW.

WARNING Ensure that the Right Door Interlock Switch is not cheated; this will prevent the elevator from moving up when the Tray Interlock Switch is cheated.

Check 1.

REMOVE ALL PAPER FROM THE TRAY.

2.

PLACE APPROXIMATELY 60 SHEETS OF 20 LB (80 GSM) PAPER INTO THE TRAY.

3.

ENTER dC106, [Tray 1] OR [Tray 2] AND MAKE 50 PRINTS.

NOTE: To access the Tray 1 and/or the Tray 2 Interlock Switches, pull out Tray 1. 3.

CHEAT THE TRAY INTERLOCK SWITCH.

4.

TRAY 2 ONLY: PUT PAPER IN TRAY 1 AND PUSH IN THE TRAY.

4.

IF A LOW PAPER CONDITION IS NOT DETECTED, GO TO THE ADJUSTMENT.

5.

OPEN THE PRINTER RIGHT DOOR. PULL OUT THE TRAY AND COUNT THE NUMBER OF SHEETS THAT REMAIN IN THE TRAY AFTER THE LOW PAPER CONDITION IS DETECTED.

5.

ENTER dC330 [7-8]. SELECT [Tray 1 Elevator UP] OR [Tray 2 Elevator UP] AND PRESS THE Continue BUTTON.

6.

PERFORM THE ADJUSTMENT IF LESS THAN 30 SHEETS OR MORE THAN 50 SHEETS REMAIN IN THE TRAY.

STAY IN dC330, [7-8]. OBSERVE Tray 1 Down/Low Paper Sensor OR Tray 2 Down/ Low Paper Sensor.

NOTE: It may be necessary to break the Glyptol seal in order to perform the adjustment.

6.

7.

PREPARE TO ADJUST THE DOWN/LOW PAPER SWITCH (Figure 1).

SETUP TOOL

2 ROTATE UNTIL THE TOP OF THE TOOL IS FLUSH WITH THE GATE

PAPER PLATE

GATE

1 POSITION THE SETUP TOOL

Figure 1 Preparing to Adjust the Down/Low Paper Sensor

Section Name

ADJ 7-2

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Preliminary Working Document No Product Name Assigned

8.

ADJ 7-3 Elevator Up Limit Switch (S714/724)

ADJUST THE DOWN/LOW PAPER SENSOR (Figure 2).

Purpose 2 ROTATE UNTIL THE DISPLAY CHANGES FROM H TO L

The purpose is to position the Elevator Up Limit switch in order to eliminate elevator overtravel.

1

Check

ROTATE UNTIL THE DISPLAY IS H

1.

OPEN THE PRINTER RIGHT DOOR.

NOTE: If this check is being done on Tray 2, lower the Tray 1 Elevator to access the Tray Interlock Switches. 2.

PULL OUT THE TRAY.

3.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

4.

REMOVE THE FEED HEAD ASSEMBLY (REP 7-0).

5.

REMOVE THE SAFETY COVER (Figure 1).

2 REMOVE THE SAFETY COVER

Figure 2 Adjusting the Down/Low Paper Sensor 9.

DEACTUATE THE TRAY INTERLOCK SWITCH.

10. REPEAT THE CHECK. 11. APPLY A SMALL AMOUNT OF ADHESIVE 63P561 (USMG) OR 600T90352 (RXL) TO THE SETSCREW ON THE LOW PAPER SENSOR.

1 REMOVE THE SCREWS (3) Figure 1 Removing the Safety Covers 6.

INSTALL THE FEED HEAD ASSEMBLY.

NOTE: Pull out Tray 1 in order to access the Tray 1 and/or Tray 2 Interlock Switches. 7.

Preliminary Working Document No Product Name Assigned

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CHEAT THE TRAY INTERLOCK SWITCH.

Section Name

ADJ 7-2, ADJ 7-3

8.

TRAY 2 ONLY: PUSH TRAY 1 INTO PRINTER.

9.

SWITCH ON THE PRINTER CIRCUIT BREAKERS.

3.

REPEAT STEP 11 OF THE CHECK.

10. RAISE THE PAPER TRAY PLATE. ENTER dC330, [7-8]. SELECT [Tray 1 Elevator UP] OR [Tray 2 Elevator UP] AND PRESS THE Continue BUTTON. 11. HANDCRANK THE LEAD SCREW AND CHECK THAT THE SWITCH ACTUATES WHEN THE PAPER TRAY PLATE IS 5.0 +/- 0.5 mm ABOVE GATE.

Adjustment 1.

HANDCRANK THE LEAD SCREWS UNTIL THE PAPER PLATE IS 5.0 +/- 0.5 mm ABOVE GATE.

2.

ADJUST THE ELEVATOR UP LIMIT SWITCH (Figure 2).

1 LOOSEN THE SCREWS (2)

2 PUSH AGAINST THE FEED HEAD UNTIL THE SWITCH ACTUATES

3 HOLD THE SWITCH AND TIGHTEN THE SCREWS

GATE

PAPER PLATE

Figure 2 Adjusting the Switch Section Name

ADJ 7-3

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Preliminary Working Document No Product Name Assigned

ADJ 7-4 Length Guide Position Purpose

3

The purpose is to adjust the Length Guide so that it reports the correct paper length.

ADJUST: 120 +/-0.5 mm

4 TIGHTEN (4)

Check NOTE: Tray 2 only: Pull out Trays 1 and 2 out of the printer. 1.

PULL OUT THE TRAY AND REMOVE THE PAPER.

2.

REMOVE THE SAFETY COVER AT THE REAR OF TRAY 1 IN ORDER TO ACCESS THE TRAY INTERLOCK SWITCHES.

WARNING Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal injury and ensure that the elevator does not move when the Tray Interlock Switch is cheated. NOTE: Access the Tray 1 or Tray 2 Elevator Interlock Switch through Tray 1. 3.

CHEAT THE TRAY INTERLOCK SWITCH.

4.

TRAY 2 ONLY: PUT PAPER IN TRAY 1 AND PUSH THE TRAY INTO PRINTER.

5.

6.

RAISE THE PAPER PLATE:

1

a.

Tray 1: Enter dC330, [7-8], [Tray 1 Elevator UP]. Press the Continue Button.

b.

Tray 2: Enter dC330, [7-8], [Tray 2 Elevator UP]. Press the Continue Button.

CHECK: +/-0.5 mm

2

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

LOOSEN

NOTE: Ensure that the Length Guide is in the center (side-to-side) of the Paper Plate opening. 7.

CHECK THE LENGTH GUIDE (Figure 1). Figure 1 Adjusting the Length Guide

Adjustment NOTE: Ensure that the Length Guide is in the center of the Paper Plate opening before tightening the screws. 1.

Preliminary Working Document No Product Name Assigned

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ADJUST THE LENGTH GUIDE (Figure 1).

Section Name

ADJ 7-4

ADJ 7-5 Length Guide Tension Purpose The purpose is to ensure that the Length Guide moves when the release lever is pressed, and that the Length Guide remains positioned against the paper stack when the tray is pushed into the printer.

RELEASE THE LEVER

Check 1.

PULL OUT THE TRAY AND REMOVE THE PAPER.

2.

PRESS THE RELEASE LEVER AND CHECK THAT THE LENGTH GUIDE MOVES FRONT TO REAR WITHIN THE CUTOUT OF THE PAPER PLATE.

3.

FILL THE TRAY WITH PAPER AND POSITION THE LENGTH GUIDE AGAINST THE REAR OF THE PAPER STACK.

4.

QUICKLY AND FIRMLY PUSH THE TRAY INTO THE PRINTER.

5.

PULL THE TRAY OUT OF THE PRINTER AND CHECK THAT THE LENGTH GUIDE REMAINED STATIONARY AGAINST THE PAPER STACK.

Adjustment 1.

IF THE LENGTH GUIDE MOVED AWAY FROM THE PAPER STACK, TURN THE NUT IN A COUNTERCLOCKWISE DIRECTION UNTIL THE LENGTH GUIDE REMAINS STATIONARY (Figure 1).

ADJUS THE NUT

Figure 1 Adjusting the Release Lever

Section Name

ADJ 7-5

2.

REPEAT THE CHECK.

3.

IF THE LENGTH GUIDE DOES NOT MOVE WHEN THE RELEASE LEVER IS PRESSED, TURN THE NUT IN A CLOCKWISE DIRECTION UNTIL THE LENGTH GUIDE CAN BE RELEASED (Figure 1).

4.

REPLACE THE LENGTH GUIDE IF THE TWO CONDITIONS CANNOT BE ACHIEVED.

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Preliminary Working Document No Product Name Assigned

ADJ 7-6 Auto Latch

3.

REMOVE THE SAFETY COVER AT THE FRONT OF THE FEED HEAD. CAUTION

Purpose The purpose is to ensure that the Auto Latch mechanism will latch the Feed Belt casting without damaging the Feed Belt.

NOTE: Unlatch the Feed Belt Casting and perform the test several times. Push the paper tray slowly and do not apply any vertical force to the paper tray. Observe the Feed Belt Casting in order to ensure that it is latched when the tray is pushed into the printer.

Adjustment 1.

OPEN THE PRINTER RIGHT DOOR AND CHEAT THE RIGHT DOOR INTERLOCK SWITCH.

2.

PULL OUT THE TRAY AND REMOVE THE PAPER.

Manually latch the mechanism before pulling out the Paper Tray. When beginning the adjustment, the casting may not automatically latch and this will prevent damage to the Feed Belt.

4.

ADJUST THE LOWER LIMIT SETSCREW SO THAT THE FEED BELT CASTING LATCHES WHEN SLOWLY PUSHING IN THE PAPER TRAY (Figure 1, STEPS 1-3).

1 CAUTION ROTATE COUNTERCLOCKWISE UNTIL THE AUTO LATCH IS FLUSH WITH THE BOTTOM OF THE CASTING

4 INSERT A 5.0 mm HEX KEY

2

3 ROTATE CLOCKWISE ANOTHER 1/2 REVOLUTION

NOTE: ROTATE CLOCKWISE IN 1/2 TURN INCREMENTS UNTIL THE FEED BELT LATCHES

Figure 1 Adjusting the Auto Latch 5.

APPLY A SMALL AMOUNT OF ADHESIVE 63P561 (USO), OR 600T90352 (RXL), TO THE LOWER LIMIT SETSCREW.

WARNING

8.

PLACE APPROXIMATELY 75 SHEETS OF PAPER (8 mm HIGH) INTO THE TRAY.

9.

CHEAT THE RIGHT DOOR INTERLOCK SWITCH.

10. WHEN THE ELEVATOR STOPS MOVING, REMOVE THE PAPER FROM THE TRAY.

Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal injury and ensure that the elevator does not move when the Tray Interlock Switch is cheated.

NOTE: Position the hex key as shown in Figure 1. This will ensure that the flats of the hex key contact the Feed Belt and the Cork Pad.

6.

CHEAT THE TRAY INTERLOCK SWITCH.

7.

TRAY 2 ONLY: PUSH TRAY 1 INTO THE PRINTER.

11. INSERT A 5 mm HEX KEY BETWEEN THE FEED BELT AND THE CENTER OF THE CORK PAD (Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-6

12. ENTER dC330, [7-8]. THE Tray 1 Stack Height Sensor OR Tray 2 Stack Height Sensor DISPLAY MUST INDICATE H. 13. HANDCRANK THE ELEVATOR UPWARD UNTIL THE DISPLAY GOES TO L.

NOTE: Lightly tap the Feed Head before measuring the gap to ensure an accurate measurement. 15. MEASURE THE GAP BETWEEN THE FEED BELT AND THE CENTER OF THE CORK PAD (Figure 2). IF THE GAP IS WITHIN SPECIFICATION CONTINUE WITH STEP 17. IF THE GAP IS NOT WITHIN SPECIFICATION, GO TO STEP 16.

INSERT A 1.0 mm GAUGE ON TOP OF THE CORK PAD AND UNDER THE FEED BELT

Purpose The purpose is to position the frame so that the Tray 1 and 2 covers are flush with the Printer Right Door.

14. REMOVE THE HEX KEY FROM THE TRAY.

1

ADJ 7-7 Front Cover Frame

CAUTION DO NOT DEFLECT THE TRAY WHEN TAKING A MEASUREMENT

Check 1.

PULL OUT THE TRAY.

2.

LOOSEN THE TWO SCREWS THAT SECURE THE TRAY COVER. ENSURE THAT THE COVER IS SEATED, THEN TIGHTEN THE SCREWS.

3.

PUSH IN THE TRAY.

NOTE: Check the alignment on the right and the left sides of the cover. 4.

CHECK THE ALIGNMENT (Figure 1).

FEED BELT

2

CHECK: THAT THE FRONT SURFACE OF THE TRAY COVER IS FLUSH WITHIN +/-1.0 mm OF THE PRINTER RIGHT DOOR

CHECK: 2.15 +0.05/-0.0 mm

CORK PAD 1.0 mm GAUGE

Figure 2 Measuring the Gap 16. PERFORM THE PAPER FEED SETUP (ADJ 7-9). DO NOT COMPLETE THIS PROCEDURE. 17. REMOVE THE CHEATER FROM THE RIGHT DOOR INTERLOCK SWITCH.

Figure 1 Checking the Alignment

18. INSTALL THE FRONT SAFETY COVER ON THE FEED HEAD. 19. REMOVE THE CHEATER FROM THE TRAY INTERLOCK SWITCH.

Adjustment 1.

Section Name

ADJ 7-6, ADJ 7-7

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE TRAY FRONT COVER AND THE LABEL PANEL (REP 7-28).

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Preliminary Working Document No Product Name Assigned

4.

ADJ 7-8 Front Cover Support

PUSH IN THE TRAY.

NOTE: Do not connect the Tray Capacity PWB connector or tighten the screws (2). Ensure that the cover is fully seated. 5.

ADJUST THE ALIGNMENT (Figure 2).

Purpose The purpose is to ensure that the Tray 1 and 2 covers are centered in the opening of the Printer Right Door. This will prevent interference between the trays and the door and also provide an even appearance.

Check 2

1.

NOTE: INSTALL THE FRONT COVER AND MOVE THE FRAME TO SET THE ALIGNMENT

CHECK THE GAPS BETWEEN THE TRAY COVERS AND THE RIGHT DOOR (Figure 1).

1 LOOSEN THE SCREWS (2)

3 OPEN THE RIGHT DOOR CHECK: FOR UNIFORM GAPS 3.0 + 0.0/-1.0 mm

FRAME

4 TIGHTEN THE SCREWS (2)

Figure 2 Adjusting the Alignment 6.

CLOSE THE RIGHT DOOR.

7.

CHECK THE POSITION OF THE COVER.

8.

REPEAT STEPS 5, 6, AND 7 UNTIL THE ALIGNMENT IS SET.

9.

OPEN THE RIGHT DOOR AND REMOVE THE TRAY COVER.

10. PULL OUT THE TRAY AND CONNECT THE TRAY CAPACITY PWB. 11. INSTALL THE LABEL PANEL AND THE TRAY COVER.

Preliminary Working Document No Product Name Assigned

Figure 1 Checking the Front Cover Gap

Adjustment 1.

PULL OUT THE TRAY.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

3.

REMOVE THE TRAY FRONT COVER AND THE LABEL PANEL (REP 7-28).

4.

PUSH IN THE TRAY.

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Section Name

ADJ 7-7, ADJ 7-8

NOTE: Do not connect the Tray Capacity PWB connector or tighten the screws (2). Ensure that the cover is fully seated. 5.

ADJUST THE FRONT COVER FRAME (Figure 2).

2 NOTE: INSTALL THE FRONT COVER AND MOVE THE FRAME TO SET THE GAPS

1 LOOSEN THE SCREWS (4) TO FINGERTIGHTEN

4 TIGHTEN THE SCREWS (4)

FRAME

3 OPEN THE RIGHT DOOR

Figure 2 Adjusting the Front Cover Frame 6.

CLOSE THE RIGHT DOOR.

7.

CHECK THE FRONT COVER GAPS.

8.

REPEAT STEPS 5, 6, AND 7 UNTIL THE GAPS ARE SET.

9.

OPEN THE RIGHT DOOR AND REMOVE THE TRAY COVER.

10. PULL OUT THE TRAY. NOTE: Connect the Tray Capacity PWB connector. 11. INSTALL THE LABEL PANEL AND TRAY COVER; CLOSE THE RIGHT DOOR.

Section Name

ADJ 7-8

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Preliminary Working Document No Product Name Assigned

ADJ 7-9 Paper Feed Setup Purpose The purpose is to check and adjust the components of either Tray 1 or 2 in one continuous procedure to ensure proper paper feeding. The following checks and adjustments are included in this procedure: •

Feed Belt Tension

•

Paper Plate Parallelism

•

Paper Plate Endplay

•

Paper Stack Height (Stack Height Sensor)

•

Stack Force (Stack Height Sensor)

•

Stack Relief Solenoid

Adjustment NOTE: The steps of this procedure must be done in sequence. Performing one of these adjustments out of sequence may cause all of the following adjustments to be out of specification. 1.

OPEN THE PRINTER RIGHT DOOR.

2.

PULL OUT THE TRAY.

3.

REMOVE THE PAPER FROM THE TRAY.

4.

CHECK THAT THE FEED HEAD HAS BEEN INSTALLED CORRECTLY. a.

Check that the bearing at the front of the Feed Head is correctly seated in the channel.

b.

Look at the Feed Head and ensure it is engaged with the Stack Relief Solenoid.

c.

Check that the front and rear bearing retainers are tight.

5.

REMOVE THE SAFETY COVER FROM THE TUBE SHAFT.

6.

REMOVE THE PAPER TRAY SETUP TOOL, LOCATED UNDER THE TRAY 1 LABEL PANEL.

7.

REMOVE THE AUTO LATCH BRACKET FROM THE FEED HEAD. CAUTION

Do not damage the Entry Guide with the setup tool or feeler stock. If the Paper Tray Setup Tool does not touch the Entry Guide, unlatch the Feed Belt and insert the feeler stock between the tool and the Entry Guide. Latch the Feed Belt and measure the gap. Unlatch the Feed Belt in order to remove the feeler stock. NOTE: Ensure that the Paper Tray Setup Tool can be inserted and removed from the left shaft without moving the shaft upward. 8.

CHECK THE FEED BELT TENSION (Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

3 CHECK: THE POSITION OF THE ECCENTRIC PIN

VIEWED FROM THE RIGHT SIDE OF THE FEED HEAD ASSEMBLY

LEFT OF CENTER

2

RIGHT OF CEN-

ENSURE THAT THE FEED BELT IS LATCHED

4 CHECK: THE PAPER TRAY SETUP TOOL MUST TOUCH THE ENTRY GUIDE, OR THERE MUST BE NO MORE THAN A 0.1 mm GAP

1 NOTE: POSITION THE PAPER TRAY SETUP TOOL

CAUTION ENTRY GUIDE

Figure 1 Checking the Feed Belt Tension 9.

IF THE CHECK IS GOOD, GO TO STEP 11. IF THE CHECK IS NOT GOOD, GO TO STEP 10.

10. ADJUST THE FEED BELT TENSION (Figure 2).

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

VIEWED FROM THE REAR OF THE FEED HEAD ASSEMBLY

1 LOOSEN THE SMALL NUT

2 POSITION THE ECCENTRIC PIN

RIGHT OF CENTER LEFT OF CENTER

3 ENTRY GUIDE

4 HOLD THE ECCENTRIC PIN AND TIGHTEN THE SMALL NUT

ROTATE THE ECCENTRIC PIN SO THAT THE PAPER TRAY SETUP TOOL CONTACTS THE ENTRY GUIDE, OR THERE IS NO MORE THAN A 0.1 mm GAP BETWEEN THE TOOL AND THE ENTRY GUIDE

Figure 2 Adjusting the Feed Belt Tension 11. REMOVE THE PAPER TRAY SETUP TOOL AND REINSTALL THE SAFETY COVER OVER THE TUBE SHAFT.

14. WHEN ADJUSTING ONLY TRAY 2: ADD PAPER TO TRAY 1 AND PUSH THE TRAY INTO THE PRINTER.

12. REINSTALL THE AUTO LATCH BRACKET.

15. RAISE THE PAPER PLATE TO THE MIDDLE POSITION:

WARNING

a.

Ensure that the Right Door Interlock Switch is not actuated. This will prevent personal injury and ensure that the elevator does not move when the Tray Interlock Switch is cheated.

Manually rotate the right front lead screw, or insert a cheater into the Printer Right Door Interlock.

b.

Enter dC330, [7-8]. Select Tray 1 Elevator Up] or [Tray 2 Elevator Up]. Press the Continue Button.

NOTE: Access the Tray 1 or Tray 2 Interlock Switch through Tray 1.

c.

Press the Stop button when the paper plate is in the middle position.

d.

Remove the cheater from the Printer Right Door Interlock.

13. CHEAT THE TRAY INTERLOCK SWITCH. Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

NOTE: This check is to ensure that the paper plate is parallel with the gate (front to rear). If this is correct, then side-to-side parallelism will be within specification. 16. CHECK THE FRONT-TO-REAR PAPER PLATE PARALLELISM (Figure 3). MEASURE FROM THE PAPER PLATE TO THE GATE

3

1

MEASUREMENT AT THE REAR OF THE TRAY MUST BE EQUAL TO THE FRONT WITHIN 1.0 mm

POSITION THE SCALE AT THE FRONT OF THE TRAY

2 RAISE THE PAPER PLATE TO THE HALF-WAY POSITION

Figure 3 Checking the Paper Plate Parallelism 17. IF THE CHECK IS GOOD, GO TO STEP 21. IF THE CHECK IS NOT GOOD, GO TO STEP 18. CAUTION Hold the left front lift nut so that it cannot rotate. The nut may break if it is allowed to rotate. NOTE: One revolution of the lift nut is equal to approximately 3.0 mm of paper plate travel. 18. ADJUST THE FRONT-TO-REAR AND SIDE-TO-SIDE PAPER PLATE PARALLELISM AS FOLLOWS: a.

Remove the paper plate and the plate supports (Figure 4).

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

3 REMOVE THE NUT

2 REMOVE THE SCREWS (4)

4 REMOVE THE PLATE

1 REMOVE THE SCREW, NUT AND GROUND WIRE FROM THE UNDER SIDE OF THE PAPER PLATE

5 REMOVE THE SUPPORTS

Figure 4 Removing the Paper Plate and the Supports b.

Rotate the right front lead screw in order to position the left front lift nut so that the tool can be properly inserted (Figure 5).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

CAUTION ROTATE THE LEAD SCREW TO POSITION THE NUT

Figure 5 Positioning the Left Front Lift Nut c.

Rotate the right front lift nut so that tool can be properly inserted (Figure 6). Do not turn the lead screw.

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

1

2

ROTATE THE NUT TO CONTACT THE TOOL

REMOVE THE RETAINER

3 PUSH

4 ROTATE THE NUT TO CONTACT THE TOOL

5 REINSTALL THE RETAINER

Figure 6 Positioning the Rear Lift Nuts d.

Position the rear lift nuts (Figure 6). Do not turn the lead screw.

e.

Reinstall the front and rear supports; ensure that they are not installed upside down.

f.

Reinstall the paper plate. Ensure that the Length Guide is in the center (side-to-side) of the paper plate opening.

g.

Check the paper plate parallelism again (Figure 7).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

MEASURE FROM THE PAPER PLATE TO THE GATE

3

1

MEASUREMENT AT THE REAR OF THE TRAY MUST BE EQUAL TO THE FRONT WITHIN 1.0 mm

POSITION THE SCALE AT THE FRONT OF THE TRAY

2 RAISE THE PAPER PLATE TO THE HALF-WAY POSITION

Figure 7 Checking the Paper Plate Parallelism 19. IF THE CHECK IS GOOD, GO TO STEP 20. IF THE CHECK IS NOT GOOD, REPEAT STEP 18 UNTIL THE PARALLELISM IS CORRECT. 20. ENSURE THAT THE GROUND WIRE AND NUT HAVE BEEN REINSTALLED. 21. CHECK THE PAPER PLATE ENDPLAY (Figure 8).

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

SUPPORT

LIFT NUT SUPPORT

LIFT NUT

3 CHECK: GAP 1.0 TO 1.5 mm

2 CHECK: GAP 0.5 TO 1.0 mm

1 PUSH THE PLATE TOWARD THE FRONT

Figure 8 Checking the Paper Plate Endplay 22. IF THE CHECK IS GOOD, GO TO STEP 25. IF THE CHECK IS NOT GOOD, GO TO STEP 23. 23. LOOSEN THE PAPER PLATE SCREWS (5) AND THE LEFT REAR SUPPORT NUT (1) (Figure 9).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

LEFT SUPPORT

LIFT NUT

SUPPORT

LIFT NUT

1.0 TO 1.5 mm ADJUST: 0.5 TO 1.0 mm

7 MOVE THE RIGHT REAR SUPPORT AGAINST THE FEELER

8 TIGHTEN THE SCREWS (2)

6 TIGHTEN THE SUPPORT NUT (1)

1

5 PUSH AND HOLD THE PLATE TO THE FRONT

3 PUSH FRONT SUPPORT AGAINST THE LIFT NUTS

4 TIGHTEN THE SCREWS (3)

2

PUT THE FEELER BETWEEN THE LIFT NUT AND THE LEFT REAR SUPPORT

HOLD THE PAPER PLATE AGAINST THE FEELER

Figure 9 Adjusting the Paper Plate Endplay NOTE: Hold the feeler gauge in place with tape or place the hex keys through the holes in the feeler gauge. 24. ADJUST THE PAPER PLATE ENDPLAY (Figure 9). 25. RAISE THE PAPER PLATE: a.

Manually rotate the right front lead screw, or insert a cheater into the Printer Right Door Interlock.

b.

Enter dC330, [7-8]. Select Tray 1 Elevator Up] or [Tray 2 Elevator Up]. Press the Continue button.

26. CHECK THE STACK HEIGHT ADJUSTMENT (Figure 10).

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

3 CHECK: THE TOOL MUST BE FLUSH TO THE PAPER PLATE AND GATE WITH NO MORE THAN 0.5 mm

PAPER PLATE

GATE

1 HANDCRANK CLOCKWISE UNTIL THE STACK HEIGHT DISPLAY GOES TO L

2 POSITION THE TOOL

Figure 10 Checking the Stack Height a.

Observe the Stack Height Sensor: Enter dC330, [7-8]. Observe the Tray 1 Stack Height Sensor or Tray 2 Stack Height Sensor display.

b.

Check the stack height (Figure 10).

27. IF THE CHECK IS GOOD, GO TO OF STEP 29. IF THE CHECK IS NOT GOOD, GO TO STEP 28. NOTE: It may be necessary to break the Glyptol seal in order to perform this adjustment. 28. ADJUST THE STACK HEIGHT (Figure 11).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

3 ROTATE COUNTERCLOCKWISE UNTIL THE STACK HEIGHT DISPLAY GOES TO L

2 ROTATE CLOCKWISE UNTIL THE STACK HEIGHT DISPLAY IS H

1 ROTATE THE LEAD SCREW UNTIL THE TOOL IS FLUSH WITH THE PAPER PLATE AND THE GATE

PAPER PLATE

Figure 11 Adjusting the Stack Height NOTE: If the Stack Height Sensor display does not change to H (Figure 12, Step 5), adjust the Auto Latch (ADJ 7-6). Continue from this point in the procedure when the Auto Latch adjustment has been completed. 29. PREPARE TO CHECK THE STACK FORCE (Figure 12).

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

2 ENSURE THAT THE STACK RELIEF SOLENOID MOVES FREELY

TURNED 90 DEGREES

1 ENSURE THAT THE FEED HEAD ASSEMBLY MOVES FREELY

3 INSTALL A 5.0 mm HEX KEY BETWEEN THE FEED BELT AND THE CORK PAD

6 HANDCRANK CLOCKWISE UNTIL THE STACK HEIGHT DISPLAY GOES TO L

5 4

NOTE: HANDCRANK COUNTERCLOCKWISE UNTIL THE STACK HEIGHT DISPLAY GOES TO H

ENSURE THAT THE HEX KEY IS IN THE CENTER OF THE FEED BELT, AND THAT THE END DOES NOT CONTACT THE ENTRY GUIDE

Figure 12 Preparing to Check the Stack Force NOTE: When the Feed Head is moved, or when the force is adjusted, the Feed Head may not return to nominal position. Before the stack force is checked or adjusted, lightly tap the Feed Head to ensure the correct position. 30. REMOVE HEX KEY AND CHECK THE STACK FORCE (Figure 13).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-9

1 INSERT A 1.0 mm GAUGE ON THE TOP OF THE CORK PAD AND UNDER THE FEED BELT TURNED 180°

FEED BELT

2

CAUTION DO NOT DEFLECT THE TRAY WHEN TAKING A MEA-

3 ADJUST: ROTATE THE NUT CLOCKWISE FROM THE TOP TO DECREASE THE GAP

1.0 mm GAUGE

CHECK: 0.15 +0.05/-0.0 mm CORK PAD

Figure 13 Checking/Adjusting the Stack Force 31. IF THE CHECK IS GOOD, GO TO STEP 33. IF THE CHECK IS NOT GOOD, GO TO STEP 32.

35. IF THE CHECK IS GOOD, GO TO STEP 38. IF THE CHECK IS NOT GOOD, GO TO STEP 36.

NOTE: If the gap is too large and cannot be set to specification, adjust the Auto Latch (ADJ 76). Continue from this point in the procedure when the Auto Latch adjustment has been completed.

NOTE: If the adjustment cannot be achieved before the screw is at the end of travel, ensure that the solenoid is energized. If the adjustment still cannot be performed with the solenoid energized, de-energize it and go to step 26 (stack height adjustment).

32. ADJUST THE STACK FORCE (Figure 13).

36. ADJUST THE STACK RELIEF SOLENOID (Figure 14).

33. REMOVE THE FEELER STOCK FROM THE PAPER PLATE. 34. CHECK THE STACK RELIEF SOLENOID. a.

Energize the solenoid by entering dC330, [7-8]. Select [Tray 1 Stack Relief] or [Tray 2 Stack Relief]. Press the Continue button.

b.

Ensure that the plunger on the solenoid is pressed in completely.

c.

Do not press the Stop button.

d.

With the solenoid still energized, observe the Tray 1 Stack Height Sensor or Tray 2 Stack Height Sensor display.

e.

Verify that the Tray 1 or 2 Stack Height Sensor display is H and changes to L when a very small amount of upward pressure is applied to the feed head.

Section Name

ADJ 7-9

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Preliminary Working Document No Product Name Assigned

1 ENERGIZE THE STACK RELIEF

3 2 SLOWLY ROTATE CLOCKWISE UNTIL THE STACK HEIGHT DISPLAY IS H

ROTATE COUNTERCLOCKWISE UNTIL THE STACK HEIGHT DISPLAY IS L, THEN CLOCKWISE UNTIL DISPLAY GOES TO H

Figure 14 Adjusting the Stack Relief Solenoid 37. REPEAT STEPS 34e and 35.

ADJ 7-10 Lock Assembly

38. DE-ENERGIZE THE STACK RELIEF SOLENOID BY ENTERING dC330, [7-8]. SELECT [Tray 1 Stack Relief] OR [Tray 2 Stack Relief].

Purpose

39. LOWER THE PAPER PLATE BY ENTERING dC330, [7-8]. SELECT [Tray 1 Elevator Dn] OR [Tray 2 Elevator Dn]. PRESS THE Continue BUTTON. 40. REMOVE THE CHEATER FROM THE PRINTER RIGHT DOOR INTERLOCK SWITCH.

Check

41. REMOVE THE CHEATER FROM THE TRAY INTERLOCK SWITCH. 42. IF THE STACK HEIGHT WAS ADJUSTED, ADJUST THE DOWN/LOW PAPER SENSOR (ADJ 7-2).

Preliminary Working Document No Product Name Assigned

The purpose is to ensure that Trays 1 and 2 are securely locked when the trays are in the closed position.

NOTE: Ensure that the trays are fully closed when checking for the 0.75 mm gap. 1.

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OPEN THE PRINTER RIGHT DOOR AND CHECK THE LOCK ASSEMBLY (Figure 1).

Section Name

ADJ 7-9

3 TIGHTEN THE NUT

1 2 ADJUST: LOOSEN THE NUT AND MOVE THE PIN FOR A GAP OF 0.75 +/- 0.25 mm

CHECK: GAP: 0.75 +/- 0.25 mm

Figure 1 Checking/Adjusting the Lock Assembly

Adjustment

ADJ 7-11 Elevator Drive Belt

1.

Purpose

ADJUST THE LOCK ASSEMBLY (Figure 1).

The purpose is to adjust the tension of the Elevator Drive Belt to prevent the binding or an erratic movement of the elevator.

Adjustment CAUTION To prevent damage to the length guide, do not press down on the bottom plate with excessive force, or move upper side of elevator across the work surface.

Section Name

ADJ 7-11

1.

REMOVE THE ELEVATOR ASSEMBLY.

2.

REMOVE THE BOTTOM PLATE (Figure 1).

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Preliminary Working Document No Product Name Assigned

2

3

REMOVE THE SCREWS (2)

TIGHTEN (4)

2 NOTE: MOVE THE ELEVATOR MOTOR TO TENSION THE BELT

3 REMOVE THE BOTTOM PLATE

1 1

REMOVE THE SCREWS (6)

LOOSEN (4)

Figure 1 Removing the Bottom Plate

Figure 2 Adjusting the Belt Tension

NOTE: The binding of the elevator will occur if the belt is too tight. Apply minimum tension to the belt. 3.

ADJUST THE BELT TENSION (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-11

Section Name

ADJ 7-11

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Preliminary Working Document No Product Name Assigned

ADJ 7-30 Elevator Drive Belt

ADJ 7-31 Stack Height/stack Height Sensor (Q735)

Purpose

Purpose

The purpose is to adjust the tension of the Elevator Drive Belt in order to prevent the elevator from erratic movement or binding.

The purpose of the Stack Height Adjustment is to ensure that the Paper Plate is parallel with the Feeder Assembly, and that the Stack Height Sensor (Q735) is adjusted to ensure that the paper stack is positioned properly.

Adjustment 1.

PULL OUT THE HIGH CAPACITY TRAY.

Adjustment

2.

REMOVE THE BOTTOM PLATE.

NOTE: These adjustment steps must be performed in sequence.

NOTE: Allow the spring-loaded idler to set the tension of the belt. Do not add more force to the belt. 3.

LOOSEN THE SCREW SECURING THE IDLER TO ADJUST THE ELEVATOR DRIVE BELT.

4.

CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (ADJ 7-31).

1.

PULL OUT THE PAPER TRAY.

2.

REMOVE THE PAPER FROM THE PAPER TRAY.

NOTE: In dC330, it will be necessary to use the UI to raise and lower the elevator. Raise the elevator to approximately 100mm from the surface around the bearing retainers. 3.

RAISE THE ELEVATOR. ENTER dC330, SELECT [7-8X], [Tray X Elevator UP] AND PRESS THE Continue BUTTON.

4.

CHECK THE PAPER PLATE PARALLELISM (Figure 1).

2 CHECK: THE MEASURED AREAS (4) MUST BE PARALLEL WITHIN 1.0 mm

NOTE: ENSURE THAT THE FRONT MEASUREMENTS ARE MADE BETWEEN THE PAPER PLATE AND THE SURFACE AROUND THE BEARING RETAINERS

1 ENSURE THAT THE PAPER PLATE IS SEATED ON THE LIFT NUTS (4)

Figure 1 Checking the Paper Plate Parallelism

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-30, ADJ 7-31

5.

IF THE CHECK IS GOOD, GO TO STEP 10. IF IT IS NOT GOOD, CONTINUE WITH STEP 6.

6.

SWITCH OFF THE PRINTER POWER.

7.

ADJUST THE PAPER PLATE PARALLELISM (Figure 2).

2 ADJUST: LIFT THE PAPER PLATE AND TURN THE LIFT NUTS TO RAISE OR LOWER THE PLATE

1 REMOVE THE SCREWS (4), AND THE CLIPS (4) FROM THE UNDERSIDE OF THE PAPER PLATE

3 MEASURE AND ADJUST THE AREAS (4) UNTIL PLATE IS PARALLEL WITHIN 1.0 mm

Figure 2 Adjusting the Paper Plate Parallelism 8.

RECHECK THE PAPER PLATE PARALLELISM. READJUST IF NECESSARY.

9.

SWITCH ON THE PRINTER POWER.

10. ENTER dC330, SELECT [7-8X]. OBSERVE Tray X Stack Height Sensor. CAUTION Do not damage the Switch Actuator when positioning the Switch Actuator on the paper plate. Before exiting dC330, lower the elevator approximately 100mm, this will avoid possible tray damage. NOTE: Trim the paper so it will lie flat on the Tray Ramp between the Length Guide and the side wall. 11. CHECK THE STACK HEIGHT SENSOR (Q735) (Figure 3).

Section Name

ADJ 7-31

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Preliminary Working Document No Product Name Assigned

FEED BELT

5 CHECK: A SMALL AMOUNT OF RESISTANCE SHOULD BE FELT AS THE PAPER IS PULLED BETWEEN THE RAMP AND THE BELT

1 PUSH THE TRAY IN UNTIL THE TRAY RAMP IS POSITIONED UNDER THE FIRST FEED BELT

TRAY RAMP

2 NOTE: POSITION A PIECE OF 20LB (80 GSM) PAPER ON TOP OF THE TRAY RAMP

3 CAUTION PUSH THE WIDTH GUIDE IN UNTIL IT IS AGAINST THE PAPER PLATE

4 HANDCRANK THE ELEVATOR UP UNTIL THE [Tray X Stack Height Sensor] CHANGES TO H

Figure 3 Checking the Stack Height Sensor 12. IF THE CHECK IS GOOD, THE PROCEDURE IS COMPLETE. IF THE CHECK IS NOT GOOD, CONTINUE WITH STEP 13. NOTE: If the Stack Height Sensor Case has slotted mounting holes, ensure that the actuator arm is horizontal to the Paper Plate. If needed, loosen the mounting hardware and adjust the switch. 13. ADJUST THE STACK HEIGHT SENSOR (Figure 4).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-31

3 IF THE [Tray X Stack Height Sensor] IS H, ROTATE THE SETSCREW CLOCKWISE UNTIL THE SENSOR CHANGES TO L

4 ROTATE THE SETSCREW COUNTERCLOCKWISE UNTIL [Tray X Stack Height Sensor] CHANGES TO H

1 POSITION A SHEET OF 20 LB (80 GSM) PAPER BETWEEN THE RAMP AND THE FEED BELT

2 HANDCRANK THE ELEVATOR UP UNTIL RESISTANCE IS FELT ON THE PAPER AS IT IS PULLED BETWEEN THE RAMP AND BELT

Figure 4 Adjusting the Stack Height Sensor 14. RECHECK THE STACK HEIGHT SENSOR. READJUST IF NECESSARY.

ADJ 7-32 Latch Assembly

15. CHECK/ADJUST THE LOW PAPER SENSOR (Q738) (ADJ 7-33).

Purpose The purpose is to ensure that HCT is securely locked into the processor when the tray is closed, and to ensure the smooth release of the Latch Assembly.

Check NOTE: Ensure that the tray is fully closed and biased to the rear of the machine. 1.

Section Name

ADJ 7-31

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CHECK THE LATCH ASSEMBLY (Figure 1).

Preliminary Working Document No Product Name Assigned

1 ENSURE THAT THE TRAY IS FULLY CLOSED

2 CHECK: MEASURE FOR A GAP OF 1.0 +/-0.5 mm

Figure 1 Checking the Latch Assembly

Adjustment NOTE: Ensure that the two screws securing the Latch Assembly and the two screws securing the Release Solenoid are tight. 1.

ADJUST THE LATCH ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-32

2 ENSURE THAT THE TRAY IS CLOSED

3 ADJUST: MOVE THE BRACKET TO ACHIEVE THE GAP OF 1.0 +/- 0.5 mm

1 LOOSEN THE NUTS (2)

4 TIGHTEN THE NUTS (2) Figure 2 Adjusting the Latch Assembly

Section Name

ADJ 7-32

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Preliminary Working Document No Product Name Assigned

ADJ 7-33 Low Paper Sensor (Q738) LOW PAPER SENSOR (Q738)

Purpose The purpose of this procedure is to ensure that the Low Paper Sensor (Q738) actuates when the paper quantity is low.

Check 1.

OPEN THE TRAY.

2.

REMOVE ALL THE PAPER FROM THE TRAY.

3.

PLACE APPROXIMATELY 50 SHEETS OF 20 LB (80 GSM) PAPER INTO THE TRAY.

4.

CLOSE THE TRAY.

NOTE: In dC330, it will be necessary to use the UI to raise and lower the elevator. 5.

RAISE THE ELEVATOR. ENTER dC330, SELECT [7-8X], [Tray X Elevator UP] AND PRESS THE Continue BUTTON.

6.

CHECK THAT THE Tray X Down/Low Paper Sensor AND THE Tray X Stack Height Sensor ARE BOTH DISPLAYING H.

Adjustment 1.

CHECK/ADJUST THE STACK HEIGHT/STACK HEIGHT SENSOR (Q735) (ADJ 7-31).

2.

SWITCH OFF THE PRINTER POWER.

3.

REMOVE THE APPROPRIATE FS LOWER REAR COVER.

4.

ACCESS THE SENSORS (PL 7.17).

5.

CHECK THAT THE SENSOR ACTUATOR ARMS ARE NOT BENT OR BROKEN.

6.

IF THE CHECK IS GOOD, CONTINUE. IF THE CHECK IS NOT GOOD, REPLACE THE SWITCH ASSEMBLY.

7.

SWITCH ON THE PRINTER POWER.

8.

OPEN THE TRAY.

NOTE: In dC330, it will be necessary to use the UI to raise and lower the elevator. 9.

1

ENSURE THAT THERE ARE 50 SHEETS OF20 LB (80 GSM) PAPER IN THE TRAY.

NOTE: ADJUST THE SCREW UNTIL THE SENSOR CHANGES TO H

10. CLOSE THE TRAY. 11. RAISE THE ELEVATOR TO THE STACK HEIGHT USING dC330. NOTE: It may be necessary to break the Glyptol seal from the screw before performing the adjustment. 12. OBSERVE THE Tray X Down/Low Paper Sensor ON THE SCREEN WHILE ADJUSTING THE LOW PAPER SENSOR (Figure 1).

Preliminary Working Document No Product Name Assigned

Figure 1 Adjusting the Low Paper Sensor 13. APPLY A SMALL AMOUNT OF ADHESIVE 63P561 (USMG) OR 600T90352 (RXL) TO THE SCREW ON THE LOW PAPER SENSOR.

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Section Name

ADJ 7-33

ADJ 7-34 Front Cover

Adjustment

Purpose

NOTE: The Manometer must be removed to access the nuts.

The purpose is to position the Front Cover flush with the Stacker Front Cover, Vertical Transport Door and Horizontal Transport Door. The Front Cover is also positioned so that there is a visually uniform gap around the cover.

1.

PULL OUT THE HIGH CAPACITY TRAY.

2.

ADJUST THE ALIGNMENT OF THE FRONT COVER (Figure 2).

Check 1.

CHECK THE ALIGNMENT OF THE FRONT COVER (Figure 1).

1 CHECK: ENSURE THAT THE COVER IS FLUSH +/-1 mm TO THE STACKER FRONT COVER AND THE DOORS

2 CHECK: ENSURE THAT THERE IS A VISUALLY UNIFORM GAP AROUND THE COVER

Figure 1 Checking the Alignment of the Cover

Section Name

ADJ 7-34

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Preliminary Working Document No Product Name Assigned

1 ADJUST: LOOSEN THE NUTS (4) TO SET THE COVER FLUSH +/- 1 mm

2 ADJUST: LOOSEN SCREWS (6) TO SET A UNIFORM GAP

Figure 2 Adjusting the Cover

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-34

ADJ 7-35 HIGH CAPACITY TRAY SWITCH ASSEMBLY Purpose The purpose of this adjustment is to ensure the proper relationship between the Low Paper Sensor, the Tray Up Limit Switch, the Tray Down Sensor, and the Tray Down Limit Switch. Proper adjustment of these switches will minimize the number of elevator faults and/or the almost fault condition 07-241 where no fault is declared on the Printer Monitor but a fault is recorded in the Printer Performance Log (PPR).

Adjustment NOTE: These adjustment steps must be performed in sequence. 1.

LOWER THE TRAY AND REMOVE ALL THE PAPER FROM THE TRAY TO BE ADJUSTED.

2.

REMOVE THE LOWER REAR IFS OR FS COVER TO ACCESS THE SWITCH ASSEMBLIES.

3.

REMOVE THE SWITCH ASSEMBLY SAFETY COVER.

4.

ENTER DC330 (FEEDER 3/4) (7-8 A/B) LOW PAPER SENSOR (Q738) ADJUSTMENT.

5.

IN DC330 RAISE THE PAPER TRAY WHILE VISUALLY ENSURING THAT THE LOW PAPER/TRAY DOWN SENSOR CHANGES LOGIC STATE.

6.

MANUALLY LOWER THE TRAY A FEW TURNS PAST THE POINT WHERE THE SWITCHES ACTIVATE. NOW SLOWLY RAISE THE TRAY WHILE WATCHING THE PRINTER MONITOR SWITCH SENSOR ICON. ADJUST AND STOP THE TRAY UPWARD MOVEMENT AT THE EXACT POINT THE SENSOR SWITCH ACTUATION POINT IS REACHED.

7.

MEASURE THE DISTANCE FROM THE TOP SURFACE OF THE UPPER ACTUATOR TAB TO THE TOP OF THE SWITCH ASSEMBLY. THE DISTANCE SHOULD BE 37MM +/- 0.5. IF THE DISTANCE IS NOT CORRECT PERFORM THE FOLLOWING STEPS Figure 1.

Section Name

ADJ 7-35

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Preliminary Working Document No Product Name Assigned

MEASUREMENT DISTANCE

UPPER ACTUATOR TAB

MEASURE AND ADJUST GAP TO 37MM +/- 0.5

UP LIMIT SWITCH (S741)

PAPER TRAY (UPPER POSITION)

LOW PAPER/TRAY DOWN SENSOR S738

UPPER ACTUATOR TAB

ADJUST: ENT SET SCREWS (UPPER)

Figure 1 ADJUST SENSOR a.

MANUALLY RAISE OR LOWER THE TRAY TO OBTAIN THE 37MM +/- 0.5 DISTANCE.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 7-35

b.

ADJUST THE SET SCREW SLOWLY UNTIL THE LOW PAPER/TRAY DOWN SENSOR ICON JUST CHANGES STATE ON THE PRINTER MONITOR. THIS SWITCH IS NOW PROPERLY ADJUSTED.

8.

MANUALLY RAISE THE TRAY UNTIL THE TRAY UP LIMIT SWITCH (S741) IS ACTUATED. A CLICKING SOUND WILL BE HEARD FROM THE SWITCH, OR THE USE OF A 120 VAC VOLTMETER CAN BE USED.

9.

MEASURE THE DISTANCE FROM THE TOP SURFACE OF THE UPPER ACTUATOR TAB TO THE TOP OF THE TRAY UP LIMIT SWITCH. THE DISTANCE SHOULD BE 34MM +/- 0.5. IF THE DISTANCE IS NOT CORRECT PERFORM THE FOLLOWING STEPS Figure 2.

Section Name

ADJ 7-35

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Preliminary Working Document No Product Name Assigned

MEASUREMENT DISTANCE

UPPER ACTUATOR TAB

MEASURE AND ADJUST GAP TO 34MM +/- 0.5

UP LIMIT SWITCH S741

PAPER TRAY (UPPER POSITION)

LOW PAPER/TRAY DOWN SENSOR S738

UPPER ACTUATOR TAB

ADJUST: ENT SET SCREWS (UPPER)

Figure 2 ADJUST SENSOR a.

RAISE OR LOWER THE TRAY TO OBTAIN THE 34MM +/- 0.5 DISTANCE.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-503

Section Name

ADJ 7-35

NOTE: Ensure that the distance of 3mm exists between actuation points of the low paper sensor (Q738) and the tray up limit switch (S741). Readjust the sensor to switch gap as necessary. One turn of the lead screw is equal to approximately 3mm. b.

ADJUST THE SET SCREW UNTIL THE TRAY UP LIMIT SWITCH (S741) HAS JUST ACTUATED.

10. ENTER DC330, LOWER THE TRAY. ENSURE THE LOW PAPER/TRAY DOWN SENSOR ICON CHANGES STATE. 11. MANUALLY RAISE THE TRAY A FEW TURNS PAST THE POINT WHERE THE SWITCHES ACTIVATE. NOW SLOWLY LOWER THE TRAY WHILE WATCHING THE PRINTER MONITOR SWITCH SENSOR ICON. ADJUST AND STOP THE TRAY DOWNWARD MOVEMENT AT THE EXACT POINT THE SENSOR SWITCH ACTUATION POINT IS REACHED. 12. MEASURE THE DISTANCE FROM THE TOP SURFACE OF THE UPPER ACTUATOR TAB TO THE TOP OF THE SWITCH ASSEMBLY. THE DISTANCE SHOULD BE 51MM +/- 0.5. IF THE DISTANCE IS NOT CORRECT PERFORM THE FOLLOWING STEPS Figure 3.

Section Name

ADJ 7-35

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Preliminary Working Document No Product Name Assigned

MEASUREMENT DISTANCE

UPPER ACTUATOR TAB

MEASURE AND ADJUST THE GAP TO 51MM +/- 0.5

UPPER ACTUATOR TAB

ADJUST: ENT SET SCREWS (LOWER POSITION)

LOW PAPER/TRAY DOWN SENSOR S737

DOWN LIMIT SWITCH S740

Figure 3 ADJUST SENSOR a.

RAISE OR LOWER THE TRAY TO OBTAIN THE 51MM +/- DISTANCE.

Preliminary Working Document No Product Name Assigned

b.

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ADJUST THE SET SCREW UNTIL THE LOW PAPER/TRAY DOWN SENSOR ICON JUST CHANGES STATE. Section Name

ADJ 7-35

13. MANUALLY LOWER THE TRAY UNTIL THE TRAY DOWN LIMIT SWITCH (S740) IS ACTUATED. A CLICKING SOUND WILL BE HEARD FROM THE SWITCH, OR THE USE OF A 120 VAC VOLTMETER CAN BE USED. 14. MEASURE THE DISTANCE FROM THE TOP SURFACE OF THE SWITCH ACTUATOR TAB TO THE TOP OF THE SWITCH ASSEMBLY. THE DISTANCE SHOULD BE 54MM +/- 0.5. IF THE DISTANCE IS NOT CORRECT PERFORM THE FOLLOWING STEPS Figure 4.

Section Name

ADJ 7-35

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Preliminary Working Document No Product Name Assigned

MEASUREMENT DISTANCE

UPPER ACTUATOR TAB

MEASURE AND ADJUST GAP TO 54MM +/- 0.5

UPPER ACTUATOR TAB

ADJUST: ENT SET SCREWS (LOWER POSITION)

LOW PAPER/TRAY DOWN SENSOR S737

DOWN LIMIT SWITCH S740

Figure 4 ADJUST SENSOR a.

MANUALLY RAISE OR LOWER THE TRAY TO OBTAIN THE 54MM +/- 0.5 DIS-

Preliminary Working Document No Product Name Assigned

0/0/00 ?-507

TANCE.

Section Name

ADJ 7-35

NOTE: Ensure that the distance of 3mm exists between actuation points of the tray down sensor (Q730) and the tray down limit switch (S740). Readjust the sensor to switch gap as necessary. One turn of the lead screw is equal to approximately 3mm. b.

ADJUST THE SET SCREW SLOWLY UNTIL THE TRAY DOWN LIMIT SWITCH (S740) IS JUST ACTUATED.

Section Name

ADJ 7-35

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Preliminary Working Document No Product Name Assigned

ADJ 8-0 Registration Transport Upper Baffles

Check

Purpose

1.

The purpose is to ensure proper alignment of the Upper Baffles, so that the idlers are located over the cross rolls.

CHECK THAT HOLES IN UPPER BAFFLES ARE ALIGNED WITH HOLES IN THE LOWER BAFFLES (Figure 1).

FRONT VIEW

4 mm HEX KEY

3

2

LOOSEN NUTS (3) TO ADJUST

LOOSEN NUTS (2) TO ADJUST

1 CHECK: THE HEX KEYS FIT THROUGH HOLES

6 mm HEX KEY

Figure 1 Checking/Adjusting the Baffles

Adjustment

ADJ 8-1 Pretransfer Baffle

1.

Purpose

ADJUST BAFFLES (Figure 1).

The purpose of this adjustment is to position the Pretransfer Baffles so that the skew between the lead and trail edge of a print does not occur.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 8-0

Check 1.

NOTE: When using 13 or 110 lb papers, the distance between X1 and X2 must be 0 +/- 1.2 mm on all 10 prints.

LOAD THE PAPER TRAY 1 WITH 11 INCH (A4) 20 LB (80 GSM) PAPER.

NOTE: The printer will generate 10 prints of the Test Pattern. Save these prints so that it can be determined in which direction the Pretransfer Baffle Cams have to move. 2.

3.

CHECK THE PRINTS FOR SKEW (Figure 1).

ENTER dC604, SELECT [Tests], [Skew], AND PRESS THE Continue BUTTON.

CHECK: THE DIFFERENCE BETWEEN DISTANCE X1 AND DISTANCE X2 MUST BE 0.00 +/- 0.8 mm ON ALL 10 PRINTS

Figure 1 Checking the Prints for Skew

Adjustment 1.

OPEN THE PRINTER FRONT DOORS AND REMOVE THE PHOTORECEPTOR INNER PANEL.

NOTE: Use the Test Pattern prints to determine in which direction the Cams have to move. 2.

ADJUST THE PRETRANSFER BAFFLE (Figure 2).

Section Name

ADJ 8-1

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Preliminary Working Document No Product Name Assigned

2

1

LOOSEN 1/2 REVOLUTION

LOOSEN SCREWS (2)

3 IF DISTANCE X2 IS FARTHER FROM THE EDGE OF THE PRINT THAN DISTANCE X1, SET THE LOWER CAM TO "0" AND ADJUST THE UPPER CAM NOTE: “0” POSITION IS THE HIGHEST POSITON OF THE CAM UPPER CAM

4

5

IF DISTANCE X1 IS FARTHER FROM THE EDGE OF THE PRINT THAN DISTANCE X2, SET THE UPPER CAM TO "0" AND ADJUST THE LOWER CAM

TIGHTEN THE SCREWS (3) LOWER CAM

Figure 2 Adjusting the Pretransfer Baffle 3.

CLOSE THE PRINTER FRONT DOORS, PRESS THE Continue BUTTON AND CHECK THE PRINTS FOR SKEW.

4.

REPEAT STEPS 2 AND 3 UNTIL THE SKEW IS WITHIN SPECIFICATION.

5.

IF THE SKEW CANNOT BE SET TO SPECIFICATION, ADJUST THE REGISTRATION TRANSPORT (ADJ 8-4).

6.

CHECK/ ADJUST THE ROS IMAGE SQUARENESS (ADJ 6-2).

7.

CHECK/ADJUST THE SIDE-TO-SIDE REGISTRATION (ADJ 8-3).

8.

CHECK/ADJUST THE TOP-TO-BOTTOM REGISTRATION (ADJ 8-2).

Preliminary Working Document No Product Name Assigned

ADJ 8-2 Top-to-Bottom Registration Purpose The purpose is to ensure that the image is transferred to the paper in the correct location with respect to the top and bottom edges of the paper.

Check 1.

ENTER dC604, SELECT [setups], [Printer Options], [Test Patterns and PQ], and [Dimensional].

2.

SELECT [Registration] AND PRESS THE Continue BUTTON.

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Section Name

ADJ 8-1

3.

CHECK THE PRINTS FOR THE TOP-TO-BOTTOM REGISTRATION (Figure 1).

2 THE REGISTER EDGE

CHECK: DISTANCE X1 MUST BE 10.0 +/- 0.65 mm

1 CHECK: ARROW MUST BE VISIBLE

THE LEAD EDGE

Figure 1 Checking the Top-To-Bottom Registration

Adjustment

ADJ 8-3 Side-to-Side Registration

1.

CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1).

Purpose

2.

ADJUST THE TOP-TO-BOTTOM REGISTRATION:

The purpose is to ensure that the image is transferred to the paper in the correct location with respect to the lead and trail edges of the paper.

a.

Use the arrows (Up to increase, Down to decrease) to position the arrow correctly, then press the Continue button.

b.

Repeat the adjustment until specification is achieved.

Section Name

ADJ 8-3

Check 1.

ENTER dC604, SELECT [Setups], [Printer Options], [Test Patterns and PQ], and [Dimensional].

2.

SELECT [Registration] AND PRESS THE Continue BUTTON.

3.

CHECK THE PRINTS FOR THE SIDE-TO-SIDE REGISTRATION (Figure 1).

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Preliminary Working Document No Product Name Assigned

LEAD EDGE

REGISTRATION EDGE

1 CHECK: ARROW MUST BE VISIBLE

2 CHECK: X3 DISTANCE MUST BE 10.0 +/- 0.65 mm

Figure 1 Checking the Side-To-Side Registration

Adjustment

ADJ 8-4 Registration Transport

1.

CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1).

Purpose

2.

ADJUST THE SIDE-TO-SIDE REGISTRATION:

The purpose of this adjustment is to move the Registration Transport into a nominal position so that skew can be eliminated by the fine adjustment of the Pretransfer Baffle.

NOTE: Decreasing the Range value increases the visibility of the X3 grid.

3.

a.

Use the left and right arrows to position the X3 distance correctly, then press the Continue button.

b.

Repeat the adjustment until specification is achieved.

CHECK/ADJUST TRANSFER BLADE TIMING (ADJ 9-9).

Preliminary Working Document No Product Name Assigned

Adjustment 1.

LOAD THE PAPER TRAY 1 WITH 11 INCH (A4) 20LB (80 GSM) PAPER.

2.

REMOVE THE PHOTORECEPTOR INNER PANEL AND INSTALL THE CHEATER IN THE RIGHT DOOR INTERLOCK SWITCH.

3.

MOVE THE UPPER AND THE LOWER PRETRANSFER BAFFLE CAMS INTO THE ZERO POSITION (Figure 1).

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Section Name

ADJ 8-4

2

1

LOOSEN 1/2 REVOLUTION

LOOSEN SCREWS (2)

3 SET THE UPPER CAM TO "0"

THE UPPER CAM

4 SET THE LOWER CAM TO "0"

5 TIGHTEN THE SCREWS (3)

THE LOWER CAM

Figure 1 Moving the Cams into the Zero Position 4.

CLOSE THE PRINTER FRONT DOORS AND ENTER dC604, [Tests].

5.

SELECT [Skew] AND PRESS THE Continue BUTTON.

NOTE: The printer will generate 10 prints of the Test Pattern. Save these prints so that it can be determined in which direction the Registration Transport has to move. 6.

EVALUATE THE PRINTS FOR SKEW (Figure 2).

Section Name

ADJ 8-4

0/0/00 ?-514

Preliminary Working Document No Product Name Assigned

CHECK: THE DIFFERENCE BETWEEN X1 DISTANCE AND X2 DISTANCE MUST BE 0.00 +/-1.0 mm ON ALL 10 PRINTS

Figure 2 Evaluating the Prints for Skew 7.

PREPARE TO MOVE THE TRANSPORT (Figure 3).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-515

Section Name

ADJ 8-4

FRONT VIEW

2 LIFT AND LATCH THE UPPER RIGHT BAFFLE

3 LOOSEN THE SCREW AND REMOVE THE REGISTRATION TRANSPORT

4 UNLATCH AND LOWER THE BAFFLES (2)

1 LIFT AND LATCH THE UPPER LEFT BAFFLE

Figure 3 Preparing to Move the Transport NOTE: Moving the Registration Transport will provide only a coarse adjustment to eliminate some of the print skew, use the prints of the Test Pattern to determine in which direction the transport has to move. 8.

MOVE THE TRANSPORT (Figure 4).

Section Name

ADJ 8-4

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Preliminary Working Document No Product Name Assigned

5 TIGHTEN THE MOUNTING HARDWARE

4 ADJUST: IF X2 DISTANCE IS FARTHER FROM THE EDGE OF THE PRINT THAN X1 DISTANCE, PUSH IN AND ROTATE THE TRANSPORT IN A COUNTERCLOCKWISE DIRECTION

3 ADJUST: IF X1 DISTANCE IS FARTHER FROM THE EDGE OF THE PRINT THAN X2 DISTANCE, PULL AND ROTATE THE TRANSPORT IN A CLOCKWISE DIRECTION

1 LIGHTLY LOOSEN THE 7 mm SCREW

2 LIGHTLY LOOSEN THE 3 mm ALLEN SCREW

Figure 4 Moving the Transport 9.

ADJ 8-5 Paper Width Timing

PRESS THE Continue BUTTON AND EVALUATE THE PRINTS FOR THE SKEW.

10. REPEAT STEPS 7-9.

Purpose

NOTE: If the skew cannot be set to the specifications, perform the fine adjustment (Pretransfer Baffle) as required.

The purpose is to measure and adjust the Paper Width Timing. The Printer will measure the elapse time between the lead edge and the trail edge of 50 prints at the Registration Transport Sensor (Q861). The Printer will then specify the correct value to be entered into memory.

11. CHECK/ADJUST THE PRETRANSFER BAFFLE (ADJ 8-1). 12. CHECK/ADJUST THE NIP RELEASE SOLENOID ASSEMBLY (ADJ 8-6).

Preliminary Working Document No Product Name Assigned

Adjustment 1.

ENTER dC703, [Setups].

2.

SELECT [Paper Width] AND PRESS THE Continue BUTTON.

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Section Name

ADJ 8-4

3.

ADJ 8-6 NIP Release Solenoid (SOL851)

FOLLOW THE INSTRUCTIONS ON THE PRINTER UI AND PERFORM THE PAPER WIDTH TIMING.

Purpose The purpose is to position the Nip Release Solenoid so that there is adequate clearance between the Pinch Rollers when running oversized paper.

Check 1.

PREPARE 2 ORANGE SHIMS AND 1 BROWN SHIM FOR THE REQUIRED GAP OF 1.78 MM.

2.

OPEN THE PRINTER RIGHT FRONT DOOR AND REMOVE THE INNER PANEL.

3.

CHEAT THE PROCESSOR INTERLOCK BYPASS SWITCH (S103).

4.

ENTER dC330 AND SELECT [8], [Nip Release], THEN PRESS THE Continue BUTTON.

5.

CHECK THE NIP: a.

Insert the shim at the rear and check the Nip between the Rollers, Check 1 (Figure 1).

3 CHECK: 1.78 mm +/- 0.25 mm AT THE REAR

4 CHECK: ZERO GAP AT THE FRONT AND REAR

1

2

SLIGHTLY LOOSEN THE NUTS (3)

ROTATE THE SCREW TO SET THE GAP AND TIGHTEN THE NUTS (3)

Figure 1 Checking/Adjusting the Nip b.

Remove the shim, press the Stop button and check for a zero gap at the front and the rear, Check 2 (Figure 1).

Section Name

ADJ 8-5, ADJ 8-6

Adjustment 1.

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PRESS THE Continue BUTTON AND ADJUST THE NIP: Preliminary Working Document No Product Name Assigned

2.

a.

Insert the shim 1.78 mm at the rear and adjust the Nip. To obtain Check 1, do step 1 and 2 (Figure 1).

b.

Remove the shim, press the Stop button and check for a zero gap at the front and the rear0 Check 2 (Figure 1).

REPEAT THE CHECK/ADJUSTMENT IF REQUIRED.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-519

Section Name

ADJ 8-6

Section Name

ADJ 8-6

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Preliminary Working Document No Product Name Assigned

ADJ 8-9 Lower Preregistration Transport Registration Baffle Assembly Purpose The purpose is to ensure that the Registration Baffle Assembly is positioned properly to allow paper to be registered without skew.

Check 1.

OPEN THE INVERTER DOOR.

2.

CHECK THE LOWER PREREGISTRATION TRANSPORT REGISTRATION BAFFLE ASSEMBLY (Figure 1).

CHECK: THAT THE REGISTRATION BAFFLE IS POSITIONED FULLY AGAINST THE TABS

TABS (2)

Figure 1 Checking the Registration Baffle

Adjustment 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE LOWER PREREGISTRATION TRANSPORT (REP 8-40).

3.

POSITION THE LOWER PREREGISTRATION TRANSPORT ON A FLAT SURFACE WITH THE REGISTRATION ASSEMBLY FACING UPWARDS.

4.

ADJUST THE REGISTRATION BAFFLE ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-521

Section Name

ADJ 8-9

1 LOOSEN NUTS (4)

3 TIGHTEN NUTS (4)

2 ADJUST: POSITION BAFFLE ASSEMBLY FULLY AGAINST THE TABS ON THE FRONT OF THE TRANSPORT

Figure 2 Adjusting the Registration Baffle 5.

REINSTALL THE LOWER PREREGISTRATION TRANSPORT.

ADJ 8-10 Lower Preregistration Transport Pivot Baffle Purpose The purpose is to ensure that the Lower Preregistration Transport Pivot Baffle is positioned properly to allow paper to pass through without jamming.

Check 1.

Section Name

ADJ 8-9

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE INVERTER DOOR.

3.

BEGIN TO CHECK THE PIVOT BAFFLE (Figure 1).

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Preliminary Working Document No Product Name Assigned

1 LOOSEN NUTS (4)

3 TIGHTEN THE NUTS (4)

2 CHECK: THAT THE BAFFLE IS POSITIONED FULLY TO THE REAR

Figure 1 Beginning to Check the Pivot Baffle 4.

REMOVE THE INVERTER REAR COVER AND SWING OUT THE INVERTER PWB PANEL.

5.

ACCESS THE REAR OF THE LOWER PREREGISTRATION TRANSPORT (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 8-10

3 LOOSEN SCREWS (2)

5 REMOVE THE SHIELD

2 REMOVE THE SHIELD

4 LOOSEN THE BOLTS (2)

1 LOOSEN SCREWS (2)

Figure 2 Accessing the Transport 6.

CHECK THE LOWER PREREGISTRATION TRANSPORT PIVOT BAFFLE (Figure 3).

Section Name

ADJ 8-10

0/0/00 ?-524

Preliminary Working Document No Product Name Assigned

CHECK: THAT THE TABS (2) ARE POSITIONED AGAINST THE FRAME AT THE TOP OF CUTOUTS

Figure 3 Checking the Pivot Baffle

Adjustment 1.

ADJUST THE PIVOT BAFFLE (Figure 4).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 8-10

1 LOOSEN NUTS (4)

VIEW FROM THE FRONT

2 3 TIGHTEN THE NUTS (4)

ADJUST: POSITION THE TABS (2) AGAINST THE FRAME AT THE TOP OF THE CUTOUTS

Figure 4 Adjusting the Pivot Baffle

Section Name

ADJ 8-10

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Preliminary Working Document No Product Name Assigned

ADJ 8-11 Lower Preregistration Transport Corrugator Rolls

Adjustment

Purpose

NOTE: Check the condition of the Leaf Springs before performing the adjustment. If the Leaf Springs were overtightened, it may be necessary to remove the springs and reform them.

The purpose of this adjustment is to ensure proper pressure on the Corrugator Rolls.

1.

2.

RAISE THE PIVOT BAFFLE.

ADJUST THE CORRUGATOR ROLLS (Figure 2).

Check 1.

OPEN THE INVERTER DOOR.

2.

RAISE THE PIVOT BAFLE ON THE LOWER PRE-REGISTRATION TRANSPORT.

3.

CHECK THE CORRUGATOR ROLL PRESSURE (Figure 1).

1 INSERT A 2.5mm ALLEN WRENCH BETWEEN THE PRE-REGISTRATION TRANSPORT TRAY AND ROLL

1 INSERT A 2.5mm ALLEN WRENCH BETWEEN THE PRE-REGISTRATION TRANSPORT TRAY AND THE ROLL (2 PLACES)

2 ADJUST: ROTATE NUT FOR A HEIGHT OF 2.5mm +/- 0.25mm BETWEEN TRAY AND ROLL (2 PLACES)

2 CHECK: FOR A HEIGHT OF 2.5mm +/- 0.25mm

Figure 2 Adjusting the Corrugator Roll Pressure

Figure 1 Checking the Corrugator Roll Pressure

Preliminary Working Document No Product Name Assigned

0/0/00 ?-527

Section Name

ADJ 8-11

ADJ 8-12 Lower Preregistration Transport Pivot Baffle Bumper

PIVOT BAFFLE

Purpose The purpose of this adjustment is to maintain the correct height between the Pivot Baffle and the Lower Preregistration Transport Tray.

1 INSERT A 6mm ALLEN WRENCH BETWEEN THE PRE-REGISTRATION TRANSPORT TRAY AND THE PIVOT BAFFLE

Check 1.

LOWER THE HORIZONTAL TRANSPORT DOOR ON THE IFS.

2.

RAISE THE PIVOT BAFFLE ON THE IFS HORIZONTAL TRANSPORT.

3.

OPEN THE INVERTER DOOR.

4.

CHECK THE HEIGHT OF THE PIVOT BAFFLE ON THE LOWER PRE-REGISTRATION TRANSPORT (Figure 1).

2 CHECK: FOR A GAP OF 6.0mm +/- 0.5mm AND THAT THE BUMPER JUST TOUCHES THE TRANSPORT

Figure 1 Checking the Pivot Baffle Height

Adjustment 1.

Section Name

ADJ 8-12

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ADJUST THE PIVOT BAFFLE BUMPER (Figure 2).

Preliminary Working Document No Product Name Assigned

ADJ 8-13 Tray 3 Oversize NIP Release Solenoid (SOL852) Purpose 3

1

TIGHTEN THE NUT

INSERT A 6mm ALLEN WRENCH

The purpose of this adjustment is to ensure that there is not any pressure on the Horizontal Transport Roller Assemblies when operating in the oversize paper mode.

Check 1.

OPEN THE INVERTER DOOR.

NOTE: The check must be made while the solenoid is energized. It may be necessary to use the Remote Hand Held Device (RHHD) to perform the check. For detailed Operating Instructions of the RHHD, go to (GP 1). 2.

ENTER dC330. SELECT [7-8A], [Tray 3 Oversize Nip Release] AND PRESS THE Continue BUTTON.

3.

CHECK THE TRAY 3 OVERSIZE NIP RELEASE SOLENOID WHILE IT IS ENERGIZED (Figure 1).

CHECK: INSERT A 0.508mm SHIM AND CHECK THE GAP

2 ADJUST: LOOSEN NUT AND ROTATE BUMPER UNTIL IT TOUCHES THE TRANSPORT

Figure 2 Adjusting the Bumper

Figure 1 Checking the Solenoid

Adjustment 1.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-529

UNLATCH AND PULL OUT TRAY 3.

Section Name

ADJ 8-12, ADJ 8-13

NOTE: The solenoid will have to be adjusted from the rear of the machine. 2.

3.

ADJUST THE TRAY 3 OVERSIZE NIP RELEASE SOLENOID (Figure 2).

REMOVE THE IFS LOWER REAR COVER.

2 ADJUST: MOVE THE SOLENOID TOWARDS THE FRONT TO INCREASE THE GAP OR TOWARDS THE REAR TO DECREASE THE GAP

3 TIGHTEN THE SCREWS (2)

1 LOOSEN THE SCREWS (2)

Figure 2 Adjusting the Solenoid 4.

PERFORM THE CHECK AGAIN. READJUST IF NECESSARY.

ADJ 8-14 IFS/FS Horizontal Transport Pivot Baffle Purpose The purpose is to ensure that the Horizontal Transport Pivot Baffle is positioned properly to allow paper to pass through without jamming.

Section Name

ADJ 8-13

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Preliminary Working Document No Product Name Assigned

Check 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE APPROPRIATE STACKER LOWER REAR COVER.

3.

LOWER THE STACKER AC RELAY PANEL.

4.

MANUALLY UNLATCH AND OPEN THE HIGH CAPACITY TRAY.

5.

REMOVE THE AC SAFETY SHIELD (Figure 1).

2 REMOVE THE SHIELD

1 REMOVE THE NUTS (2)

Figure 1 Removing the Shield 6.

CHECK THE HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 2).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-531

Section Name

ADJ 8-14

2 CHECK: THAT THE ROUND TABS (2) ARE POSITIONED AGAINST FRAME

1 CHECK: THAT THE TABS (3) ARE POSITIONED AGAINST FRAME AT TOP OF CUTOUTS

Figure 2 Checking the Baffle

Adjustment 1.

ADJUST THE HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 3).

Section Name

ADJ 8-14

0/0/00 ?-532

Preliminary Working Document No Product Name Assigned

1

4 ADJUST: MOVE THE BAFFLE TOWARDS THE REAR UNTIL THE ROUND TABS (2) ARE POSITIONED AGAINST THE FRAME AND TIGHTEN THE NUTS (6)

LOOSEN THE NUTS (6)

3 LOOSEN THE NUTS (6)

2 ADJUST: POSITION THE TABS (3) AGAINST THE FRAME IN TOP OF CUTOUTS AND TIGHTEN THE NUTS (6)

Figure 3 Adjusting the Baffle

Preliminary Working Document No Product Name Assigned

0/0/00 ?-533

Section Name

ADJ 8-14

ADJ 8-15 Intermediate Horizontal Transport Pivot Baffle

2.

Purpose

3.

MANUALLY UNLATCH TRAY 4 AND PUSH IT OPEN.

4.

LOWER THE AC RELAY PANEL.

5.

REMOVE THE AC SAFETY SHIELD (Figure 1).

6.

ADJUST THE INTERMEDIATE HORIZONTAL TRANSPORT PIVOT BAFFLE (Figure 1).

The purpose is to ensure that the Horizontal Transport Pivot Baffle is positioned properly to allow paper to pass through without jamming.

REMOVE THE STACKER LOWER REAR COVER FROM THE FS.

Adjustment 1.

SWITCH OFF THE PRINTER POWER.

1 LOOSEN NUTS (2)

4 ADJUST: POSITION THE HINGE ALL THE WAY DOWN AND TIGHTEN NUTS (2)

VIEW ROTATED 90°

2 ADJUST: POSITION THE BAFFLE ALL THE WAY TO THE REAR AND TIGHTEN THE NUTS (2)

3 LOOSEN NUTS (2)

Figure 1 Adjusting the Pivot Baffle

Section Name

ADJ 8-15

0/0/00 ?-534

Preliminary Working Document No Product Name Assigned

ADJ 9-0 Toner Thumper

Adjustment

Purpose

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

The purpose is to position the thumper screw, so that the thumper contacts the bottle.

2.

OPEN THE XEROGRAPHIC DRAWER (REP 9-34).

3.

ADJUST THE THUMPER (Figure 1).

RIGHT FRONT VIEW

TONER BOTTLE

3 TIGHTEN THE JAM NUT

2

TONER DISPENSER ASSEMBLY

ADJUST SCREW FOR 9.5+/-1.0 mm GAP

1 LOOSEN THE JAM NUT

Figure 1 Adjusting the Thumper

ADJ 9-1 Developer Zone Roll

Purpose The purpose is to improve the copy quality by ensuring that the Developer Zone Roll is aligned in the area of optimal development within the Developer Assembly. The Zone Roll is moved from the nominal position (white Bearing Housings) to either the left, or to the right, by using the appropriate color-coded Bearing Housing.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-535

Section Name

ADJ 9-0

Check

5.

NOTE: White opaque correction fluid (or an equivalent marking medium) is needed in order to perform this check.

CLEAN THE SUPPORT PADS, AND APPLY A THIN COATING OF WHITE OPAQUE CORRECTION FLUID. LOWER AND SEAT THE PR MODULE BEFORE THE FLUID IS DRY.

WARNING

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

RAISE THE PR MODULE COMPLETELY.

Support the PR Module when working in the area below it. Failure to take precautions could result in injury in the event of an accidental failure of the PR Module hydraulic support system.

4.

LOCATE THE OUTBOARD AND THE INBOARD SUPPORT PADS FOR THE LEFT DEVELOPER ZONE ROLL (THE METAL PADS BETWEEN ROLL 1 AND ROLL 2, SHOWN ON Figure 1).

Cover the cavity of the Developer Assembly in order to prevent contamination of the Developer Material.

CAUTION

6.

1 MEASURE FROM THE LEFT EDGE TO THE CENTER OF IMPRESSION IN THE FLUID

PERFORM THE CHECK (Figure 1): a.

Measure the distance from the left edge of the support pad to the center of the impression in the correction fluid.

b.

Record the measurement for the Outboard support pad.

c.

Record the measurement for the Inboard support pad.

d.

If the distance from the left edge of the support pad to the center of the impression is between 5.5 +/- 0.5 mm, Outboard and Inboard, the alignment is in specification.

Adjustment 1.

OBSERVE THE EXAMPLE IN Figure 2, AND USE THE FOLLOWING PROCESS TO DETERMINE THE COLOR OF THE BEARING HOUSING WHICH MUST BE INSTALLED (PART OF TABLE 3 FOR THE EXISTING OUTBOARD BEARING HOUSING IS SHOWN IN THE FOLLOWING EXAMPLE).

ROLL 2

LEFT OUTBOARD SUPPORT PAD ROLL 1

Figure 1 Checking the Roll Position

Section Name

ADJ 9-1

0/0/00 ?-536

Preliminary Working Document No Product Name Assigned

b.

1 SELECT THE TABLE FOR THE EXISTING BEARING HOUSING COLOR

Locate the column in that table which includes the value of the measurement recorded in Step 6b of the Check. The correct color of the Bearing Housing to be installed, is listed below the value in the applicable table. Table 1 : VIOLET Existing OUTBOARD Bearing Housing

3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

WHITE

YELLOW

VIOLET (Adjustment not (In Specification) available)

6.0 - 7.0 mm

7.0 - 8.0 mm (Adjustment not available)

Table 2 : YELLOW Existing OUTBOARD Bearing Housing 3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

BROWN

WHITE

YELLOW VIOLET (In Specification)

6.0 - 7.0 mm

7.0 - 8.0 mm (Adjustment not available)

Table 3 : WHITE Existing OUTBOARD Bearing Housing

2 LOCATE THE COLUMN THAT INCLUDES THE RECORDED VALUE TO DETERMINE THE COLOR OF THE REPLACEMENT HOUSING

3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

GRAY

BROWN

WHITE YELLOW (In Specification)

6.0 - 7.0 mm

7.0 - 8.0 mm VIOLET

Table 4 : BROWN Existing OUTBOARD Bearing Housing 3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

(Adjustment not available)

GRAY

BROWN WHITE (In Specification)

6.0 - 7.0 mm

7.0 - 8.0 mm YELLOW

Table 5 : GRAY Existing OUTBOARD Bearing Housing Figure 2 Determining the Bearing Housing Color NOTE: Along with the color, the positioning bosses on all but the white Bearing Housings are marked in order to indicate the direction and distance the Zone Roll is displaced from nominal. Determine the Zone Roll displacement while viewing from the front of the Machine. •

3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

(Adjustment not available)

(Adjustment not available)

GRAY BROWN (In Specification)

3.

Violet (-2): Moves the Outboard end of roll 2 mm to the left Yellow (-1): Moves the Outboard end of roll 1 mm to the left

a.

Select the table which corresponds to the color of the existing Inboard Bearing Housing.

b.

Locate the column in that table which includes the value of the measurement recorded in Step 6b of the Check. The correct color of the Bearing Housing to be installed, is listed below the value in the applicable table.

Yellow (-1): Moves the Inboard end of roll 1 mm to the right • • •

White (Nominal): Originally installed in all PR Modules. Brown (+1): Moves the Outboard end of roll 1 mm to the right

Table 6 : GRAY Existing INBOARD Bearing Housing

Brown (+1): Moves the Inboard end of roll 1 mm to the left

3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

Gray (+2): Moves the Outboard end of roll 2 mm to the right

WHITE

BROWN

GRAY (Adjustment not (In Specification) available)

Gray (+2): Moves the Inboard end of roll 2 mm to the left 2.

USE THE FOLLOWING TABLES (1 - 5) IN ORDER TO DETERMINE THE COLOR OF THE OUTBOARD BEARING HOUSING TO BE INSTALLED (PL 9.4). a.

Select the table which corresponds to the color of the existing Outboard Bearing Housing.

Preliminary Working Document No Product Name Assigned

7.0 - 8.0 mm WHITE

USE THE FOLLOWING TABLES (6 - 10) IN ORDER TO DETERMINE THE COLOR OF THE INBOARD BEARING HOUSING TO BE INSTALLED (PL 9.4)

Violet (-2): Moves the Inboard end of roll 2 mm to the right •

6.0 - 7.0 mm

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6.0 - 7.0 mm

7.0 - 8.0 mm (Adjustment not available)

Table 7 : BROWN Existing INBOARD Bearing Housing 3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

YELLOW

WHITE

BROWN GRAY (In Specification)

6.0 - 7.0 mm

7.0 - 8.0 mm (Adjustment not available)

Section Name

ADJ 9-1

ADJ 9-2 NVM Read/Write

Table 8 : WHITE Existing INBOARD Bearing Housing 3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

6.0 - 7.0 mm

VIOLET

YELLOW

WHITE BROWN (In Specification)

7.0 - 8.0 mm

Purpose

GRAY

The purpose is to read or write values in MIN NVM Addresses as needed in order to perform a Xerographic Setup procedure.

Table 9 : YELLOW Existing INBOARD Bearing Housing 3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

6.0 - 7.0 mm

(Adjustment not available)

VIOLET

YELLOW WHITE (In Specification)

Adjustment

7.0 - 8.0 mm

1.

BROWN

NOTE: Ensure that the correct values are entered in NVM or there will be an erroneous setup. 2.

Table 10 : VIOLET Existing INBOARD Bearing Housing 3.0 - 4.0 mm

4.0 - 5.0 mm

5.0 - 6.0 mm

6.0 - 7.0 mm

(Adjustment not available)

(Adjustment not available)

VIOLET YELLOW (In Specification)

7.0 - 8.0 mm WHITE

4.

REMOVE THE LEFT DEVELOPER ZONE ROLL, AND THE BEARING HOUSING(S) WHICH MUST BE REPLACED.

5.

INSTALL THE PROPER BEARING HOUSING(S) (OUTBOARD AND/OR INBOARD), ENSURING THAT THE TWO POSITIONING BOSSES ARE SECURELY SEATED IN THE FRAME OF THE PR MODULE.

6.

SEAT THE INBOARD BEARING OF THE ZONE ROLL IN THE INBOARD HOUSING, THEN PUSH THE OUTBOARD BEARING INTO THE OUTBOARD HOUSING.

7.

REPEAT THE CHECK (STEPS 5 AND 6).

8.

REINSTALL THE PHOTORECEPTOR AND THE PHOTORECEPTOR INNER PANEL.

9.

RESTORE THE PRINTER POWER.

Section Name

ADJ 9-1, ADJ 9-2

ENTER dC131, [NVM Read/Write].

SELECT [MIN] OR [PHN] AS REQUIRED.

3.

ENTER THE ADDRESS NUMBER ON THE CONTROL PANEL.

4.

SELECT [Enter] ON THE Address DISPLAY.

5.

ENTER THE DESIRED DATA VALUE ON THE CONTROL PANEL.

6.

SELECT [Enter] ON THE Data DISPLAY.

7.

PERFORM THIS PROCEDURE FOR EACH MIN AND PHN ADDRESS REQUIRING DATA CHANGE.

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Preliminary Working Document No Product Name Assigned

ADJ 9-3 Xerographic Setup Purpose

b.

Press the Lamp Test Switch (S901). Ensure that all segments of the Pretransfer Lamp (DS901) and the Precharge Lamp (DS902) are lit.

c.

If either lamp does not function correctly proceed to the PQ 9-624, Precharge/Pretransfer Lamps RAP.

The purpose of this procedure is to adjust the Xerographic process control parameters. 5.

Adjustment To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. NOTE: If NVM was lost or a NODE INIT was performed, check/adjust the NVM Node Initialization Recovery (ADJ 9-15). NOTE: Excessive removal of the Dicorotron housing, (not shields), can cause premature failure of the dicorotron and/or connectors. Do not remove the dicorotrons for cleaning or inspection until directed to do so by HFSI requirements or RAP diagnostics. 1.

ENTER THE DIAGNOSTICS MODE. SELECT [SCP], [HFSI], [Dicorotrons]. PERFORM THE MAINTAINENCE ACTIONS FOR ALL ITEMS EXCEEDING THEIR SERVICE INTERVAL. SELECT [Reset Count] AS REQUIRED.

NOTE: If the toner is low in the bottle, the Xerographic Set-up procedure will not be completed. 2.

WARNING Do not touch the ESV if the Printer is switched on. High voltage is present on the ESV when the Printer is in the operating mode. CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. Do not clean the Dicorotron Housing or Wires. Do not put grease from the insulator onto housing. 6.

CLEAN THE DSS AND THE ESV WITH A CLEAN, SOFT, LINT FREE CLOTH.

7.

CLEAN THE FOLLOWING COMPONENTS WITH A SOFT, DRY, LINT-FREE CLOTH ONLY:

ENSURE THAT THERE IS AN ADEQUATE SUPPLY OF TONER IN THE TONER BOTTLE.

NOTE: Developer must be prepared in order to refresh its triboelectric properties. This is accomplished by running enough prints to purge the toner from the new developer and dispense fresh toner. 3.

IF NEW DEVELOPER WAS INSTALLED, PERFORM THE DEVELOPER PREPARATION, OTHERWISE GO TO STEP 4 BELOW. a.

8.

Place at least two reams (1000 sheets) of A4 (8 1/2 x 11) or a larger paper size in Tray 1.

NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if additional information is needed. b.

Enter dC131, NVM Read/Write.

c.

Select [MIN].

NOTE: MIN Address 250 is the PGen Reference Increment value. Decreasing this value creates a darker patch, extending the tone down cycle. An extended tone down cycle forces the purging of toner from the developer material. MIN NVM address 250 data value will be automatically updated during the TC/PGen Setup.

4.

SWITCH OFF THE PRINTER POWER.

9.

a.

Patch Generator (REP 9-36)

b.

Belt Hole Sensor

c.

POP Sensor (Q904) Cleaning (REP 9-60).

d.

Dicorotron Shields only (REP 9-39)

e.

Clean the bottom of the Cleaner Housing (REP 9-26)

INSPECT THE XEROGRAPHIC MODULES FOR DIRT AND ANY DAMAGE. CLEAN OR REPAIR AS REQUIRED. USE THE VACUUM CLEANER IN ORDER TO CLEAN THE FOLLOWING COMPONENTS: a.

PR Module

b.

PR Ground Brush

c.

Developer Assembly (REP 9-5)

d.

MIM Cavity Cooling Fan

EMPTY THE DEVELOPER CATCH TRAY.

10. RESTORE THE PRINTER POWER. 11. ENSURE THAT ALL COVERS ARE CORRECTLY INSTALLED TO PREVENT AMBIENT LIGHT FROM ENTERING THE XEROGRAPHIC MODULE.

d.

Enter Address 250. Reduce the existing Data value by 5.

e.

Enter dC909. Select [Printer Options], [Tray 1], [Stacker A], [Test Patterns and PQ], [XERO].

12. IF A NEW INSTALL AND/OR A MIN NODE INIT WAS PERFORMED, OR THE DSS WAS REPLACED DURING THIS SERVICE CALL, PERFORM THE DSS SATURATION (ADJ 9-13). WHEN COMPLETED, CONTINUE WITH STEP 12.

f.

Select [Patch Test].

13. CHECK THE CHARGE DICOROTRON BALANCE (ADJ 9-6).

g.

Program 1000 Prints. Press Continue.

NOTE: If the Xerographic Set-Up IS NOT initiated due to an HSFI replacement of Developer material, perform 15.

ENSURE THAT ALL ELEMENTS OF THE PRETRANSFER LAMP (DS901) AND THE PRECHARGE LAMP (DS902) ARE OPERATING CORRECTLY AS FOLLOWS: a.

Pull out the Xerographic Drawer, and open the Photoreceptor module in order to observe the lamps.

Preliminary Working Document No Product Name Assigned

14. IF THE XEROGRAPHIC SETUP IS INITIATED DUE TO THE HFSI REPLACEMENT OF DEVELOPER MATERIAL, ONLY THE [TC/PGEN] PORTION OF DC951 IS REQUIRED, PERFORM THE FOLLOWING:

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Section Name

ADJ 9-3

a.

Enter dC951. Select [TC/PGen], [Printer Options], [Tray 1], [Stacker A]. Press Continue.

c.

If the solid area density block 3 is greater than STD: RESTORE or, the background is greater than ALL: BKGD, go below to 20.

b.

Go to Step 15.

d.

If this is a MICR Machine, enter [Printer Options], [PQ]. Select [MICR14], [Fine Adjust]. Program 15 prints and press Continue.

15. PERFORM THE XEROGRAPHIC SET-UP: a.

Enter dC951. Select [Load Defaults], [Confirm].

NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if additional information is needed. b.

Enter dC131, [NVM Read/Write].

c.

Select [MIN].

d.

Check the following NVM addresses and verify the Data values are as listed in the appropriate level Software dC 131 Table (Section 6, General Procedures, in the Service Manual).

Value

a.

ii.

If the average Signal Strength of all the characters is greater than 160, go below to 20.

124

243

125

244

202

245

210

251

220

260

225

466

228

466

Program 500 prints.

NOTE: Do not increase the [Patch Gen Ref] by more than two bits at one time, or more than 6 bits total. Refer to the PQ 9-609, Low Image Darkness RAP if a problem occurs. b.

Min Address

Value

Increase the value of the [Patch Gen Ref] by one or two bits.

c.

Press Continue. Allow at least 250 prints before evaluating the print quality.

d.

Repeat 19 until the Toner Concentration is in specification.

20. DECREASE THE TONER CONCENTRATION: a.

Program 500 prints.

NOTE: Do not decrease the [Patch Gen Ref] by more than two bits at one time, or more than 6 bits total. (Do not change the Toner Concentration below the value of 26.) If there is a problem with the adjustment that requires more than 6 bits, go to the PQ 9-610, High Image Darkness RAP.

e.

Enter dC314. Check the Power Supply Calibration values using the HVAC/HVDC Calibration Cards located in the Printer Log Book.

f.

Enter dC951. Select [ROS Correction]. Perform the ROS Low Correction Factor (ADJ 6-3).

g.

Select [Xero], [Printer Options], [Tray 1], [Stacker A].

h.

If the average Signal Strength of all the characters is less than 100, go below to 19.

19. INCREASE THE TONER CONCENTRATION BY PERFORMING THE FOLLOWING:

Table 1 Min Address

i.

b.

Decrease the value of the [Patch Gen Ref] by one or two bits.

c.

Press Continue. Allow at least 250 prints before evaluating the print quality.

NOTE: Adjusting "Exposure" in Fine adjust has no effect on actual exposure. If PQ problems are encountered, use the appropriate PQ RAP. d.

Load two reams of A4 (8 1/2 x 11) or a larger paper size in Tray 1. Select [Xero], Press Continue.

Repeat 20 until the Toner Concentration is in specification.

21. CHECK THE 1-PIXEL @ 600 SPI LINES. NOTE: This routine runs prints 1 pixel at 600 SPI quadrilles.

NOTE: A message will indicate Xero Setup Successfully Completed, and the Fine Adjust Button will appear on the Setups scorecard.

a.

Enter dC951. Select [600 SPI Pattern].

b.

Select [Printer Options]. Select the tray with the longest size paper available.

NOTE: The [Fine Adjust] icon is only enabled after portions of the Xerographic Setup are successfully completed. Exiting dC951 before completing the Fine Adjustment will disable the [Fine Adjust] icon. The icon will not appear again unless certain parts of the Xerographic Setup are performed.

c.

Program 15 prints. Press Continue.

d.

Compare the print to the XTP #564.001 (82E4161). Use the Printer 1 Pixel Line Visual Reference to evaluate the 1-pixel lines. The 1-Pixel lines must be visible in both the fast scan and slow scan directions. In addition no visible structured (patterned) background should be observed (Figure 1).

16. SELECT [Fine Adjust]. PROGRAM 15 PRINTS. PRESS Continue. 17. SELECT THE PRINT WITH THE HIGHEST BACKGROUND. 18. COMPARE THE PRINT SELECTED WITH THE XTP #564.001 (82E4161), AND CHECK THE FOLLOWING: a.

If the solid area density block 3 is equal to the STD: RESTORE block, and the background is less than or equal to ALL: BKGD, go to 21.

b.

If the solid area density block 3 is less than the STD: RESTORE block, go below to 19.

Section Name

ADJ 9-3

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Preliminary Working Document No Product Name Assigned

CHECK: 1-PIXEL LINE MUST BE VISIBLE IN BOTH DIRECTIONS

Figure 1 Checking the 1-Pixel Lines NOTE: If the ROS Calibration % was changed, it is necessary to rerun the Xerographic setup but do not change the ROS Calibration % back to the value on the ROS assembly in 15 of the setup. NOTE: Adjusting "Exposure in Fine Adjust" has no effect on actual Exposures. If PQ problems continue, Go to the appropriate PQ RAP. e.

If the 1-Pixel Lines are not visible in both directions, or if the 1-Pixel Lines are visible in both directions, but there is background, Enter dC951. Select [ROS Correction]. Ensure that the ROS Calibration % on the screen is equal to the value on the ROS assembly. Press Continue.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-541

Section Name

ADJ 9-3

ADJ 9-5 Patch Generator Timing

c.

Enter dC131 MIN, enter address 129 and record the initial value.

Purpose

d.

Enter dC131 MIN, enter address 128. Add 15 to the value recorded from address 129 and enter this new combined number into address 128.

e.

NOTE: Prior to performing this procedure ensure that the ROS Magnification setup is correct (ADJ 6-1).

Enter dC909. Select [Charge Control] open, [Patch Print] Yes. select 25 prints and press Continue.

f.

Examine a print with a patch. The white area should be centered around the patch. It is this white area that is moved when adjusting dC 909 setups pgen timing.

Check

g.

If the check is good, restore dc131 MIN address 128 to its initial data value. If not proceed to the adjustment.

The purpose is to ensure that the patch generator is properly exposing the patch.

1.

Perform the following procedure: a.

Save the setup parameters at the printer.

Adjustment

b.

Enter dC131 MIN, enter address 128 and record the initial value.

1.

Enter dC909. Select [Setups], [P Gen Timing]. Use the arrows to move the exposure window right or left to vary the position of the Pgen exposure. Select [Enter] (Figure 1).

EXPOSURE WINDOW

WHITE AREA CENTERED AROUND THE PATCH

UNEXPOSED PATCH LESS THAN 2.0 mm LEAD EDGE AND TRAIL EDGE OF PATCH

Figure 1 Checking the Patch Generator Timing 2.

Select [Tests], [Charge Control] open, [Patch Print] Yes. Select 25 Prints. Press Continue.

3.

Examine a print with a patch. The white area around the patch should be centered. Repeat steps 1 and 2 until the patch is centered.

4.

Enter dC131 MIN, address 128 and restore it to the initial data value.

Section Name

ADJ 9-5

5.

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Perform Xerographic Setup (ADJ 9-3).

Preliminary Working Document No Product Name Assigned

ADJ 9-6 Charge Dicorotron Balance Purpose The purpose is to ensure a uniform charging of the Photoreceptor. The adjustment is performed by raising or lowering the front end of the Dicorotrons.

Check NOTE: Use the longest size paper available. NOTE: When performing Dicorotron balance, it is critical that the balance be set as uniformly as possible to ensure even Signal Strength Inboard to Outboard. 1.

ENTER dC131, [MIN] LOC 128. RECORD THE CURRENT VALUE.

2.

SELECT [MIN] LOC 129. ADD 10 TO LOC 129 VALUE AND ENTER THIS NEW NUMBER IN LOC 128.

3.

ENTER dC909. SELECT [Print Options], [Test Patterns and PQ], [Xerographic], [Normal], [Tests], [Patch Test]. CHANGE [Charge Control] TO Open. SELECT 7 PRINTS, AND PRESS THE Continue BUTTON.

4.

INSPECT THE PRINTS FOR A VERY LIGHT BACKGROUND.

NOTE: If the Background is too dark, re-enter [MIN] Loc 128, increase the value by 10 or less, and repeat Steps 3 and 4. 5.

COMPARE THE TEST PATTERN DENSITIES FROM TOP TO BOTTOM (Figure 1).

Preliminary Working Document No Product Name Assigned

0/0/00 ?-543

Section Name

ADJ 9-6

1 CHECK: HALFTONE DENSITIES ARE EQUAL

2

3

CHECK: LINE PAIR DENSITIES ARE EQUAL

CHECK: SOLID DENSITIES ARE EQUAL

Figure 1 Comparing the Densities 6.

IF THE DENSITIES ARE UNIFORM, CHANGE THE [MIN] LOC 128 BACK TO THE VALUE RECORDED AT THE BEGINNING OF THIS PROCEDURE.

7.

IF THE DENSITIES ARE NOT UNIFORM, PERFORM THE ADJUSTMENT.

Adjustment CAUTION Do not adjust the Charge Dicorotron Balance with the Printer in the run mode or with the covers removed in order to avoid the damage to the Photoreceptor Belt. NOTE: The adjustment screw can be accessed through the hole in the ROS Lower Inner Panel. The illustration shows the panel removed. NOTE: The Charge '2' Dicorotron is not used in the DP180. 1.

Section Name

ADJ 9-6

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ADJUST THE DICOROTRONS (Figure 2).

Preliminary Working Document No Product Name Assigned

ADJ 9-7 Charge Dicorotron Height Purpose The purpose is to ensure the correct Photoreceptor charging by positioning the Charge Dicorotron rails at the correct distance from the PR Belt.

1 LOOSEN SCREW

Check 1.

POWER OFF THE PRINTER, THE CIRCUIT BREAKERS AND DISCONNECT ALL OF THE POWER CORDS.

NOTE: This adjustment will require some persistent effort and an understanding of the interaction between the adjusting screw and the stop screw. Failure to obtain the correct spacing will result in inaccurate dark decay calculations and/or excessive stress on the Charge Dicorotrons due to an erroneous AC Voltage set-up. 2.

ENSURE THAT THE SHIM KIT (600T41511) IS AVAILABLE.

3.

OPEN THE PRINTER FRONT DOORS, AND REMOVE THE ROS LOWER INNER PANEL.

3

CAUTION

TIGHTEN SCREW

Do not expose the PR Belt to light for more than a few minutes in order to avoid the light shock. Fully cover the PR Belt with paper to decrease light exposure. CAUTION When checking the height, do not apply a downward pressure on the shim because the PR Belt will deflect downwards and cause an erroneous measurement.

2 ADJUST USING THE TOP SCREW ONLY

NOTE: CLOCKWISE ROTATION LOWERS THE DICOROTRONS, COUNTERCLOCKWISE ROTATION RAISES THE DICOROTRONS

NOTE: Use a flashlight in order to illuminate the edge of the shim when checking the Dicorotron height. 4.

CHECK THE CHARGE DICOROTRON HEIGHT AT BOTH THE REAR AND THE FRONT ENDS (Figure 1). a.

Carefully place 20 lb (80 gsm) sheets of paper between the PR Belt and the Dicorotron in order to protect the PR Belt. Align the long edges with the rear edge and front edge of the PR Belt.

b.

Fully cover the rest of the PR Belt with paper to decrease light exposure.

c.

Make a 3.00 mm (0.120 in) thick shim, from the Shim Kit (600T41511), using 4 coral shims.

Figure 2 Adjusting the Charge Dicorotron Balance

2.

a.

Lower the Dicorotrons in order to increase the image density at the top of the print.

b.

Raise the Dicorotrons in order to decrease the image density at the top of the print.

PRESS THE Continue BUTTON, AND REPEAT THE CHECK UNTIL THE DENSITIES ARE UNIFORM.

3.

IF SPECIFICATION CANNOT BE ACHIEVED, CHECK/ADJUST THE CHARGE DICOROTRON HEIGHT (ADJ 9-7).

4.

CHANGE THE VALUE IN LOC 128 TO THE ONE RECORDED AT THE BEGINNING OF THE PROCEDURE.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-545

d.

Gently slide the 3.00 mm shim between the Dicorotron and the sheet of paper.

e.

If there is a gap between the Dicorotron and the shim, continue. If the Dicorotron touches the shim, the Dicorotron must be raised.

f.

Make a 3.25 mm (0.130 in) thick shim, from the Shim Kit (600T41511), using 4 coral, and 1 brown shim.

g.

Gently slide the 3.25 mm shim between the Dicorotron and the sheet of paper.

h.

If the shim just touches the Dicorotron or can not easily be inserted, the adjustment is within specification. If there is a gap between the Dicorotron and the shim, the Dicorotron must be lowered.

Section Name

ADJ 9-6, ADJ 9-7

RIGHT SIDE VIEW

NOTE: THE SHIM MUST BE 100 MM FROM THE REAR EDGE AND THE FRONT EDGE OF THE PR BELT

3 TIGHTEN SCREW

100 MM

1 CHECK: THE HEIGHT MUST BE 3.25 +/- 0.25 mm AT BOTH THE REAR AND FRONT ENDS OF DICOROTRONS

2 TURN THE TOP SCREW FOR FRONT HEIGHT AND THE BOTTOM SCREW FOR REAR HEIGHT UNTIL A SLIGHT DRAG IS FELT IN THE SHIM PACK

100 MM

1

PR BELT

20 LB (80 GSM) SHEETS OF PAPER

LOOSEN SCREW

Figure 1 Checking and Adjusting the Charge Dicorotron Height

Adjustment

ADJ 9-8 Photoreceptor Seam Timing

NOTE: CLOCKWISE rotation of the adjustment screws LOWERS the Dicorotrons. COUNTERCLOCKWISE rotation RAISES the Dicorotrons

Purpose The purpose is to adjust the position of the Photoreceptor Belt Seam in order to prevent the image of the seam from being printed on over-size paper.

1.

ADJUST THE DICOROTRON HEIGHT, FRONT AND REAR.

2.

RECHECK THE DICOROTRON HEIGHT, FRONT AND REAR AND READJUST AS REQUIRED.

Adjustment

3.

RESTORE THE PRINTER TO OPERATING CONDITION.

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section.

4.

VERIFY THE CHARGE DICOROTRON BALANCE (ADJ 9-6).

5.

PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

Section Name

ADJ 9-7

NOTE: Place at least two reams (1000 sheets) of A4 (8 1/2 x 11) or a larger paper size in Tray 1. 1.

ENTER dC 909. SELECT [Printer Options], [Test Patterns and PQ], AND [Xerographic].

2.

SELECT [Setups], [Seam Position], AND PRESS THE Continue BUTTON.

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Preliminary Working Document No Product Name Assigned

3.

CHECK THE PRINTS TO ENSURE THAT THE ARROWS ON THE PRINT ALIGN WITH THE SEAM IMAGE.

4.

USE THE LEFT AND RIGHT ARROW TO POSITION THE SEAM CORRECTLY, THEN SELECT THE ENTER BUTTON ON THE SCREEN.

5.

PRESS THE CONTINUE BUTTON.

6.

REPEAT THE ADJUSTMENT UNTIL SPECIFICATION IS ACHIEVED.

ADJ 9-9 Transfer Blade Timing Purpose The purpose is to set the solenoid actuation times to ensure that the Transfer Blade contacts the prints, and does not contact the Photoreceptor Belt.

Adjustment NOTE: Ensure that the Transfer Blade Timing Kit (kit # 130k44671) and the Transfer Blade Tool (PL 9.11). 1.

2.

CHECK/ADJUST THE FOLLOWING: a.

Pretransfer Baffle (ADJ 8-1).

b.

Side-to-Side Registration (ADJ 8-3).

CHECK THE PROGRAMMED PAPER SIZES. a.

Select the Tools file drawer.

b.

Select [Tray Size...].

NOTE: Tray Length Switches define four distinct length zones. Customer paper sizes are assigned to each zone using the Tray Size screen. The paper sizes (4) must be set to default values to ensure proper solenoid operation during the dC703 timing setup. c.

Record the dimensions (4) programmed for Tray 1.

d.

Input the default values (Table 1). Table 1 Tray

Default Paper Dimensions

(50/60 Hz)

8.5 x 11.00

Tray 1

8.27 x 11.69 8.5 x 13.00 8.5 x 14.00

(50 Hz) Tray 2

8.5 x 10.00

NOTE: (50 Hz); Tray 1 cannot be programmed for both 10 and 11 inch papers at one time. Tray 2 is programmed for the 254 mm (10 inch) default to adjust Solenoid 1, and Tray 1 is programmed for the defaults to adjust Solenoids 2, 3, and 4. 3.

LOAD THE PAPER TRAYS.

NOTE: Larger paper sizes can be simulated during this procedure by placing a shorter size paper in the tray, and moving the Length Guide to the desired position identified in Table 2. NOTE: If the shorter required paper sizes are not available, (11 inch for 60 Hz or 254 mm for 50 Hz), the timing of Solenoid 1 cannot be adjusted. The NVM default timing values, loaded in step 10, will be used for Solenoid 1. To adjust the remaining solenoids refer to Table 2. Load the paper required for each solenoid to be adjusted. a.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-547

(50/60 Hz); Load Tray 1 with 11 inch (279 mm) paper.

Section Name

ADJ 9-8, ADJ 9-9

b.

(50 Hz); Load Tray 2 with 254 mm (10 inch) paper. Table 2 Table 2. Paper Length Requirements

Solenoid Actuated

Paper/Length Guide Position

(60 Hz) 1

11 inch

2

11.69 inch

3

13 inch

4

14 inch or greater

(50 Hz)

4.

1

254 mm

2

279 mm

3

297 mm

4

331 mm or greater

TRANSFER DICOROTRON

VERIFY TRANSFER BLADE CONFIGURATION. a.

Enter dC105 [Configuration], observe the Transfer Blade Configuration, and select:

1

(60 Hz); [11-14 inch].

DEPRESS THE BLADE HANDLE AND REMOVE THE BLADE

(50 Hz); [10-13 inch]. NOTE: If a dC105 change was required, switch off printer power, wait 30 seconds, and then switch on printer power to set the NVM. CAUTION Do not perform this procedure if the solenoids are warm. If an extended print run was made, allow at least 15 minutes before continuing in order to cool the solenoids. Open the Printer front doors to help cool the machine. The software compensates for temperature changes of the solenoids updating the timing. An erroneous set-up will result if the adjustment is made with hot solenoids. 5.

OPEN THE PRINTER FRONT DOORS. CAUTION

Handle the Transfer Blade with care. Do not bend or crease the clear plastic strip. 6.

REMOVE THE TRANSFER BLADE (Figure 1).

Figure 1 Removing the Transfer Blade CAUTION Press the tape firmly against the Blade around pad so that the pad does not move. Ensure that the top edge of the Ink Pad (under the adhesive tape) is carefully and accurately aligned with the top edge of the Transfer Blade, otherwise a timing setup error will result. Apply the ink to the underside of the pad (the upper surface is covered with plastic). Do not put too much ink on the pad or a setup error may result. 7.

Section Name

ADJ 9-9

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ATTACH THE ADHESIVE SIDE OF THE INK PAD TO THE TOP SURFACE OF THE TRANSFER BLADE (Figure 2).

Preliminary Working Document No Product Name Assigned

140 +/- 10 mm

TOP VIEW

CAUTION THE ALIGNED EDGES

FRONT

Figure 2 Attaching the Ink Pad NOTE: After extended use, the ink will flow under the adhesive, and loosen the ink pad. Use additional adhesive tape, if available, to attach the ink pad more securely. Place a piece of tape close to each side of the pad. Attach the adhesive tape to the top surface first, then fold it tightly around the Mylar edge of the Transfer Blade, and attach it to the bottom side of the blade. 8.

CAREFULLY PUT ABOUT 4 DROPS OF INK ON THE UNDERSIDE OF THE INK PAD.

9.

INSTALL THE TRANSFER BLADE (REP 9-48).

NOTE: Larger paper sizes can be simulated during this procedure by placing a shorter paper size into the paper tray, and by moving the Length Guide to the desired position. Use the correct paper size, when available, to reduce the risk of Photoreceptor Belt damage. NOTE: (50 Hz); Select Tray 2 to adjust Solenoid 1. Select Tray 1 to adjust Solenoids 2, 3, and 4. b.

Program a 15 print job, and press Continue.

CAUTION

Table 3

Contamination of the Photoreceptor Belt will occur if the blade is actuated too early or too late. Loading the default values for the solenoids ensures that the blade (ink pad) contacts only the print.

Solenoid Actuated

Paper/Length Guide Position

(60 Hz) 1

11 inch

a.

Select dC703, [Transfer Blade], [Solenoid 1], [Load Defaults].

2

11.7 inch

b.

Select [Solenoid 2] [Load Defaults].

3

13 inch

c.

Select [Solenoid 3] [Load Defaults].

4

14 inch or greater

d.

Select [Solenoid 4] [Load Defaults].

(50 Hz)

e.

Select [Tabs] [Load Defaults].

10. LOAD THE TIMING DEFAULTS.

11. CHECK THE TRANSFER BLADE TIMING. NOTE: Steps 11 and 12 will be repeated for each of the four (4) solenoids. Start with the adjustment of [Solenoid 1]. NOTE: Selecting a [Solenoid X] icon allows access to the PHN NVM Address to adjust the Data value. Icon selection does not energize a specific solenoid. Solenoid operation is determined by the Length Guide position (Length Switch conditions) and the paper size programmed for that position. a.

c.

1

254 mm

2

279 mm

3

297 mm

4

331 mm or greater

Use the last four prints, an erroneous set-up will result if the initial prints are used. Determine the gap between the lead edge of print and the ink stripe, and the gap between the trail edge of print and the ink stripe (Figure 3).

Select [Solenoid X]. Refer to the Table 3 for the paper size (Length Guide position) required for desired solenoid operation.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 9-9

1 MEASURE FROM THE END OF INK STRIPE TO THE EDGE OF THE PRINT

NOTE: SOLENOIDS 1-4 LE 3 +/- 1 mm.

c.

Press the Continue button, and repeat the check/adjustment until the lead and trail edge gaps are in specification.

d.

Repeat Steps 11 and 12 for the remaining solenoids. CAUTION

Width of paper used to set up Tabs must match the paper width in tray size. NOTE: Paper length of 11.7 (297 mm) or less may be used for the tabs set-up. Do not use Tab Stock.

NOTE: SOLENOIDS 1-4 TE 7 +/- 1 mm.

13. CHECK/ADJUST TRANSFER BLADE TIMING FOR TABS. a.

Select [Tabs], program for a job of 15 prints, and press the Continue button.

NOTE: The Transfer Blade Timing specification for [Tabs] is 0.0 mm gap between Trail Edge of print and the ink stripe. To avoid placing an ink on the Photoreceptor Belt during this adjustment, the trail edge gap is set to 1.0 mm, the Transfer Blade (ink pad) is removed, then the gap is decreased by 3 counts to achieve the specification of 0.0 mm.

NOTE: TABS TE SET TO 1.0 +/- 1 mm.

b.

Using the last four prints, determine the gap between the trail edge of print and the ink stripe.

c.

Change the Trail Edge Adjustment gap to 1.0 mm using the arrows to change the Current Value, and press [Enter]. (Left arrow increases the gap.)

d.

Carefully remove the Transfer Blade from the Transfer Dicorotron (REP 9-48).

e.

Using the right arrow change the Trail Edge Adjustment by a value of negative 3 (3 displayed in box) and press [Enter].

INK STRIPE

CAUTION Ensure that the edge of the Transfer Blade is not damaged. A damaged edge will scratch the Photoreceptor, and/or will cause a copy quality defect. 14. REMOVE THE INK PAD FROM THE TRANSFER BLADE, AND CLEAN THE BLADE WITH A SOFT, CLEAN CLOTH AND WATER.

BACK OF PRINT

15. INSTALL THE TRANSFER BLADE (REP 9-48). 16. RESTORE THE PRINTER TO THE OPERATING CONDITION.

REGISTERED EDGE OF PRINT

17. RESTORE THE CUSTOMER REQUIRED TRAY SIZES.

NOTE: 3 counts = 1 mm

a.

Select the Tools file drawer.

b.

Enter [Tray Size...].

c.

Restore the Tray programmed paper sizes recorded in Step 2c. CAUTION

Do not use any solvent to clean the Photoreceptor Belt if it is contaminated with ink. Solvents can embed the ink in the Photoreceptor thus causing a permanent mark and ink spot(s) on the prints. Clean an ink spot only by carefully wiping it with a clean cloth and water.

Figure 3 Checking the Transfer Blade Timing 12. ADJUST THE TRANSFER BLADE TIMING. NOTE: The software will not allow changes greater than 50 bits at one time. If the required change is greater than 50, select [Enter], run prints, then repeat adjustment by adding the remaining bits, and by pressing [Enter]. a.

Change the Lead Edge Adjustment gap to 3.0 mm +/- 1.0 mm using the arrows to change the Current Value, and press [Enter]. (Right arrow increases the gap.)

b.

Change the Trail Edge Adjustment gap to 7.0 mm +/- 1.0 mm using the arrows to change the Current Value, and press [Enter]. (Left arrow increases the gap.)

Section Name

ADJ 9-9

18. ENSURE INK FROM TRANSFER BLADE DID NOT CONTACT THE PHOTORECEPTOR BELT.

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a.

Enter dC606 [Light Dusting], program for 25 prints, and press the Continue button.

b.

Check the prints for contamination of the Photoreceptor Belt by ink, and if contamination is present, perform Photoreceptor Spot Cleaning (REP 9-55).

Preliminary Working Document No Product Name Assigned

ADJ 9-10 PR Module Positioning Tool Instructions, TAG P318 Purpose The purpose is to align the PR Module with the Transfer Assist Device in order to ensure good print quality. PR DRIVE ROLL

Check NOTE: Do not attempt to perform this procedure without the following special service materials on hand: •

PR Module Positioning Tool (600T02180).

•

Photoreceptor Drive Alignment Tool.

•

Zone Roll Kit.

•

Blade Timing Ink Kit.

•

PR Drive Roll.

1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

3.

ENSURE OUT BOARD END OF TOOL AND OUT BOARD END OF PR DRIVE ROLL ARE EVEN

REMOVE THE FOLLOWING: a.

Photoreceptor Inner Panel.

b.

Transfer Dicorotron (REP 9-49)

c.

Preclean, and Detack Dicorotrons (REP 9-39)

d.

Waste Bottle (REP 9-32).

e.

Photoreceptor (REP 9-35).

f.

Pre fuser Transport Assembly (REP 10-12).

g.

Pre transfer Baffle (REP 8-5).

h.

Rear MIM Covers.

i.

Transfer Assist Device (REP 9-50)

DICOROTRON GUIDE

TOOL Figure 1 View of Tool Installed with Buttons Collapsed 5.

REMOVE THE TOOL FROM THE MACHINE. MEASURE AND RECORD THE GAP AT THE INBOARD BUTTON AS INDICATED IN (Figure 2).

DISCONNECT THE TRANSFER, PRECLEAN, AND DETACK CONNECTORS FROM THE TRANSFER, PRECLEAN, AND DETACK DICOROTRON GUIDES AT THE REAR OF THE MACHINE (REP 9-40).

•

If the gap measures more than 1.9 +/- 0.1 mm, go to Adjustment Step 1.

•

If the gap measures less than 1.9 +/- 0.1 mm, complete Adjustment Step 1 through 5, then go to Adjustment Step 9.

NOTE: In the next step, the PR Module Positioning Tool is installed to obtain the initial dimension for the Rear Hinge Adjusting Plates.

•

If the gap measures 1.9 +/- 0.1 mm, read the Note preceeding Check Step 6, then, continue with Check Step 6.

4.

INSTALL THE PR MODULE POSITIONING TOOL. SEE (Figure 1). a.

Loosen thumbscrews, collapse buttons, and tighten thumbscrews. See (Figure 2).

b.

Hang the tool over the top of the Dicorotron Guide.

c.

Bias tool towards the front of the machine with the outboard button even with the outboard end of the PR Drive Roll. See (Figure 1).

d.

Loosen both Thumbscrews. The Buttons will expand, touching the PR Drive Roll.

e.

Tighten both Thumbscrews to lock Buttons.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 9-10

NOTE: The product of the above math represents how far the PR Module must be moved to the right.

MEASURE GAPS HERE

1. LOOSEN THUMBSCREWS

8.

MOVE PR MODULE TO RIGHT. SEE (Figure 3). a.

Using feeler gauges, make a shim that is equal to the results obtained in Adjustment Step 7.

b.

Loosen the Left Hinge Screw.

c.

Insert the shim between the Left Hinge Adjusting Plate and the Photoreceptor Module Frame.

d.

Bias the Left Hinge Adjusting Plate toward the Photoreceptor Module Frame, tighten the Left Hinge Screw, and remove the shim,

e.

Loosen the Right Hinge Screw.

f.

Bias the Photoreceptor Module and the Right Hinge Adjusting Plate to the right and tighten the Right Hinge Screw.

3. TIGHTEN THUMBSCREWS

2. COLLAPSE BUTTONS

Figure 2 PR Positioning Tool 9. NOTE: In the next step, the PR Module Positioning Tool is installed to obtain the initial dimension for adjusting the PR Positioning Guide. 6.

7.

INSTALL THE PR MODULE POSITIONING TOOL. Loosen thumbscrews, collapse buttons, and tighten thumbscrews. See (Figure 2).

b.

Hang the tool over the top of the Dicorotron Guide.

c.

Bias tool towards the front of the machine with the outboard button even with the outboard end of the PR Drive Roll. See (Figure 1). Loosen both Thumbscrews. The Buttons will expand, touching the PR Drive Roll.

e.

Tighten both Thumbscrews to lock Buttons.

Perform Check Steps 6 and 7.

SUBTRACT DIMENSION MEASURED IN CHECK STEP 5 FROM 1.9 MM NOTE: The product of the math in the preceding step represents how far the PR Module must be moved to the left.

NOTE: Figure 3 shows the Left Hinge Adjustment Plate measurement and movement. The Right Hinge Adjustment Plate procedure is the same except that the feeler gauge is inserted at the Right Hinge Adjustment Plate and the direction of PR Module movement is reversed. a.

REMOVE THE TOOL FROM THE MACHINE. MEASURE AND RECORD THE GAP AT THE OUT BOARD BUTTON AS INDICATED IN (Figure 2).

Using feeler gauges, make a shim that is equal to the results obtained in Adjustment Step 9.

b.

Loosen the Right Hinge Screw.

•

If the gap measures more than 1.9 +/- 0.1 mm, complete Adjustment Steps 1 through 5, and go to Adjustment Step 11.

c.

Insert the shim between the Right Hinge Adjusting Plate and the Photoreceptor Module Frame. See (Figure 3).

•

If the gap measures less than 1.9 +/- 0.1 mm, complete Adjustment Steps 1 through 5, and go to Adjustment Step 14.

d.

Bias the Right Hinge Adjusting Plate toward the Photoreceptor Module Frame, tighten the Right Hinge Screw, and remove the shim.

•

If the gap measures 1.9 +/- 0.1 mm, then go to Adjustment Step 17.

e.

Loosen the Left Hinge Screw.

f.

Bias the Photoreceptor Module and Left Hinge Adjusting Plate to the left and tighten the Left Hinge Screw.

Adjustment 1.

Repeat procedure until the gap measured in Check Step 5 is 1.9 +/- 0.1 mm.

h.

10. MOVE THE PR MODULE TO THE LEFT

a.

d.

g.

REMOVE THE SCREWS SECURING THE PHOTORECEPTOR DRIVE ASSEMBLY AND PULL THE ASSEMBLY AWAY FROM THE BACK PLATE OF THE FRAME TO DISENGAGE IT FROM THE PHOTORECEPTOR MODULE. REPLACE THE PR DRIVE ROLL.

3.

LOOSEN THE CABLE FROM THE DRAWER LATCH HANDLE.

4.

LOOSEN THE TWO SCREWS SECURING CLEANER BRACKET TO FRAME. SEE (Figure 3).

5.

LOOSEN THE TWO NUTS SECURING THE POSITIONING GUIDE TO PR MODULE. SEE (Figure 3).

6.

REMOVE AND DISCARD THE E RING FROM THE RIGHT PHOTORECEPTOR MODULE HINGE PIN. SEE (Figure 3).

7.

SUBTRACT 1.9 MM FROM THE DIMENSION MEASURED IN CHECK STEP 5.

Section Name

Repeat procedure until the gap measured in Check Step 5 is 1.9 +/- 0.1 mm.

h.

Perform Check Steps 6 and 7.

11. SUBTRACT 1.9 MM FROM THE DIMENSION MEASUREMENT IN CHECK STEP 7.

2.

ADJ 9-10

g.

NOTE: The product of the above math represents how far the PR Module must be moved to the right. 12. MOVE THE POSITIONING GUIDE A DISTANCE TO THE RIGHT EQUAL TO THE RESULTS OBTAINED IN ADJUSMENT STEP 11 AND TIGHTEN THE (2) SCREWS. 13. REPEAT PROCEDURE AS NEEDED UNTIL THE 1.9 +/- 0.1 MM DIMENSION IS ACHIEVED, THEN GO TO ADJUSTMENT STEP 17. 14. SUBTRACT DIMENSION MEASURED IN CHECK STEP 7 FROM 1.9 MM.

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Preliminary Working Document No Product Name Assigned

NOTE: The product of the math in the above step represents how far the PR Module must be moved to the left. 15. MOVE THE POSITIONING GUIDE A DISTANCE TO THE LEFT EQUAL TO THE RESULTS OBTAINED IN ADJUSMENT STEP 14 AND TIGHTEN THE (2) SCREWS.

16. REPEAT PROCEDURE AS NEEDED UNTIL THE 1.9 +/- 0.1 MM DIMENSION IS ACHIEVED. 17. REINSTALL THE PHOTORECEPTOR DRIVE ASSEMBLY. 18. TIGHTEN THE TWO SCREWS SECURING THE CLEANER BRACKET TO THE FRAME

2. LOSSEN CLEANER SCREWS (2)

2. INSERT 1. LOOSEN

RIGHT HINGE ADJUSTMENT PLATE

4. TIGHTEN 3. MOVE HINGE ADJUSTING PLATE

FRAME

4. REMOVE AND DISCARD E-RING FROM THE RIGHT PR MODULE HINGE PIN MOVEGUIDE TO ADJUST

3. LOOSEN POSITIONING GUIDE NUTS BEHIND FRAME (2)

1. LOOSEN CABLE

Figure 3 View of Left Hinge Adjustment Plate 19. RECONNECT THE TRANSFER, PRECLEAN, AND DETACK CONNECTORS TO THE TRANSFER, PRECLEAN, AND DETACK DICORTRON GUIDES AT THE REAR OF THE MACHINE (REP 9-40). Preliminary Working Document No Product Name Assigned

20. REINSTALL THE FOLLOWING:

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a.

Pre transfer Baffle (REP 8-5).

b.

Prefuser Transport (REP 10-12). Section Name

ADJ 9-10

c.

Drawer Latch Cable

ADJ 9-11 Photoreceptor Tension

d.

Photoreceptor (REP 9-35).

e.

Waste Bottle (REP 9-32).

Purpose

f.

Transfer Dicorotron (REP 9-49).

g.

Preclean, and Detack Dicorotrons (REP 9-39).

h.

Photoreceptor Inner Panel.

i.

Rear MIM Covers.

j.

Transfer Assist Device (REP 9-50).

The purpose is to obtain tension on the Photoreceptor Belt in order to prevent slippage.

Adjustment

21. VISUALLY VERIFY THAT THE TRANSFER ASSIST BLADE HAS COMPLETELY LIFTED OFF THE PHOTORECEPTOR.

1.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

2.

REMOVE THE LEFT DEVELOPER ZONE ROLL 1 (REP 9-4).

NOTE: Lower the PR Module in order to check the rear gap. 3.

CHECK/ADJUST THE PR BELT TENSION (Figure 1).

22. CHECK / ADJUST THE FOLLOWING: •

Zone Roll (ADJ 9-1)

•

Photoreceptor Drive Alignment (REP 4-31) , go to “Replace,” step 1a.

•

Image Squareness (ADJ 6-2).

•

Image Magnification (ADJ 6-1).

•

Image registration, [dC-604]

•

Transfer Assist Blade Timing (ADJ 9-9).

2 CHECK: FOR +2/-1 mm GAP (FRONT AND REAR)

1 LATCH THE PR TENSION

23. MARK OFF PROCESSOR TAG P-318. SERVICE NOTES: •

1.9 +/- 0.1 mm will give acceptable results under most conditions

•

Further improvement in 2nd side deletion performance can be achieved by using a gap of 1.7 +/- 0.1 mm at the risk of TAB contamination.

•

At low relative humidity, toner from the Photoreceptor can contaminate the TAB without direct contact. If this occurs readjust to 2.2 +/- 0.1 mm.

•

This adjustment combined with the 3-layer TAB can deliver superior long-term 2nd side deletion performance.

3 ADJUST LENGTH OF CABLE

Figure 1 Checking/Adjusting the Tension 4. Section Name

ADJ 9-10, ADJ 9-11

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REINSTALL THE LEFT DEVELOPER ZONE ROLL AND PHOTORECEPTOR. Preliminary Working Document No Product Name Assigned

ADJ 9-12 ESV Height Purpose The purpose is to position the ESV at the correct height above the Photoreceptor Belt in order to ensure that the charge voltage on the belt is accurately measured.

a.

Carefully place one sheet of 20 lb (80 gsm) paper on the Photoreceptor Belt, below the ESV, in order to protect the PR from scratches.

b.

Using 2 orange and 1 yellow shim, from the Shim Kit (600T41511), make a shim that is 2.03 mm (0.80 in.) thick.

c.

Gently slide the 2.03 mm shim between the ESV and the sheet of paper. A very slight resistance should be felt. If no resistance is felt or the shim cannot be inserted without deflecting the PR Belt downward then go to the adjustment. If the check is good, continue to Step d.

Check To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. DISCONNECT ALL PRINTER POWER.

2.

REMOVE THE ROS ASSEMBLY (REP 6-1).

3.

REINSTALL THE PHOTORECEPTOR BELT AND THE PRINTER LEFT TOP COVER.

4.

REMOVE THE ROS LOWER INNER PANEL.

WARNING Do not touch the ESV if the Printer is switched on. High voltage is present on the ESV when the Printer is in the operating mode. 5.

d.

Remove the 2.03 mm shim but do not remove the sheet of paper at this time.

e.

Using 2 orange and 1 blue shim, from the Shim Kit (600T41511), make a shim that is 1.65 mm (0.65 in.) thick.

f.

Gently slide the 1.65 mm shim between the ESV and the sheet of paper. Ensure that no resistance is felt. If the check is good, remove the shim and paper, and go to Step 6. If the check is not good, remove the shim, and go to the adjustment.

6.

REMOVE THE PRINTER LEFT TOP COVER.

7.

REINSTALL THE ROS ASSEMBLY.

8.

REINSTALL ALL PANELS, AND CLOSE ALL DOORS.

Adjustment

CHECK THE ESV HEIGHT (Figure 1) AS FOLLOWS: NOTE: If necessary the toner bottle can be removed to provide additional access to the adjusting screws. Ensure that the ESV remains parallel to the PR. 1.

PATCH GENERATOR

ADJUST THE ESV HEIGHT (Figure 2).

ESV

1 CHECK: 2.1 +/-0.4 mm

PR BELT

Figure 1 Checking the ESV Height Preliminary Working Document No Product Name Assigned

0/0/00 ?-555

Section Name

ADJ 9-12

4 ADJUST: LOWER THE PATCH GENERATOR UNTIL THE ESV JUST TOUCHES THE SHIMS

3 INSERT 2 ORANGE AND 1 YELLOW SHIM 2.03 mm

5 TIGHTEN THE HARDWARE

2 MOVE THE PATCH GENERATOR UP FULLY

1 LIGHTLY LOOSEN SCREWS (2)

Figure 2 Adjusting the ESV Height 2.

VERIFY THE ESV HEIGHT.

ADJ 9-13 DSS Saturation

3.

Perform Xerographic Setup (ADJ 9-3).

Purpose The purpose is to obtain the best solid area image density while keeping the background areas clean, and also to reduce the variation in toner concentration setups between Printers. The adjustment is performed by adjusting the Toner concentration setpoint based on DSS Saturation.

Adjustment To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. Section Name

ADJ 9-12

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Preliminary Working Document No Product Name Assigned

1.

SWITCH OFF PRINTER POWER.

Table 1 4135/4635 MIN NVM Address

NOTE: Check the status of the Developer Material on the HSFI screen. If approaching or at end of life, replace the Developer Material (REP 9-4) before performing this procedure. CAUTION Do not clean the DSS with the vacuum cleaner. Do not scratch the window of DSS. Use Xerox anti-static solution (8R90275) to clean the DSS with a clean, soft, lint free cloth. The ESV should be cleaned using a clean, dry, lint free cloth. Switch off the Printer power before cleaning the ESV and DSS. The Printer will perform a Power Up Sequence when the power is switched on, and will ensure that the ESV Monitor measurements and the DSS calibrations are performed with the components clean. 2.

CLEAN THE DSS WITH A CLEAN, SOFT, LINT FREE CLOTH.

3.

RESTORE PRINTER POWER.

4.

LOAD A4 (8 1/2 X 11) OR A LARGER PAPER SIZE IN TRAY 1.

5.

MAKE 15 PRINTS AS FOLLOWS:

6.

Enter dC909.

b.

Select [Printer Options], [Tray 1], [Test Patterns and PQ], [Xerographic], press the Continue button.

7.

Enter dC131, [MIN]. Enter 250 in the Address display. Add 2 to the value shown in the Data display, enter the new Data value, and press [Enter].

c.

Enter dC606, and select [Test Pattern Generation].

d.

Select [Light Dusting] and [Printer Options].

e.

Program 200 prints, and press the Continue button.

f.

Go back to 3 and repeat Steps 3 - 6 until the toner concentration is acceptable.

If the patches on the prints are not a minimum of 15 mm wide, go to PQ 9-621, Patch Gen/Patch Integrity RAP.

a.

If the average is 65 or less, go below to Step 13.

b.

If the average is equal to or greater than 65 (patches are light) then perform the following: Go back to and repeat Steps 8 - 13. If the average continues to be greater than 65, switch off the Printer, disconnect all Printer power, and replace the DSS (REP 9-38). Restore the Printer power, switch on the Printer, and repeat .

INCREASE THE TONER CONCENTRATION. a.

Current value -18

12. CALCULATE THE AVERAGE OF THE FIVE RECORDED READINGS TAKEN FOR ID 2,4,6 for DSS.

If the solid area block number 3 is equal to or greater than the STD/LT: UM block then the toner concentration is acceptable. Continue below with .

b.

Current value -12

296

11. PROGRAM 100 PRINTS, AND PRESS THE Continue BUTTON. AFTER 30 PRINTS HAVE BEEN MADE OBSERVE THE ESV-DSS Patch Readings SCREEN, AND RECORD FIVE CONSECUTIVE READINGS OF For ID 2,4,6 for DSS, THEN PRESS THE Stop BUTTON.

COMPARE THE SOLID AREA BLOCK NUMBER 3, FROM THE LAST THREE XEROGRAPHIC PRINTS, TO THE STD/LT: UM BLOCK ON XTP #564.001 (82E4161). a.

Changed Data Value

NOTE: If a 9-213 Fault is declared in the following step, Exit dC909. Enter dC951, select [Forced Converge] and Press the Continue Button to successfully get the Machine through a set-up initialization. Then return to in this procedure.

a.

a.

Current Data Value

295

c.

ENTER dC131, [NVM Read/Write], [MIN], AND PERFORM THE FOLLOWING:

d.

Change the MIN NVM values for Addresses 250, 295 and 296 back to the original values (recorded in Step 10).

e.

Add 22 to the average calculated above in Step 12, and change the Data value in Address 247 to the new Data value.

13. PERFORM THE XEROGRAPHIC SET-UP (ADJ 9-3).

NOTE: A dirty DSS will cause an erroneous calibration of the DSS. 8.

SELECT [ESV-DSS Test] and [DSS Recalibrate].

NOTE: After the DSS Recalibrate run a job in any mode to complete a power up sequence. 9.

SELECT [Patch Test], PROGRAM 10 PRINTS, AND PRESS THE Continue BUTTON.

NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if additional information is needed. 10. ENTER dC131, [MIN], record the current Data values (for future reference), and then change the Data values per the Table. Table 1 4135/4635 MIN NVM Address

Current Data Value

Changed Data Value

126

Current value +50

128

Current value +20

250

Current value -05

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 9-13

ADJ 9-14 DSS Timing

Adjustment CAUTION

Purpose DSS Timing reflects a certain number of Machine clocks from when a ROS control patch latent image is created until the developed patch should be read by the DSS. The primary purpose of the DSS Timing routine is historical; that is, some early development problems required this check to ensure the Machines ran per design intent. DSS Timing currently is generally a constant value and this routine is not required in normal Field Service actions.

Do not attempt to adjust DSS Timing to compensate for hardware problems such as an incorrectly installed ROS, a misaligned or racked Photoreceptor or a bent DSS Bracket. The DSS Timing value should normally be 63. 1.

USING THE UP AND DOWN ARROWS SELECT A HIGHER NUMBER TO MOVE THE HISTOGRAM TO LEFT, OR A LOWER NUMBER TO MOVE THE HISTOGRAM TO THE RIGHT.

Check

2.

SELECT [Enter], RERUN THE ROUTINE ADJUSTING THE DSS TIMING VALUE UNTIL THE HISTOGRAM IS CENTERED AT THE LOWEST POINT.

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section. 1.

THE FOLLOWING DESCRIBES THE DSS TIMING ROUTINE: a.

DSS Timing allows feedback to aid in establishing the IRD read timing of the Control patch. This routine runs in a non-imaging mode, but paper will be fed for patch transfer to allow visual inspection.

b.

During this routine closed loop toner control is suspended (operates in open loop toner control) which turns off all toner control faults.

c.

The value used for this routine is a decimal number (range limited from 0 to 100) IrdAdj (MIN NVM location 259). This value will be displayed on the screen when the IRD READ TIMING is entered.

d.

A histogram with a range of -50 to +50 for DSS Timing, in 10 digit increments, and a range of 50 to -255 DSS Readings will be displayed. The histogram will update as the routine runs.

e.

Upon entering the routine the current IrdAdj value will be displayed, along with the blank histogram. After pressing Continue, the processor will execute a normal cycle up with print scheduling suspended (dead cycling), and run in standard PQ mode. While the drives are running the routine will schedule paper to transfer each toner control patch the machine produces. The routine will automatically change the IrdAdj from the current value to a value of -50 to 50 in steps of 10. The routine will average 5 IRD reads for each change in IrdAdj, and update the histogram. At the conclusion of the routine the current value of IrdAdj will be displayed.

NOTE: During the running of the DSS timing routine if any machine fault occurs, it will be necessary to clear the fault and to start the entire routine over. 2.

ENTER dC909. SELECT [Setups], [DSS Timing]. PRESS Continue.

3.

AT THE CONCLUSION OF THE ROUTINE, CHECK THAT THE CENTER OF THE ZERO ON THE SCALE IS IN THE CENTER OF THE BLACK ONLY BARS OF THE HISTOGRAM.

4.

IF THE ZERO IS NOT CENTERED IN THE BLACK ONLY BARS PERFORM THE DSS TIMING ADJUSTMENT.

Section Name

ADJ 9-14

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Preliminary Working Document No Product Name Assigned

ADJ 9-15 NVM Node Initialization Recovery (60HZ, 50HZ)

e.

Purpose

f.

Belt Seam Timing (ADJ 9-8).

g.

Top-To-Bottom Registration (ADJ 8-2 ADJ 8-2).

The purpose is to restore the critical NVM values, and perform the required Printer set-ups whenever a Node Initialization is performed.

ROS Magnification Set-up (ADJ 6-1 ADJ 6-1).

h.

Fuser Roll Temperature (ADJ 10-6).

i.

Metering Roll Temperature (ADJ 10-7 ADJ 10-7).

Adjustment

6.

NOTE: If either MIN or PHN were not initialized, do not perform this procedure.

NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if required.

1.

NOTE: Refer to the IOT Software Release Document (Appendix A of the Dash 11) for all unique NVM values for the software level on this Machine.

ENTER dC131, [MIN].

ENTER dC131, [PHN].

NOTE: Refer to NVM READ/WRITE (ADJ 9-2), if required. 7. NOTE: Refer to the IOT Software Release Document (Appendix A of the Dash 11) for all unique NVM values for the software level on this Machine. 2.

ACCESS EACH [MIN] NVM ADDRESS IN THE TABLE, AND ENTER THE DATA VALUES FOR 50 OR 60 HZ MACHINE AS LISTED IN THE APPROPRIATE LEVEL dC 131 SOFTWARE TABLE (SECTION 6, GENERAL PROCEDURES, IN THE SERVICE MANUAL).

ACCESS EACH [PHN] NVM ADDRESS IN THE TABLE, AND ENTER THE DATA VALUES FOR 50 OR 60 HZ MACHINE AS LISTED IN THE APPROPRIATE LEVEL dC 131 SOFTWARE TABLE (SECTION 6, GENERAL PROCEDURES, IN THE SERVICE MANUAL): Table 2 PHN Address

Table 1 MIN Address

Data Value

265 MIN Address

Data Value

178

260

243

397

a.

Paper Width Timing Setup (ADJ 8-5 ADJ 8-5).

244

401

b.

Side-To-Side Registration (ADJ 8-3 ADJ 8-3).

8.

245 3.

Data Value

251

EXIT dC131.

9.

CHECK/ADJUST THE FOLLOWING:

c.

Transfer Blade Timing (ADJ 9-9).

d.

Duplex Timing Setup (ADJ 10-14 ADJ 10-14).

Save Set Up Procedure.

NOTE: The calibration values for the HVAC and HVDC Power Supplies can be found on the calibration cards that are stored in the Machine Log Book. If the calibration cards are not in the Log Book, it will be necessary to switch off the Printer, and remove the HVAC and the HVDC PWB Boards (REP 1-9, REP 1-10). Record the calibration values, and reinstall the PWBs. Do not remove the calibration cards from the PWBs. 4.

5.

CALIBRATE THE HVAC AND HVDC POWER SUPPLIES: a.

Enter dC314, [POWER Supply Calibration].

b.

Use the arrows to put the HVAC calibration value into [Current Value], and select [Enter].

c.

Select [DC Power Supply].

d.

Use the arrows to put the HVDC calibration value into [Current Value], and select [Enter].

e.

Exit dC314.

CHECK/ADJUST THE FOLLOWING: a.

DSS Saturation (ADJ 9-13)

b.

Patch Generator Timing (ADJ 9-5)

c.

ROS Low Correction Factor (ADJ 6-3)

d.

Xerographic Set-up (ADJ 9-3)

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 9-15

ADJ 9-16 Spots Blade Contact

7.

Purpose

INSTALL THE BLADE BRACKET INTO THE FRONT AND REAR BLADE GUIDES, AND CHECK THAT THE SPOTS BLADE BRACKET MOVES FREELY.

The purpose is to ensure that the Spots Blade contacts the Photoreceptor Belt with the correct amount of pressure.

NOTE: Position one sheet of 8.5 X 14 (A3) 20lb (80 gsm) paper fully under the bottom of the tool, then check the contact with an additional strip of paper (1 Inch wide) at the front and at the rear.

Check

8.

CHECK THE BLADE CONTACT (Figure 2).

CAUTION Do not close the Xerographic Drawer with the blade bracket or blade tool in position or damage to the printer may occur NOTE: The Spots Blade Contact Check/Adjustment must be performed with the Spots Blade Tool 30E77630 and 8.5 x 14 (A3) 20lb (80 gsm) paper. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

REMOVE THE SPOTS BLADE (REP 9-58).

4.

PUSH PHOTO DRAWER IN.

5.

PULL FUSER ASSEMBLY OUT.

6.

INSTALL THE BLADE TOOL (30E77630) ON THE BLADE BRACKET (Figure 1).

SPOTS BLADE BRACKET

2 TIGHTEN THE NUTS (2)

1 INSTALL THE TOOL

Figure 1 Installing the Blade Tool on the Blade Bracket Section Name

ADJ 9-16

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Preliminary Working Document No Product Name Assigned

3 ADJUST: THE CLOCKWISE ROTATION OF THE ADJUSTMENT SCREWS WILL DECREASE THE DRAG AND THE COUNTERCLOCKWISE ROTATION OF THE ADJUSTMENT SCREWS WILL INCREASE THE DRAG

REAR ADJUSTING SCREW

1

2

PLACE ONE SHEET OF 20 LB (80 GSM) PAPER UNDER THE TOOL

CHECK: FOR THE SLIGHT DRAG AT THE FRONT AND THE REAR

FRONT ADJUSTING SCREW

Figure 2 Checking/Adjusting the Blade Contact 9.

IF THE CHECK IS GOOD, REMOVE THE PAPER, AND RESTORE THE PRINTER TO THE OPERATING CONDITION.

Adjustment

ADJ 9-17 PR Mini-rug Height Purpose The purpose is to ensure that the Mini-Rug is set to the correct height above the surface of the PR Module to provide support for the PR Belt and as a datum for setting the Spots Blade Contact.

NOTE: One revolution of the adjusting screw will move the tool 0.5 mm. 1.

ADJUST THE BLADE CONTACT (Figure 2).

2.

VERIFY STEP 6 OF THE CHECK UNTIL THE BLADE CONTACT IS IN SPECIFICATION.

Adjustment 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE PHOTORECEPTOR BELT (REP 9-35).

3.

LOWER AND LATCH THE PR MODULE.

4.

MAKE A FEELER GAUGE OUT OF 1 STRIP OF 20 LB/80 GSM PAPER 15 MM WIDE. CAUTION

Do not overtighten the mounting screws when adjusting the Mini-Rug Height. The Spring Washers can be flattened, and will not support the Mini-Rug correctly. NOTE: The Mini-Rug Set-up Tool (30K39390) is stored in the Spare Parts Cabinet. 5. Preliminary Working Document No Product Name Assigned

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ADJUST THE MINI-RUG HEIGHT (Figure 1). Section Name

ADJ 9-16

1 HOLD DOWN THE TOOL

3 CAUTION ADJUST THE SCREWS (4) FOR VERY SLIGHT DRAG AT THE REAR AND THE FRONT OF THE RUG

2 INSERT THE PAPER STRIP

Figure 1 Adjusting the PR Mini-Rug 6.

CLOSE THE XEROGRAPHIC DRAWER.

ADJ 9-18 Preclean Dicorotron Height

7.

CHECK/ADJUST THE SPOTS BLADE CONTACT (ADJ 9-16).

8.

INSTALL THE PHOTORECEPTOR BELT (REP 9-35).

Purpose The purpose is to ensure that the bottom of the Preclean Dicorotron is at the correct distance from the Photorecptor Belt.

Check NOTE: Before beginning this adjustment, ensure the following are available:

Section Name

ADJ 9-18

•

Preclean Set-up Tool (18E620)

•

Preclean Height Shims (14E17650)

1.

POWER OFF THE PRINTER, THE CIRCUIT BREAKERS AND DISCONNECT ALL OF THE POWER CORDS.

2.

OPEN THE PRINTER FRONT DOORS AND OPEN THE XEROGRAPHIC DRAWER (REP 9-34).

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Preliminary Working Document No Product Name Assigned

CAUTION Do not expose the PR Belt to light for more than a few minutes in order to avoid the light shock. Fully cover the PR Belt with paper to decrease light exposure. CAUTION When checking the height, do not apply a downward pressure on the shim because the PR Belt will deflect downwards and cause an erroneous measurement. NOTE: Use a flashlight in order to illuminate the edge of the shim when checking the Dicorotron height. 3.

CAREFULLY PLACE 20 LB. (80 GSM) SHEETS OF PAPER BETWEEN THE PR BELT AND THE ENTIRE LENGTH OF THE PRECLEAN DICOROTRON. CLOSE AND LATCH THE XEROGRAPHIC DRAWER (REP 9-34). PLACE PAPER OVER THE REST OF THE PR BELT TO PROTECT IT FROM LIGHT EXPOSURE.

NOTE: When interference is felt at the Shim in the following Steps, the Dicorotron is at the correct distance from the PR Belt. Check at the front and the rear of the Dicorotron individually. 4.

TO CHECK THE DISTANCE BETWEEN THE DICOROTRON AND THE PR BELT, PERFORM THE FOLLOWING AT BOTH THE DICOROTRON FRONT AND REAR: a.

Position the 4.00 mm Preclean Setup Tool between the Preclean Dicorotron front and the PR Belt. i.

If interference is felt when positioning the tool, the Dicorotron is too close to the Belt and Shims between the Dicor Rail and Bracket may have to be removed.

ii.

If no interference is not felt, place one Shim on top of the Setup Tool. If interference is felt when this Shim is placed on the tool, the Dicorotron is the correct distance from the PR Belt. Repeat the Check at the Dicorotron rear.

iii.

If no interference is felt with one Shim on the Setup Tool, continue with Step b.

b.

Stack the Preclean Height Shims on top of the Setup Tool, one at a time. When interference is felt between the Dicorotron and the Shim, remove the last Shim (the one interfering with the Dicorotron).

c.

Record how many Shims are required to ensure the Dicorotron is the proper distance from the PR Belt.

5.

REPEAT STEP 4 AT THE PRECLEAN DICOROTRON REAR.

6.

IF SHIMS MUST BE ADDED OR REMOVED, PERFORM THE ADJUSTMENT.

Adjustment 1.

REMOVE THE CLEANER MANIFOLD (REP 9-24).

2.

REMOVE THE LEFT REAR PROCESSOR COVER (REP 4-1).

3.

PREPARE TO REMOVE THE CLEANER EXHAUST DUCT (Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 9-18

1 CUT THE CABLE TIES

2 REMOVE THE CONNECTORS: PRECLEAN, TRANSFER AND DETACK DICOROTRONS

Figure 1 Accessing the Exhaust Duct 4.

REMOVE THE 10 mm SCREW SECURING THE EXHAUST DUCT COUPLING OF THE CLEANER MANIFOLD TO THE REAR FRAME.

6.

INSERT/REMOVE THE SHIMS AS DETERMINED IN (Figure 2).

CAUTION There is the potential for loose toner to come out when removing the Exhaust Duct Tube. It is recommended that a cloth be stuffed in the Exhaust Duct Tube before removing. NOTE: Removing the Exhaust Duct provides access to the Rear Mounting Bracket for the Preclean Dicorotron Rail. 5.

ROTATE THE PLASTIC EXHAUST DUCT COUPLING CLOCKWISE UNTIL IT STOPS, THEN PULL IT TOWARD THE REAR.

Section Name

ADJ 9-18

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Preliminary Working Document No Product Name Assigned

CLEANER HOUSING

1 LOOSEN THE TWO 7mm NUTS TO OBTAIN A 3 TO 4mm GAP BETWEEN THE RAIL AND THE BRACKET

FRONT BRACKET

DICORTRON RAIL

2 INSERT OR REMOVE THE SHIMS, AS REQUIRED

3 TIGHTEN THE NUTS (2)

Figure 2 Installing the Shims 7.

RECHECK THE PRECLEAN DICOROTRON TO PR BELT GAP, .

ADJ 9-19 Developer Drive Assembly Alignment Purpose The purpose is to ensure that the Developer Drive Assembly is properly aligned to the Developer Housing Assembly.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 9-18

Adjustment 1.

ENSURE THAT THE XEROGRAPHIC DRAWER IS CLOSED AND LATCHED.

2.

LOOSEN THE FUSER-DEVLEOPER DRIVE BELT (REP 4-39).

3.

LOOSEN THE DEVELOPER DRIVE ASSEMBLY BOLTS (4) APPROXIMATELY ONE TURN EACH, JUST ENOUGH TO ALLOW THE ASSEMBLY TO BE EASILY MOVED UP, DOWN, LEFT AND RIGHT TO SEEK ALIGNMENT OF THE DEVELOPER DRIVE ASSEMBLY COUPLING WITH THE DEVELOPER HOUSING COUPLING.

NOTE: The following step is the Preliminary Check to ensure alignment. 4.

WHILE HOLDING THE DEVELOPER DRIVE ASSEMBLY AGAINST THE MACHINE REAR PLATE, IN THE LOCATION THAT SEEMS TO ALIGN IT WITH THE DEVELOPER HOUSING, ROTATE THE LARGE PULLEY ON THE DRIVE ASSEMBLY COUNTERCLOCKWISE. LISTEN FOR AN AUDIBLE CLICK OF THE SPRING-LOADED DRIVE COUPLING AS IT ENGAGES WITH THE DEVELOPER HOUSING COUPLING.

5.

CONTINUE TO HOLD THE DEVELOPER DRIVE ASSEMBLY AGAINST THE MACHINE REAR PLATE AND TIGHTEN THE BOLTS (4).

6.

TIGHTEN THE FUSER-DEVELOPER DRIVE BELT (ADJ 4-21).

7.

WHILE HOLDING THE DRIVE BELT, HAND-CRANK THE DEVELOPER DRIVE PULLEY IN A CLOCKWISE DIRECTION TO ENSURE THE BELT IS SEATED IN THE PULLEY GROOVES. CAUTION

To ensure that the Final Check (Step 9) provides accurate feedback, it is very important that in the next step, the Xerographic Drawer is closed and latched very gently. 8.

OPEN THE XEROGRAPHIC DRAWER APPROXIMATELY 3 INCHES AND THEN VERY GENTLY CLOSE AND LATCH THE DRAWER.

9.

WHILE HOLDING THE DRIVE BELT, HAND-CRANK THE DEVELOPER DRIVE PULLEY COUNTER-CLOCKWISE. THERE SHOULD BE THREE (3) AUDIBLE CLICKS WITHIN ONE REVOLUTION OF THE PULLEY. THIS IS THE FINAL CHECK TO ENSURE THAT THE DEVELOPER DRIVE ASSEMBLY IS CORRECTLY ALIGNED. IF THREE (3) AUDIBLE CLICKS ARE NOT HEARD, REPEAT THE PROCESS.

10. IF REPEATING THE PROCESS DOES NOT SUCCESSFULLY ALIGN THE DRIVE ASSEMBLY, REPLACE THE DEVELOPER DRIVE ASSEMBLY (REP 9-5).

Section Name

ADJ 9-19

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Preliminary Working Document No Product Name Assigned

ADJ 10-0 Fuser Roll Thermostat (THS1002)

Check WARNING

Purpose The purpose is to position the thermostat so that it will detect an overheat condition, and not cause damage to the Fuser Roll.

Fuser is hot. CAUTION If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 1.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS.

2.

REMOVE THE FUSER ROLL AND HEAT ROD (REP 10-1).

3.

CHECK THE THERMOSTAT (Figure 1).

1

2

CHECK: THERMOSTAT IS FLUSH WITH BRACKET

ADJUST: LOOSEN, ROTATE THERMOSTAT 90 DEGREES, THEN MOVE THE THERMOSTAT INTO POSITION

Figure 1 Checking/Adjusting the Thermostat

Adjustment

2.

INSTALL THE FUSER ROLL AND HEAT ROD (REP 10-1).

NOTE: Rotate the Thermostat 90 degrees before moving the Thermostat into specification. NOTE: Ensure that the Thermostat Mounting Bracket is positioned correctly, and remains in the correct position when it is tightened. 1.

ADJUST THE THERMOSTAT (Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-0

ADJ 10-1 Metering Roll Overheat Thermostat (THS1001)

2.

CAUTION

Purpose The purpose is to place the thermostat in the correct position, so that it will detect an overheat condition, and not cause damage to the Metering Roll.

Check 1.

REMOVE THE PRINT TRANSPORT INNER PANEL.

OPEN THE PRINTER FRONT DOORS.

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 3.

IF FUSER IS HOT, INSTALL A CHEATER IN THE PROCESSOR INTERLOCK BYPASS SWITCH (S103), AND USE HOT SPECIFICATION.

4.

CHECK THE THERMOSTAT (Figure 1).

1 CHECK: 1.8 +/- 0.1 mm (HOT) OR 1.9 +/- 0.1 mm (COLD)

2 ADJUST: MOVE THE THERMOSTAT INTO POSITION

Figure 1 Checking/Adjusting the Thermostat

Adjustment

ADJ 10-2 Pressure Roll (Contact ARC)

NOTE: Rotate the Thermostat 90 degrees before moving the Thermostat into specification.

Purpose

NOTE: Ensure that the Thermostat Mounting Bracket is positioned correctly, and remains in the correct position when it is tightened. 1.

ADJUST THE THERMOSTAT (Figure 1).

The purpose is to ensure that the width of the nip between the Pressure Roll and the Fuser Roll is correct and uniform.

Check NOTE: This procedure uses the chalk pouch (99P3211) for greater accuracy. 1.

Section Name

ADJ 10-1

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STABILIZE THE FUSER TEMPERATURE:

Preliminary Working Document No Product Name Assigned

WARNING Keep Fuser Agent away from eyes. Fuser is very hot. a.

Enter dC701, [Fuser Setups], select [Fuser Roll Prep], and press the Continue button.

b.

Repeat Step 1a two more times before continuing.

ADJUST: TURN THE ADJUSTING NUTS

CAUTION If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 2.

DECREASE

PULL OUT THE FUSER AND INSTALL A CHEATER IN THE PRINTER INTERLOCK BYPASS SWITCH (S103).

INCREASE

CAUTION Do not scratch the fuser roll. 3.

ENTER dC701, [Fuser Setups] AND SELECT [Contact Arc].

4.

INSERT A CLEAN SHEET OF 14 INCH PAPER BETWEEN THE FUSER ROLL AND THE PRESSURE ROLL. (FOLD THE INBOARD CORNER TO BE ABLE TO IDENTIFY THE DIFFERENCE BETWEEN THE IB AND OB ENDS.) PRESS THE CONTINUE BUTTON. THE ROLLS WILL AUTOMATICALLY CAM IN FOR THREE SECONDS. REMOVE THE SHEET AND DUST THE IMPRINT OF THE CONTACT ARC AREA WITH THE CHALK POUCH (99P3211). MEASURE THE WIDTH OF THE CONTACT ARC BLUE IMAGE PER Figure 1.

100 mm Figure 2 Adjusting the Contact Arc

Adjustment 1.

ADJUST THE CONTACT ARC (Figure 2).

2.

REPEAT STEPS 3-5 OF THE CHECK AS REQUIRED.

3. CHECK: 15.5 +/- 0.5 mm, 16.5 +/- 0.5 mm (w/MICR) AND WITHIN 0.25 mm IN BOTH PLACES

CHECK/ADJUST THE FOLLOWING: a.

Stripper Finger Baffle Clearance (ADJ 10-15).

b.

Fuser Roll Temperature (ADJ 10-6).

100 mm

IMAGE OF CONTACT ARC

Figure 1 Checking the Contact Arc 5.

FOLLOW THE ADJUSTMENT PROCEDURE PER Figure 2 AS REQUIRED.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-2

ADJ 10-4 Air Knife Manifold and Fuser Roll

Check WARNING

Purpose The purpose is to ensure proper clearance between the Air Knife Manifold and Fuser Roll, and to prevent the prints from wrapping around the Fuser Roll.

Fuser is hot. CAUTION If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. The Fuser must be hot, and the Pressure Roll should not be cammed in for this adjustment. 1.

OPEN THE FUSER AND CHECK THE AIR KNIFE MANIFOLD CLEARANCE: a.

Prepare 9 strips of 20 LB (80 GSM) paper 1 inch wide.

b.

Position the paper strips (Figure 1).

1 POSITION 8 1-INCH STRIPS OF 20 LB (80 GSM) PAPER ON THE FUSER ROLL

2 PUSH DOWN ON STRIPPER ASSEMBLY SO THAT THE SHAFT IS RESTING ON FRAME WHILE CHECKING Figure 1 Checking the Manifold Clearance c.

Check at the front, slight drag with 8 strips, heavy drag with 9 strips, and no drag with 7 strips.

d.

Check the drag at the rear.

Adjustment NOTE: Ensure that the shaft touches the frame at the front and the rear when tightening the screws. 1.

Section Name

ADJ 10-4

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ADJUST THE AIR KNIFE MANIFOLD CLEARANCE (Figure 2).

Preliminary Working Document No Product Name Assigned

2 POSITION 8 SHEETS OF PAPER AND CLOSE THE STRIPPER ASSEMBLY

3 NOTE: PUSH DOWN MANIFOLD AND TIGHTEN THE SCREWS (4)

1 LOOSEN THE SCREWS AT THE FRONT (2) AND THE REAR (2)

Figure 2 Adjusting the Manifold Clearance 2.

REPEAT THE CHECK IF REQUIRED AND REMOVE ALL PAPER FROM THE FUSER.

ADJ 10-5 Air Knife Pressure, Pressure Regulator, Compressor (MOT1002) Purpose The purpose is to ensure proper air pressure to the Air Knife for Fuser stripping.

Check

Preliminary Working Document No Product Name Assigned

1.

ENTER dC330.

2.

SELECT [10], [Compressor] AND PRESS THE Continue BUTTON.

3.

CHECK THE PRESSURE GAUGE = 19 TO 21 PSI (Figure 1).

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Section Name

ADJ 10-4

ADJ 10-6 Fuser Roll Temperature Purpose The purpose is to ensure that the temperature is correct for proper fusing of the prints.

Check CAUTION

2 ADJUST: REMOVE COVER AND ROTATE THE KNOB ON THE PRESSURE REGULATOR

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 1.

1

CLEAN THE FUSER ROLL THERMISTORS RT1001 AND RT1003 (Figure 1).

CLEAN THE THERMISTORS WITH FUSER AGENT

CHECK: PRESSURE GAUGE = 19 - 21 PSI

Figure 1 Checking/Adjusting the Air Pressure

Adjustment 1.

ADJUST PRESSURE REGULATOR (Figure 1).

2.

PRESS THE Stop BUTTON AND EXIT dC330.

Figure 1 Cleaning the Fuser Roll Thermistors (RT1001 & RT1003) 2.

Section Name

ADJ 10-6

ENTER dC701 [Thermistor Cal]. ENSURE THAT THE THERMISTOR TAG VALUES MATCH THE VALUES ENTERED ON THE IOT SCREEN FOR BOTH THERMISTORS.

3.

ENTER dC701, [Fuser Setups] AND SELECT [Fuser Roll Temp].

4.

INSTALL CHEATER IN THE PROCESSOR INTERLOCK BYPASS SWITCH (S103) AND PULL OUT THE FUSER.

5.

INSTALL THE TEMPERATURE TAPE (99P3080) ONTO HOLDER (Figure 2).

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Preliminary Working Document No Product Name Assigned

1 2

HOLD THE TAPE 1 INCH FROM THE OUTBOARD END OF THE FUSER ROLL FOR 10 SECONDS

INSTALL THE TEMPERATURE TAPE

w/o MICR: The tape is Black at the Temperature on the Screen. Actual Temperature should be Gray, 395°F (202°C).

1 BEND THE HOLDER

GRAY 420°F 410°F 400°F 390°F 380°F TEST TAPE READINGS 216°C 210°C 204°C 199°C 193°C GRAY

Figure 2 Installing the Tape onto Holder 6.

WAIT FOR THE [Ready to measure temperature.] MESSAGE.

7.

CHECK THE FUSER ROLL TEMPERATURE (Figure 3).

370°F 188°C

w/MICR: The tape is Black at the Temperature on the Screen. Actual Temperature should be Gray, 415°F (213°C)

Figure 3 Checking the Fuser Roll Temperature

Adjustment 1.

PRESS [Increase] OR [Decrease] USING THE UP OR DOWN ARROWS AS REQUIRED, THEN PRESS [Enter].

NOTE: 1 increment=0.5°C. 2.

Preliminary Working Document No Product Name Assigned

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REPEAT STEPS 5-7 OF THE CHECK.

Section Name

ADJ 10-6, ADJ 10-7

ADJ 10-7 Metering Roll Temperature

WARNING

Purpose

Keep Fuser Agent away from Eyes. Fuser is very hot.

The purpose is to ensure that the Metering Roll temperature is correct, in order to control the viscosity of Fuser Agent, for proper metering.

6.

CHECK THE METERING ROLL TEMPERATURE (Figure 2).

Check

1

CAUTION

CHECK: HOLD THE TAPE ON MIDDLE OF METERING ROLL FOR 10 SECONDS

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 1.

CLEAN THE THERMISTOR (RT1002) WITH FUSER AGENT (Figure 1).

CLEAN THE THERMISTOR WITH FUSER AGENT

2 CHECK: TAPE IS BLACK AT TEMPERATURE SPECIFIED ON SCREEN, OR AT 116-121°C (240-250°F), IF NOT SPECIFIED

GRAY OR BLACK AT 127°C (260°F)

WHITE OR GRAY AT 132°C (270°F)

Figure 2 Checking Metering Roll Temperature

Figure 1 Cleaning the Metering Roll Thermistor (RT1002) 2.

ENTER dC701, [Fuser Setups], AND SELECT [Meter Roll Temp].

Adjustment

3.

INSTALL CHEATER IN THE PROCESSOR INTERLOCK BYPASS SWITCH (S103) AND PULL OUT THE FUSER.

1.

4.

INSTALL THE TEMPERATURE TAPE (130E2290) ONTO THE HOLDER (Figure 2).

5.

WAIT FOR THE [Ready to measure temperature.] MESSAGE.

NOTE: 1 increment=0.5°C. 2.

Section Name

ADJ 10-7

PRESS [Increase] OR [Decrease] USING THE UP OR DOWN ARROWS AS REQUIRED, THEN PRESS [Enter].

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REPEAT STEPS 4 - 7 OF THE CHECK.

Preliminary Working Document No Product Name Assigned

ADJ 10-8 Decurler Exit Baffle

Check

Purpose

1.

REMOVE THE DECURLER ASSEMBLY (REP 10-14).

The purpose is to ensure the proper decurling of paper as it exits from the decurler. The Exit Baffle imposes a curl in the opposite direction from the curl imposed by the decurler belts.

2.

CHECK THE CLEARANCE BETWEEN BAFFLE AND BELT (Figure 1).

2 CHECK: 0.5 +/- 0.1 mm BETWEEN BAFFLE AND BELT

3 ADJUST: LOOSEN SCREW AND USE A SCREWDRIVER TO ADJUST BAFFLE

1 MOVE THE LEVER COMPLETELY TO THE LEFT

Figure 1 Checking/Adjusting the Baffle

Adjustment

ADJ 10-9 Duplex Gate and Solenoid (SOL1002)

1.

Purpose

ADJUST THE BAFFLE (Figure 1).

The purpose is to ensure that the solenoid opens the gate completely.

Check 1.

Preliminary Working Document No Product Name Assigned

REMOVE THE PRINTER RIGHT TOP COVER (REP 4-0).

2.

CHEAT THE TOP COVER INTERLOCK SWITCH.

3.

ENTER dC330, SELECT [10], [Duplex Gate] AND PRESS THE Continue BUTTON.

4.

CHECK DUPLEX GATE AND SOLENOID (Figure 1).

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Section Name

ADJ 10-8

5 ADJUST: MOVE SOLENOID BRACKET

4 ADJUST: LOOSEN SCREWS

3 CHECK: THE GATE TOUCHES RUBBER GROMMET

1

2

CHECK: PUSH AND HOLD THE TOP BAFFLE DOWN

CHECK: THE WASHER ON PLUNGER TOUCHES THE SOLENOID

Figure 1 Checking/Adjusting Duplex Gate and Solenoid

Adjustment

ADJ 10-10 Decurler Sensor (Q1011)

1.

Adjustment

ADJUST THE DUPLEX GATE AND SOLENOID (Figure 1).

Section Name

ADJ 10-10, ADJ 10-11

1.

REMOVE THE DECURLER ASSEMBLY (REP 10-14).

2.

ADJUST THE DECURLER JAM SENSOR (Figure 1).

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Preliminary Working Document No Product Name Assigned

ADJ 10-11 Left and Right Drawer Slide Purpose The purpose is to ensure that the locating pins are centered with the locating bearings on the Fuser Assembly to avoid wear of the locating pins, and to allow the smooth opening and closing of the Fuser.

Check 1.

REMOVE THE FUSER INNER PANEL.

2.

CHECK THE FRONT LOCATING PIN (Figure 1).

1 CHECK: CHECK THAT THE LOCATING PIN IS CENTERED WITH THE BEARING WHEN CLOSING THE FUSER

POSITION THE SENSOR COMPLETELY TO THE LEFT

NOTE: IF THE LOCATING PIN TOUCHES THE BEARING, ADJUSTMENT IS REQUIRED

Figure 1 Adjusting the Decurler Jam Sensor

Figure 1 Checking the Front Locating Pin

Preliminary Working Document No Product Name Assigned

3.

REMOVE THE PRINTER LEFT AND RIGHT REAR COVERS (REP 4-1).

4.

CHECK THE REAR LOCATING PINS (Figure 2).

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Section Name

ADJ 10-10, ADJ 10-11

1 CHECK: CHECK THAT THE LOCATING PINS ARE CENTERED WITH THE BEARINGS WHEN CLOSING THE FUSER

NOTE: IF THE LOCATING PINS TOUCH THE BEARINGS, ADJUSTMENT IS REQUIRED

Figure 2 Checking the Rear Locating Pins

Adjustment 1.

PULL OUT TRAY 1.

2.

SWITCH OFF THE PRINTER CIRCUIT BREAKERS. CAUTION

Do not pull the Fuser out when the Slide Brackets are loose, to avoid difficulty in engaging the Fuser Assembly with the locating pins. If this were to occur, adjust and tighten brackets to the scribe lines in order to close Fuser Assembly. NOTE: The Brackets should be adjusted in the following sequence: Left Rear, Right Rear, Right Front, and Left Front. 3.

ADJUST THE REAR BRACKETS (Figure 3).

Section Name

ADJ 10-11

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Preliminary Working Document No Product Name Assigned

NOTE: KEEP THE BRACKETS SQUARE WITH THE FRAME

1

4

LOOSEN THE SCREWS (2)

LIFT UP ON THE BRACKET TO REMOVE THE PLAY IN THE SLIDE AND TIGHTEN THE SCREWS

3

2

LOOSEN THE SCREWS (2)

NOTE: IF THE LOCATING PINS CONTACT THE TOP OF THE BEARING, LIFT UP WITH MORE FORCE WHEN ADJUSTING.

LIFT UP ON THE BRACKET TO REMOVE THE PLAY IN THE SLIDE AND TIGHTEN THE SCREWS NOTE: IF THE LOCATING PINS CONTACT THE BOTTOM OF THE BEARING, LIFT UP WITH LESS FORCE WHEN ADJUSTING.

Figure 3 Adjusting the Rear Brackets 4.

ADJUST THE FRONT BRACKETS (Figure 4).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-11

1 LOOSEN THE SCREWS (4)

NOTE: KEEP THE BRACKETS SQUARE WITH THE FRAME

3 LIFT UP ON THE BRACKET TO REMOVE THE PLAY IN THE SLIDE AND TIGHTEN THE SCREWS

2 LIFT UP ON THE BRACKET TO REMOVE THE PLAY IN THE SLIDE AND TIGHTEN THE SCREWS NOTE: IF THE PIN IS OFF THE CENTER HORIZONTALLY, ADJUST THE LEFT BRACKET.

NOTE: IF THE PIN IS OFF THE CENTER VERTICALLY, ADJUST THE RIGHT BRACKET

Figure 4 Adjusting the Front Brackets 5.

REPEAT THE CHECK.

ADJ 10-12 Fuser Latch Assembly

6.

ADJUST THE FUSER LATCH ASSEMBLY (ADJ 10-12).

Purpose The purpose is to ensure that the Fuser latches easily when closed.

Check

Section Name

ADJ 10-11

1.

REMOVE THE FUSER INNER PANEL.

2.

CHECK THE FUSER LATCH ASSEMBLY (Figure 1).

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Preliminary Working Document No Product Name Assigned

2

1 CHECK: CHECK THAT THE FUSER LATCHES EASILY WHEN CLOSED

CHECK: PUSH AND PULL ON THE FRONT FRAME AND CHECK FOR THE MINIMUM PLAY OF 0.25MM WHEN CLOSED

Figure 1 Checking the Fuser Latch Assembly

Adjustment 1.

ADJUST THE FUSER LATCH ASSEMBLY (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-12

4 TIGHTEN THE SCREWS (2)

1

3

LOOSEN THE SCREWS (2)

ADJUST: TURN THE SETSCREW COUNTERCLOCKWISE A FEW REVOLUTIONS, THEN TURN CLOCKWISE UNTIL IT JUST STOPS (DO NOT TIGHTEN)

2 PUSH AND HOLD THE FUSER IN COMPLETELY

Figure 2 Adjusting the Fuser Latch Assembly 2.

REPEAT THE CHECK.

ADJ 10-13 Donor Roll Contact ARC Purpose The purpose is to ensure that the Donor Roll contacts the Fuser Roll along the entire length, and is not skewed.

Check WARNING Keep Fuser Agent away from eyes. Fuser is very hot.

Section Name

ADJ 10-12

1.

SELECT A PAPER TRAY THAT HAS 14 INCH PAPER.

2.

STABILIZE THE FUSER TEMPERATURE:

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a.

Enter dC701, Fuser Setups, select [Fuser Roll Preparation], and press the Continue button.

b.

Repeat Step 2b two more times (to stabilize the roll) before continuing.

Preliminary Working Document No Product Name Assigned

CAUTION

d.

Check that Donor Roll Links hang correctly at both ends.

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems. 3.

PULL OUT THE FUSER DRAWER AND INSTALL A CHEATER IN THE PROCESSOR INTERLOCK BYPASS SWITCH (S103).

4.

SELECT Contact Arc. CAUTION

Do not scratch the Fuser Roll. 5.

INSERT A CLEAN SHEET OF 14-INCH PAPER BETWEEN THE FUSER ROLL AND DONOR ROLL.

6.

PRESS THE Continue BUTTON. THE ROLLS WILL AUTOMATICALLY CAM IN FOR 3 SECONDS.

7.

USE THE DUSTING BAG TO APPLY BLUE POWDER TO THE CONTACT ARC AREA ON THE FUSER ROLL SIDE OF THE SHEET (note dust bag P/N: 99P3211). ADJUSTMENT

8.

CHECK THE CONTACT ARC (Figure 1).

CHECK: APPROXIMATE WIDTH: 3 mm ACROSS ENTIRE LENGTH

IMAGE OF CONTACT ARC

Figure 1 Checking the Contact Arc NOTE: There is no adjustment for Donor Roll Contact Arc. Check and replace components as required as described in Step 1. 9.

IF THE DONOR ROLL CONTACT ARC IS NOT WITHIN SPECIFICATION: a.

Check that Loading Arms are not bent, and replace them if required.

b.

Check that the Camming Stops are positioned correctly.

c.

Check the condition of Compression Springs.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-13

ADJ 10-14 Duplex Timing

ADJ 10-15 Stripper Finger Baffle Clearance

Purpose

Purpose

The purpose of the adjustment is to synchronize the print information with the paper when running the duplex mode.

The purpose is to ensure that the Stripper Finger Baffle is adjusted properly with respect to the Pressure Roll to prevent the prints from wrapping around the Pressure Roll, and also to prevent the Stripper Finger Baffle from scraping or cutting into the Pressure Roll.

Adjustment 1.

ENTER dC702, SELECT [Duplex Timing], FOLLOW THE INSTRUCTIONS ON THE UI AND PERFORM THE DUPLEX TIMING.

Check CAUTION Remove the Preclean Dicorotron (REP 9-39) if a long copy run was just completed (15 minutes or longer). This will avoid contamination of the PR, and avoid possible blurred image problems. NOTE: Eleven inch paper may be substituted for this procedure if necessary. 1.

PLACE 100 OR MORE SHEETS OF 14-INCH 20 POUND OR 80 GSM PAPER INTO TRAY 1.

NOTE: The Fuser Roll Prep is performed three times to ensure the diameter of the Pressure Roll is stable when cammed later. The diameter of the roll grows 1.1 mm from cold to thermally stable condition. 2.

PERFORM THE FOLLOWING IN ORDER TO STABILIZE THE PRESSURE ROLL TEMPERATURE/DIAMETER: a.

Enter dC701, [Fuser Setups].

b.

Select [Fuser Roll Prep], [Printer Options], [Tray 1], [Fuser Roll Prep], and press [Continue].

c.

Press [Continue], and repeat two more times.

WARNING Fuser is hot. Avoid touching hot surfaces. 3.

PULL FUSER OUT AND INSTALL CHEATER IN PRINTER INTERLOCK BYPASS SWITCH (S103). CAUTION

Press Stop to disengage cam as soon as CHECK is complete, to prevent damage to rolls. NOTE: The Pressure Roll must be cammed for the following steps.

Section Name

ADJ 10-14, ADJ 10-15

4.

SELECT [Stripper], AND PRESS Continue TO ENGAGE PRESSURE ROLL CAM.

5.

CHECK STRIPPER FINGER BAFFLE CLEARANCE (Figure 1).

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Preliminary Working Document No Product Name Assigned

STRIPPER FINGER BAFFLE

4 3 CHECK: A SLIGHT DRAG IS FELT WHEN PULLING THE STRIPS OUT; 15 STRIPS WILL HAVE NO DRAG AND 17 STRIPS WILL HAVE MORE DRAG

REPEAT THE CHECK AT THE CENTER AND THE REAR END

PRESSURE ROLL

2

1 OPEN THE STRIPPER ASSEMBLY AND PUT 1-INCH WIDE STRIPS OF 20 LB/80 GSM PAPER BETWEEN STRIPPER FINGER BAFFLE AND THE PRESSURE ROLL AT THE FRONT END

CLOSE STRIPPER ASSEMBLY AND HOLD IT DOWN SO THAT THE SHAFT IS RESTING ON THE FRAME

Figure 1 Checking the Stripper Finger Baffle Clearance

Adjustment 1.

NOTE: The Fuser Roll Prep is performed three times to ensure the diameter of the Pressure Roll is stable when cammed later. The diameter of the roll grows 1.1 mm from cold to thermally stable condition. 2.

b.

Select [Fuser Roll Prep], [Printer Options], [Tray 1], [Fuser Roll Prep], and press [Continue].

c.

Press [Continue] and repeat two more times.

CHECK THE PRESSURE ROLL CONTACT ARC (ADJ 10-2).

PERFORM THE FOLLOWING IN ORDER TO STABILIZE THE PRESSURE ROLL TEMPERATURE/DIAMETER: a.

Enter dC701 [Fuser Setups].

Preliminary Working Document No Product Name Assigned

WARNING Fuser is hot. Avoid touching hot surfaces. 3.

PULL FUSER OUT AND INSTALL CHEATER IN PRINTER INTERLOCK BYPASS SWITCH (S103).

4.

SELECT [Stripper] AND PRESS Continue TO ENGAGE PRESSURE ROLL CAM.

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Section Name

ADJ 10-15

CAUTION Press Stop to disengage cam as soon as adjustment is complete, to prevent damage to rolls. NOTE: The Pressure Roll must be cammed for the following adjustment. 5.

ADJUST STRIPPER FINGER BAFFLE CLEARANCE (Figure 2).

5 REPEAT CHECK

1 LOOSEN SCREWS (2 FRONT AND 2 REAR)

4 GENTLY PUSH DOWN ON STRIPPER FINGER BAFFLE AND TIGHTEN SCREWS (2 FRONT AND 2 REAR)

3 ENSURE THAT THE SHAFT IS RESTING ON FRAME (FRONT AND REAR)

2 PUT SHEETS OF 20 LB/80 GSM PAPER BETWEEN THE STRIPPER FINGER BAFFLE AND PRESSURE ROLL Figure 2 Adjusting the Stripper Finger Baffle Clearance 6.

PRESS Stop TO DISENGAGE PRESSURE ROLL.

ADJ 10-16 Relief Valve Purpose The purpose is to ensure that the Relief Valve in the Printer opens at the designated air pressure.

Section Name

ADJ 10-15

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Preliminary Working Document No Product Name Assigned

Check

6.

IF GAUGE REGISTERS 29 PSI, PERFORM AIR KNIFE PRESSURE, PRESSURE REGULATOR, COMPRESSOR (MOT1002) (ADJ 10-5).

1.

ENTER dC330 AND SELECT [10], [Compressor], AND PRESS [Continue].

2.

OPEN THE EM FRONT DOOR.

Adjustment

3.

REMOVE THE EM INNER PANEL.

1.

REMOVE THE PRINTER RIGHT REAR COVER.

CAUTION

2.

UNLATCH AND OPEN THE TONER FILTER ASSEMBLY.

Do not continue to increase the air pressure when the needle on the gauge starts to quiver. When the needle begins to quiver, rotate the knob in the opposite direction until the quivering stops.

3.

ADJUST THE AIR PRESSURE TO 30 PSI (Figure 2).

4.

CHECK THE AIR PRESSURE AT THE PRINTER AIR GAUGE (Figure 1).

1 CAUTION ROTATE THE PRESSURE REGULATOR ON THE SIDE OF THE PRINTER AIR GAUGE TO INCREASE THE AIR PRESSURE

2 CHECK: AIR PRESSURE CANNOT BE ADJUSTED TO 29 PSI OR MORE AND RELIEF VALVE CAN BE HEARD VENTING THE AIR

Figure 1 Checking the Air Pressure 5.

IF GAUGE REGISTERS HIGHER THAN 29 PSI, PERFORM THE ADJUSTMENT.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-16

5.

CHECK/ADJUST AIR KNIFE PRESSURE, PRESSURE REGULATOR, COMPRESSOR (MOT1002) (ADJ 10-5).

2 ADJUST: ROTATE TO CLOCKWISE TO INCREASE AIR PRESSURE, AND ROTATE COUNTERCLOCKWISE TO DECREASE AIR PRESSURE

1 PEEL BACK THE LABEL

Figure 2 Adjusting the Relief Valve 4.

IF SPECIFICATION CANNOT BE ACHIEVED, GO TO 10-702, Fuser Air System Checkout RAP.

Section Name

ADJ 10-16

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Preliminary Working Document No Product Name Assigned

ADJ 10-17 Thermistor Cal

3.

CHECK THAT THE VALUES ON THE TAG ON THE OUTBOARD THERMISTOR (RT1001) MATCH THE VALUES ON THE IOT SCREEN. IF THE VALUES DO NOT MATCH, PERFORM THE ADJUSTMENT.

4.

CHECK THAT THE VALUES ON THE TAG OF THE INBOARD THERMISTOR (RT1003) MATCH THE VALUES ON THE IOT SCREEN. IF THE VALUES DO NOT MATCH, PERFORM THE ADJUSTMENT.

Purpose The purpose is to ensure that the Thermistor Cal values are entered correctly into NVM for the outboard and inboard thermistors.

Check

Adjustment CAUTION

1.

If the Printer just completed a long copy run (15 minutes or longer), remove the Preclean Dicorotron before performing this procedure in order to avoid contamination of the PR, and to avoid possible blurred image problems.

2.

OPEN THE FUSER DRAWER

3.

SELECT [R1] FOR THE OUTBOARD THERMISTOR.

NOTE: The Range values that are listed on the IOT screen are incorrect. The correct range values are 175 to 225 for R1, 120 to 170 for R2, and 60 to 110 for R3. 1.

CLEAN THE FUSER ROLL THERMISTORS RT1001 AND RT1003 (Figure 1).

SELECT [Thermistor Cal].

4.

ENTER THE R1 VALUE FOR THE OUTBOARD THERMISTOR ONTO THE KEYPAD.

5.

SELECT [ENTER].

6.

REPEAT STEPS 3 - 5 FOR R2 AND R3.

7.

SELECT [R1] FOR THE INBOARD THERMISTOR.

8.

ENTER THE R1 VALUE FOR THE INBOARD THERMISTOR ONTO THE KEYPAD.

9.

SELECT [ENTER].

10. REPEAT STEPS 7 - 9 FOR R2 AND R3 11. CLOSE THE FUSER DRAWER. 12. PERFORM THE FUSER ROLL TEMPERATURE ADJUSTMENT (ADJ 10-6).

CLEAN THE THERMISTORS WITH FUSER AGENT

Figure 1 Cleaning the Fuser Roll Thermistors (RT1001 & RT1003 2.

ENTER dC701, [Fuser Setups] AND SELECT [Thermistor Cal].

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-17

ADJ 10-18 Prefuser Transport Purpose The purpose is to ensure that there is a proper gap between the Prefuser Transport and the Stripper Roll to reduce copy handling jams.

Check For FX Machines ONLY, the following (Table 1) lists the recommended light weight paper handling NVM Setpoints and Adjustments. Table 1 COMPONENTS

SPECIFICATON

Prefuser Transport Gap (mm)

2.25 +/- 0.25

Detack Current (bits)

Node: MIN, Location 202, Value=133

Transfer Current (bits)

Node: MIN, Location 210, Value=112 CAUTION

The Photoreceptor is extremely sensitive to light exposure. Limit the exposure of the Photoreceptor light to less than (2) minutes. If the belt module will be exposed to light any longer than two minutes, remove the belt from the belt module and place it immediately in the protective photoreceptor bag or place the bag over the Photoreceptor with it on the belt module. 1.

REMOVE AND PROTECT THE PHOTORECEPTOR BELT (REP 9-35).

WARNING Always wear safety glasses when handling a Dicorotron. Do not touch a Dicorotron wire. It is covered with glass and could cause an injury if it breaks. 2.

REMOVE THE DETACK DICOROTRON (REP 9-39). NOTE: Use the long shim stock (three coral) to create a 2.5 +/- 0.25 mm shim pack. Position the shim pack on a transport belt and apply tape to the metal surfaces of the transport and across the shim stock pack to hold it in place.

3.

CHECK THE PREFUSER TRANSPORT (Figure 1).

Section Name

ADJ 10-18

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Preliminary Working Document No Product Name Assigned

2 NOTE: POSITION AND HOLD A SHIM STOCK OF 2.5 +/- 0.25 mm AGAINST THE TRANSPORT BELT

3 CLOSE THE TRANSPORT SO THAT THE HANDLE CONTACTS THE ADJUSTABLE STOP

STRIPPER ROLL

2.5 +/- 0.25 mm

1 PULL BACK AND LATCH THE TRANSPORT

4 PR DRIVE ROLL

THE SHIM STOCK SHOULD JUST CONTACT THE STRIPPER ROLL +/- 0.25 mm

Figure 1 Checking the Prefuser Transport 4.

IF THE PREFUSER TRANSPORT GAP IS CORRECT, REINSTALL THE DETACK DICOROTRON AND THE PHOTORECEPTOR BELT. IF THE GAP IS NOT CORRECT, PERFORM THE ADJUSTMENT.

Adjustment NOTE: If the 2.5 mm gap cannot be obtained, perform the PR Belt Module Alignment, ADJ 910. 1.

ADJUST THE PREFUSER TRANSPORT (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-18

2 PUSH THE ADJUSTABLE STOP AGAINST THE HANDLE UNTIL THE SHIM STOCK JUST LIFTS OFF THE PHOTORECEPTOR STRIPPER ROLL

2.5 +/- 0.25 mm

1 LOOSEN THE NUTS (2) JUST ENOUGH TO ALLOW THE ADJUSTABLE STOP TO MOVE

3 PR DRIVE ROLL

TIGHTEN THE NUTS (2) THAT HOLD THE ADJUSTABLE STOP

Figure 2 Adjusting the Prefuser Transport 2.

REINSTALL THE PHOTORECEPTOR BELT.

3.

REINSTALL THE DETACK DICOROTRON.

4.

ENSURE THAT THE PREFUSER TRANSPORT HANDLE CONTACTS THE ADJUSTABLE STOP AND THAT THERE IS NO INTERFERENCE BETWEEN THE TRANSPORT AND THE DETACK GUIDE. REMOVE THE DETACK GUIDE FROM THE DETACK DICOROTRON ONLY IF IT INTERFERES WITH THE PREFUSER TRANSPORT (Figure 3).

Section Name

ADJ 10-18

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Preliminary Working Document No Product Name Assigned

REMOVE THE DETACK GUIDE IF REQUIRED

Figure 3 Removing the Detack Guide

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 10-18

Section Name

ADJ 10-18

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Preliminary Working Document No Product Name Assigned

ADJ 11-1 Inverter Gate Solenoid (SOL1108)

Check

Purpose

1.

The purpose is to ensure that the Gate does not contact with the Top Baffle of the Inverter, or does not interfere with the paper path, when actuated by the Inverter Gate Solenoid.

2.

OPEN THE INVERTER DOOR.

3.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

4.

CHECK THE INVERTER GATE SOLENOID (Figure 1).

SWITCH OFF THE PRINTER POWER.

REAR VIEW

2 SEAT THE PLUNGER FULLY

LEFT SIDE VIEW

3 CHECK: FOR A GAP OF 1.5 +/-0.25 mm

1 OPEN THE PIVOTING ASSEMBLY

RIGHT SIDE VIEW

Figure 1 Checking the Solenoid

Adjustment 1.

ADJUST THE INVERTER GATE SOLENOID (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-1

3 MOVE THE SOLENOID LEFT SIDE VIEW

2 SEAT THE PLUNGER FULLY

1 LOOSEN SCREWS (2)

4 ADJUST: TO ACHIEVE A GAP OF 1.5 +/-0.25 mm, POSITION THE SHIM IN NIP BETWEEN THE ROLLERS

5 TIGHTEN SCREWS (2)

Figure 2 Adjusting the Solenoid 2.

REINSTALL THE INVERTER TRANSPORT.

ADJ 11-2 Gate Flat Spring Purpose The purpose is to ensure that the spring is free to contact the Passive Gate without rubbing against the machine frame.

Check

Section Name

ADJ 11-1

1.

SWITCH OFF THE PRINTER POWER.

2.

OPEN THE INVERTER DOOR.

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Preliminary Working Document No Product Name Assigned

NOTE: It may be necessary to remove the Inverter Transport (REP 11-1) to Check/Adjust the Gate Flat Spring. NOTE: The art shows the rear Gate Flat Spring. However, this procedure also applies to the front Gate Flat Spring. 3.

CHECK/ADJUST THE SPRING CLEARANCE (Figure 1).

3

2

LOOSEN NUTS (2)

CHECK: THE SPRING IS FLUSH WITH THE ALLEN WRENCH

4

1

ADJUST: UNTIL SPRING IS FLUSH WITH THE ALLEN WRENCH

INSERT A 2.0 mm ALLEN WRENCH

5 TIGHTEN NUTS (2)

GATE FLAT SPRING

INVERTER MOTOR RIGHT SIDE VIEW

Figure 1 Checking and Adjusting the Spring Clearance

ADJ 11-3 Inverter Output Baffle

Purpose The purpose is to ensure that sufficient pressure is applied between the Top and Middle Drive Shafts, so that the Passive Gate touches the Inverter frame, in order to maintain a clear paper path.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-3

Check

Adjustment

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

NOTE: Ensure that the Pivoting Assembly is fully latched. 1.

ADJUST THE INVERTER OUTPUT BAFFLE (Figure 2).

NOTE: Ensure that the Pivoting Assembly is fully latched. 3.

CHECK THE INVERTER OUTPUT BAFFLE (Figure 1).

2

1

CHECK: FOR A GAP OF 5.0mm +/-0.25mm

INSERT A 5.0mm ALLEN WRENCH

Figure 1 Checking the Output Baffle

Section Name

ADJ 11-3

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Preliminary Working Document No Product Name Assigned

3

2

ADJUST: TO ACHIEVE A GAP OF 5.0mm +/-0.25mm

INSERT A 5.0mm ALLEN WRENCH

1 LOOSEN SCREWS (2)

4 TIGHTEN THE SCREWS (2)

Figure 2 Adjusting the Output Baffle 2.

REINSTALL THE INVERTER (REP 11-1).

ADJ 11-4 Inverter Top And Bottom Hinges Purpose The purpose is to ensure a smooth paper path alignment between the top and bottom sections of the Inverter.

Check

Preliminary Working Document No Product Name Assigned

1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

3.

CHECK THE HINGE ALIGNMENT (Figure 1).

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Section Name

ADJ 11-3

CHECK: FOR A GAP OF 10.0mm +/-0.25mm

Figure 1 Checking the Hinge Alignment

Adjustment 1.

ADJUST THE HINGE ALIGNMENT (Figure 2).

Section Name

ADJ 11-4

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Preliminary Working Document No Product Name Assigned

1 LOOSEN SCREWS (2)

5 PUSH TOP HINGE FULLY AGAINST THE PIVOTING ASSEMBLY AND TIGHTEN THE SCREWS (2)

2 LOOSEN SCREWS (2)

4 TIGHTEN THE SCREWS (2)

3 ADJUST: TO ACHIEVE A GAP OF 10.0mm +/-0.25mm

Figure 2 Adjusting the Hinge Alignment 2.

CHECK/ADJUST THE PIVOTING ASSEMBLY ALIGNMENT (ADJ 11-8).

3.

CHECK/ADJUST THE INVERTER OUTPUT BAFFLE (ADJ 11-3).

4.

REINSTALL THE INVERTER TRANSPORT.

ADJ 11-6 Stacker Preregistration Transport Corrugator Rolls Purpose The purpose is to ensure that the print is registered properly against the Stacker Preregistration Transport edge.

Check

Preliminary Working Document No Product Name Assigned

1.

REMOVE THE INVERTER TOP COVER (REP 4-52).

2.

REMOVE THE INVERTER LEFT SIDE COVER (REP 4-54).

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Section Name

ADJ 11-4

3.

OPEN THE STACKER PREREGISTRATION TRANSPORT BAFFLE.

4.

CHECK THE STACKER PREREGISTRATION TRANSPORT CORRUGATOR ROLL PRESSURE (Figure 1).

2 CHECK: A HEIGHT OF 2.5 mm +0.1mm/-0.4mm BETWEEN THE ROLL AND PREREGISTRATION TRANSPORT TRAY (3 PLACES)

1 INSERT A 2.5mm ALLEN WRENCH

Figure 1 Checking the Corrugator Rolls

Adjustment 1.

ADJUST THE STACKER PREREGISTRATION TRANSPORT CORRUGATOR ROLLS (Figure 2).

Section Name

ADJ 11-6

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Preliminary Working Document No Product Name Assigned

2

1

ADJUST: ROTATE THE NUT TO ACHIEVE A HEIGHT OF 2.5 mm +0.1mm/-0.3mm (3 PLACES)

INSERT A 2.5mm ALLEN WRENCH

Figure 2 Adjusting the Corrugator Rolls

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-6

ADJ 11-7 Inverter Pivoting Assembly Alignment

Adjustment

Purpose

NOTE: Ensure that the Pivoting Assembly is fully latched.

The purpose is to ensure that the Pivoting Assembly is aligned with the Inverter frame in order to ensure a smooth paper path.

1.

ADJUST THE PIVOTING ASSEMBLY ALIGNMENT (Figure 2).

Check 1.

SWITCH OFF THE PRINTER POWER.

3

2.

REMOVE THE INVERTER TRANSPORT (REP 11-1).

TIGHTEN THE NUTS (2)

NOTE: Ensure that the Pivoting Assembly is fully latched. 3.

CHECK THE PIVOTING ASSEMBLY ALIGNMENT (Figure 1).

1 2

LOOSEN NUTS (2)

ADJUST: UNTIL THE FRONT SURFACES ARE FLUSH +/-0.25 mm

CHECK: THAT THE FRONT SURFACES ARE FLUSH +/-O.25 mm

Figure 2 Adjusting the Pivoting Assembly Alignment 2.

REINSTALL THE INVERTER TRANSPORT (REP 11-1).

Figure 1 Checking the Pivoting Assembly Alignment

Section Name

ADJ 11-7

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Preliminary Working Document No Product Name Assigned

ADJ 11-8 Sample Tray Gate Solenoid (SOL1110)

Adjustment

Purpose

NOTE: It may be necessary to open the Inverter Door and access the solenoid screws from the front of the machine.

The purpose of this adjustment is to ensure that the Sample Tray Gate will open fully, when the solenoid is energized.

1.

ADJUST THE SAMPLE TRAY GATE SOLENOID (Figure 2).

Check 1.

REMOVE THE INVERTER REAR COVER.

2.

ENTER dC330.

3.

SELECT [10], AND [Sample Tray Gate].

NOTE: It may be necessary to use the Remote Hand Held Device (RHHD) to perform the Check and Adjustment. For detailed Operating Instructions of the RHHD, go to (GP 1). 4.

PRESS THE Continue BUTTON AND ENERGIZE THE SOLENOID.

5.

CHECK THE SAMPLE TRAY GATE SOLENOID (Figure 1).

1 LOOSEN THE SCREWS (2)

2 ADJUST: MOVE THE SOLENOID DOWN UNTIL THE PIN IS POSITIONED AGAINST FRAME ON THE RIGHT SIDE OF THE CUTOUT

3 TIGHTEN THE SCREWS (2) CHECK: THAT THE PIN IS POSITIONED AGAINST FRAME ON THE RIGHT SIDE OF THE CUTOUT

Figure 2 Adjusting the Solenoid Figure 1 Checking the Solenoid

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-8

ADJ 11-9 A3 NIP Release Solenoid (SOL1111) Purpose The purpose of this adjustment is to ensure that the Inverter Idler Rolls are not contacting the drive rolls when the solenoid is energized. This will allow A3 Paper to be properly registered.

2 CHECK: FOR A GAP OF 4mm +/-0.25mm

Check 1.

OPEN THE INVERTER DOOR.

2.

ENTER dC330.

3.

SELECT [10], AND [Nip Release A3].

NOTE: It may be necessary to use the Remote Hand Held Device (RHHD) to perform the Check and Adjustment. For detailed Operating Instructions of the RHHD, go to (GP 1). 4.

PRESS THE Continue BUTTON AND ENERGIZE THE SOLENOID.

5.

CHECK THE A3 NIP RELEASE SOLENOID (Figure 1).

1 INSERT A 4mm ALLEN WRENCH BETWEEN THE SHAFT AND THE BAFFLE FRAME

Figure 1 Checking the Solenoid

Adjustment NOTE: Energize and deenergize the solenoid to ensure that the gap is set correctly. 1.

Section Name

ADJ 11-9

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ADJUST THE A3 NIP RELEASE SOLENOID (Figure 2).

Preliminary Working Document No Product Name Assigned

4

1

TIGHTEN THE SCREWS (2)

LOOSEN SCREWS (2)

2 ADJUST: MOVE THE SOLENOID TOWARDS THE REAR TO INCREASE THE GAP OR TOWARDS THE FRONT TO DECREASE THE GAP

3 INSERT A 4mm ALLEN WRENCH TO SET A GAP OF 4mm +/-0.25mm

Figure 2 Adjusting the Solenoid

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-9

ADJ 11-10 Bypass Transport/Purge Transport

Check

Purpose

NOTE: The Bypass Transport and Purge Transport adjustment is performed in the same manner. The Bypass Transport is shown in this procedure.

The purpose of this adjustment is to ensure that the Bypass Transport or Purge Transport is properly positioned in the paper path.

1.

PRESS THE Bin Unload BUTTON TO LOWER THE APPROPRIATE STACKER ELEVATOR.

2.

OPEN THE APPROPRIATE STACKER TOP COVER.

3.

CHECK THE POSITION OF THE TRANSPORT (Figure 1).

2 CHECK: FOR A GAP OF 0.0 TO 0.5mm BETWEEN THE TRANSPORT TABS AND THE FRAME

1 CHECK: THAT THE TRANSPORT IS SETTING ON THE TABS

Figure 1 Checking the Transport Position 4.

OPEN THE STACKER DOORS AND VIEW THE POSITION OF THE TRANSPORT (Figure 2).

Section Name

ADJ 11-10

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Preliminary Working Document No Product Name Assigned

1 CHECK: THAT THE TRANSPORT IS SETTING ON THE FRAME

Figure 2 Checking the Transport Position

Adjustment 1.

REMOVE THE STACKER TOP REAR COVER.

2.

PREPARE THE TRANSPORT FOR ADJUSTMENT (Figure 3).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-10

2

3

LOOSEN NUTS (2)

LOOSEN NUTS (2)

1 TIGHTEN THE NUT ON EACH COUNTERBALANCE UNTIL THE PRESSURE IS OFF THE FRAME

VIEW SHOWN WITH STACKER TOP COVER REMOVED

4 LOOSEN SCREWS (4) ON EACH COUNTERBALANCE

Figure 3 Preparing the Transport for Adjustment 3.

ADJUST THE TRANSPORT (Figure 4).

Section Name

ADJ 11-10

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Preliminary Working Document No Product Name Assigned

1 MOVE THE TRANSPORT TO SET A GAP OF 0.0 TO 0.5mm BETWEEN THE TRANSPORT TABS AND FRAME

3 RETIGHTEN THE HARDWARE

2 PUSH DOWN ON TRANSPORT TO ENSURE THAT IT IS SETTING ON THE TABS IN FRONT AND THE FRAME IN REAR

Figure 4 Adjusting the Transport

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-10

ADJ 11-11 Bypass/Purge Transport Gate Solenoid (SOL1104)

3

Purpose

TIGHTEN THE BRACKET MOUNTING SCREW

The purpose of this adjustment is to ensure the Transport Gate is fully raised when the Bypass/ Purge Transport Gate Solenoid is energized.

1 LOOSEN BRACKET MOUNTING SCREW

Check 1.

OPEN THE APPROPRIATE STACKER TOP COVER.

2.

ENTER dC330. SELECT [11X1] AND [Bypass Gate].

3.

PRESS THE Continue BUTTON.

4.

CHECK THAT THE TRANSPORT GATE IS FULLY RAISED WHEN THE SOLENOID IS ENERGIZED.

Adjustment 1.

ENSURE THAT THE TRANSPORT GATE IS IN THE DOWN POSITION.

2.

ADJUST THE TRANSPORT GATE SOLENOID (Figure 1).

BYPASS GATE

2 ADJUST: MOVE THE BRACKET UNTIL THE GATE JUST BEGINS TO RAISE THEN LOWER THE GATE UNTIL IT JUST TOUCHES THE FRAME

Figure 1 Adjusting the Solenoid 3.

Section Name

ADJ 11-11

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RECHECK THE TRANSPORT GATE SOLENOID.

Preliminary Working Document No Product Name Assigned

ADJ 11-12 Post Inverter Latch Purpose

1

The purpose of this adjustment is to ensure that the proper gap is maintained between the Post Inverter Pivoting Assembly and inner baffle frame.

POSITION A 0.254mm SHIM SO THAT IT IS CAPTURED BETWEEN THE TABS (2) AND INNER BEARING SURFACES (2)

Check 1.

OPEN THE INVERTER DOOR.

2.

UNLATCH AND OPEN THE INVERTER PIVOTING ASSEMBLY.

3.

UNLATCH AND OPEN THE POST INVERTER PIVOTING ASSEMBLY.

4.

PREPARE TO CHECK THE POST INVERTER LATCH (Figure 1).

TABS

2 CLOSE THE PIVOTING ASSEMBLY

Figure 1 Preparing to Check the Latch NOTE: It will be necessary to trim one end of the.254mm Shim Stock (brown), in order to check the gap between the Latch Mechanism and the catch (step 3, Figure 2). 5.

Preliminary Working Document No Product Name Assigned

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CHECK THE POST INVERTER LATCH (Figure 2).

Section Name

ADJ 11-12

2 PUSH IN ON PIVOTING ASSEMBLY

1 CHECK: THAT DRAG IS PRESENT WHEN PULLING OUT THE SHIM

3 CHECK: FOR A GAP OF 0.254mm BY INSERTING A SHIM

Figure 2 Checking the Latch

Adjustment 1.

ADJUST THE POST INVERTER LATCH (Figure 3).

Section Name

ADJ 11-12

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Preliminary Working Document No Product Name Assigned

1 SECURE THE NUT ON THE REAR OF THE LATCH ASSEMBLY

2 LOOSEN

3 ADJUST: MOVE THE LATCH MECHANISM TO ACHIEVE GAP (2 PLACES)

4 INSERT THE 0.254mm SHIM AND RECHECK (2 PLACES)

Figure 3 Adjusting the Latch

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-12

ADJ 11-13 Sample Tray and Purge Tray Corrugator Rolls Purpose The purpose of this adjustment is to ensure that the Sample Tray and Purge Tray Slip Nip has the correct amount of corrugation.

Check 1.

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. UNPLUG ALL POWER CORDS. NOTE: The Sample Tray is shown for performing the adjustment. The Purge Tray adjustment will be performed the same way.

2.

FOR THE SAMPLE TRAY, PERFORM THE FOLLOWING: a.

3.

4.

REMOVE THE IFS LEFT SIDE COVER (REP 4-54).

b.

OPEN THE SAMPLE TRAY COVER.

c.

REMOVE THE PIN AND LOWER THE RIGHT BAFFLE.

d.

CONTINUE WITH STEP 4.

FOR THE PURGE TRAY, PERFORM THE FOLLOWING: a.

OPEN THE PURGE TRAY TOP COVER.

b.

REMOVE THE NUT AND DISCONNECT THE CABLE THAT SECURES THE PURGE TRANSPORT TOP BAFFLE TO THE PURGE TRAY TOP COVER.

c.

LOWER THE BAFFLE.

d.

PLACE A WEIGHT ON THE TOP BAFFLE SO THAT THE TONGUE OF THE BAFFLE IS FULLY SEATED IN THE GROOVE OF THE LOWER BAFFLE AND WILL NOT RAISE EASILY.

e.

CONTINUE WITH STEP 4.

REMOVE THE GROUND BRUSH FROM THE END OF THE TRANSPORT BAFFLE FOR EASIER VIEWING AND ADJUSTMENT. SAMPLE TRAY (PL 11.23), PURGE TRAY (PL 11.16). NOTE: The Slip Nip Setup Tools (2) are stored in the Manometer storage bracket located behind the Feeder Cover of the HCT Drawer Assembly.

5.

CHECK THE SLIP NIP CORRUGATION (Figure 1).

Section Name

ADJ 11-13

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Preliminary Working Document No Product Name Assigned

2 ENSURE THAT THE MAGNET ON THE SET-UP TOOL IS FLAT AGAINST THE GROUND BRUSH MOUNTING SURFACE

3 CHECK: IF THE BRACKET DEFLECTS, PERFORM THE ADJUSTMENT

4 5

1 INSERT THE SET-UP TOOL

IF ONE SIDE CHECKS OK, REPEAT THE PROCESS ON THE OTHER SIDE

CHECK: IF THERE IS A GAP, PERFORM THE ADJUSTMENT

Figure 1 Checking the Slip Nip Corrugation

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-13

Adjustment NOTE: The Idler Assembly should move freely on the mounting bracket. 1.

LOOSEN THE NUTS (2) WHICH FASTEN THE SLIP NIP IDLER ASSEMBLY TO THE LEFT AND RIGHT MOUNTING BRACKETS.

2.

ADJUST THE SLIP NIP CORRUGATION (Figure 2).

Section Name

ADJ 11-13

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Preliminary Working Document No Product Name Assigned

4 CHECK: ENSURE THAT THE MOUNTING BRACKETS DO NOT DEFLECT

3 LOWER THE SLIP NIP IDLER ASSEMBLY SO THAT THE WHITE ROLLS ARE RESTING ON THE SET-UP TOOLS

5 HOLD THE IDLER ASSEMBLY SHAFT AND TIGHTEN THE NUTS (2)

1 ;LOOSEN THE NUTS (2)

2 INSERT BOTH SET-UP TOOLS

Figure 2 Adjusting the Slip Nip Corrugation 3.

REMOVE THE SETUP TOOLS AND RETURN THEM TO THE MANOMETER STORAGE BRACKET.

Preliminary Working Document No Product Name Assigned

4.

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REINSTALL THE GROUND BRUSH.

Section Name

ADJ 11-13

5.

RETURN THE BAFFLE TO THE OPERATING POSITION.

ADJ 11-14 Inverter Transport Motor Belt Tension

6.

APPLY POWER AND VERIFY CORRECT PRINTER OPERATION.

Purpose The purpose is to adjust the Motor belt tension to ensure that there is no belt slippage.

Check 1.

SWITCH OFF THE PRINTER POWER AND CIRCUIT BREAKERS. UNPLUG ALL POWER CORDS.

2.

REMOVE THE IFS TOP COVER (REP 4-52).

3.

REMOVE THE IFS LEFT SIDE COVER (REP 4-54).

Adjustment

Section Name

ADJ 11-13, ADJ 11-14

1.

REMOVE THE INVERTER TRANSPORT ASSEMBLY (REP 11-1).

2.

PLACE THE INVERTER TRANSPORT ASSEMBLY ON A FLAT WORK SURFACE AS SHOWN AND ADJUST THE MOTOR BELT TENSION (Figure 1).

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Preliminary Working Document No Product Name Assigned

2 LIFT THE MOTOR UNTIL ABOUT A 30 DEGREE ANGLE IS FORMED BETWEEN THE FRAME AND THE WORK SURFACE

1 LOOSEN SCREWS (4)

3 TIGHTEN THE SCREWS (4)

WORK SURFACE

Figure 1 Adjusting the Motor Belt Tension 3.

REINSTALL THE INVERTER TRANSPORT ASSEMBLY (REP 11-1).

Preliminary Working Document No Product Name Assigned

4.

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APPLY PRINTER POWER AND VERIFY CORRECT PRINTER OPERATION. Section Name

ADJ 11-14

Section Name

ADJ 11-14

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Preliminary Working Document No Product Name Assigned

ADJ 11-25 Disk Home Position

NOTE: The following step is performed while the disks are rotating. Ensure that the gap is measured between the frame and disk as shown in the previous Figure.

Purpose

3.

The purpose is to ensure that the Disks return to their correct Home Position.

WHILE CHECKING THE GAP, ADJUST THE DISK HOME POSITION (Figure 2).

Check 1.

ENTER dC203. SELECT [Setups], [Disk Home], [Stacker X] AND [Home Position].

2.

AFTER THE ELEVATOR HAS REACHED THE DOWN POSITION, PRESS THE Continue BUTTON. THE DISKS WILL BEGIN TO ROTATE AT THIS TIME.

NOTE: The following step is performed while the disks are rotating. Ensure that the gap is measured between the frame and disk as shown in Figure. 3.

AS THE DISKS ROTATE, CHECK THE HOME POSITION (Figure 1).

U CHANNEL

REGISTRATION WALL

CHECK: FOR A GAP OF 6 +/- 1mm BETWEEN THE BACK OF THE REGISTRATION WALL AND DISK Figure 1 Checking the Home Position 4.

PRESS THE Stop BUTTON TO STOP THE DISKS FROM ROTATING.

Adjustment 1.

REMOVE THE STACKER FRONT COVER (REP 4-49).

2.

PRESS THE Continue BUTTON TO BEGIN THE DISKS ROTATING.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-25

3 ADJUST: ROTATE SENSOR BRACKET DOWNWARD UNTIL A GAP OF 6 +/-1mm IS ACHIEVED BETWEEN THE FRAME AND DISK

2 ROTATE SENSOR BRACKET UPWARD UNTIL THE SCREW CONTACTS THE BOTTOM OF THE SLOT

1 LOOSEN NUT

Figure 2 Adjusting the Home Position 4.

PRESS THE Stop BUTTON.

ADJ 11-26 Disk Gate Height

5.

CHECK/ADJUST THE DISK GATE HEIGHT (ADJ 11-26).

Purpose The purpose is to ensure that the Disk Gate is at the correct height to allow paper to pass under it without a jam occurring.

Check NOTE: This adjustment can be performed only after the Disk Home Position Check/Adjustment has been completed. 1.

CHECK/ADJUST THE DISK HOME POSITION (ADJ 11-25).

2.

REMOVE THE STACKER FRONT COVER (REP 4-49).

3.

SELECT [Gate Height], AND PRESS THE Continue BUTTON. THE DISK WILL ROTATE TO THE HIGH POSITION AT THIS TIME.

NOTE: Keep downward pressure on the Bypass Transport when performing the checks or adjustment. 4.

Section Name

ADJ 11-25

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CHECK THE DISK GATE HEIGHT WHEN IT IS IN THE HIGH POSITION (Figure 1).

Preliminary Working Document No Product Name Assigned

GATE

CHECK: THAT THE GATE IS JUST ABOVE THE TRAIL EDGE ASSIST BELTS WITHOUT TOUCHING THE TRAIL EDGE ASSIST SHAFT

VIEW FROM INSIDE STACKER AREA

Figure 1 Checking the Gate in the High Position NOTE: In Figure 2, the Front Bumper and Disk Gate are shown with the Bypass Transport raised slightly. The check will have to be viewed from inside the Stacker area while keeping downward pressure on the Bypass Transport. 5.

CHECK THE DISK GATE HEIGHT WHEN IT IS IN THE LOW POSITION (Figure 2).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-26

1 MANUALLY ROTATE THE DISK UNTIL THE GATE IS IN THE LOW POSITION

3

2

TIGHTEN THE NUT

CHECK: THAT THE GATE REST ON THE FRONT BUMPER

2 ADJUST: ROTATE THE SETSCREW CLOCKWISE TO RAISE THE GATE OR COUNTERCLOCKWISE TO LOWER THE GATE

FRONT BUMPER

VIEW SHOWN WITH THE BYPASS TRANSPORT RAISED SLIGHTLY

1 LOOSEN THE NUT

Figure 2 Checking the Gate in the Low Position

Adjustment 1.

RAISE THE BYPASS TRANSPORT.

2.

ADJUST THE DISK GATE HEIGHT (Figure 3).

Section Name

ADJ 11-26

Figure 3 Adjusting the Gate Height 3.

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REPEAT THE CHECKS, AND READJUST IF NECESSARY.

Preliminary Working Document No Product Name Assigned

ADJ 11-27 Stack Height Purpose The purpose is to ensure that the Stack Height is at the specified height for stacking.

Check 1.

OPEN THE APPROPRIATE STACKER TOP COVER AND PLACE A CHEATER IN THE TOP COVER INTERLOCK SWITCH.

2.

ENTER dC330 AND SELECT [11X2].

NOTE: Observe the Stack Height Sensor icon to ensure that when the elevator stops, the icon changes from L to H. 3.

SELECT [Elevator UP] AND PRESS THE Continue BUTTON.

4.

REMOVE THE CHEATER FROM THE FS INTERLOCK BYPASS SWITCH.

5.

OPEN THE STACKER DOORS.

6.

ROTATE THE STACKER ELEVATOR DRIVE BELT AND LOWER THE STACKER ELEVATOR UNTIL THE Stack Height Sensor CHANGES TO L.

7.

ROTATE THE STACKER ELEVATOR DRIVE BELT AND RAISE THE STACKER ELEVATOR UNTIL THE Stack Height Sensor JUST CHANGES TO H.

8.

CHECK THE STACK HEIGHT (Figure 1).

CHECK: FOR A GAP OF 62.5mm TO 66.5mm BETWEEN THE PALLET AND THE CENTER OF THE DISK SHAFT

Figure 1 Checking the Gap

Adjustment

Preliminary Working Document No Product Name Assigned

1.

REMOVE THE APPROPRIATE STACKER FRONT COVER (REP 4-49).

2.

ROTATE THE STACKER ELEVATOR DRIVE BELT AND LOWER THE STACKER ELEVATOR UNTIL THE Stack Height Sensor CHANGES TO L.

3.

ADJUST THE STACK HEIGHT (Figure 2).

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Section Name

ADJ 11-27

ADJ 11-28 Right Guide Purpose The purpose is to ensure that the right and left edges of the Print Stack are aligned properly.

Check 1.

ENTER dC203. SELECT [Setups] AND [Stacker X].

2.

ENTER A QUANTITY OF 200 ON THE UI CONTROL PANEL.

3.

PRESS THE Continue BUTTON.

4.

WHEN THE JOB IS COMPLETE, OPEN THE STACKER TOP COVER AND RAISE THE BYPASS OR PURGE TRANSPORT.

5.

CHECK THE RIGHT GUIDE (Figure 1).

1 LOOSEN NUT

2 ADJUST: MOVE THE SENSOR DOWN TO INCREASE THE GAP AND UP TO DECREASE THE GAP

Figure 2 Adjusting the Stack Height 4.

ROTATE THE STACKER ELEVATOR DRIVE BELT AND RAISE THE STACKER ELEVATOR UNTIL THE Stack Height Sensor JUST CHANGES TO H.

5.

RECHECK THE GAP AND READJUST IF NECESSARY.

6.

CHECK/ADJUST THE STACKER OVERTRAVEL UP SWITCH (S1140) (ADJ 11-30).

Section Name

ADJ 11-27, ADJ 11-28

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Preliminary Working Document No Product Name Assigned

ADJ 11-29 Back Guide Purpose 1 ROTATE GEAR UNTIL THE RIGHT GUIDE WALL IS FULLY EXTENDED

The purpose is to ensure that the rear and front edges of the Print Stack are aligned properly.

Check 1.

ENTER dC203. SELECT [Setups], AND [Stacker X].

2.

ENTER A QUANTITY OF 200 ON THE UI CONTROL PANEL.

3.

RAISE THE STACKER TOP COVER AND PLACE A CHEATER IN THE TOP COVER INTERLOCK SWITCH.

4.

PRESS THE Continue BUTTON.

NOTE: The Back Guide Tamper Arm should allow the print to settle on the stack without any interference. If interference is present, the Back Guide is positioned to far forward. 5.

AS THE JOB IS RUNNING, VIEW BETWEEN THE TRANSPORT AND THE FRAME TO ENSURE THAT THE BACK GUIDE TAMPER ARM IS ALLOWING THE PRINT TO SETTLE ON THE STACK.

6.

WHEN THE JOB IS COMPLETE, PRESS THE Bin Unload BUTTON AND PULL OUT THE STACKER DRAWER.

7.

CHECK THE FRONT AND REAR EDGES OF THE PRINT STACK TO ENSURE THAT THEY ARE ALIGNED PROPERLY AND NOT SHINGLED.

Adjustment NOTE: In dC203, [Setups], [Stacker X], the up arrow under Back Guide will move the Back Guide towards the rear. The down arrow will move the Back Guide towards the front. 1.

ADJUST THE BACK GUIDE.

2.

RECHECK THE BACK GUIDE AND READJUST IF REQUIRED.

CHECK: 2 THAT THE RIGHT GUIDE JUST TOUCHES THE STACK OF PRINTS

Figure 1 Checking the Guide

Adjustment NOTE: In dC203, [Setups], [Stacker X] the right arrow under Right Guide will move the guide to the right. The left arrow will move the Right Guide to the left. 1.

ADJUST THE RIGHT GUIDE.

2.

RECHECK THE RIGHT GUIDE AND READJUST IF REQUIRED.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-28, ADJ 11-29

ADJ 11-30 Stacker Overtravel Up Switch (S1140) Purpose The purpose is to ensure that the Stacker Overtravel Up Switch is properly adjusted to avoid Guide damage due to a Stack Height Sensor failure.

Check 1.

ENTER dC330, AND SELECT [11X2].

NOTE: Observe the Stack Height Sensor icon to ensure that when the elevator stops, the icon changes from L to H. 2.

SELECT [Elevator UP] AND PRESS THE Continue BUTTON.

3.

CHECK THE STACK HEIGHT (Figure 1).

NOTE: If the Stack Height requires adjustment, ensure to record the amount of gap between the Pallet surface and the center of the Disk Shaft for use in step 7. 4.

IF THE CHECK IS GOOD, CONTINUE WITH STEP 5. IF THE CHECK IS NOT GOOD, ADJUST THE STACK HEIGHT (ADJ 11-27) THEN CONTINUE WITH STEP 7.

5.

RECORD THE AMOUNT OF GAP BETWEEN THE PALLET SURFACE AND THE CENTER OF THE DISK SHAFT.

6.

OPEN THE STACKER DOORS.

7.

ROTATE THE STACKER ELEVATOR DRIVE BELT, AND RAISE THE ELEVATOR AN ADDITIONAL 4.5mm +/-1mm ABOVE THE RECORDED STACK HEIGHT GAP.

8.

REMOVE THE APPROPRIATE UPPER REAR COVER FROM THE STACKER.

9.

CHECK THE STACKER OVERTRAVEL UP SWITCH (Figure 1). CHECK: THAT THE ACTUATOR ARM IS IN THE CORRECT POSITION TO ACTUATE THE SWITCH

Figure 1 Checking the Switch

Adjustment

Section Name

ADJ 11-30

1.

OPEN THE STEPPER PWB PANEL.

2.

ADJUST THE STACKER OVERTRAVEL UP SWITCH (Figure 2).

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Preliminary Working Document No Product Name Assigned

3 TIGHTEN THE SCREWS (2)

2 ADJUST: POSITION THE SWITCH UNTIL THE ACTUATOR ARM ACTUATES THE SWITCH

1 LOOSEN THE SCREWS (2)

Figure 2 Adjusting the Switch

ADJ 11-31 Pallet Lift Frame Parallelism

NOTE: The bottom edge of the four Lift Frame Retainers may extend below the Lift Frame. Ensure that the check is made between the bottom edge of the Lift Frame and the same Elevator Base surface in all four places.

Purpose The purpose is to ensure that the Pallet Lift Frame is parallel within the Elevator Assembly.

5.

CHECK THE PALLET LIFT FRAME PARALLELISM (Figure 1).

Check NOTE: Be prepared to press the Stop button when the Elevator is between the halfway down position and the down position. 1.

ENTER dC330. SELECT [11X2], [Elevator DN] AND PRESS THE Continue BUTTON.

2.

PRESS THE Stop BUTTON WHEN THE ELEVATOR IS BETWEEN THE HALFWAY DOWN POSITION AND THE DOWN POSITION.

3.

OPEN THE STACKER DOORS.

4.

REMOVE THE MAIN PALLET.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-30

1 NOTE: ROTATE THE ELEVATOR DRIVE BELT AND LOWER THE LIFT FRAME UNTIL IT JUST CONTACTS THE SCALE

2 CHECK: THAT THE DISTANCE BETWEEN THE LIFT FRAME AND THE ELEVATOR BASE IS EQUAL AT THE FOUR LEAD SCREW LOCATIONS +/- 1mm

Figure 1 Checking the Lift Frame

Adjustment 1.

SWITCH OFF THE PRINTER POWER.

2.

REMOVE THE STACKER FRONT COVER (REP 4-49).

3.

REMOVE THE PALLET LIFT FRAME (REP 11-58).

4.

ADJUST THE FOUR LIFT NUTS (Figure 2).

Section Name

ADJ 11-31

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ADJ 11-32 Container Size Sensors (Q1126, Q1127, Q1128) ADJUST: ROTATE EACH LIFT NUT (4) DOWN UNTIL IT JUST CONTACTS THE SCALE +/- 1mm

Purpose The purpose is to properly align a Container with the Container Size Sensor.

Check 1.

ENTER dC330. SELECT [11X2], [Elevator UP]. PRESS Continue, RAISE THE PALLET LIFT FRAME TO THE TOP OF THE STACKER AND OPEN THE STACKER DOORS.

2.

SLIDE THE PALLET BASE OUT OF THE STACKER ASSEMBLY.

3.

CHECK THE CONTAINER SIZE SENSORS (Figure 1).

CONTAINER SENSOR

CHECK: THAT THE TOP SURFACE OF THE SENSORS IS PARALLEL WITH THE TOP EDGE OF THE MOUNTING BRACKET Figure 2 Adjusting the Lift Nuts 5.

REINSTALL THE PALLET LIFT FRAME.

ALIGNMENT BLOCK

Figure 1 Checking the Sensors

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-31, ADJ 11-32

4.

IF REQUIRED, ALIGN THE SENSORS WITH THE TOP EDGE OF THE MOUNTING BRACKET.

5.

SLIDE THE STACKER SUPPORT ASSEMBLY BACK IN AND CLOSE THE STACKER DOORS.

6.

ENTER dC330. SELECT [11X2], [Elevator DN] AND PRESS THE Continue BUTTON TO LOWER THE ELEVATOR ASSEMBLY.

NOTE: A Container Pallet is flat and fits inside a Paper Container which has side walls. Use an 11 X 17 or an A3 Container Pallet to perform the Check and Adjustment. If one is not available, the Check and Adjustment can be done with any size Paper Container. 7.

OPEN THE STACKER DOORS AND SLIDE THE PALLET BASE OUT.

8.

PRESS THE GREEN BUTTON ON THE MAIN PALLET ASSEMBLY. THE DECAL ON THE MAIN PALLET WILL CHANGE FROM A BLACK TO A GREEN PICTURE INDICATING THAT IT IS READY TO ACCEPT THE CONTAINER PALLET OR THE PAPER CONTAINER.

NOTE: Ensure that the identification number on the Container Pallet or Paper Container is on the outboard side near the red stripe on the Main Pallet Assembly. 9.

PLACE THE CONTAINER PALLET OR THE PAPER CONTAINER PINS ONTO THE HOLES OF THE MAIN PALLET.

10. SLIDE THE PALLET BASE INTO THE STACKER COMPLETELY. NOTE: It will be necessary to remove a Hinge Pin from the Inverter Door to perform the Check and Adjustment. 11. CHECK THE CONTAINER SIZE SENSORS WITH THE CONTAINER PALLET OR THE PAPER CONTAINER INSTALLED (Figure 2).

Section Name

ADJ 11-32

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Preliminary Working Document No Product Name Assigned

1 NOTE: ENSURE THAT THE SUPPORT TRAY IS COMPLETELY IN BEFORE DOING THE CHECK

2 INSERT HINGE PIN THROUGH THE HOLE IN THE CONTAINER PALLET (11 x 17 AND A3) OR THROUGH THE SMALL HOLE IN PAPER CONTAINER (8.5 x 11 AND A4)

3 CHECK: THAT THE SLOT IN THE CONTAINER SENSOR ALIGNS WITH HOLE IN THE CONTAINER PALLET OR SMALL HOLE IN THE PAPER CONTAINER (THE HINGE PIN SHOULD FALL INTO CONTAINER SENSOR SLOT IF PROPERLY ALIGNED)

NOTE: A3 CONTAINER PALLET SHOWN, A PAPER CONTAINER HAS SIDEWALLS

Figure 2 Checking the Sensor 12. IF NO ADJUSTMENT IS REQUIRED: a.

Reinstall The Hinge Pin In The Inverter Door.

b.

If the Container Sensor Assembly mounting screws ARE loose, go to in this procedure.

c.

If the Container Sensor Assembly mounting screws ARE NOT loose, go to 17 in this procedure.

2.

SELECT [Elevator UP], PRESS Continue. WHEN THE ELEVATOR ASSEMBLY GETS TO THE TOP OF THE STACKER, OPEN THE DOORS.

3.

PULL THE STACKER SUPPORT OUT.

4.

LOOSEN THE TWO CONTAINER SENSOR ASSEMBLY MOUNTING BRACKET SCREWS (LEAVE HAND TIGHT).

5.

SLIDE THE STACKER SUPPORT ASSEMBLY BACK IN AND CLOSE THE DOORS.

Adjustment

6.

SELECT [Elevator DN], press Continue TO LOWER THE ELEVATOR ASSEMBLY.

1.

7.

OPEN THE STACKER DOORS AND SLIDE THE PALLET BASE OUT.

8.

PLACE A CONTAINER PALLET OR A PAPER CONTAINER ONTO THE MAIN PALLET.

REMOVE THE CONTAINER PALLET OR THE PAPER CONTAINER, SLIDE THE PALLET BASE BACK IN AND CLOSE THE STACKER DOORS.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-32

9.

SLIDE THE PALLET BASE INTO THE STACKER COMPLETELY.

10. ADJUST THE CONTAINER SIZE SENSORS (Figure 3).

1 INSERT THE HINGE PIN THROUGH THE HOLE IN THE CONTAINER PALLET (11 x 17 AND A3) OR THROUGH THE SMALL HOLE IN THE PAPER CONTAINER (8.5 x 11 AND A4)

2 ADJUST: MOVE MOUNTING BRACKET UNTIL THE SLOT IN THE CONTAINER SENSOR ALIGNS WITH THE HOLE IN THE CONTAINER PALLET OR THE PAPER CONTAINER (THE HINGE PIN SHOULD FALL INTO CONTAINER SENSOR SLOT IF PROPERLY ALIGNED)

3 REMOVE HINGE PIN AND REINSTALL IN INVERTER DOOR

CONTAINER SENSOR ASSEMBLY MOUNTING BRACKET HARDWARE

Figure 3 Adjusting the Sensor 11. REMOVE THE CONTAINER PALLET OR THE PAPER CONTAINER, SLIDE THE PALLET BASE BACK IN AND CLOSE THE STACKER DOORS.

16. ENTER dC330, SELECT [11X2],[Elevator DN] AND PRESS Continue TO LOWER THE ELEVATOR ASSEMBLY.

12. SELECT [Elevator UP]. PRESS Continue, TO RAISE MAIN PALLET ASSEMBLY TO THE TOP OF THE STACKER AND OPEN THE DOORS.

17. AFTER THE ELEVATOR ASSEMBLY IS DOWN, PLACE A PAPER CONTAINER ON THE STACKER MAIN PALLET ASSEMBLY AND VERIFY THAT THE MACHINE IS PROPERLY IDENTIFYING THE PAPER CONTAINER IN THE MACHINE PER TABLE 1.

13. PULL THE STACKER SUPPORT OUT. 14. TIGHTEN THE CONTAINER SENSOR ASSEMBLY HARDWARE BEING CAREFUL NOT TO MOVE THE CONTAINER SENSOR ASSEMBLY. 15. SLIDE THE PALLET BASE IN AND CLOSE THE STACKER DOORS.

Section Name

ADJ 11-32

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Preliminary Working Document No Product Name Assigned

NOTE: The correct module letter (A/B/C/D) must be inserted for the letter X in order to properly identify the Sensor state. The Sensor readings can be found in dC330, [11X1]. 18. VERIFY THAT THE MACHINE IS PROPERLY IDENTIFYING THE PAPER CONTAINER. Table 1 Container Size Identification Container Size...

State

8.5 X 11

Sensor A

H

8.5 X 11

Sensor B

L

8.5 X 11

Sensor C

L

11 X 17

Sensor A

L

11 X 17

Sensor B

L

11 X 17

Sensor C

H

A3

Sensor A

L

A3

Sensor B

L

A3

Sensor C

H

A4

Sensor A

H

A4

Sensor B

L

A4

Sensor C

H

19. IF THE PAPER CONTAINER IS NOT BEING PROPERLY IDENTIFIED, REPEAT THE ADJUSTMENT PROCEDURE STARTING WITH 1.

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-32

ADJ 11-33 Back Guide Squareness

2.

PLACE A CHEATER IN THE STACKER TOP COVER INTERLOCK SWITCH.

Purpose

3.

ENTER dC203. SELECT [Edge Guides], [Stacker X], AND [Back Guide].

4.

PRESS THE [Continue] BUTTON. WHEN THE BACK GUIDE IS FULLY EXTENDED, PRESS THE Stop BUTTON.

The purpose of the Back Guide Squareness Adjustment is to ensure that the Back Guide is square to the Reg Wall.

Check

NOTE: Approximately ten sheets of Card Stock will be required to perform the Check and Adjustment.

1.

5.

OPEN THE APPROPRIATE STACKER TOP COVER AND RAISE THE BYPASS/PURGE TRANSPORT.

CHECK THE BACK GUIDE SQUARENESS (Figure 1).

REG WALL

2 CHECK: THAT THE BACK GUIDE IS SQUARE WITH THE REG WALL +/-.5MM

1 POSITION APPROXIMATELY TEN SHEETS OF CARD STOCK AGAINST THE BACK GUIDE AND REG WALL

Figure 1 Checking the Squareness

Adjustment NOTE: After the two screws located on the right have been loosened, the right side of the Back Guide can be pivoted until it is square with the Reg Wall. 1.

ADJUST THE BACK GUIDE SQUARENESS (Figure 2).

Section Name

ADJ 11-33

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Preliminary Working Document No Product Name Assigned

4 TIGHTEN THE SCREWS (2)

1 LOOSEN THE SCREWS (2)

3 RECHECK THE BACK GUIDE SQUARENESS AND ADJUST IF REQUIRED

2 ADJUST: POSITION THE BACK GUIDE UNTIL IT IS SQUARE WITH THE REG WALL +/-.5mm

Figure 2 Adjusting the Squareness

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-33

ADJ 11-34 Right Guide Moving Wall Squareness

NOTE: Rotate the Tamper Motor gear to position the Moving Wall in or out.

Purpose

2.

POSITION THE MOVING WALL UNTIL IT JUST TOUCHES THE PRINT STACK.

The purpose of the Right Guide Moving Wall Squareness Adjustment is to ensure that the Moving Wall is square to the Print Stack.

3.

CHECK THAT THE MOVING WALL IS SQUARE TO THE PRINT STACK.

1.

Check 1.

Adjustment ADJUST THE MOVING WALL SQUARENESS (Figure 1).

CHECK/ADJUST THE RIGHT GUIDE (ADJ 11-28).

2 LOOSEN NUTS (2)

1 ROTATE THE GEAR UNTIL THE NUTS (3) CAN BE ACCESSED

3 EXTEND WALL UNTIL IT JUST TOUCHES THE PRINT STACK

6 RECHECK AND ADJUST IF REQUIRED

5

4

CAREFULLY RETRACT THE WALL AND TIGHTEN THE NUTS (3)

SQUARE THE WALL TO THE PRINT STACK

Figure 1 Adjusting the Squareness

Section Name

ADJ 11-34

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Preliminary Working Document No Product Name Assigned

ADJ 11-35 Stacker Module Paper Path Adjustment Purpose The purpose is to ensure that the stacker module paper path is properly aligned. Ensure that all IFS/MM/ and FS modules are level, (per Install Manual), before beginning this procedure.

Check NOTE: Three and four module systems require the following additional adjustments to ensure that the paper path is properly aligned. 1.

PLACE A REFERENCE LINE ON THE BAFFLE, PARALLEL TO THE PAPER PATH, 56 MM FROM THE INSIDE SURFACE OF THE WELDMENT SIDE FRAME (Figure 1). a.

2.

3.

Place tolerance reference lines 3 mm to each side of the reference line.

CHECK THE PAPER OFFSET AS IT ENTERS THE SECOND MODULE. a.

Place a cheater in the Top Cover Interlock switch of the second module.

b.

Lower the top transport baffle.

c.

Using dC106 run 100 prints to the last stacker. Observe the location of the outboard paper edge as it passes over the reference lines.

THE OUTBOARD EDGE OF THE PAPER SHOULD PASS WITHIN 3 MM OF THE CENTER REFERENCE LINE.

Figure 1 Position of Reference Lines on the Disk Module Weldment. 4.

Preliminary Working Document No Product Name Assigned

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IF THE PAPER IS OBSERVED TO BE OUTSIDE THE OUTBOARD TOLERANCE REFERENCE LINE, THEN THE BYPASS TRANSPORT IN THE PREVIOUS MODULE REQUIRES ADJUSTMENT. a.

Prepare the Bypass Transport for adjustment (Figure 2).

b.

Adjust the transport (Figure 3).

Section Name

ADJ 11-35

Figure 4 Preparing the Transport for Adjustment

Figure 2 Preparing the Transport for Adjustment

Figure 5 Adjusting the Transport

Figure 3 Adjusting the Transport 5.

6.

VERIFY THAT THE EDGE OF THE PAPER IS WITHIN THE TOLERANCE REFERENCE LINES.

7.

REPEAT THIS ADJUSTMENT PROCEDURE WITH EACH OF THE REMAINING MODULES.

IF THE PAPER EDGE IS OBSERVED TO BE OUTSIDE THE INBOARD TOLERANCE REFERENCE LINE, ADJUST THE BYPASS TRANSPORT

8.

UNLOCK THE COUNTER BALANCE NUTS (Figure 6).

9.

REINSTALL ALL COVERS.

a.

Prepare the Transport for adjustment (Figure 4).

10. VERIFY SYSTEM OPERATION.

b.

Adjust the transport (Figure 5).

Section Name

ADJ 11-35

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Preliminary Working Document No Product Name Assigned

Figure 6 Adjusting the Transport for Normal Operation

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 11-35

Section Name

ADJ 11-35

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Preliminary Working Document No Product Name Assigned

ADJ 13-1 Bypass Transport Stacker Output Gate: Purpose The purpose is to adjust the Bypass Transport Stacker Output Gate (Purge Gate) to the proper position.

Check 1.

OPEN THE F/S TOP COVER.

2.

PLACE A CHEATER IN THE TOP COVER INTERLOCK SWITCH.

3.

ENTER dC330. Select [Third Party], [Fin 1] [Stacker Output Gate]. Press Continue.

4.

ENSURE THAT THE GATE IS BOTTOMED ON THE LOWER BAFFLE AND THAT ALL SLACK IS REMOVED FROM THE CABLE.

Adjustment 1.

OPEN THE F/S TOP COVER.

2.

PLACE A CHEATER IN THE TOP COVER INTERLOCK SWITCH.

3.

ENTER dC330. SELECT [Third Party], [Fin 1] [Stacker Output Gate]. PRESS Continue.

NOTE: Ensure that the plunger remains fully engaged in the solenoid while performing the adjustment. 4.

ADJUST THE BYPASS TRANSPORT GATE (Figure 1).

Preliminary Working Document No Product Name Assigned

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Section Name

ADJ 13-1

1

3

LOOSEN THE MOUNTING NUT

TIGHTEN THE MOUNTING NUT

2 ADJUST: MOVE THE BRACKET UNTIL THE GATE IS BOTTOMED AND THE SLACK IS REMOVED FROM THE CABLE

Figure 1 Adjusting the Gate 5.

CHECK THAT THE GATE DOES NOT OBSTRUCT THE PAPER PATH WHEN NOT ENERGIZED.

ADJ 13-2 Bypass Transport Purge Baffle: Purpose The purpose is to adjust the Bypass Transport Purge Baffle to the proper position.

Check 1.

Section Name

ADJ 13-1

OPEN THE F/S TOP COVER.

2.

DETACH THE PURGE BAFFLE FROM THE F/S TOP COVER.

3.

CHECK THAT THE PURGE BAFFLE IS BIASED TO THE REAR AGAINST THE BYPASS TRANSPORT FRAME.

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Preliminary Working Document No Product Name Assigned

Adjustment 1.

2.

ENSURE THAT THE LOCATING TABS OF THE PURGE BAFFLE ARE IN THE LOCATING SLOTS OF THE F/S FRAME (FRONT AND REAR).

3.

ADJUST THE BYPASS TRANSPORT PURGE BAFFLE (Figure 1).

DETACH THE PURGE BAFFLE FROM THE F/S TOP COVER.

1

2

ENSURE THAT THE LOCATING TAB IS LOCATED IN THE SLOT

LOOSEN SCREWS (4), AND NUTS (2)

4 TIGHTEN THE SCREWS (4), AND THE NUTS (2)

3 ADJUST: BIAS THE BAFFLE TO THE RIGHT AND TO THE REAR AGAINST THE FRAME

Figure 1 Adjusting the Baffle 4.

ATTACH THE PURGE BAFFLE TO THE F/S TOP COVER. ENSURE THAT THE LOCATING TABS ENTER THE LOCATING SLOTS WHEN THE BAFFLE IS CLOSED.

ADJ 13-3 Bypass Transport Exit Baffle: Purpose The purpose is to adjust the Bypass Transport Exit Baffle to the proper position.

Check 1. Preliminary Working Document No Product Name Assigned

0/0/00 ?-647

OPEN THE F/S TOP COVER. Section Name

ADJ 13-3

2.

CHECK THAT THE EXIT BAFFLE IS BIASED TO RIGHT AND TO THE REAR AGAINST THE BYPASS TRANSPORT FRAME.

Adjustment 1.

ENSURE THAT THE LOCATING TABS OF THE EXIT BAFFLE ARE IN THE LOCATING SLOTS OF THE F/S FRAME (FRONT AND REAR).

2.

ADJUST THE BYPASS TRANSPORT EXIT BAFFLE (Figure 1).

1 ENSURE THAT THE LOCATING TAB IS LOCATED IN THE SLOT

2 LOOSEN SCREWS (4), AND NUTS (2)

4 TIGHTEN THE SCREWS (4), AND THE NUTS (2)

3 ADJUST: BIAS BAFFLE TO THE RIGHT AND TO THE REAR AGAINST THE FRAME

Figure 1 Adjusting the Baffle

Section Name

ADJ 13-3

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Preliminary Working Document No Product Name Assigned

ADJ 13-4 Transition Module Main Drive Motor:

Check

Purpose

1.

REMOVE THE TRANSITION MODULE REAR AND TOP COVERS.

The purpose is to adjust the Transition Module Main Drive Motor to ensure the pulleys are aligned correctly.

2.

CHECK THAT THE TRANSITION MODULE MAIN DRIVE MOTOR IS 56.5 +/- 1mm FROM THE VERTICAL TRANSPORT SIDE PLATE (Step 1, Figure 1).

2 LOOSEN THE BOLTS THAT SECURE THE MOTOR (4)

3 ADJUST: POSITION THE MOTOR TO BE 56.5 +/- mm FROM THE VERTICAL SIDE PLATE

4 TIGHTEN THE BOLTS THAT SECURE THE MOTOR (4)

1 CHECK: THAT THE MOTOR IS 56.5 +/- mm FROM THE VERTICAL SIDE PLATE

Figure 1 Checking / Adjusting the Pulley

Adjustment

ADJ 13-5 Transition Module Height:

1.

LOOSEN THE TRANSITION MODULE MAIN DRIVE MOTOR AND DRIVE BELT.

Purpose

2.

ADJUST THE TRANSITION MODULE MAIN DRIVE MOTOR (Steps 2 through 4, Figure 1).

The purpose is to adjust the Transition Module to the correct height with relation to the feeder stacker.

3.

RETENSION THE TRANSITION MODULE MAIN DRIVE MOTOR DRIVE BELT.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-649

Section Name

ADJ 13-4

Check 1.

2.

OPEN THE F/S TOP COVER.

CHECK THE TRANSITION MODULE HEIGHT (Figure 1). PERFORM INBOARD AND OUTBOARD.

1 CHECK: PLACE THE 6 INCH SCALE ON THE LOWER BAFFLE OF THE DISK MODULE WELDMENT AND CHECK THAT THE TRANSITION MODULE IS WITHIN +/- 1mm OF THE HEIGHT OF THE DISK MODULE WELDMENT LOWER BAFFLE

Figure 1 Checking the Transition Module Height

Adjustment NOTE: If the transition module was too low in step 1, rotate the adjusting bolts Clockwise to raise the transition module. If the transition module was too high in step 1, rotate the adjusting bolts Counterclockwise to lower the transition module. 1.

ADJUST THE TRANSITION MODULE HEIGHT. Figure 2).

Section Name

ADJ 13-5

0/0/00 ?-650

Preliminary Working Document No Product Name Assigned

1 LOOSEN THE NUTS (6)

2 ADJUST: ROTATE THE ADJUSTMENT BOLTS (2) TO RAISE OR LOWER THE TRANSITION MODULE

3 TIGHTEN THE NUTS (6)

Figure 2 Adjusting the Transition Module Height 2.

CHECK TO ENSURE THAT THE HEIGHT OF THE TRANSITION MODULE TO VERIFY IT IS STILL CORRECT.

ADJ 13-6 Transition Module Inboard/Outboard Position:

3.

ENSURE THAT THE TRANSITION MODULE LEGS ARE JUST TOUCHING THE FLOOR.

The purpose is to adjust the Transition Module to the correct Inboard/Outboard dimension.

Purpose Check

Preliminary Working Document No Product Name Assigned

1.

OPEN THE F/S TOP COVER AND PLACE A CHEATER IN THE TOP COVER INTERLOCK SWITCH.

2.

RUN A JOB OF 50 PRINTS TO THE THIRD PARTY DEVICE.

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Section Name

ADJ 13-5

3.

CHECK THAT THE EDGE OF THE PRINT IS 26mm +/- 3mm FROM THE INSIDE EDGE OF THE TRANSITION MODULE VERTICAL TRANSPORT FRAME (Figure 1).

CHECK: CHECK THAT THE EDGE OF THE PRINT IS 26mm +/- 3mm FROM THE INSIDE EDGE OF THE TRANSITION MODULE VERTICAL TRANSPORT FRAME

Figure 1 Checking the Transition Module Height

Adjustment 1.

ADJUST THE TRANSITION MODULE INBOARD/OUTBOARD POSITION (Figure 2).

Section Name

ADJ 13-6

0/0/00 ?-652

Preliminary Working Document No Product Name Assigned

3 TIGHTEN THE NUTS (4)

1 LOOSEN THE NUTS (4)

2 ADJUST: POSITION THE TRANSITION MODULE TO ACQUIRE A GAP OF 26 +/- 3mm

Figure 2 Adjusting the Transition Module Height NOTE: If the gap is greater than 29mm move the Transition Module toward the rear. If the gap is less than 23mm move the Transition Module toward the front. 2.

RUN 50 PRINTS TO THE THIRD PARTY DEVICE AND VERIFY THAT THE PRINTS ARE 26mm +/- 3mm FROM THE INSIDE OF THE TRANSITION MODULE VERTICAL TRANSPORT FRAME.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-653

Section Name

ADJ 13-6

Section Name

ADJ 13-6

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Preliminary Working Document No Product Name Assigned

5. Parts List Overview Overview .........................................................................................................................

5-5

5. Parts List 1. Printer Electrical PL 1.1 LINE INTERFACE MODULE AND COMPONENTS............................................ PL 1.2 LINE INTERFACE MODULE (50HZ) ................................................................... PL 1.3 LINE INTERFACE MODULE (60HZ) ................................................................... PL 1.4 PRINTER PWB PANEL ....................................................................................... PL 1.5 AC DISTRIBUTION PANEL:50HZ ONLY ............................................................ PL 1.6 AC DISTRIBUTION PANEL:60HZ ONLY ............................................................ PL 1.7 PRINTER ELECTRICAL COMPONENTS ........................................................... PL 1.8 MIN PWB PANEL ................................................................................................ PL 1.9 LOW VOLTAGE POWER SUPPLY ..................................................................... PL 1.10 LOW VOLTAGE POWER SUPPLY ASSEMBLY COMPONENTS.................... PL 1.11 PRINTER CARD CAGE ASSEMBLY ................................................................ PL 1.14 POWER CORDS ............................................................................................... PL 1.15 PRINTER INTERLOCK BYPASS SWITCH AND REAR COMPONENTS ........

5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19

1. IFS and FS Electrical PL 1.16 IFS AND FS ELECTRICAL COMPONENTS ..................................................... PL 1.17 IFS ELECTRICAL COMPONENTS (1 OF 2)..................................................... PL 1.18 IFS ELECTRICAL COMPONENTS (2 OF 2)..................................................... PL 1.19 FS ELECTRICAL COMPONENTS (1 OF 2) ...................................................... PL 1.20 FS ELECTRICAL COMPONENTS (2 OF 2) ......................................................

5-20 5-21 5-22 5-23 5-24

1. BTM Electrical PL 1.21 BTM ELECTRICAL COMPONENTS .................................................................

5-25

2. Printer UI PL 2.1 UI COMPONENTS (1 OF 4) ................................................................................ PL 2.2 UI COMPONENTS (2 OF 4) ................................................................................ PL 2.3 UI COMPONENTS (3 OF 4) ................................................................................ PL 2.4 UI COMPONENTS (4 OF 4) ................................................................................ PL 2.5 UI COVERS .........................................................................................................

5-26 5-27 5-28 5-29 5-30

4. Covers and Drives PL 4.1 PRINTER RIGHT DOOR AND LEFT DOOR....................................................... PL 4.2 ELECTRICAL MODULE DOOR, TOP COVER AND INNER PANEL.................. PL 4.3 PRINTER INNER PANELS.................................................................................. PL 4.4 PHOTORECEPTOR INNER PANEL LABELS .................................................... PL 4.5 PRINTER RIGHT TOP COVER COMPONENTS ................................................ PL 4.6 PRINTER LEFT TOP COVER ASSEMBLY......................................................... PL 4.7 ELECTRICAL MODULE LEFT SIDE COVER AND REAR COVER .................... PL 4.8 PRINTER REAR COVERS .................................................................................. PL 4.9 MIM COOLING FAN ............................................................................................ PL 4.10 INVERTER LEFT SIDE COVER AND TRIM STRIPS ....................................... PL 4.11 INVERTER DOOR AND RH COVERS .............................................................. Revision DocuPrint 180F Service Manual

5-31 5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39 5-40 5-41

PL 4.12 STACKER COVERS.......................................................................................... PL 4.13 FEEDER COVER, RH AND LOWER DOORS .................................................. PL 4.14 IFS AND FS TOP COVERS............................................................................... PL 4.15 IFS AND FS REAR COVERS ............................................................................ PL 4.16 PROCESSOR DRIVES (1 OF 2) ....................................................................... PL 4.17 PROCESSOR DRIVES (2 OF 2) ....................................................................... PL 4.18 PRINT HANDLING MODULE DRIVES (1 OF 2) ............................................... PL 4.19 PRINT HANDLING MODULE DRIVES (2 OF 2) ............................................... PL 4.20 MOTOR BRACKET ASSEMBLY ....................................................................... PL 4.21 CASTERS AND REAR UI BRACKET................................................................ PL 4.22 IFS FRAMES ..................................................................................................... PL 4.23 FS FRAMES ...................................................................................................... PL 4.24 BTM FS PURGE/EXIT BYPASS FRAME AND COVER.................................... PL 4.25 BTM FRAME AND COVER (1 OF 2) ................................................................. PL 4.26 BTM FRAME AND COVER (2 OF 2) ................................................................. PL 4.27 INPUT ENABLEMENT COVERS (1 OF 2) ........................................................ PL 4.28 INPUT ENABLEMENT COVERS (2 OF 2) ........................................................

5-42 5-43 5-44 5-45 5-46 5-47 5-48 5-49 5-50 5-51 5-52 5-53 5-54 5-55 5-56 5-57 5-58

6. ROS PL 6.1 ROS ASSEMBLY (1 OF 2) .................................................................................. PL 6.2 ROS ASSEMBLY (2 OF 2) ..................................................................................

5-59 5-60

7. Paper Trays PL 7.1 ELEVATOR COMPONENTS ............................................................................... PL 7.2 LENGTH GUIDE COMPONENTS ....................................................................... PL 7.3 FRONT SUPPORT AND COVERS ..................................................................... PL 7.4 SWITCH PLATE ASSEMBLY .............................................................................. PL 7.5 FRONT SUPPORT .............................................................................................. PL 7.6 REAR SUPPORT................................................................................................. PL 7.7 ELEVATOR DRIVES (1 OF 2) ............................................................................. PL 7.8 ELEVATOR DRIVES (2 OF 2) ............................................................................. PL 7.9 ELEVATOR MOTOR COVERS ........................................................................... PL 7.10 FEED HEAD DRIVES MECHANISM (1 OF 2)................................................... PL 7.11 FEED HEAD DRIVES MECHANISM (2 OF 2)................................................... PL 7.12 FEED BELT ASSEMBLY ................................................................................... PL 7.13 FEED HEAD ROLLS AND SENSORS .............................................................. PL 7.14 HCT ASSEMBLY ............................................................................................... PL 7.15 HCT ASSEMBLY COMPONENTS (1 OF 4) ...................................................... PL 7.16 HCT ASSEMBLY COMPONENTS (2 OF 4) ...................................................... PL 7.17 HCT ASSEMBLY COMPONENTS (3 OF 4) ...................................................... PL 7.18 HCT ASSEMBLY COMPONENTS (4 OF 4) ......................................................

5-61 5-62 5-63 5-64 5-65 5-66 5-67 5-68 5-69 5-70 5-71 5-72 5-73 5-74 5-75 5-76 5-77 5-78

8. Paper Feeding PL 8.1 VERTICAL TRANSPORT ASSEMBLY................................................................ PL 8.2 VERTICAL TRANSPORT SUPPORTS ............................................................... PL 8.3 REGISTRATION TRANSPORT ASSEMBLY (1 OF 3) ........................................ PL 8.4 REGISTRATION TRANSPORT ASSEMBLY (2 OF 3) ........................................ PL 8.5 REGISTRATION TRANSPORT ASSEMBLY (3 OF 3) ........................................

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Parts List

PL 8.6 REGISTRATION TRANSPORT, JAM ACCESS HANDLE ASSEMBLY.............. PL 8.7 CROSS ROLLS DRIVE ASSEMBLY ................................................................... PL 8.8 PREFUSER TRANSPORT AND PRETRANSFER BAFFLE ............................... PL 8.9 PREFUSER TRANSPORT ASSEMBLY.............................................................. PL 8.10 NIP RELEASE SOLENOID ASSEMBLY ........................................................... PL 8.11 IDLER BRACKET ASSEMBLY.......................................................................... PL 8.12 HCT FEEDER ASSEMBLY COMPONENTS (1 OF 2) ...................................... PL 8.13 HCT FEEDER ASSEMBLY COMPONENTS (2 OF 2) ...................................... PL 8.14 HCT FEEDER COMPONENTS ......................................................................... PL 8.15 AIR SYSTEM DRIVE ASSEMBLY..................................................................... PL 8.16 VERTICAL TRANSPORT ASSEMBLY.............................................................. PL 8.17 VERTICAL TRANSPORT COMPONENTS (1 OF 2) ......................................... PL 8.18 VERTICAL TRANSPORT COMPONENTS (2 OF 2) ......................................... PL 8.19 LOWER TURN TRANSPORT ASSEMBLY ....................................................... PL 8.20 FS HORIZONTAL TRANSPORT ASSEMBLY .................................................. PL 8.21 FS HORIZONTAL TRANSPORT COMPONENTS (1 OF 2).............................. PL 8.22 FS HORIZONTAL TRANSPORT COMPONENTS (2 OF 2).............................. PL 8.23 INTERMEDIATE HORIZONTAL TRANSPORT................................................. PL 8.24 LOWER PREREGISTRATION TRANSPORT ASSEMBLY............................... PL 8.25 LOWER PREREGISTRATION TRANSPORT COMPONENTS (1 OF 2) .......... PL 8.26 LOWER PREREGISTRATION TRANSPORT COMPONENTS (2 OF 2) .......... PL 8.27 IFS HORIZONTAL TRANSPORT ASSEMBLY ................................................. PL 8.28 IFS HORIZONTAL TRANSPORT COMPONENTS (1 OF 2)............................. PL 8.29 IFS HORIZONTAL TRANSPORT COMPONENTS (2 OF 2).............................

5-84 5-85 5-86 5-87 5-88 5-89 5-90 5-91 5-92 5-93 5-94 5-95 5-96 5-97 5-98 5-99 5-100 5-101 5-102 5-103 5-104 5-105 5-106 5-107

8. Paper Feeding (W/Tag P-299) PL 8.30 REGISTRATION TRANSPORT ASSEMBLY (1 OF 3) ...................................... PL 8.31 REGISTRATION TRANSPORT ASSEMBLY (2 OF 3) ...................................... PL 8.32 REGISTRATION TRANSPORT ASSEMBLY (3 OF 3) ...................................... PL 8.33 CROSS ROLLS DRIVE ASSEMBLY .................................................................

5-108 5-109 5-110 5-111

9. Xerographics PL 9.1 PR MODULE ASSEMBLY AND DRAWER ASSEMBLY ..................................... PL 9.2 PR MODULE COMPONENTS (1 OF 4) .............................................................. PL 9.3 PR MODULE COMPONENTS (2 OF 4) .............................................................. PL 9.4 PR MODULE COMPONENTS (3 OF 4) .............................................................. PL 9.5 PR MODULE COMPONENTS (4 OF 4) .............................................................. PL 9.6 DRAWER ASSEMBLY COMPONENTS (1 OF 2) ............................................... PL 9.7 DRAWER ASSEMBLY COMPONENTS (2 OF 2) ............................................... PL 9.8 ENVIRONMENTAL COMPONENTS ................................................................... PL 9.9 OZONE FILTER ASSEMBLY .............................................................................. PL 9.10 DICOROTRONS ................................................................................................ PL 9.11 TRANSFER ASSIST DEVICE AND DETACK DICOROTRON ......................... PL 9.12 TRANSFER ASSIST DEVICE COMPONENTS ................................................

5-112 5-113 5-114 5-115 5-116 5-117 5-118 5-119 5-120 5-121 5-122 5-123

9. Developer and Cleaning PL 9.13 DEVELOPER ASSEMBLY ................................................................................ PL 9.14 DEVELOPER HOUSING ASSEMBLY (1 OF 5) ................................................ PL 9.15 DEVELOPER HOUSING ASSEMBLY (2 OF 5) ................................................ PL 9.16 DEVELOPER HOUSING ASSEMBLY (3 OF 5) ................................................ PL 9.17 DEVELOPER HOUSING ASSEMBLY (4 OF 5) ................................................ PL 9.18 DEVELOPER HOUSING ASSEMBLY (5 OF 5) ................................................

Parts List

5-124 5-125 5-126 5-127 5-128 5-129

PL 9.19 TONER DISPENSER ASSEMBLY .................................................................... PL 9.20 TONER FILTER ASSEMBLY (1 OF 2) .............................................................. PL 9.21 TONER FILTER ASSEMBLY (2 OF 2) .............................................................. PL 9.22 CLEANER ASSEMBLY...................................................................................... PL 9.23 WASTE TONER DUCT ASSEMBLY ................................................................. PL 9.24 CLEANER ASSEMBLY COMPONENTS (1 OF 2) ............................................ PL 9.25 CLEANER ASSEMBLY COMPONENTS (2 OF 2) ............................................ PL 9.26 PR SPOTS BLADE ............................................................................................ PL 9.27 POWERED VENT DUCT...................................................................................

5-130 5-131 5-132 5-133 5-134 5-135 5-136 5-137 5-138

10. Print Transports and Fuser PL 10.1 FUSER ASSEMBLY .......................................................................................... PL 10.2 FUSER COMPONENTS (1 OF 4)...................................................................... PL 10.3 FUSER COMPONENTS (2 OF 4)...................................................................... PL 10.4 FUSER COMPONENTS (3 OF 4)...................................................................... PL 10.5 FUSER COMPONENTS (4 OF 4)...................................................................... PL 10.6 STRIPPER COMPONENTS .............................................................................. PL 10.7 FUSER ROLL ASSEMBLY ................................................................................ PL 10.8 METERING ASSEMBLY (1 OF 2) ..................................................................... PL 10.9 METERING ASSEMBLY (2 OF 2) ..................................................................... PL 10.10 AIR SYSTEMS COMPONENTS (1 OF 2)........................................................ PL 10.11 AIR SYSTEMS COMPONENTS (2 OF 2)........................................................ PL 10.12 DECURLER ASSEMBLY................................................................................. PL 10.13 DECURLER COMPONENTS .......................................................................... PL 10.14 POSTFUSER TRANSPORTS MODULE ......................................................... PL 10.15 TOP TRANSPORT ASSEMBLY (1 OF 5)........................................................ PL 10.16 TOP TRANSPORT ASSEMBLY (2 OF 5)........................................................ PL 10.17 TOP TRANSPORT ASSEMBLY (3 OF 5)........................................................ PL 10.18 TOP TRANSPORT ASSEMBLY (4 OF 5)........................................................ PL 10.19 TOP TRANSPORT ASSEMBLY (5 OF 5)........................................................ PL 10.20 EXIT TRANSPORT ASSEMBLY ..................................................................... PL 10.21 DUPLEX INVERTER ASSEMBLY COMPONENTS (1 OF 4).......................... PL 10.22 DUPLEX INVERTER ASSEMBLY COMPONENTS (2 OF 4).......................... PL 10.23 DUPLEX INVERTER ASSEMBLY COMPONENTS (3 OF 4).......................... PL 10.24 DUPLEX INVERTER ASSEMBLY COMPONENTS (4 OF 4)..........................

5-139 5-140 5-141 5-142 5-143 5-144 5-145 5-146 5-147 5-148 5-149 5-150 5-151 5-152 5-153 5-154 5-155 5-156 5-157 5-158 5-159 5-160 5-161 5-162

11. Paper Transport PL 11.1 PREREGISTRATION AND BLOWER ASSEMBLIES........................................ 5-163 PL 11.2 PREREGISTRATION TRANSPORT ASSEMBLY ............................................. 5-164 PL 11.3 PREREGISTRATION HOUSING ASSEMBLY .................................................. 5-165 PL 11.4 PREREGISTRATION PIVOT BAFFLE ASSEMBLY.......................................... 5-166 PL 11.5 STACKER OFFSET ASSEMBLY ...................................................................... 5-167 PL 11.6 BACK GUIDE ASSEMBLY (1 OF 2) .................................................................. 5-168 PL 11.7 BACK GUIDE ASSEMBLY (2 OF 2) .................................................................. 5-169 PL 11.8 FRONT GUIDE ASSEMBLY.............................................................................. 5-170 PL 11.9 RIGHT GUIDE ASSEMBLY ............................................................................... 5-171 PL 11.10 BYPASS TRANSPORT ASSEMBLY ............................................................... 5-172 PL 11.11 BYPASS TRANSPORT COMPONENTS......................................................... 5-173 PL 11.12 PURGE TRANSPORT COMPONENTS (1 OF 2)............................................ 5-174 PL 11.13 PURGE TRANSPORT COMPONENTS (2 OF 2)............................................ 5-175 PL 11.14 BYPASS TRANSPORT, MIDDLE MODULE BYPASS TRANSPORT AND PURGE TRANSPORT COMPONENTS ....................................................................................... 5-176

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Revision DocuPrint 180F Service Manual

PL 11.15 BYPASS TRANSPORT AND MIDDLE MODULE BYPASS TRANSPORT TOP BAFFLE.................................................................................................................................. 5-177 PL 11.16 PURGE TRANSPORT TOP BAFFLE .............................................................. 5-178 PL 11.17 STACKER ELEVATOR ASSEMBLY (1 OF 3) ................................................. 5-179 PL 11.18 STACKER ELEVATOR ASSEMBLY (2 OF 3) ................................................. 5-180 PL 11.19 STACKER ELEVATOR ASSEMBLY (3 OF 3) ................................................. 5-181 PL 11.20 PALLET ASSEMBLY ....................................................................................... 5-182 PL 11.21 STACKER INNER COVERS ........................................................................... 5-183 PL 11.22 POST INVERTER AND INVERTER TRANSPORTS ...................................... 5-184 PL 11.23 INVERTER COMPONENTS (1 OF 2) ............................................................. 5-185 PL 11.24 INVERTER COMPONENTS (2 OF 2) ............................................................. 5-186 PL 11.25 PIVOTING ASSEMBLY ................................................................................... 5-187 PL 11.26 POST INVERTER TRANSPORT COMPONENTS (1 OF 2) ........................... 5-188 PL 11.27 POST INVERTER TRANSPORT COMPONENTS (2 OF 2) ........................... 5-189 PL 11.28 POST INVERTER TRANSPORT PIVOT BAFFLE ASSEMBLY ...................... 5-190 PL 11.29 IFS, FS, AND MM DISK MODULE WELDMENT ASSEMBLY ........................ 5-191 PL 11.30 IFS DISK MODULE WELDMENT .................................................................... 5-192 PL 11.31 FS AND MM DISK MODULE WELDMENT ..................................................... 5-193 PL 11.32 CHUTE BAFFLE .............................................................................................. 5-194 PL 11.33 BTM BYPASS TRANSPORT ASSEMBLIES................................................... 5-195 PL 11.34 BTM BYPASS TRANSPORT (1 OF 2) ............................................................ 5-196 PL 11.35 BTM BYPASS TRANSPORT (2 OF 2) ............................................................ 5-197 PL 11.36 BTM PURGE TRANSPORT TOP BAFFLE ..................................................... 5-198 PL 11.37 BTM BYPASS TRANSPORT TOP BAFFLE ASSEMBLY ............................... 5-199 PL 11.38 BTM BYPASS TRANSPORT ENT BAFFLE ASSEMBLY ............................... 5-200 PL 11.39 BTM ASSEMBLIES ......................................................................................... 5-201 PL 11.40 BTM VERTICAL TRANSPORT ASSEMBLY ................................................... 5-202 PL 11.41 BTM PAPER TRANSPORT ASSEMBLY ........................................................ 5-203

24. Electrical Connectors and Fasteners PL 24.1 CONNECTORS PIN AND SOCKET HOUSING (1 OF 2).................................. PL 24.2 CONNECTORS PIN AND SOCKET HOUSING (2 OF 2).................................. PL 24.3 CONNECTORS PINS AND SOCKETS ............................................................. PL 24.4 TERMINALS ...................................................................................................... PL 24.5 ELECTRICAL MISCELLANEOUS ITEMS .........................................................

5-204 5-205 5-206 5-207 5-208

25. Consumables and Field Tools PL 25.1 FIELD TOOLS AND SPECIAL TOOLS ............................................................. PL 25.2 CONSUMABLES ...............................................................................................

5-209 5-209

Common Hardware Common Hardware A-MA ............................................................................................... Common Hardware MA-BAN .......................................................................................... Part Number Index ..........................................................................................................

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Parts List

Parts List

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Overview

USMG - United States Marketing Group

The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components.

USO - United States Operations V - Volt

Organization Parts Lists

W/ - With

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.

W/O - Without XCL - Xerox Canada Limited

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.

XLA - Xerox Latin America

Common Hardware

Symbology

The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations. Dimensions are in millimeters unless otherwise identified.

Symbology used in the Parts List section is identified in the Symbology section.

Subsystem Information

Part Number Index

Brackets

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.

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.

Other Information Tag

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: A - Amp DH - Document Handler EMI - Electro Magnetic Induction HZ - Hertz MNL - Multinational NOHAD - Noise Ozone Heat Air Dirt P/O - Part Of PWB - Printed Wiring Board REF - Reference R/E - Reduction/Enlargement

The notation "Tag" in the part description indicates that the item is the entire Tag. The notation "P/O Tag" indicates that the item is only part of a tag change, or modification, to the equipment. A Tag Identifier is a one-letter code that indicates the subsystem areas of a modification (same Tag number). B-200 - Binder C-200 - Controller D-200 - Document Handler F-200 - Finisher P-200 - Printer R-200 - RIS U-200 - User Interface When a part or an assembly has a Tag associated with it, check the change Tag Index in the General Information section of the Service Data for the name and purpose of the modification.

RX - Rank Xerox

Preliminary Working Document No Product Name Assigned

0/0/00 ?-5

Section Name

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 Symbology The following symbols are used in the Parts List sections of the documentation An item number within a shaded box shows that the part has an adjustment procedure. Check the Adjustment section for the adjustments specifications or procedure. An item number within an unshaded box shows that the part has a procedure in the Repairs Section. Check the procedure for the correct sequence of repair, for warnings, for cautions, for notes, and for other special conditions. An item number within a shaded box and an unshaded box shows that the part has an adjustment procedure and a repair procedure. Check the Repairs section and Adjustment section for more information. A Tag number within a circle and pointing to an item number shows that the part has been changed by the tag number within the circle. 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. A Tag number within a circle with no apex shows that the entire drawing has been changed by the tag number within the circle. Information on the modification is in the Change Tag Index. A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle. An asterisk within a circle and pointing to an item number shows that the part has been changed by several tags. The Tag numbers will be indicated in the parts list description of the item indicated. An asterisk within a circle having a shaded bar and pointing to an item number shows that the part is the configuration before the part was changed by several tag. The Tag numbers will be indicated in the parts list description of the item indicated.

Section Name

0/0/00 ?-6

Preliminary Working Document No Product Name Assigned

PL 1.1 LINE INTERFACE MODULE AND COMPONENTS Item

Part

Description

1

101K32730

–

101K32720

–

101K32760

2

105E3600

3 4 5

50P2096 20105P859 –

6

142K1510

–

142K1520

–

142K1500

7

–

8

140K16591

9 10 11

116P20301 120E5220 –

12 13

– 600K70900

LINE INTERFACE MODULE (60HZ)(TAG P-306) LINE INTERFACE MODULE (60HZ)(W/ DUAL LAMP)(TAG P306) LINE INTERFACE MODULE (50HZ)(TAG P-306) AUTOTRANSFORMER (T101) (50HZ ONLY) RECEPTACLE FUSER TRANSFORMER (T1001) CHASSIS HOUSING (P/O PL 1.1 Item 1) LINE FILTER (FL101) (60HZ)(DUAL CORD) LINE FILTER (FL101) (50HZ ONLY) LINE FILTER (FL101) (60HZ)(SINGLE) LINE INTERFACE MODULE (P/O PL 1.1 Item 1) 3 PHASE DETECTION PWB (50HZ ONLY) PWB STANDOFF (50HZ ONLY) SHIELD (60HZ ONLY) TERMINAL BLOCK (TB3) (P/O PL 1.1 Item 1) RESISTOR (P/O PL 1.1 Item 1) SINGLE TO DUAL CORD CONVERTER KIT (W/ITEM 6 AND REF: PL 1.14 Item 1)

PL 1.1

PL 1.2 PL 1.3

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Parts List

PL 1.1

PL 1.2 LINE INTERFACE MODULE (50HZ) Item

Part

Description

1

--

2 3 4 5

9P1366 28P80090 28P1183 108E4000

6 7 8

26P2081 – 709W21304

9 10

113P90064 –

11

109E230

12 13

105E850 109E511

14

–

LINE INTERFACE MODULE (P/O PL 1.1 Item 1) SPRING WASHER RETAINER CIRCUIT BREAKER (CB104) (CB105) STUD HEAT SINK (P/O PL 1.2 Item 1) FUSER RELAY (K1002, K1004, K1005, K1007) RECEPTACLE OUTLET CHASSIS HOUSING (P/O PL 1.2 Item 1) POWER RELAY (25A) (K1001, K1006) FUSER INDUCTOR (L1001) POWER ON RELAY (4 POLE, 25A)(K101) CIRCUIT BREAKER MOUNTING PLATE (P/O PL 1.2 Item 1)

Parts List

PL 1.2

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PL 1.3 LINE INTERFACE MODULE (60HZ) Item

Part

Description

1

--

2 3 4

28P80090 107E2571 108E4010

5

108E4030

6 7

28P1183 –

8

709W21304

9 10

113E3020 109E230

11

109E511

12 13 14

105E850 26P2081 9P1366

LINE INTERFACE MODULE (REFER PL 1.1 Item 1) WASHER HEAT SINK MAIN POWER CIRCUIT BREAKER (CB101, CB102) MAIN POWER CIRCUIT BREAKER (CB103) RETAINER CHASSIS HOUSING (P/O PL 1.3 Item 1) FUSER RELAY 14 INCH LAMP (K1002) METERING ROLL (K1004) MIN COMPRESSOR (K1005) 11 INCH LAMP (K1007) RECEPTACLE OUTLET POWER RELAY (25A) (K1001, K1006) POWER ON RELAY (4 POLE, 25A)(K101) FUSER INDUCTOR (L1001) STUD SPRING

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Parts List

PL 1.3

PL 1.4 PRINTER PWB PANEL Item

Part

Description

1 2 3 4 5 6

26P1734 9P1609 28P859 28P1127 3P25202 –

7 8

4P101 117K15090

QUARTER TURN FASTENER SPRING WASHER RETAINER PLUNGER PRINTER PWB PANEL (P/O PL 1.4 Item 18) BUMPER LOCAL BUS COMMUNICATION CABLE (444MM LONG)(75 OHMS) PHN CORE PWB PHN DIO PWB (1) PHN DIO PWB (2) PHN DIO PWB (6) REGISTRATION SERVO PWB LOCAL BUS COMMUNICATION CABLE (1905MM)(75 OHMS) WIRE (P/O PL 1.4 Item 22) CONNECTOR BLOCK (P/O PL 1.4 Item 22) PHN AC REMOTE PWB (1) PHN AC REMOTE PWB (2) LOCAL BUS COMMUNICATION CABLE (230MM LONG) (75 OHMS) CLOTH PAD PRINTER PWB PANEL ASSEMBLY RECEPTACLE LOCAL BUS COMMUNICATION CABLE (1905MM)(75 OHMS) TAB SOL DRIVER PWB REGISTRATION SERVO KIT SERVO JUMPER HARNESS (TAG P-481) INVERTER PWB (TAG P-481) CABLE TIE

9 10 11 12 13 14

160K7873 160K23990 160K28310 117K15130 – –

15

140K26352

16

117K15000

17 18

19E2700 101K4105

19 20

50P680 117K15140

21 22 23

160K8203 600K24744 962K610

24 25

160K79760 420W10701

PL 1.4 PL 1.4

PL 1.4 PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.14

PL 1.4 PL 1.4 PL 2.2

PL 1.4 PL 1.4

PL 1.4

PL 1.4

PL 1.4 PL 1.4 PL 1.4

PL 1.4

PL 1.4

Parts List

PL 1.4

PL 1.4

Co mm Co

PL 1.4

PL 1.4

PL 1.4 PL 1.4

PL 1.4 PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.4

PL 1.18 Item 1

PL 1.4

PL 1.8

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PL 1.4

Revision DocuPrint 180F Service Manual

PL 1.5 AC DISTRIBUTION PANEL:50HZ ONLY Item

Part

Description

1

101K32711

2 3 4 5 6 7 8 9 10

– 26P1734 9P1609 28P859 28P1127 30E4652 109P662 120P863 109P397

11

109E511

12 13 14 15 16

109E241 109E262 – 109K82 102K110

AC DISTRIBUTION PANEL ASSEMBLY (TAG P-306) CHASSIS (P/O PL 1.5 Item 1) QUARTER TURN FASTENER SPRING WASHER RETAINER BRACKET ROS POWER RELAY (K109) RELAY CLIP INTERLOCK RELAY (K102), PRINT POWER RELAY (K403) FINISHER/MIM POWER RELAY (K107) MAIN DRIVE RUN RELAY (K402) LVPS AC RELAY (K105) TERMINAL (P/O PL 1.5 Item 1) POWER CONTROL RELAY (K108) NOISE SUPPRESSOR

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Parts List

PL 1.5

PL 1.6 AC DISTRIBUTION PANEL:60HZ ONLY Item

Part

Description

1

101K32701

2 3 4 5 6 7 8 9 10

– 26P1734 9P1609 28P859 28P1127 30E4652 109E262 120P863 109E340

11

109P397

12 13 14 15

109E241 – 102K110 109K82

AC DISTRIBUTION PANEL ASSEMBLY (TAG P-306) CHASSIS (P/O PL 1.6 Item 1) QUARTER TURN FASTENER SPRING WASHER RETAINER BRACKET LVPS AC POWER RELAY (K105) RELAY CLIP MAIN DRIVE START RELAY (K401) INTERLOCK RELAY (K102), PRINT POWER RELAY (K403) MAIN DRIVE RUN RELAY (K402) TERMINAL (P/O PL 1.6 Item 1) NOISE SUPPRESSOR POWER CONTROL RELAY (K108)

Parts List

PL 1.6

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PL 1.7 PRINTER ELECTRICAL COMPONENTS Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

105K1385 30K19421 101K3986 140K26352 140K5221 140K16825 152S10088 30K15110 30K7851 30K22041 413W10714 50P1934 – 27E510 101K3825 – – 105K472

19

152K21671

HVAC OUTPUT MODULE CABLE BRACKET ESV ASSEMBLY MIN AC REMOTE PWB (1) HVAC PWB HVDC PWB RIBBON CABLE BRACKET BOTTOM BRACKET TOP BRACKET BEARING RECEPTACLE HV CHASSIS (P/O PL 1.7 Item 15) WING NUT HV CHASSIS ASSEMBLY INSULATOR (P/O PL 1.7 Item 1) BRACKET (P/O PL 1.7 Item 1) HVAC OUTPUT POWER MODULE (P/O PL 1.7 Item 1) HVAC HARNESS

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Parts List

PL 1.7

PL 1.8 MIN PWB PANEL Item

Part

Description

1 2 3 4 5 6 7 8

26P816 9E8520 28P859 48K26780 3P25202 28P1127 50P680 117K15000

9

117K15020

10

117K15030

11

117K15110

12 13

160K7873 160K23960

14 15 16 17

140K14840 160K23990 117K2311 113E5520

18

–

19

–

20

110E1740

QUARTER TURN FASTENER SPRING WASHER DOOR PANEL ASSEMBLY PLUNGER RETAINER QUARTER TURN RECEPTACLE LOCAL BUS COMMUNICATION CABLE (230MM LONG)(75 OHMS) LOCAL BUS COMMUNICATION CABLE (635MM LONG)(75 OHMS) LOCAL BUS COMMUNICATION CABLE (813MM LONG)(75 OHMS) SYSTEM BUS COMMUNICATION CABLE (2286MM LONG)(75 OHMS) MIN CORE PWB MIN ADA PWB (1) MIN ADA PWB (2) MIB PWB (1) MIB PWB (2) MIN DIO PWB GROUND WIRE SOCKET CONNECTOR ASSEMBLY SOCKET CONNECTOR (P/O PL 1.8 Item 17) SOCKET CONNECTOR NUT (P/O PL 1.8 Item 17) SWITCH (MIN 24 VDC MONITOR)(Q462)

Parts List

PL 1.8

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Revision DocuPrint 180F Service Manual

PL 1.9 LOW VOLTAGE POWER SUPPLY Item

Part

Description

1 2 3 4

30K8262 30K8271 30E17223 600K13537

5

600K70710

RIGHT SUPPORT BRACKET LEFT SUPPORT BRACKET BRACKET LOW VOLTAGE POWER SUPPLY ASSEMBLY IFS POWER SUPPLY REPLACEMENT KIT (TAG P-304)

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Parts List

PL 1.9

PL 1.10 LOW VOLTAGE POWER SUPPLY ASSEMBLY COMPONENTS Item

Part

Description

1

–

2 3

112K163 112K172

4

112K184

5 6

140K15723 109P397

7

–

8

127E5660

9

53E1810

P/O LVPS ASSEMBLY (REFER PL 1.9 Item 4) POS. 1 POWER INPUT PWB POS. 2 OUTPUT A PWB (5VDC, +12 VDC), POS. 3 OUTPUT A PWB (5VDC, +15 VDC) POS. 4, DC OUTPUT B PWB (+5 VDC, -15 VDC), POS. 5, DC OUTPUT B PWB (24 VDC), POS. 6, DC OUTPUT B PWB (24 VDC), POS. 7, DC OUTPUT B PWB (24 VDC), POS. 8, DC OUTPUT B PWB (24 VDC), POS. 9, DC OUTPUT B PWB (+34 VDC), POS. 10, DC OUTPUT B PWB (-34 VDC) POS. 11, CONTROL PWB 24V LVPS INTERLOCK RELAY (K104), 34V LVPS INTERLOCK RELAY (K103) FILTER BRACKET (PART OF ITEM 1) LOW VOLTAGE POWER SUPPLY COOLING FAN AIR FILTER

Parts List

PL 1.10

11/00 5-16

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PL 1.11 PRINTER CARD CAGE ASSEMBLY Item 1 2 3 4 – 5 6 7 8 9 10 11 12 13

Part

Description

152K12761 – 160K40580 160K43701 160K53981 160K23541 105K24530 2K38431 127P2260 420W10701 117K7950 120E1340 162K17110 101K26070

FAN POWER HARNESS PRINTER CARD CAGE EDN PWB SLB PWB (W/O 240) (TAG P-302) SLB PWB (W/ 240) (TAG P-303) PIXEL PWB ROS LVPS PWB CARD CAGE COVER FAN CABLE TIE VIDEO CABLE (COAXIAL) BLIND HOLD ROS SIGNAL HARNESS BACKPLANE

PL 1.8 Item 10

PL 6.1 Item 4

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PL 1.8 Item 8

11/00 5-17

Parts List

PL 1.11

PL 1.14 POWER CORDS Item

Part

Description

1

116E1440

–

116E7080

2

–

3 – –

101K26461 101K26471 101K29930

4

600K59300

TERMINAL BLOCK (5 POLE) (SINGLE POWER)(TB101) TERMINAL BLOCK (6 POLE) (DUAL POWER)(TB101) ISOLATION BOX (SINGLE NOT SHOWN) ISOLATION BOX (DUAL) ELCI (30A)(60HZ) (DUAL POWER) ELCI (50A)(60HZ) (DUAL POWER) ELCI (60A)(60HZ) (3 PHASE CONNECTION) CONNECTOR KIT (60HZ) (SINGLE POWER)(60A 4 POLE 5 WIRE) RECEPTOR KIT (60HZ) (SINGLE POWER) SINGLE TO DUAL CORD CONVERTER KIT (W/ ITEM 1 AND PL 1.1 Item 6)

5

600K59310

6

600K70900

Parts List

PL 1.14

PL 1.1 Item 6

Common

11/00 5-18

Revision DocuPrint 180F Service Manual

PL 1.15 PRINTER INTERLOCK BYPASS SWITCH AND REAR COMPONENTS Item 1 2 3

Part

Description

111P452 30K17530 110P2542

MECHANICAL PRINT METER INTERLOCK BRACKET PROCESSOR INTERLOCK BYPASS SWITCH (S103)

PL 4.19

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Parts List

PL 1.15

PL 1.16 IFS AND FS ELECTRICAL COMPONENTS Item

Part

Description

1 – 2 3 4 5 6

26P1458 26P1885 9E8520 28P859 28P1127 50P680 --

7 8 9

3P25202 26P816 101K25870

–

101K25890

10 11 12 13 14 15 16 17 18 19 20

113E5520 117K11300 101K5875 101K26620 – – – 713W73230 – – 117K15180

21

117K15880

22

–

STUD STUD SPRING WASHER RETAINER RECEPTACLE SHARED LINE BRACKET (NOT SPARED) PLUNGER STUD STEPPER PANEL ASSEMBLY (FS/MM) STEPPER PANEL ASSEMBLY (IFS) BANANA JACK CONNECTOR ESD GROUND WIRE CORE PWB PANEL AC RELAY PANEL JACK (P/O PL 1.16 Item 10) NUT (P/O PL 1.16 Item 10) RELAY PANEL CONNECTOR LOCKNUT (P/O PL 1.16 Item 17) JACK (P/O PL 1.16 Item 17) LOCAL BUS SHARED LINE (770MM) LOCAL BUS SHARED LINE (1000MM) TERMINAL BLOCK

PL 1.17

PL 1.18

PL 1.16

PL 1.20 PL 1.17

PL 1.19

PL 1.17

Parts List

PL 1.16

11/00 5-20

PL 1.19

Revision DocuPrint 180F Service Manual

PL 1.17 IFS ELECTRICAL COMPONENTS (1 OF 2) Item

Part

Description

1 2

160K23990 140K26352

3 4

120P863 109E340

5

109P645

PHN DIO PWB (5A) FSN AC REMOTE PWB (2A) FSN AC REMOTE (3A) CLIP FEEDER MAIN DRIVE START RELAY, (K804) (K4) STACKER MAIN DRIVE START RELAY, (K1106) (K6) INVERTER MAIN DRIVE START RELAY, (K1108) (K8) INVERTER/STACKER INTERLOCK RELAY, (K111) (K1) FEEDER INTERLOCK RELAY, (K112) (K2) STACKER ELEVATOR RELAY, (K1109) (K9) FEEDER MAIN DRIVE RUN RELAY, (K803) (K3) STACKER MAIN DRIVE RUN RELAY, (K1105) (K5) INVERTER MAIN DRIVE RUN RELAY, (K1107) (K7) CORE PWB #1 CORE PWB #2 (MID MOD ONLY) PLUNGER BRACKET STOP ASSEMBLY BRACKET (P/O PL 1.17 Item 9) RECEPTACLE SHARED LINE (2240MM) SHARED LINE (533MM)

6

709W21304

7

160K7873

8 9 10 11 12 13

3P25202 30K15572 – 50P680 117K15870 –

PL 1.16

PL 1.20

PL 2.2

PL 1.16 Item 12

PL 1.16 Item 13

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Parts List

PL 1.17

PL 1.18 IFS ELECTRICAL COMPONENTS (2 OF 2) Item

Part

Description

1

160K23990

2 3 4 5 6 7 8

117K15190 117K15160 117K15090 140K26352 117K15170 160K24000 110E1740

FSN DIO PWB (1A) FSN DIO PWB (2A) FSN DIO PWB (3A) SHARED LINE (1778MM) SHARED LINE (305MM) SHARED LINE (444MM) FSN AC REMOTE PWB (1A) SHARED LINE (940MM) FSN STEPPER PWBA 24 VDC LVPS MONITOR SENSOR (Q1162A)

PL 1.17 Item 7

PL 1.16 Item 9

Parts List

PL 1.18

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Revision DocuPrint 180F Service Manual

PL 1.19 FS ELECTRICAL COMPONENTS (1 OF 2) Item 1

Part

Description

109E340

FEEDER MAIN DRIVE START RELAY, (K804) (K4) STACKER MAIN DRIVE START RELAY, (K1106) (K6) INVERTER/STACKER INTERLOCK RELAY, (K111) (K1) FEEDER INTERLOCK RELAY, (K112) (K2) STACKER ELEVATOR RELAY, (K1109) (K9) FEEDER MAIN DRIVE RUN RELAY, (K803) (K3) STACKER MAIN DRIVE RUN RELAY, (K1105) (K5) CLIP FSN AC REMOTE PWB (3A) PLUNGER BRACKET STOP ASSEMBLY BRACKET (P/O PL 1.19 Item 7) RECEPTACLE

2

109P645

3

709W21304

4 5 6 7 8 9

120P863 140K26352 3P25202 30K15572 – 50P680

PL 1.16 Item 16

PL 1.16

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Parts List

PL 1.19

PL 1.20 FS ELECTRICAL COMPONENTS (2 OF 2) Item

Part

Description

1

160K23990

2 –

600K9921 105K1831

3 4 5 6

117K15160 117K15180 160K24000 110E1740

7 8

140K26352 127K3820

–

127K12000

FSN DIO PWB (1B) FSN DIO PWB (2B) FSN DIO PWB (3B) FEEDER/STACKER 24VDC LVPS FEEDER/STACKER 24VDC LVPS (ALTERNATE) SHARED LINE (305MM) SHARED LINE (770MM) FSN STEPPER PWBA 24 VDC LVPS MONITOR SENSOR (Q1162B) FSN AC REMOTE PWB (1A) FEEDER/STACKER 24V LVPS COOLING FAN (MOT108) FEEDER/STACKER 24V LVPS COOLING FAN (MOT108) (ALTERNATE) SHIELD

9

55K9421

Parts List

PL 1.20

PL 1.16 Item 19

PL 1.16

11/00 5-24

Revision DocuPrint 180F Service Manual

PL 1.21 BTM ELECTRICAL COMPONENTS Item

Part

Description

1

–

2 3 4 5 6 7 8 9 10 11 12 13

– 160K23990 3P25202 – – – – 140K24311 117K14641 160K7873 – 117K15160

14 15

– 117K15890

16 17 18 19

– 702W11833 702W11433 109E340

20 21

109P645 709W21304

22 23 24 25

110E1740 – 140K49480 –

26

–

27 28

92E55580 120P863

TRANSITION MODULE OUTPUT MODULE FRAME CONNECTOR (J3/P813) TMN DIO PWB PLUNGER CONNECTOR (J6/P811) CONNECTOR (J7/P810) CONNECTOR (J2/P812) CONNECTOR (J2/P814) OPTO ISOLATOR PWB SIGNAL CABLE TMN CORE PWB CONNECTOR (J5/P817) COMMUNICATION LINE (TO TMN DIO PWB) (305MM) CONNECTOR (J1/P806) COMMUNICATION LINE (FS INTERFACE) TERMINAL BLOCK (TB10) RUN CAPACITOR (C70)(15MF) START CAPACITOR (C71)(20MF) TMN MAIN DRIVE START RELAY (K72) TMN INTERLOCK RELAY (K76) TMN MAIN DRIVE RUN RELAY (K73) SENSE SWITCH 24 DVC (S84) TERMINAL BLOCK (TB12) TERMINATOR PWB TRANSITION MODULE OUTPUT SHIELD (P/O PL 1.21 Item 1) SUPPORT BRACKET (P/O PL 1.21 Item 1) JAM LABEL 19 HOLD DOWN CLIP

Revision DocuPrint 180F Service Manual

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Parts List

PL 1.21

PL 2.1 UI COMPONENTS (1 OF 4) Item

Part

Description

1 – 2 3 4

123E1500 123K5890 110P2483 3K4650 103E521

5

–

6 7 8 9 10

– – 101P3030 160K49620 117S24927

11

117K15040

12 13 14 15 16

117S25001 117S25003 117S25002 117S25004 –

CRT MONITOR ALTERNATE UI INTERLOCK SWITCH KNOB BRIGHTNESS CONTROL ASSEMBLY POTENTIOMETER (R202) (P/O PL 2.1 Item 4) WASHER (P/O PL 2.1 Item 4) NUT (P/O PL 2.1 Item 4) PWB GUIDE CPIOP2 PWB RIBBON CABLE (500MM LONG)(30 WIRES) LOCAL BUS COMMUNICATION CABLE (1244MM LONG) RED VIDEO CABLE (1524MM) GREEN VIDEO CABLE (1524MM) BLUE VIDEO CABLE (1524MM) VIDEO SYNC CABLE (1524MM) BRACKET

Parts List

PL 2.1

Common

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Revision DocuPrint 180F Service Manual

PL 2.2 UI COMPONENTS (2 OF 4) Item

Part

Description

1 2 3 4 5

25E313 16E4491 26E5111 19E9321 160K71570

6 – 7

117K33680 117K24490 117S24928

8 9 10

160K24063 21E2440 117K17680

11 12 13 14

19E2450 5E2233 117P23978 117K15000

15

117K15210

16

117K15200

TILT BAR BUSHING SHOULDER BOLT TILT SHOE UIM CORE PWB (TAG U-20) (REPAIR KIT, REFER TO PL 2.3 item 11) FLOPPY DATA CABLE (TAG U-21) FLOPPY DATA CABLE RIBBON CABLE (100MM) (40 WIRES) VIDEO ENGINE PWB (TAG U-19) TILT CAP RIBBON CABLE (127MM) (40 WIRES) CABLE MOUNT PADS WEAR RING GROUND STRAP LOCAL BUS COMMUNICATION CABLE (230MM LONG) SYSTEM BUS COMMUNICATION CABLE SYSTEM BUS COMMUNICATION CABLE (1990MM LONG)

PL 2.3 Item 8

PL 1.14

PL 1.4 PL 2.1

Revision DocuPrint 180F Service Manual

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Parts List

PL 2.2

PL 2.3 UI COMPONENTS (3 OF 4) Item

Part

Description

1 2 3 4 5 6 7

53E2301 117K1490 127P2260 – 142S10149 117P23978 121E16460

8 –

121E11710 121E16650

9 10 11 12

142K690 15E37060 600K88510 600K53203

FILTER AIR FAN CORD FAN CARD GUIDE AC EMI FILTER (FL105) GROUND STRAP SOLID STATE RDD (SMSD) (64MB)(TAG U-20) 3.5 INCH FLOPPY DISK DRIVE 1MB 3.5 IN. FLOPPY DISK DRIVE (TAG U-21)(P/O PL 2.3 Item 12) DC EMI FILTER (FL106) RIGID DISK DRIVE PLATE SMSD REPAIR KIT FLOPPY REPAIR KIT (TAG U-21)

Parts List

PL 2.3

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Revision DocuPrint 180F Service Manual

PL 2.4 UI COMPONENTS (4 OF 4) Item

Part

Description

1 2 3 4 5 6 7

48K46180 9E8490 19P80487 123E791 56E490 56E481 –

8 9 10

14E14590 – –

11 12 13 14 15

140K6001 14E5040 48K46170 118E8080 891E82030

UI FRONT COVER ASSEMBLY SPRING RIBBON CABLE CLAMP TOUCH SCREEN FRAME BEZEL FRAME BEZEL LENS KEYBOARD BUTTON (P/O PL 2.4 Item 1) SPACER FOAM STRIP (P/O PL 2.4 Item 1) CONTINUE BUTTON (P/O PL 2.4 Item 1) CONTROL PANEL PWB RETAINER UI FRONT COVER INSULATOR UI DP 180MX EPS LABEL

PL 2.4 PL 2.4

PL 2.4

PL 2.4

PL 2.4

PL 2.4 PL 2.4 PL 2.4

Common PL 2.4

Common

PL 2.4

PL 2.4 PL 2.4 PL 2.4

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PL 2.4

PL 2.4

Parts List

PL 2.4

PL 2.5 UI COVERS Item

Part

Description

1 2 3 4 5

48K46210 – 2E62080 48K46230 –

6 7 8

4E2801 3E13300 110P2407

9

91E61730

BASE FRONT COVER SWIVEL COVER HOUSING COVER BASE REAR COVER ACCESS DOOR (P/O PL 2.5 Item 1) BUMPER LATCH LOCAL/REMOTE POWER SWITCH, (S102) LOCAL/REMOTE LABEL

Parts List

PL 2.5

11/00 5-30

Revision DocuPrint 180F Service Manual

PL 4.1 PRINTER RIGHT DOOR AND LEFT DOOR Item

Part

Description

1 2

29E8690 –

3 4 5 6

– 3E13010 30K7420 –

7 8 9 10 11 12 13 14 15 16 17 18

48E30820 4P820 9E17910 3S6255 – 30K12723 30E46430 29E9220 120E3260 30E46420 30K12713 –

19 20 21

29E8701 9E15100 –

22 23 24 25 26 27 28 29

15E7860 15E7870 21E7360 49E56200 49E56190 3K5480 3E25870 802K24500

HINGE PIN (UPPER) PRINTER RIGHT DOOR ASSEMBLY DOOR HINGE (P/O PL 4.1 Item 2) KEEPER HINGE PRINTER RIGHT DOOR (P/O PL 4.1 Item 2) FLIPPER DOOR BUMPER SPRING HINGE DOOR HINGE (P/O PL 4.1 Item 18) DOOR STOP BRACKET (RIGHT) PIVOT PIN BRACKET (RIGHT) PIVOT PIN INTERLOCK ACTUATOR PIVOT PIN BRACKET (LEFT) DOOR STOP BRACKET (LEFT) PRINTER LEFT DOOR ASSEMBLY HINGE PIN (LOWER) SPRING PRINTER LEFT DOOR (P/O PL 4.1 Item 18) ACTUATOR PLATE (LEFT) ACTUATOR PLATE (RIGHT) END CAP FILLER BRACKET FILLER BRACKET LATCH HANDLE NAMEPLATE RETAINER COMMON HARDWARE SET SCREW AAH (NOT SHOWN) SEPARATE ORDER NAMEPLATE BOTTOM RETAINER LEFT DOOR TRIM STRIP RIGHT DOOR TRIM STRIP

30 31 32 33

802K24480 802E36770 56S3201 56S3202

Revision DocuPrint 180F Service Manual

Common

Common

PL 4.1

PL 4.1

PL 4.1

PL 4.1

PL 4.1

Com mon PL 4.1

PL 4.1

Com mon

PL 4.1

PL 4.1

Common

PL 4.1

PL

PL 4.1 Item

PL 4.1

PL 4.1

PL 4.1 Com mon PL 4.1

Com mon PL 4.1

PL 4.1 PL 4.1

PL 4.1

11/00 5-31

PL 4.1

Com mon

PL 4.1

PL 4.1 Item

PL 4.1

PL 4.1 PL 4.1 PL 4.1

Com mon PL 4.1

PL 4.1

PL 4.1

PL 4.1 Item

PL 4.1

Com mon

PL 4.1

PL 4.1

PL 4.1 PL 4.1

PL 4.1 PL 4.1

PL 4.1

Com mon

PL 4.1 Com

Parts List

PL 4.1

PL 4.2 ELECTRICAL MODULE DOOR, TOP COVER AND INNER PANEL Item

Part

Description

1 2 3

– 50E2710 2K39610

4

–

5 6 7 8 9 10 11 12 13 14

26E4240 28E2680 16E2280 29E8701 29E8690 30K50220 29E9220 30E46420 30K12713 48K43030

15

56S3200

ELECTRICAL MODULE DOOR QUARTER TURN RECEPTACLE ELECTRICAL MODULE INNER PANEL ASSEMBLY ELECTRICAL MODULE INNER PANEL (P/O PL 4.2 Item 3) QUARTER TURN FASTENER WASHER GROMMET HINGE PIN (LOWER) HINGE PIN (UPPER) TRIM STRIP PIVOT PIN PIVOT PIN BRACKET DOOR STOP BRACKET ELECTRICAL MODULE TOP COVER EM DOOR TRIP STRIP

PL 4.2

PL 4.2

PL 4.2

PL 4.2 PL 4.2 PL 4.2

PL 4.2 PL 4.2

PL 4.2 PL PL 4.2 PL 4.2 4.2 PL 4.2

PL 4.2

PL 4.2

Parts List

PL 4.2

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Revision DocuPrint 180F Service Manual

PL 4.3 PRINTER INNER PANELS Item

Part

Description

1

2K15384

2 3 4

16E2270 28E2680 –

5 6

26E4230 –

7 8

30K22551 2K15311

9

2K17593

–

48K26540

10 11

50E2710 110K3530

12

2K17952

13

–

14 15

110E1521 –

16 17

91E18092 91E18071

PRINT TRANSPORT INNER PANEL ASSEMBLY GROMMET WASHER PRINT TRANSPORT INNER PANEL (P/O PL 4.3 Item 1) QUARTER TURN FASTENER ROS UPPER INNER PANEL (P/O PL 4.3 Item 12) FUSER INNER PANEL REGISTRATION TRANSPORT INNER PANEL ASSEMBLY ROS LOWER INNER PANEL ASSEMBLY LOWER INNER PANEL ASSEMBLY (MICR ONLY) QUARTER TURN RECEPTACLE PRINTER PROCESSOR RIGHT DOOR INTERLOCK SWITCH (S105) AND LEFT SWITCH (S106) LEFT DOOR INTERLOCK ROS UPPER INNER PANEL ASSEMBLY ROS LOWER INNER PANEL (P/O PL 4.3 Item 9) MAIN POWER SWITCH REGISTRATION TRANSPORT INNER PANEL(P/O PL 4.3 Item 8) LABEL (CLEAR AREA 4) LABEL (CLEAR AREA 2)

PL 1.15

PL 4.4

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.3

PL 4.4 PHOTORECEPTOR INNER PANEL LABELS Item

Part

Description

1 2 3 4 5 6 7

91E15201 91P42201 91P42301 91P42501 91P44801 – –

8 9 10 11 12

28P1183 28P497 9P1366 26E4730 2K18040

AREA 5 LABEL UNLATCHED LABEL LATCHED LABEL RETRACT LABEL CAUTION LABEL LABEL PHOTORECEPTOR INNER PANEL (P/O PL 4.4 Item 12) RETAINER WASHER SPRING STUD PHOTORECEPTOR INNER PANEL ASSEMBLY

Parts List

PL 4.4

11/00 5-34

Revision DocuPrint 180F Service Manual

PL 4.5 PRINTER RIGHT TOP COVER COMPONENTS Item

Part

Description

1

48K46260

2 3 4

3E13010 3E25870 –

5 6 7

120E3260 9E15100 –

8 9

3K5530 110K3530

10 11 12 13 – 14 –

36K461 – 29E12820 73E11420 50K32570 91E56950 96E76150

PRINTER RIGHT TOP COVER ASSEMBLY KEEPER TOP COVER HANDLE PRINTER RIGHT TOP COVER (P/ O PL 4.5 Item 1) INTERLOCK ACTUATOR SPRING ACTUATOR PLATE (P/O PL 4.5 Item 1) LATCH PLATE PRINTER TOP COVER INTERLOCK SWITCH (S104) COUNTER BALANCE SEAL (P/O PL 4.5 Item 1) PIVOT SAMPLE TRAY KIT SAMPLE TRAY ASSEMBLY SAMPLE TRAY LABEL SAMPLE TRAY LABEL

PL 4.5

PL 4.5

PL 4.5

PL 4.5

PL 4.5 Common

Common

PL 4.5

PL 4.5 Com mon

PL 4.5

PL 4.5

PL 4.5

Common

PL 4.5 PL 4.5

PL 4.5 Item

PL 4.5 Item 9

PL 4.5

PL 4.5

Revision DocuPrint 180F Service Manual

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Com mon

Parts List

PL 4.5

PL 4.6 PRINTER LEFT TOP COVER ASSEMBLY Item

Part

Description

1

48K43050

2

–

3 4 5

30E61060 – 4E2100

PRINTER LEFT TOP COVER ASSEMBLY PRINTER LEFT TOP COVER (P/O PL 4.6 Item 1) BRACKET LATCH BRACKET BUMPER

Parts List

PL 4.6

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Revision DocuPrint 180F Service Manual

PL 4.7 ELECTRICAL MODULE LEFT SIDE COVER AND REAR COVER Item

Part

Description

1

48K8180

2 3 4 5

26E4240 28E2680 16E2280 –

6

48K57090

7

–

8 9 10

– – –

11 12 13

16E380 2K19622 –

14 15 16 17 18 19 20

26E7970 28E4730 35K3090 2K24790 53K1541 2E38930 2E38920

PRINTER LEFT SIDE COVER ASSEMBLY QUARTER TURN FASTENER WASHER GROMMET PRINTER LEFT SIDE COVER (P/ O PL 4.7 Item 1) ELECTRICAL MODULE REAR COVER ASSEMBLY ELECTRICAL MODULE REAR COVER (P/O PL 4.7 Item 6) GROMMET (P/O PL 4.7 Item 6) WASHER (P/O PL 4.7 Item 6) QUARTER TURN FASTENER (P/O PL 4.7 Item 6) QUARTER TURN RECEPTACLE FILTER COVER ASSEMBLY FILTER COVER (P/O PL 4.7 Item 12) QUARTER TURN FASTENER RETAINER GASKET COVER FILTER EXTERNAL LOUVER COVER INTERNAL LOUVER COVER

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.7

PL 4.8 PRINTER REAR COVERS Item

Part

Description

1

2K17803

2

48K9590

3 4 5 6 7 8

16E2270 – 2E34650 30K35541 2E34660 –

9 10 11 12 13 14

2E18971 26E4230 28E2680 – 2E20311 600K82680

–

600K82681

PRINTER RIGHT REAR COVER ASSEMBLY PRINTER LEFT REAR COVER ASSEMBLY GROMMET REAR COVER (P/O PL 4.8 Item 2) LOUVER COVER (INSIDE) COVER LOUVER COVER (OUTSIDE) PIVOT BRACKET (P/O PL 4.8 Item 2) FILTER DOOR STUD WASHER WASHER (P/O PL 4.8 Item 2) REAR PANEL PARTICULATE FILTER KIT (60HZ)(TAG P-314) PARTICULATE FILTER KIT

Parts List

PL 4.8

11/00 5-38

Revision DocuPrint 180F Service Manual

PL 4.9 MIM COOLING FAN Item 1 2 3 4 5 6 7 8 9 10 11 12

Part

Description

– 127E5850 19E13710 55E11230 30K31870 35E10610 35E10630 35E10620 120E500 152K32411 1E17060 30K19931

MIM COOLING FAN ASSEMBLY MIM COOLING FAN (MOT107) CLIP GUARD BRACKET SEAL SEAL SEAL CABLE TIE HARNESS RETAINER LATCH BRACKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.9

PL 4.10 INVERTER LEFT SIDE COVER AND TRIM STRIPS Item

Part

Description

1 2 3 4 5 6 7 8 9 10

1K14842 1K10896 1K54090 – 48K46020 1E39400 1K54100 1K54080 2K32771 –

11 12

2E39610 2E39450

REAR TRIM STRIP REAR TRIM STRIP TOP TRIM STRIP LOCATING STUD INVERTER LEFT SIDE COVER TOP TRIM STRIP FRONT TRIM STRIP FRONT TRIM STRIP LOWER INVERTER COVER INNER COVER (ALSO SHOWN ON PL1.15) INNER SAFETY COVER INNER COVER

Parts List

PL 4.10

11/00 5-40

Revision DocuPrint 180F Service Manual

PL 4.11 INVERTER DOOR AND RH COVERS Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

2E32200 2K28510 48K46130 26E4240 28E2680 – 50E2710 15E15740 – 120E3260 68E23580 68K670 3E13010 – 91E59121 91E59132 91E59143 3E14171 110K3530

20 21 22 23

15K8401 30E67993 3K6941 56S3077

–

56S3207

EXTRUSION (SHORT) EXTRUSION (LONG) RH COVER STUD WASHER GROMMET RECEPTACLE PLATE ACTUATOR BRACKET ACTUATOR SWITCH BRACKET BRACKET KEEPER INVERTER DOOR LABEL LABEL LABEL FRAME HINGE INVERTER INTERLOCK SWITCH (S1153) LATCH LATCH MOUNTING BRACKET FRAME HINGE PIN INVERTER TRIM STRIP (MID MOD 4.75 GEN) INVERTER TRIM STRIP

PL 4.11

Revision DocuPrint 180F Service Manual

11/00 5-41

Parts List

PL 4.11

PL 4.12 STACKER COVERS Item

Part

Description

1 2

152K30563 140K11202

3

96E80530

4 – 5 – – 6 7 8 – 9 10 11 12

91E59161 91E59151 96E80490 96E80500 91K10530 3E45890 – 91E59181 91E59171 3P2502 2K28182 2K28192 110K3530

13 14 15 16 17

15E16140 4P101 30K34871 30K34981 56S3078

–

56S3208

STACKER HARNESS STACKER CONTROL PANEL PWB STACKER CONTROL PANEL LABEL FS JAM CLEARANCE LABEL IFS JAM CLEARANCE LABEL LABEL (A) LABEL (B) LABEL SET (C,D,5,6) BUTTON STACKER FRONT COVER FS JAM CLEARANCE LABEL IFS JAM CLEARANCE LABEL MAGNETIC CATCH LH STACKER DOOR RH STACKER DOOR STACKER RIGHT DOOR INTERLOCK SWITCH, (S1138) STACKER LEFT DOOR INTERLOCK SWITCH, (S1163) CATCH DOOR PLATE BUMPER LH PIVOT BRACKET RH PIVOT BRACKET STACKER TRIM STRIP (MID MOD 4.75 GEN) STACKER TRIM STRIP

Parts List

PL 4.12

11/00 5-42

Revision DocuPrint 180F Service Manual

PL 4.13 FEEDER COVER, RH AND LOWER DOORS Item

Part

Description

1 2 3 4 5 6 7 8

3E14191 91E59111 48K45870 3E13010 30E79891 91E59091 15K8401 110K3530

9 10

30E67993 110K2690

11 12 13 14 15 16 17 18

91E59101 48K45890 3E14171 15K9290 4E3060 30K32662 30E29084 110P2441

19

–

20 21

3K6941 29E8701

FRAME HINGE LABEL LOWER DOOR KEEPER ACTUATOR LABEL LATCH VERTICAL TRANSPORT DOOR INTERLOCK SWITCH (S1118) HORIZONTAL TRANSPORT DOOR INTERLOCK SWITCH (S1120) LATCH MOUNTING BRACKET INTERLOCK BYPASS SWITCH ASSEMBLY LABEL RH DOOR FRAME HINGE STUD PLATE BUMPER BRACKET SWITCH BRACKET INTERLOCK BYPASS SWITCH (S1152) SWITCH BRACKET (P/O PL 4.13 Item 10) FRAME HINGE PIN COVER HINGE PIN

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.13

PL 4.14 IFS AND FS TOP COVERS Item

Part

Description

1 2 3 4 5 6 7 8 9 10

9E24101 50E12511 36K471 2K28510 48K45960 30K36630 – 113K1040 123E1010 –

11 12 13 14 15 16 17 18 19 20 21 22 23

48K44901 2E26673 30E65131 55E23370 12K2630 15K9310 48K45980 48K45940 3E39541 3E13010 15K9290 68E6410 –

24

–

25 26 27

15K24790 30K29012 –

28 29

4E5240 15E31720

LEAF SPRING PURGE TRAY COUNTERBALANCE EXTRUSION (LONG) INVERTER TOP COVER BRACKET HARNESS (P/O PL 4.14 Item 5) INDICATOR LAMP ASSEMBLY LAMP LAMP HOLDER (P/O PL 4.14 Item 8) PURGE TOP COVER INNER COVER (CHM) BRACKET DEFLECTOR CABLE LATCH PLATE TOP COVER TOP FILLER COVER HANDLE CATCH PLATE LATCH BRACKET LENS INNER COVER (P/O PL 4.14 Item 5) LENS OUTER COVER (P/O PL 4.14 Item 5) FILLER PLATE SNAP BRACKET PURGE TOP COVER (P/O PL 4.14 Item 11) BUMPER PLATE

Parts List

PL 4.14

11/00 5-44

Revision DocuPrint 180F Service Manual

PL 4.15 IFS AND FS REAR COVERS Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Part

Description

2K28691 26E4240 28E2680 16E2270 50E2710 15E15740 2K28510 2E32200 2K28500 2K28481 50E7660 50E7650 30K42950

REAR INVERTER COVER STUD WASHER GROMMET RECEPTACLE PLATE EXTRUSION (LONG) EXTRUSION (SHORT) UPPER REAR COVER LOWER REAR COVER DEBRIS GUARD (FS) DEBRIS GUARD (IFS) GUARD BRACKET

Revision DocuPrint 180F Service Manual

11/00 5-45

Parts List

PL 4.15

PL 4.16 PROCESSOR DRIVES (1 OF 2) Item

Part

Description

1 2 3 4

423W61350 7K1401 9E6270 423W73250

5 6 7 8 9 10

7K8320 31K4310 26P3773 31K1720 31K1700 23E15120

11 12 13 14 15 16 17 18 19

21E5040 423W12351 9P5450 31K4300 120E6620 20K5080 15K5790 9E12220 –

20 21 22 23

5E330 9P4413 29E4830 –

24 25

– –

DECURLER DRIVE BELT DECURLER DRIVE ASSEMBLY DECURLER BELT IDLER SPRING DECURLER INTERMEDIATE DRIVE BELT PREFUSER DRIVE ASSEMBLY CLEANER DRIVE BELT IDLER SHOULDER SCREW PREFUSER BELT IDLER PREFUSER BELT IDLER (FIXED) PREFUSER DRIVE BELT (134T)(TAG P-295) INSULATING CAP CLEANER DRIVE BELT SPRING CLEANER DRIVE SUPPORT LOCKING KEY CLEANER DRIVE PULLEY CLEANER DRIVE PLATE SPRING DECURLER INTER DRIVE PULLEY (P/O PL 4.16 Item 5) COUPLING SPRING KEY PREFUSER DRIVE HOUSING (P/ O PL 4.16 Item 5) BEARING (P/O PL 4.16 Item 14) CLEANING KIT

Parts List

PL 4.16

11/00 5-46

Revision DocuPrint 180F Service Manual

PL 4.17 PROCESSOR DRIVES (2 OF 2) Item

Part

Description

1 2 3

2K4692 9E43350 23E470

4 5 6 7 8 9 10

7K2900 5K830 26P3773 20K4590 9E42550 423W899 7K9570

11 12

2E28570 20K1530

13 14 15 16 17 18 19

19E13060 499W10009 9E2760 21E1240 26K780 5K2550 –

20 21 22 23

5E640 21E1250 9E3630 –

24 25

5E510 –

26 27 28 29 30 31 32

– 20K240 20K970 30E19970 – 600K31880 23P1346

33 34 35 36 37 38

31K170 22K55571 20K4520 29E25440 29E25450 600K88610

39

600K88270

DEVELOPER DRIVE ASSEMBLY IDLER SPRING FUSER-DEVELOPER DRIVE BELT FUSER DRIVE ASSEMBLY DRIVE BELT IDLER SHOULDER SCREW BI-PULLEY MIM BELT IDLER SPRING MIM SYNCH BELT PHOTORECEPTOR DRIVE (TAG P-317) BELT COVER FUSER-DEVELOPER IDLER PULLEY CLIP DRIVE PULLEY SPRING CAP FLYWHEEL MOUNTING STUD FLYWHEEL FUSER DRIVE HOUSING (P/O PL 4.17 Item 4) FUSER DRIVE COUPLING CAP SPRING DEVELOPER DRIVE HOUSING (P/O PL 4.17 Item 1) DEVELOPER DRIVE COUPLING PR DRIVE COUPLING (P/O PL 4.17 Item 10 AND PL 4.17 Item 39) SPRING (P/O PL 4.17 Item 10) ROLLER PULLEY (29T) IDLER BRACKET SPRING BRACKET 6MM DRIVE SHAFT KIT PHOTORECEPTOR DRIVE BELT (75T) IDLER ARM LINEAR IDLER (TAG P-295) FLYWHEEL (TAG P-295) KEY (3X3X40) (TAG P-295) KEY (3X3X9) PR CONSTANT VELOCITY DRIVE KIT (TAG P-317) CONSTANT VELOCITY DRIVE REPAIR KIT (TAG P-317)

Revision DocuPrint 180F Service Manual

PL 4.18 Item 2 PL 9.3 PL 9.3

PL 4.17 Item

11/00 5-47

Parts List

PL 4.17

PL 4.18 PRINT HANDLING MODULE DRIVES (1 OF 2) Item

Part

Description

1

127E11330

–

127E11340

2 3 4

20K5070 20K1860 121K9960

5

101K760

6 7 8 9 10

9P5167 31K370 26P3773 20K300 30K11081

11 12

23E620 30K11071

13

–

14

–

15 16

9P3470 5E520

MAIN DRIVE MOTOR (MOT 401)(60HZ)(TAG P-292) MAIN DRIVE MOTOR (MOT 401)(50HZ)(TAG P-292) MIM SYNC DRIVE PULLEY (40G) PHM DRIVE PULLEY VERTICAL TRANSPORT CLUTCH ASSEMBLY VERTICAL TRANSPORT CLUTCH HOUSING DRIVE BELT IDLER SPRING PHM DRIVE BELT IDLER SHOULDER SCREW PULLEY (FIXED) TRAY 2 FEEDER DRIVE BRACKET ASSEMBLY PHM DRIVE BELT TRAY 1 FEEDER DRIVE BRACKET ASSEMBLY TRAY 1 FEEDER DRIVE HOUSING (P/O PL 4.18 Item 12) TRAY 2 FEEDER DRIVE HOUSING (P/O PL 4.18 Item 10) SPRING COUPLING

Parts List

PL 4.18

11/00 5-48

Revision DocuPrint 180F Service Manual

PL 4.19 PRINT HANDLING MODULE DRIVES (2 OF 2) Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12

5E1533 28E2990 – 22K16990 423W58450 20E13410 – 20K1660 6K14930 702W9822 23P1346 9E7170

13 14 15 16

20K1413 7E4350 5E1722 –

17 18

– 102E15690

19 20

102E1340 102E10380

21 22

19E5590 30P33911

23

600K29140

24

160K33470

WEAR ELEMENT COUPLING BEARING RETAINER SHAFT (P/O PL 4.19 Item 9) IDLER BRACKET INVERTER DRIVE BELT PULLEY (28T) TOP TRANSPORT DRIVE BELT TOP TRANSPORT DRIVE SHAFT ASSEMBLY CAPACITOR BOOT INTERMEDIATE DRIVE BELT INTERMEDIATE DRIVE TENSION SPRING INTERMEDIATE DRIVE GEAR (38T) COUPLING BEARING BLOCK (P/O PL 4.19 Item 9) PULLEY (P/O PL 4.19 Item 9) MAIN DRIVE RUN CAPACITOR (C401) (60HZ)(TAG P-292) CAPACITOR CAP (60HZ ONLY) MAIN DRIVE START CAPACITOR (C402) (60HZ)(TAG P-292) CAP RUN CLAMP (TAG P-292) CAPACITOR BRACKET (TAG P292) BYPASS INTERMEDIATE DRIVE KIT SOFT START PWB (50HZ) (TAG P-289)

Revision DocuPrint 180F Service Manual

11/00 5-49

Parts List

PL 4.19

PL 4.20 MOTOR BRACKET ASSEMBLY Item

Part

Description

1 2 3

9E8670 2K24142 23E1320

4

127E11340

–

127E11330

5 6 7

5K840 20K980 102E10380

8 9 10 11

– 102E1340 702W9822 102E15690

12 13 14 15

55K8380 – 55K8370 –

16

702W1529

17

–

18

30P33911

19 20

26E2750 –

21 22

91P40691 600K62370

23

–

SPRING JACKSHAFT FUSER-DEVELOPER INTERMEDIATE DRIVE BELT (118T) FUSER-DEVELOPER DRIVE MOTOR (MOT402)(50HZ) (TAG P289) FUSE-DEVELOPER DRIVE MOTOR (MOT402)(60HZ) (TAG P292) INTERMEDIATE BELT IDLER MOTOR PULLEY (36T) FUSER-DEVELOPER START CAPACITOR (C404)(60HZ) (TAG P-292) HARNESS CAPACITOR CAP CAPACITOR BOOT FUSER-DEVELOPER RUN CAPACITOR (C403)(60HZ) (TAG P-292) LEFT DIRT SHIELD FLYWHEEL (P/O PL 4.20 Item 20) RIGHT DIRT SHIELD FUSER DEVELOPER DRIVE PULLEY RUN CAPACITOR BRACKET (TAG P-292) MOTOR BRACKET (P/O PL 4.20 Item 20) START CAPACITOR BRACKET (TAG P-292) SHOULDER SCREW FLYWHEEL REPAIR KIT (TAG P189) CAUTION LABEL (50HZ) 50HZ MOTOR REPAIR KIT (TAG P-492) HARNESS (NOT SHOWN)(P/O PL 4.20 Item 22)

Parts List

PL 4.20

11/00 5-50

Revision DocuPrint 180F Service Manual

PL 4.21 CASTERS AND REAR UI BRACKET Item

Part

Description

1 2 3

17K213 – –

4 5 6

17K202 26E4360 30E69241

CASTER ASSEMBLY CASTER (P/O PL 4.21 Item 1) SHOCK MOUNT (P/O PL 4.21 Item 1) CASTER DOCKING STUD REAR UI BRACKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.21

PL 4.22 IFS FRAMES Item 1 2 3 4 5 6 7 8 9 10 11 12

Part

Description

1K16780 1K16770 3E470 409W1765 6E1040 3E460 11E250 17E963 26E4180 26E4360 17E4162 26E6590

UPPER RIGHT FRONT GUSSET REAR STRAP GUSSET REAR LATCH SPRING DOCKING SHAFT FRONT LATCH FRONT LEVER SWIVEL CASTER PILOT STUD DOCKING STUD NON-SWIVEL CASTER DOCKING POINT SCREW

Parts List

PL 4.22

11/00 5-52

Revision DocuPrint 180F Service Manual

PL 4.23 FS FRAMES Item 1 2 3 4 5 6 7

Part

Description

1K16780 1K16770 17E963 117S23170 26E4180 17E4162 30K32752

UPPER RIGHT FRONT GUSSET REAR STRAP GUSSET SWIVEL CASTER WIRE PILOT STUD NON-SWIVEL CASTER BRACKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.23

PL 4.24 BTM FS PURGE/EXIT BYPASS FRAME AND COVER Item 1 2 3 4 5 6 7 8 9 10 11

Part

Description

48K44901 – 36K471 12K2630 55E23370 15K9310 3E39541 50E12511 15K24790 15E31720 9E24101

PURGE TRAY TOP COVER TOP COVER (P/O PL 4.24 Item 1) COUNTER BALANCE CABLE DEFLECTOR LATCH PLATE HANDLE PURGE TRAY PLATE FILLER PLATE LEAF SPRING

PL 4.24

PL 4.2 PL 4.24 PL 4.24

PL 4.24

PL 4.24

PL 4.24 PL 4.24

Common

Common

PL 4.24

PL 4.24

PL 4.24

Parts List

PL 4.24

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Revision DocuPrint 180F Service Manual

PL 4.25 BTM FRAME AND COVER (1 OF 2) Item

Part

Description

1

–

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

48K47990 16E2270 28E2680 26E4240 2K54211 48K48010 48K48030 2E32200 2K28510 – 3K6941 – 48K47970 110K3530 15K8401 – 120E3260 3E13010 – 15K12030 15K12090

TRANSITION MODULE ASSEMBLY TOP COVER GROMMET WASHER 1/4 TURN FASTENER REAR COVER UPPER SIDE COVER LOWER SIDE COVER FRAME BRACKET FRAME BRACKET FRAME STUD PLATE DOOR HINGE HINGE PIN (P/O PL 4.25 Item 12) FRONT DOOR INTERLOCK SWITCH LATCH PLATE BRACKET (P/O PL 4.25 Item 1) INTERLOCK ACTIVATOR DOOR BRACKET MATRIX CARD LOWER MOUNTING PLATE FRAME MOUNTING PLATE

PL PL PL PL PL PL 4.25

PL 4.25

PL 4.25 PL 4.25

PL 4.25 PL 4.25

PL 4.25 PL 4.25

PL 4.25

PL 4.25 PL 4.25

PL 4.25

PL 4.25 PL 4.25 PL 4.25 PL 4.25

PL 4.25

PL 4.25

PL 4.25

PL 4.25

PL 4.25

Revision DocuPrint 180F Service Manual

PL 4.25

PL 4.25

11/00 5-55

PL 4.25

PL 4.25

Parts List

PL 4.25

PL 4.26 BTM FRAME AND COVER (2 OF 2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part

Description

– – 1K54390 4E2240 1K31860 15E15740 30K47920 – 22K27680 409W3279 2K28510 2E32200 50K18450 92E55590 1K54380 50E2710 92E55580 14E23400 17K1561

TRANSITION MODULE ASSY COVER (P/O PL 4.26 Item 1) TOP GUTTER TOP BUMPER REAR SIDE GUTTER 1/4 TURN PLATE STUD BRACKET ADAPTER BRACKET IDLER IDLER SPRING FRAME BRACKET FRAME BRACKET BOTTOM PAN (ALTERNATE) CLEAR JAM LABEL (20) FRONT SIDE GUTTER 1/4 TURN RECEPTACLE CLEAR JAM LABEL (19) GUTTER SPACER LEG FRAME

Parts List

PL 4.26

11/00 5-56

Revision DocuPrint 180F Service Manual

PL 4.27 INPUT ENABLEMENT COVERS (1 OF 2) Item

Part

Description

1 2 3 4 5 6 7

97S1515 48K47510 16E7150 6E24730 2E32200 2K28510 –

8 9 10 11 12

16E2270 28E2680 26E4240 50E2710 15E15740

INPUT ENABLEMENT KIT RIGHT HAND COVER LATCH BUSHING LATCH SHAFT FRAME BRACKET FRAME BRACKET INTERFACE BRACKET (P/O PL 4.27 Item 1) GROMMET WASHER 1/4 TURN FASTENER RECEPTACLE PLATE

Revision DocuPrint 180F Service Manual

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Parts List

PL 4.27

PL 4.28 INPUT ENABLEMENT COVERS (2 OF 2) Item

Part

Description

1

--

2

–

3 4

117K14641 –

5 6

3P25202 140K24311

INPUT ENABLEMENT KIT (P/O PL 4.27 Item 1) OPTO PWB BRACKET (P/O PL 4.28 Item 1) INTERFACE CABLE INPUT ENABLEMENT HARNESS (P/O PL 4.28 Item 1) PWBA STANDOFF OPTO ISO PWBA

Parts List

PL 4.28

11/00 5-58

Revision DocuPrint 180F Service Manual

PL 6.1 ROS ASSEMBLY (1 OF 2) Item

Part

Description

1 2

62K8023 –

3

127E10433

4 5 6

– 48K47420 –

7

–

8 9 10 11

19E3450 19E11320 19E14411 600K58540

–

600K67452

12 13 14 15

162K23910 162K23900 600K82470 600K75230

VLD ROS ASSEMBLY (TAG P-310) ROS BASE COVER (P/O PL 6.1 Item 1) DC BRUSHLESS MPA (W/ TAG P310) CRCM PWB (P/O PL 6.1 Item 11) SCAN COVER COLLIMATOR SHIELD (P/O PL 6.1 Item 1) COLLIMATOR PWB (P/O PL 6.1 Item 1) ROS CLAMP ROS CLAMP RAIL CLIP CRCM ASSEMBLY KIT (W/TAG P293) CRCM ASSEMBLY KIT (W/ TAG P310) EOS/SOS HARNESS 20-P CVLDD/CRCM CABLE VLD COLLIMATOR CRCM FIRMWARE KIT (W/ TAG P310) (NOT SHOWN)

Revision DocuPrint 180F Service Manual

PL 1.11 Item

11/00 5-59

Parts List

PL 6.1

PL 6.2 ROS ASSEMBLY (2 OF 2) Item

Part

Description

1

--

2 3

48K47660 55K5390

ROS ASSEMBLY (P/O PL 6.1 Item 1) ROS COVER LIGHT SHIELD

Parts List

PL 6.2

11/00 5-60

Revision DocuPrint 180F Service Manual

PL 7.1 ELEVATOR COMPONENTS Item

Part

Description

1 – 2

50K25570 50K10690 –

3 4

14E16151 30S52884

–

30S52885

5

–

6 7 8

– 26E3510 130S21011

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

419W101 6E21280 30S50752 10E4540 10E4530 30S37758 2E6220 18P371 30K17461 25K160 25P868 152K17331 26P4505 – – –

TRAY 2 ELEVATOR ASSEMBLY TRAY 1 ELEVATOR ASSEMBLY ELEVATOR BASE (P/O PL 7.1 Item 1) BLOCK/RAMP STACK RELIEF SOLENOID ASSEMBLY (SOL811) (TRAY 1) STACK RELIEF SOLENOID ASSEMBLY (SOL821) (TRAY 2) STACK RELIEF SOLENOID (P/O PL 7.1 Item 4) SPRING (P/O PL 7.1 Item 4) SCREW STACK HEIGHT SENSOR (Q711)(TRAY 1), (Q721)(TRAY 2) CABLE CLAMP LOCK PIN BRACKET LEFT SLIDE RIGHT SLIDE SUPPORT COVER SET-UP TOOL CABLE SUPPORT ASSEMBLY CABLE BAR CABLE TIE BAR ELEVATOR CABLE HARNESS SCREW PIN (P/O PL 7.1 Item 17) HINGE (P/O PL 7.1 Item 17) SUPPORT SLIDE (P/O PL 7.1 Item 17)

Revision DocuPrint 180F Service Manual

PL PL 7.1 7.1

PL PL 7.1 7.1

11/00 5-61

Parts List

PL 7.1

PL 7.2 LENGTH GUIDE COMPONENTS Item

Part

Description

1

--

2

–

3 4

– 38K1261

–

38K1271

5

–

6

130K26130

TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) ELEVATOR BASE (P/O PL 7.2 Item 1) CABLE CLAMP (P/O PL 7.2 Item 1) LENGTH GUIDE ASSEMBLY (TRAY 1) LENGTH GUIDE ASSEMBLY (TRAY 2) LENGTH GUIDE FRAME (P/O PL 7.2 Item 4) LENGTH SENSOR A (Q712)(TRAY 1) (Q722)(TRAY 2) (Q713)(TRAY 1) (Q723)(TRAY 2) SHAFT (P/O PL 7.2 Item 4) BEARING (P/O PL 7.2 Item 4) PLATE (P/O PL 7.2 Item 4) SCREW SPRING LENGTH GUIDE (TRAY 1) LENGTH GUIDE (TRAY 2) BRACKET (P/O PL 7.2 Item 4) TRAY FILL LABEL LENGTH SENSOR COVER PAPER PLATE ASSEMBLY PAPER PLATE (P/O PL 7.2 Item 16) TRAY LOAD LABEL PAD LENGTH GUIDE LABEL MYLAR REINFORCEMENT TRAY HARNESS (TRAY 1) HARNESS (TRAY 2) (P/O PL 7.2 Item 1) WIRE (TRAY 1 AND 2) WIRE (TRAY 2) WIRE (TRAY 1 AND 2) LABEL

7 8 9 10 11 12 – 13 14 15 16 17

– – – 26P4098 9P4631 38E6780 38E7800 – 91E12040 2P11924 50K10670 –

18 19 20 21 22 –

91E12050 19P3686 91E56570 – 152K20942 –

23 24 25 26

117K3000 117S8737 117K2990 –

PL 7.2

PL 7.2 PL 7.2

PL 7.2 PL

PL 7.2

Com mon

PL 7.2 Item

Parts List

Common

PL 7.2 PL 7.2 Com Common mon PL 7.5

Com mon PL 7.2 Item Common Com mon

PL 7.2 PL 7.2

PL 7.2 PL 7.2

PL 7.2

PL 7.2 Com mon PL

PL 7.2 PL 7.2

7.2 PL 7.2

PL 7.2

PL 7.2

PL 7.2

PL 7.2

PL 7.2 PL 7.2 Item

PL 7.2

PL 7.2

PL

11/00 5-62

PL 7.2

Revision DocuPrint 180F Service Manual

PL 7.3 FRONT SUPPORT AND COVERS Item

Part

1 2 3 – 4 5 6 7 8 – 9 10

91P41902 2E9981 2E12191 3K3262 120K240 9P4952 3E5230 30K10302 30K9882 3E5240 140K7391

11 12 – 13 14 – 15 – 16

3E4980 30K9892 30K10312 56K2460 48K43250 48K45160 30K9332 30K9342 30S42060

–

30S42059

17 –

96E72510 892E27180

– –

96E72500 892E27190

18 19 20 21

3K4781 48K32270 702W11633 56K2450

Description TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) LOAD PAPER LABEL LABEL PANEL (TRAY 1) LABEL PANEL (TRAY 2) LOCK ARM LOCK ACTUATOR SPRING CATCH RIGHT BRACKET (TRAY 2) RIGHT BRACKET (TRAY 1) CLIP TRAY CAPACITY PWB (UNLOCK SWITCH) (S716)(TRAY 1), (S726)(TRAY 2) BUTTON LEFT BRACKET (TRAY 1) LEFT BRACKET (TRAY 2) BEZEL FRONT COVER (TRAY 1) FRONT COVER (TRAY 2) FRONT COVER FRAME (TRAY 1) FRONT COVER FRAME (TRAY 2) FRONT COVER SUPPORT (TRAY 1) FRONT COVER SUPPORT (TRAY 2) PAPER LEVEL LABEL (TRAY 1) PAPER LEVEL LABEL (TRAY 1)(DP 6.0 GEN) PAPER LEVEL LABEL (TRAY 2) PAPER LEVEL LABEL (TRAY 2)(DP 6.0 GEN) LATCH SAFETY COVER CAPACITOR (C722) BEZEL ASSEMBLY

Revision DocuPrint 180F Service Manual

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Parts List

PL 7.3

PL 7.4 SWITCH PLATE ASSEMBLY Item

Part

Description

1

--

2

15K5050

–

15K5060

3 4 5 6 7 8 9 – 10

– 120P1361 9P4422 118P1502 26P20304 62P1869 62S1940 62S1950 710W2025

11

130K26120

12 13 –

26P4453 14E17540 14E17550

TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) SWITCH PLATE ASSEMBLY (TRAY 1) SWITCH PLATE ASSEMBLY (TRAY 2) PLATE (P/O PL 7.4 Item 2) CAM ACTUATOR SPRING INSULATOR SET SCREW CAM CAM (TRAY 1) CAM (TRAY 2) ELEVATOR DOWN LIMIT SWITCH (S715)(TRAY 1), (S725)(TRAY 2) DOWN/LOW PAPER SENSOR (Q714)(TRAY 1), (Q724)(TRAY 2) SEMS SCREW SPACER (TRAY 1) SPACER (TRAY 2)

Parts List

PL 7.4

11/00 5-64

Revision DocuPrint 180F Service Manual

PL 7.5 FRONT SUPPORT Item

Part

Description

1

--

2 3 4 5 6 – 7 8

9P1698 20K1240 13P2505 27P1126 26P3798 26P3796 413W8205 30K35380

–

30K36760

9 10 11 12 13 – 14

27P1205 30S39161 – 117S23142 26P4222 26P4221 31P3205

TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) SPRING PULLEY LEAD SCREW RETAINER LIFT NUT LEAD SCREW (TRAY 2) LEAD SCREW (TRAY 1) BEARING FRONT SUPPORT FRAME (TRAY 1) FRONT SUPPORT FRAME (TRAY 2) LIFT NUT PAPER PLATE SUPPORT CLAMP (P/O PL 7.5 Item 1) WIRE LEAD SCREW (TRAY 1) LEAD SCREW (TRAY 2) FRONT RETAINER

Revision DocuPrint 180F Service Manual

11/00 5-65

Parts List

PL 7.5

PL 7.6 REAR SUPPORT Item

Part

Description

1

--

–

50K25570

2 3 – 4 5 6 7

27P1126 26P3797 26P3799 20K1240 413W8205 13P2505 110E6850

8 9 10

30P33868 9P1698 30S53073

–

30S53082

11 12 13 14 15 –

19P4310 30S34950 30P36798 – 30S53097 30S53096

TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) P/O TRAY 2 ELEVATOR (REFER PL 7.1 Item 1) LIFT NUT LEAD SCREW (TRAY 1) LEAD SCREW (TRAY 2) PULLEY BEARING RETAINER ELEVATOR UP LIMIT SWITCH (S714) (TRAY 1) (S724)(TRAY 2) SWITCH BRACKET SPRING REAR SUPPORT FRAME (TRAY 1) REAR SUPPORT FRAME (TRAY 2) RETAINER PAPER PLATE SUPPORT PAPER PLATE SUPPORT CLAMP (P/O PL 7.6 Item 1) SUPPORT FRAME (TRAY 1) SUPPORT FRAME (TRAY 2)

Parts List

PL 7.6

11/00 5-66

Revision DocuPrint 180F Service Manual

PL 7.7 ELEVATOR DRIVES (1 OF 2) Item

Part

Description

1

--

2

–

3 – 4 5

2S15742 48K32280 420W11001 2P13126

6 7 8 9

20K1240 423W6350 9P4945 127P2552

10 11

117S23142 102P630

12 13

702W4522 120P20320

–

120P20321

14

–

TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) ELEVATOR BASE (P/O PL 7.7 Item 1) BOTTOM COVER (TRAY 1) BOTTOM COVER (TRAY 2) CABLE TIE INTERLOCK ACTUATOR HOUSING ELEVATOR DRIVE PULLEY ELEVATOR DRIVE BELT SPRING ELEVATOR MOTOR (MOT711)(TRAY 1), (MOT721)(TRAY 2) GROUND WIRE ELEVATOR MOTOR CAPACITOR (C711)(TRAY 1), (C721)(TRAY 2) CAPACITOR BRACKET INTERLOCK ACTUATOR (TRAY 1)(S710) (SEE PL 7.9 Item 1) INTERLOCK ACTUATOR (TRAY 2)(S720) (SEE PL 7.9 Item 1) GROUND BRACKET (P/O PL 7.7 Item 1)

Revision DocuPrint 180F Service Manual

11/00 5-67

Parts List

PL 7.7

PL 7.8 ELEVATOR DRIVES (2 OF 2) Item

Part

Description

1

50K10690

2

–

3 4 5 6 7 8 9

20P3448 30K22500 26P4037 20S3449 423W65250 26P4036 9E9350

TRAY 1 AND TRAY 2 ASSEMBLY (P/O PL 7.1 Item 1) ELEVATOR BASE (P/O PL 7.8 Item 1) IDLER ROLLER IDLER BRACKET IDLER STUD IDLER PULLEY ELEVATOR BELT ROLL STUD SPRING

Parts List

PL 7.8

11/00 5-68

Revision DocuPrint 180F Service Manual

PL 7.9 ELEVATOR MOTOR COVERS Item

Part

Description

1

110P2340

2 3 4

30P36359 101E5200 91P4728

TRAY INTERLOCK SWITCH (S710)(TRAY 1), (S720)(TRAY 2) SWITCH BRACKET ELEVATOR MOTOR COVER LABEL

Revision DocuPrint 180F Service Manual

11/00 5-69

Parts List

PL 7.9

PL 7.10 FEED HEAD DRIVES MECHANISM (1 OF 2) Item

Part

Description

1

22K15011

2

–

3 4 4a 4b

35P3112 600S7637 – –

5 6 7 8 9 10 11 12 13 14 15 16 17 18

28E1990 6E8051 28P1815 22S24821 28P1818 20E2010 23E1340 2P16449 26P4114 23E1350 20K1110 22K2720 30K43630 413W456

FEED HEAD ASSEMBLY (TRAY 1 AND 2) FEED HEAD FRAME (P/O PL 7.10 Item 1) SEAL FEED BELT KIT FEED BELT (P/O PL 7.10 Item 4) RETARD ROLL (LOCATED ON PL 7.13 Item 10) (P/O PL 7.10 Item 4) WASHER TAKEAWAY SHAFT THRUST WASHER TAKEAWAY ROLL THRUST WASHER TAKEAWAY PULLEY TAKEAWAY DRIVE BELT DIRT SHIELD SETSCREW FEED CLUTCH BELT FEED PULLEY FEED BELT ASSEMBLY BEARING BEARING

PL 7.10 PL 7.10

PL 7.10 Item

PL 7.10

PL 7.10

PL 7.10 Item PL 7.10

PL 7.10

PL 7.10

PL 7.10 Item

PL 7.10 Item PL 7.10 Common

PL 7.10

PL 7.10 PL 7.10 PL 7.10

PL 7.10

PL 7.10 PL 7.10

Parts List

PL 7.10

11/00 5-70

PL 7.10

Revision DocuPrint 180F Service Manual

PL 7.11 FEED HEAD DRIVES MECHANISM (2 OF 2) Item

Part

Description

1

--

2

–

3

–

4 5 6 7 8 9 10 11 12

9P4858 28P1818 6K7640 20K1101 30P34644 22P5606 91E12020 9E3620 91P41601

FEED HEAD ASSY (P/O PL 7.10 Item 1) FEED HEAD FRAME (P/O PL 7.11 Item 1) TENSION IDLER (P/O PL 7.11 Item 1) SPRING THRUST WASHER TUBE SHAFT ASSEMBLY PULLEY SPRING SUPPORT IDLER ROLLER LABEL LATCH SPRING FEED HEAD LATCH LABEL (US ENGLISH) FEED BELT LATCH ARM (P/O PL 7.11 Item 14) FEED BELT LATCH ARM ASSEMBLY SHAFT PIVOT TUBE (P/O PL 7.11 Item 6) COUPLING HARNESS

13

–

14

3K1520

15 16 17 18

6K7510 – 5P3378 152K6902

PL 7.11 Item PL 7.11 PL 7.11 PL 7.11

PL 7.11

PL 7.11

PL 7.11

PL 7.11

PL 7.11 PL 7.11

PL Com- 7.11 mon

Com mon PL 7.11

Common Com mon

Com mon

Common

PL 7.11 Common

PL 7.11

PL 7.11

PL 7.11

Co Co Co mm mm PL mm 7.11 PL 7.11

Revision DocuPrint 180F Service Manual

11/00 5-71

Parts List

PL 7.11

PL 7.12 FEED BELT ASSEMBLY Item

Part

Description

1

--

2

22K2720

3 4 5 6 7 8 9 10 11

22P5987 20S3683 20S3684 22P4018 6E7571 28P1709 28P1815 26P3913 –

12

121E4450

13 14 15

9P4694 28P1866 –

16 17 18 19 – 20 21

420W10701 30K6851 20K681 30K6862 30K16000 35P3112 28P778

FEED HEAD ASSEMBLY (P/O PL 7.10 Item 1) P/O FEED BELT ASSY (REFER PL 7.10 Item 16) FEED BELT SPOOL FEED BELT IDLER FEED BELT PULLEY IDLER ROLLER DRIVE SHAFT THRUST WASHER THRUST WASHER ECCENTRIC PIN FEED HEAD FRAME (P/O PL 7.12 Item 1) FEED CLUTCH (CL811)(TRAY 1), (CL821)(TRAY 2) TENSION SPRING THRUST WASHER FEED BELT SPOOL SHAFT (P/O PL 7.12 Item 1) CABLE TIE FEED BELT SPOOL BRACKET FEED CLUTCH PULLEY AUTO LATCH BRACKET (TRAY 1) AUTO LATCH BRACKET (TRAY 2) SEAL THRUST WASHER

Parts List

PL 7.12

11/00 5-72

Revision DocuPrint 180F Service Manual

PL 7.13 FEED HEAD ROLLS AND SENSORS Item

Part

Description

1

--

2

–

3 4

2E20920 9P4398

5

130P811

FEED HEAD ASSEMBLY (P/O PL 7.10 Item 1) FEED HEAD FRAME (P/O PL 7.13 Item 1) FRONT SAFETY COVER TAKEAWAY IDLER ROLL TENSIONING SPRING TAKEAWAY ROLL SENSOR ASSEMBLY (Q811)(TRAY 1) (Q821)(TRAY 2) STACK RELIEF SENSOR ASSEMBLY (Q812)(TRAY 1)(Q812) (TRAY 2) IDLER BRACKET IDLER SHAFT CABLE CLAMP THRUST WASHER RETARD ROLL (PART OF FEED BELT KIT) (REFER TO PL 7.10 Item 4b) ENTRY GUIDE RETARD BRAKE TAKEAWAY IDLER ROLL SAFETY COVER BRACKET SENSOR DETECTOR (P/O PL 7.13 Item 5) SENSOR EMITTER (P/O PL 7.13 Item 5) RELEASE PAPER LABEL (US ENGLISH) REAR SAFETY COVER MISFEED LABEL (US ENGLISH) SPRING CLIP SETSCREW (CUP POINT)

6 7 8 9 10

30S29910 6E7590 419W1401 28P1815 –

11 12 13 14 15

38K6660 19E11191 22S24511 2K8310 –

16

–

17

91P41701

18 19 20 21

2E20930 91P41801 19E9440 26P20307

Revision DocuPrint 180F Service Manual

PL PL 7.13 7.13 Com mon

PL 7.13

PL PL 7.13

Com mon

PL 7.1

PL 7.13

Com mon

PL 7.13

PL 7.13 PL 7.13

Com mon

Co PL mmPL 7.13 7.13

PL 7.13

Co mm

PL 7.13

PL 7.13 Co mm

Com

PL 7.13

PL 7.13

Com mon

PL 7.13 PL 7.13 PL 7.13

11/00 5-73

PL 7.13

PL 7.13

PL 7.13 PL 7.13

PL 7.13 PL 7.13

Parts List

PL 7.13

PL 7.14 HCT ASSEMBLY Item

Part

Description

1

50K17382

2 3 4 5 6

15K8761 110E1250 27P506 – 2E40360

HCT ELEVATOR ASSEMBLY (TAG P-69) LOCK TRAY CLOSED SWITCH (S730) NUT BRACKET AC SAFETY SHIELD

Parts List

PL 7.14

11/00 5-74

Revision DocuPrint 180F Service Manual

PL 7.15 HCT ASSEMBLY COMPONENTS (1 OF 4) Item 1

Part

Description

--

HCT ELEVATOR ASSEMBLY (P/O PL 7.14 Item 1) ELEVATOR BASE (P/O PL 7.15 Item 1) COVER SUPPORT BRACKET (P/ O PL 7.15 Item 1) BRACKET HCT PAPER TRAY (TAG P-69) ARROW LABEL PAPER LEVEL LABEL PAPER LEVEL LABEL (DP 6.0 GEN) FLUFFER HOSE (P/O PL 7.15 Item 1) PAPER LOAD LABEL (50HZ) PAPER LOAD LABEL (60HZ) CABLE HOLDER LABEL (3) LABEL (4) LABEL SET (5, 6, C, D) (M/M)(NOT P/O PL 7.15 Item 1) BRACKET (P/O PL 7.15 Item 1) HOSE CLAMP BUTTON TRAY CAPACITY PWB (UNLOCK SWITCH)(S736) MANOMETER (P/O PL 7.15 Item 1) SWITCH BRACKET FEEDER COVER WRENCH (9.5MM, 16MM, 22MM) WRENCH (9.5MM, 11.5MM, 15MM) RETAINING SPRING BEZEL

2

–

3

–

4 5 6 7 –

30K11591 50E17770 91E12050 96E72520 892E27200

8

60K270

9 – 10 11 – –

92E8980 91E45432 120E1340 96E80510 96E80520 91K10530

12 13 14 15

– 19E20740 3E4980 140K7391

16

–

17 18 19 20

68E48070 – 93E690 93E700

21 22

9E44720 56K2460

PL 7.15 PL 7.15

PL 7.15

PL 7.15 omon

PL 7.15 PL 7.15

PL 7.15

PL 7.15

PL 7.15 Common

PL 7.15

PL 7.15 Common

PL 7.15

PL 7.15

PL 7.15 PL 7.15

PL 7.15 PL 7.15

Revision

PL 7.1

PL 7.15

PL 7.15

PL 7.15

DocuPrint 180F Service Manual

Com mon

11/00 5-75

PL 7.15

PL 7.15

Parts List

PL 7.15

PL 7.16 HCT ASSEMBLY COMPONENTS (2 OF 4) Item

Part

Description

1

--

2

–

3 4 5 6 7

– – 38K9670 26E3772 –

8 9 10 11

38K2314 110K1896 120E1340 130K26120

12 13 14 15 16 17 18

26E17630 14E19721 9K740 30K16101 38K8101 130K26130 30K32224

HCT ELEVATOR ASSEMBLY (P/O PL 7.14 Item 1) ELEVATOR BASE (P/O PL 7.16 Item 1) LABEL (P/O PL 7.16 Item 5) LABEL (P/O PL 7.16 Item 5) LENGTH GUIDE ASSEMBLY SCREW LENGTH GUIDE (P/O PL 7.16 Item 5) GUIDE ASSEMBLY STACK HEIGHT SENSOR (Q735) CABLE HOLDER LENGTH SENSOR A (Q742), LENGTH SENSOR B (Q733) SETSCREW SHIM SPRING UNIVERSAL SUPPORT BACKSTOP WIDTH SENSOR (Q734) FRONT SUPPORT

Parts List

PL 7.16

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Revision DocuPrint 180F Service Manual

PL 7.17 HCT ASSEMBLY COMPONENTS (3 OF 4) Item

Part

Description

1

--

2

–

3 4 5 6

120E1331 19P3681 13E5260 110K2653

HCT ELEVATOR ASSEMBLY (P/O PL 7.14 Item 1) ELEVATOR BASE (P/O PL 7.17 Item 1) HARNESS BRIDGE BUSHING CLAMP BUSHING SWITCH ASSEMBLY TRAY DOWN SENSOR (Q737) LOW PAPER SENSOR (Q738) POSITION C SENSOR (Q739) DOWN SWITCH (S741) UP LIMIT SWITCH (S740) SWITCH COVER (P/O PL 7.17 Item 1) SAFETY COVER (P/O PL 7.17 Item 1) LEAD SCREW ASSEMBLY HCF AC HARNESS (P/O PL 7.17 Item 1) RELEASE SOLENOID ASSEMBLY RELEASE SOLENOID (SOL731) BRACKET (P/O PL 7.17 Item 11) CABLE TIE (P/O PL 7.17 Item 1) ELEVATOR SIGNAL HARNESS (P/ O PL 7.17 Item 1) ANTIBACKLASH NUT ANTIBACKLASH NUT (P/O PL 7.17 Item 9) PULLEY/BEARING (P/O PL 7.17 Item 9)

7

–

8

–

9 10

6K2920 –

11 12 13 14 15

30K21222 121E1610 – – –

16 –

27K110 –

17

–

Common

Common

Com

Common

Common

Common

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Parts List

PL 7.17

PL 7.18 HCT ASSEMBLY COMPONENTS (4 OF 4) Item

Part

Description

1

--

2

–

3 4

120E3660 702W12233

5

127K1540

6 7

20E3560 –

8 9 10 11 12

– 10K714 10K724 423W50 –

13 14

600K36440 –

15

–

HCT ELEVATOR ASSEMBLY (P/O PL 7.14 Item 1) ELEVATOR BASE (P/O PL 7.18 Item 1) CABLE HOLDER (TAG P-42) ELEVATOR DRIVE MOTOR CAPACITOR (C731) ELEVATOR DRIVE MOTOR (MOT731) IDLER PULLEY IDLER BRACKET (P/O PL 7.18 Item 1) EXTENSION SPRING LEFT SIDE RIGHT SIDE ELEVATOR DRIVE BELT BOTTOM COVER (P/O PL 7.18 Item 1) GROUNDING CLIP CHEESE HEAD SCREW (P/O PL 7.18 Item 1) CHEESE HEAD SCREW (P/O PL 7.18 Item 1)

Parts List

PL 7.18

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PL 8.1 VERTICAL TRANSPORT ASSEMBLY Item

Part

Description

1

22K15101

2 3 4

6K10470 6K601 600S6991

5

–

6

130K17476

7 8 9 10 11 12 13 14 15 16

– 5E420 6K1751 409W1469 5E370 5E1812 20K7610 9E79660 30K3331 423W148

17 18 19 20

30K24080 – 30E60960 600K54730

VERTICAL TRANSPORT ASSEMBLY (TAG P-163) UPPER SHAFT LOWER SHAFT VERTICAL TRANSPORT BELT (1 BELT PER ORDER) TRANSPORT FRAME (P/O PL 8.1 Item 1) VERTICAL TRANSPORT SENSOR (Q851) CABLE TIE (P/O PL 8.1 Item 1) FLEXIBLE COUPLING SHAFT SPRING DRIVE COUPLING DRIVE COUPLING INSERT DOG PULLEY (24T) (TAG P-281) SPRING (TAG P-281) IDLER VERTICAL TRANSPORT DRIVE BELT (73T) (TAG P-281) BRACKET PULLEY (P/O PL 8.1 Item 20) BRACKET VERTICAL TRANSPORT BELT KIT (TAG P-281)

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Parts List

PL 8.1

PL 8.2 VERTICAL TRANSPORT SUPPORTS Item

Part

Description

1 2 3 4 5 6 7 8

30K53681 30K53691 30K53701 15K535 6E1924 30K26790 32E2071 –

9

–

10

–

11

–

12

–

13

–

14 15

30K31752 600K34680

DUPLEX MAGNETIC STRIPS TRAY 1 MAGNETIC STRIPS TRAY 2 MAGNETIC STRIPS SUPPORT PLATE IDLER SHAFT BRACKET INSTALLATION GUIDE LATCH BRACKET (P/O OF PL 8.2 Item 15) SPRING BUSHING (P/O PL 8.2 Item 14) TORSION SPRING (P/O PL 8.2 Item 14) TRAY 1 LATCH (P/O PL 8.2 Item 14) PIVOT SHAFT (P/O PL 8.2 Item 14) HINGE BRACKET (P/O PL 8.2 Item 14) LATCH BRACKET DUPLEX PAPER GUIDE KIT (TAG P-510)

PL 8.10

Parts List

PL 8.2

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PL 8.3 REGISTRATION TRANSPORT ASSEMBLY (1 OF 3) Item

Part

Description

1

22K44881

2 – 3 4 5 6 7 8 9 10 11 12 13 –

50K31042 50K52890 50K5282 26P20800 55E34250 31K1650 3E3990 3E524 3E531 22K16940 409W1513 14E3321 30E4853 68E59360

14 15 16 17 18 19 20 21

32E621 125E420 116P1750 117S23170 30K13000 19E1971 30E4842 55K8820

22 23 24 25 26

19E3621 117K16410 130K29890 68E62990 68E63000

REGISTRATION TRANSPORT ASSEMBLY UPPER TRAY UPPER TRAY (TAG P-481) RIGHT TRAY SCREW SKI PAPER BAFFLE CROSS ROLL IDLER HANDLE HINGE HINGE SERVO PINCH ROLL SHAFT SPRING LIFT BLOCK SERVO NIP BRACKET SERVO NIP BRACKET(TAG P481) GUIDE STATIC BRUSH TERMINAL GROUND WIRE SPRING BRACKET SPRING CLIP BAFFLE SUPPORT LOWER RIGHT BAFFLE ASSEMBLY FLAT SPRING HARNESS (TAG P-481) SENSOR (TAG P-481) SENSOR BRACKET (TAG P-481) SENSOR BRACKET (TAG P-481)

PL 8.30

PL 8.4

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Parts List

PL 8.3

PL 8.4 REGISTRATION TRANSPORT ASSEMBLY (2 OF 3) Item

Part

Description

1

--

2 –

50K6104 50K17880

3 4 5 6 7 8

– 19E1110 38K11250 1K1110 130E342 127K17911

9 10

6K13290 423W59750

11 12 13 14 15 16 17

409W3185 22K16990 19E3390 55K403 9E9281 – 38K2189

REGISTRATION TRANSPORT ASSEMBLY (P/O PL 8.3 Item 1) LOWER TRAY ASSEMBLY LOWER TRAY ASSEMBLY (TAG P-481) CABLE CLAMP SPRING CLIP FRONT SUPPORT TRANSPORT STRIP SENSOR (Q861) SERVO MOTOR/ENCODER (MOT862) SERVO SHAFT REGISTRATION TRANSPORT DRIVE BELT (97T) SPRING IDLER ROLL RETAINER CLIP TURN BAFFLE ASSEMBLY SPRING REFLECTOR (P/O PL 8.4 Item 2) REGISTRATION GUIDE

PL 8.31

Common

Common

Parts List

PL 8.4

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PL 8.5 REGISTRATION TRANSPORT ASSEMBLY (3 OF 3) Item

Part

Description

1

--

2

121K2844

3

–

4 5 6 7 8

– 31K3011 419W201 – –

9 10 11 12 13 14 15 16 17

123K690 122P523 30K54370 – 9P4437 32P1726 – 125E420 –

REGISTRATION TRANSPORT ASSEMBLY (P/O PL 8.3 Item 1) CROSS ROLL SOLENOID ASSY (SOL861)(SOL862) SOLENOID BRACKET (P/O PL 8.5 Item 2) O-RING (P/O PL 8.5 Item 2) CROSS ROLL IDLER CABLE CLAMP IDLER BRACKET (REF: PL 8.11) NIP RELEASE SOLENOID (REF: PL 8.10) LIGHT ASSEMBLY LAMP LAMP SUPPORT IDLER BRACKET SPRING GUIDE PINCH SHAFT STATIC BRUSH BRUSH BRACKET

PL 8.32

PL 8.10

PL 8.11

PL 8.3

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Parts List

PL 8.5

PL 8.6 REGISTRATION TRANSPORT, JAM ACCESS HANDLE ASSEMBLY Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part

Description

30K16602 30K20730 130E1110 12E2120 12K971 12E1160 30K13940 409W3503 7E6500 3E3990 26P20802 9E8640 7E6510 413W35357 30K16730 – –

BRACKET ASSEMBLY BRACKET CROSS ROLL SENSOR (Q871) LINK NO. 3 LINK NO. 2 LINK NO. 1 BRACKET ASSEMBLY SPRING RATCHET (2 TEETH) HANDLE SCREW SPRING PAWL BEARING LINK MOUNT BRACKET BRACKET BRACKET

Parts List

PL 8.6

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Revision DocuPrint 180F Service Manual

PL 8.7 CROSS ROLLS DRIVE ASSEMBLY Item

Part

Description

1

–

2 –

127K14462 127E9532

3 4 5 6 7 8 9 –

702W933 1K7722 6K651 423W61550 6K661 423W63750 423W61950 –

10 11 12 13

6K671 19E4150 20E23191 –

CROSS ROLLS DRIVE ASSEMBLY CROSS ROLLS AC MOTOR CROSS ROLLS AC MOTOR (50HZ ONLY) CAPACITOR (C861) DRIVE FRAME SHAFT BELT (115T)(50HZ) SHAFT BELT (137T) BELT (119T)(50HZ) BELT (60HZ)(PART NUMBER SAME AS ITEM 6) SHAFT BEARING RETAINER CLIP PULLEY (32T)(50HZ) SPRING (P/O PL 8.7 Item 1, PL 8.7 Item 17 AND PL 8.7 Item 18) IDLER (P/O PL 8.7 Item 1 AND PL 8.7 Item 17) EXTENSION SPRING (60HZ) (TAG P-290) EXTENSION SPRING (50HZ) (TAG P-290) IDLER (P/O PL 8.7 Item 1) IDLER REPAIR KIT (ONE PER ORDER) IDLER REPAIR KIT (ONE PER ORDER) CROSS ROLLS KIT (3 PER ORDER)

14

–

15

409W2218

–

409W3216

16 17

– 600K24530

18

600K23050

19

600K7301

PL 8.7 PL 8.7 PL 8.7

PL 8.33

PL 8.7 PL 8.7

PL 8.7

Common

Common

Com mon Common Common

PL 8.7

PL 8.7

PL

CR OS

Com PL 8.7

PL 8.7 PL 8.7

PL 8.7

Com mon

PL 8.7

Com mon PL 8.7

Com mon PL 8.7

Common PL 8.7

PL 8.7 PL 8.7

EXT ENS

PL 8.7 Common

BEL T

PL 8.7

PL 8.7

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.7

PL 8.8 PREFUSER TRANSPORT AND PRETRANSFER BAFFLE Item

Part

Description

1

22K14502

2 3 4 5

30S51752 8E3210 15S7516 55K1491

6 7

– –

8 9

9P4889 –

10 11 12 13

8K961 30K1953 30K701 15K4761

PREFUSER TRANSPORT ASSEMBLY BRACKET ECCENTRIC PLATE PLATE PRETRANSFER BAFFLE ASSEMBLY SHAFT (P/O PL 8.8 Item 5) PRETRANSFER BAFFLE (P/O PL 8.8 Item 5) SPRING INNER BAFFLE (P/O PL 8.8 Item 5) INBOARD CAM BRACKET BRACKET PLATE

Parts List

PL 8.8

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Revision DocuPrint 180F Service Manual

PL 8.9 PREFUSER TRANSPORT ASSEMBLY Item

Part

Description

1

--

2 3 4 5

– 117K2450 30E2030 127P2347

6 7 8 9 10 11 12 13 14 15 16

– 130K42680 54K980 6K2100 2K26160 3E8491 120E200 6K300 120E1240 – –

17

–

18 19 20 21

15E3910 – 15E31230 –

PREFUSER TRANSPORT ASSEMBLY (P/O PL 8.8 Item 1) NUT (P/O PL 8.9 Item 1) GROUND WIRE MOUNTING BAR PREFUSER VACUUM MOTOR (MOT1001) CABLE CLAMP (P/O PL 8.9 Item 1) PREFUSER SENSOR (Q1009) MANIFOLD IDLER SHAFT COVER HANDLE (TAG P-259) OUTBOARD RETAINER DRIVE ROLL INBOARD RETAINER PREFUSER BELTS INBOARD BELT (P/O PL 8.9 Item 15) OUTBOARD BELT (P/O PL 8.9 Item 15) WIRE RETAINER AIR DUCT (P/O PL 8.9 Item 1) HANDLE PLATE GASKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.9

PL 8.10 NIP RELEASE SOLENOID ASSEMBLY Item

Part

Description

1

–

2

–

3

–

4 5 6 7

12K1792 12K2150 – 121E6000

8

–

9 10

31K3252 6K11112

11 12

600K57550 –

NIP RELEASE SOLENOID ASSEMBLY MOUNTING BRACKET (P/O PL 8.10 Item 1) CABLE (P/O PL 8.10 Item 10 AND PL 8.10 Item 11) IDLER LINK LINK PIN (P/O PL 8.10 Item 1) NIP RELEASE SOLENOID (SOL844) SPLIT BEARING (P/O PL 8.10 Item 1) ARM RE-REGISTRATION SHAFT ASSEMBLY CABLE/PIN KIT (W/ TAG P-282) PIN (P/O PL 8.10 Item 11)

Parts List

PL 8.10

PL 8.2

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Revision DocuPrint 180F Service Manual

PL 8.11 IDLER BRACKET ASSEMBLY Item 1 2 3 4 5

Part

Description

– 125E420 22K17670 9P4437 32E621

IDLER BRACKET STATIC BRUSH IDLER ROLLER SPRING GUIDE

PL 8.11

PL 8.11 Item 2

PL 8.11 Item 1

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.11

PL 8.12 HCT FEEDER ASSEMBLY COMPONENTS (1 OF 2) Item

Part

Description

1 2

22K50890 –

3

–

4 5 6 7 8 9 10 11

2E8490 27P506 110E460 – 30K41521 130K52680 – –

FEEDER ASSEMBLY (TAG P-63) FEED HEAD ASSEMBLY (P/O PL 8.12 Item 1) AIR KNIFE BRACKET (P/O PL 8.12 Item 1) SWITCH COVER NUT OVERTRAVEL SWITCH (S742) AIR KNIFE (P/O PL 8.12 Item 1) GATE BRACKET FEED SENSOR (Q857) ACTUATOR (P/O PL 8.12 Item 9) DAMPER BRACKET (P/O PL 8.12 Item 1)

Parts List

PL 8.12

11/00 5-90

Revision DocuPrint 180F Service Manual

PL 8.13 HCT FEEDER ASSEMBLY COMPONENTS (2 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 –

22K6781 19E5260 6K2970 30K27786 5E7481 38E9541 22K4871 117E6780 15E40000 600K8340 –

FEED HEAD ASSEMBLY (P/O PL 8.12 Item 1) FEED HEAD HOUSING BEARING CLIP DRIVE SHAFT PLENUM PLATE DRAG BRAKE CORRUGATOR IDLER SHAFT FLAT CONDUCTOR CABLE PLENUM SPACER FEED BELT KIT (6 PER KIT) FEED HEAD BELT (P/O PL 8.13 Item 1)

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.13

PL 8.14 HCT FEEDER COMPONENTS Item

Part

Description

1

127K17090

–

127K17100

2

702W11433

3 4 5 6 7 –

409W3191 22K14780 54K322 419W22950 35E390 35E6090

8 9 10 11

54E180 423W64650 423W71850 702W12233

FEEDER MAIN DRIVE MOTOR (MOT831)(60HZ) FEEDER MAIN DRIVE MOTOR (MOT831)(50HZ) CAPACITOR (10MFD START) (C830) SPRING IDLER VACUUM DUCT HOSE CLAMP O-RING BELT O-RING BELT (HIGH ALTITUDE ONLY) BLOWER HOSE SYNCH BELT (9MM WIDE) SYNCH BELT (9MM WIDE) CAPACITOR (20MFD RUN) (C831)

Parts List

PL 8.14

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Revision DocuPrint 180F Service Manual

PL 8.15 AIR SYSTEM DRIVE ASSEMBLY Item 1 2 3 4

Part

Description

127K4974 127K1570 127K2024 20K2280

AIR DRIVES ASSEMBLY BLOWER MOTOR (MOT832) HCF BLOWER MOTOR PULLEY (HIGH ALTITUDE ONLY) MOTOR PULLEY O-RING PULLEY SPRING BRACKET (P/O PL 8.15 Item 1) BRACKET (P/O PL 8.15 Item 1) FLAT SPRING (P/O PL 8.15 Item 1) PICKOFF LINK EXTENSION SPRING WASHER (P/O PL 8.15 Item 1) BUSHING (P/O PL 8.15 Item 1) IDLER BRACKET CLUTCH BRACKET BLOCK HCT FEED CLUTCH (CL831) WEAR COUPLING BLOWER MOTOR CAPACITOR (C832) MOUNTING BRACKET (P/O PL 8.15 Item 1) O-RING BELT O-RING BELT (HIGH ALTITUDE ONLY) HIGH ALTITUDE PULLEY AND BELT KIT

– 5 6 7 8 9

20K320 20E4840 9E24900 – – –

10 11 12 13 14 15 16 17 18 19

12K3562 9E12320 – – 30K55200 30K23360 14K2700 121K3380 5E1533 702W11533

20

–

21 –

35E390 35E6090

22

98K2950

PL PL 8.1 PL 8.15

PL 8.15

PL 8.15 Com PL 8.15

PL 8.15

PL 8.15

PL 8.15

Com PL 8.15 mon

Revision

PL 8.1 Com mon PL 8.15

Com mon

PL 8.15

PL 8.15 PL 8.15

PL 8.15 PL PL 8.15 8.15

Co MO mm TO

Com mon

11/00 5-93

Co mm

PL 8.15

Co mm

PL 8.15 Co mm

PL 8.15

DocuPrint 180F Service Manual

Com mon

PL 8.15

Co PL mm 8.15 PL 8.15

PL 8.15

PL 8.15

Co mm PL 8.15

PL 8.15

Parts List

PL 8.15

PL 8.16 VERTICAL TRANSPORT ASSEMBLY Item

Part

Description

1

22K45480

2 3

– 22K7245

VERTICAL TRANSPORT ASSEMBLY SLIDE LOWER TURN TRANSPORT ASSEMBLY

Parts List

PL 8.16

11/00 5-94

Revision DocuPrint 180F Service Manual

PL 8.17 VERTICAL TRANSPORT COMPONENTS (1 OF 2) Item

Part

Description

1

--

2

–

3 4 5 6 7

– 413W10555 6E10471 9E11661 –

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

152K15784 130K40412 30E29700 6K4293 413W10355 15E7131 6E10461 3E3990 12K1683 6K4272 6K15130 125E420 413W15355 6E10481 6K15150 6K15140

VERTICAL TRANSPORT ASSEMBLY (P/O PL 8.16 Item 1) VERTICAL TRANSPORT FRAME (P/O PL 8.17 Item 1) SLIDE PAD (P/O PL 8.17 Item 1) BEARING CATCH SHAFT CATCH SPRING PLATE SPRING PLATE (P/O PL 8.17 Item 1) JAM HARNESS SENSOR (Q832) SWITCH BRACKET DRIVE SHAFT SLEEVE SPLIT BEARING SHAFT LINK LATCH SHAFT HANDLE FRONT LATCH DRIVE SHAFT DRIVE SHAFT GROUND BRUSH SPLIT BEARING BAFFLE SHAFT TAR SHAFT ASSEMBLY SHAFT

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.17

PL 8.18 VERTICAL TRANSPORT COMPONENTS (2 OF 2) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

6E10040 9P4417 55K3923 117S23171 32E1471 117S23172 – 32P1726 12E2310 9P4437 409W3094 125E420 55K3934 28E3100 423W80050 22K14780 22K14810 409W3338 22K11292 22K16450 –

VERTICAL TRANSPORT ASSEMBLY (P/O PL 8.16 Item 1) VERTICAL TRANSPORT FRAME (P/O PL 8.18 Item 1) PIVOT SHAFT TORSION SPRING UPPER PIVOT BAFFLE WIRE TURN GUIDE WIRE ROLLER (P/O PL 8.18 Item 21) GUIDE REAR LATCH ARM EXTENSION SPRING EXTENSION SPRING BRUSH LOWER PIVOT BAFFLE RETAINER BELT (300G) ROLLER ROLLER EXTENSION SPRING ROLLER ASSEMBLY ROLLER IDLER PLATE (P/O PL 8.18 Item 1)

Parts List

PL 8.18

11/00 5-96

Revision DocuPrint 180F Service Manual

PL 8.19 LOWER TURN TRANSPORT ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

– 55E5580 125E420 30E68570 6K4243 28E3100 3E3990 420W10701 117S23171 9P4417 – 32P1726 22K11292 409W3094 152K15774 130K40412

18 19 20 21 22 23

30E29700 29E10710 55K3893 6E10040 22K16450 –

LOWER TURN TRANSPORT ASSY (P/O PL 8.16 Item 3) FRAME (P/O PL 8.19 Item 1) BAFFLE BRUSH BRACKET DRIVE SHAFT RETAINER HANDLE CABLE TIE WIRE SPRING ROLLER (P/O PL 8.19 Item 14) GUIDE ROLLER ASSEMBLY SPRING HARNESS TURN BAFFLE TRANSPORT SENSOR (Q853) BRACKET SPACER PIVOT BAFFLE PIVOT SHAFT ROLLER IDLER PLATE (NOT SPARED)

Revision DocuPrint 180F Service Manual

11/00 5-97

Parts List

PL 8.19

PL 8.20 FS HORIZONTAL TRANSPORT ASSEMBLY Item 1 2 3 4 5 6 7 8 9 10

Part

Description

423W78150 423W62850 12E4610 22K6933 30K34970 22K6924 123K1650 122P523 103K380 30K38401

BELT BELT LINK SPRING INTERFACE TRANSPORT BRACKET H2 TRANSPORT LIGHT HOUSING LAMP RESISTOR BRACKET

Parts List

PL 8.20

11/00 5-98

Revision DocuPrint 180F Service Manual

PL 8.21 FS HORIZONTAL TRANSPORT COMPONENTS (1 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

– 6K7961 6K5123 6K5113 125E420 30E62752 30K34101 30K35111 3E3990 30K34080 30K34092 12E4530 413W15155 29P4240 409W1369 28E3100

FS HORIZONTAL TRANSPORT ASSY (P/O PL 8.20 Item 6) FRAME (P/O PL 8.21 Item 1) INPUT DRIVE SHAFT H1 DRIVE SHAFT (S) H1 DRIVE SHAFT (D) BRUSH BRACKET LH BASE SUPPORT RH BASE SUPPORT HANDLE PIVOT BRACKET HANDLE BRACKET LINK BEARING PIVOT SPRING RETAINER

Revision DocuPrint 180F Service Manual

11/00 5-99

Parts List

PL 8.21

PL 8.22 FS HORIZONTAL TRANSPORT COMPONENTS (2 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14 15

– 55K3674 3E2741 117S23170 – 32P1726 23E5910 409W3094 125E420 409W3338 22K14830 22K11292 22K16450 –

16 17 18

– 22K17830 28E3100

FS HORIZONTAL TRANSPORT ASSEMBLY (P/O PL 8.20 Item 6) FRAME (P/O PL 8.22 Item 1) BAFFLE HINGE WIRE ROLLER (P/O PL 8.22 Item 13) GUIDE BELT SPRING BRUSH SPRING IDLER BRACKET ROLLER ASSEMBLY ROLLER IDLER PULLEY (30T) (P/O PL 8.22 Item 1) IDLER PLATE (P/O PL 8.22 Item 1) BELT IDLER RETAINER

Parts List

PL 8.22

11/00 5-100

Revision DocuPrint 180F Service Manual

PL 8.23 INTERMEDIATE HORIZONTAL TRANSPORT Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10

– 6K4033 28E3100 55K3654 – 6E21700 152K15754 30E36691 130K40412

11 12 13 14 15 16

– 125E420 409W3094 22K11292 – 32P1726

FS INTERFACE TRANSPORT ASSY (P/O PL 8.20 Item 4) FRAME (P/O PL 8.23 Item 1) DRIVE SHAFT RETAINER BAFFLE BRACKET (P/O PL 8.23 Item 1) SHAFT HARNESS BRACKET HORIZONTAL TRANSPORT SENSOR (Q854) BRACKET (P/O PL 8.23 Item 1) BRUSH SPRING ROLLER ASSEMBLY ROLLER (P/O PL 8.23 Item 14) GUIDE

Revision DocuPrint 180F Service Manual

11/00 5-101

Parts List

PL 8.23

PL 8.24 LOWER PREREGISTRATION TRANSPORT ASSEMBLY Item

Part

Description

1

22K8695

2

423W78150

IFS INPUT PRE-REG TRANSPORT BELT

Parts List

PL 8.24

11/00 5-102

Revision DocuPrint 180F Service Manual

PL 8.25 LOWER PREREGISTRATION TRANSPORT COMPONENTS (1 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7

– 6K5013 12E3481 125E420 30E36691 130K40412

8 9

152K15764 –

10 11 12 13 14 15 16 17 18

– 22K56250 – – 423W8050 409W3338 22K14850 – –

19 20 21

– 14K1603 28E3100

IFS INPUT PRE-REG TRANSPORT ASSEMBLY (P/O PL 8.24 Item 1) FRAME (P/O PL 8.25 Item 1) HARDNIP SHAFT FLEXIBLE CABLE BRUSH BRACKET PRE-REGISTRATION SENSOR (Q850) HARNESS DRIVE SHAFT (P/O PL 8.26 Item 18) SHAFT (P/O PL 8.26 Item 18) CORRUGATOR ROLL RETAINER (P/O PL 8.26 Item 18) RETAINER (P/O PL 8.26 Item 18) BELT SPRING IDLER BRACKET HOUSING (P/O PL 8.26 Item 18) IDLER PLATE (P/O PL 8.25 Item 17) ROLLER (P/O PL 8.25 Item 17) BLOCK RETAINER

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.25

PL 8.26 LOWER PREREGISTRATION TRANSPORT COMPONENTS (2 OF 2) Item

Part

Description

1

--

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

– 55K19560 30K21780 3E2741 117S23170 409W1249 413W15155 12E2661 30E36721 29P4240 3E3990 4P101 22K11292 – 32P1726 21P744 55K4533 9E14420 6E8311 22E3321 55K5190 409W3094 27P1160 68E14330 4E300

IFS INPUT PRE-REG TRANSPORT ASSEMBLY (P/O PL 8.24 Item 1) FRAME (P/O PL 8.26 Item 1) PIVOT BAFFLE PIVOT BRACKET HINGE WIRE SPRING BEARING LINK PIVOT FRAME BRACKET PIVOT HANDLE BUMPER ROLLER ASSEMBLY ROLLER (P/O PL 8.26 Item 14) GUIDE TUBE CAP BAFFLE ASSEMBLY CROSS ROLL SPRING SHAFT ROLLER REG BAFFLE SPRING NUT PIVOT BRACKET BUMPER

Parts List

PL 8.26

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Revision DocuPrint 180F Service Manual

PL 8.27 IFS HORIZONTAL TRANSPORT ASSEMBLY Item

Part

Description

1

22K9074

2 3 4 5 6

423W78150 123K1650 122P523 103K380 30K38401

IFS HORIZONTAL TRANSPORT ASSEMBLY BELT LIGHT HOUSING LAMP RESISTOR BRACKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.27

PL 8.28 IFS HORIZONTAL TRANSPORT COMPONENTS (1 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14 15

– 30K35111 30K34101 125E420 152K21614 28E3100 6K5113 6K7961 – 22K14830 22K17830 423W59750 409W3338 423W64050

IFS HORIZONTAL TRANSPORT ASSEMBLY (P/O PL 8.27 Item 1) FRAME (P/O PL 8.28 Item 1) RH SUPPORT LH SUPPORT BRUSH HARNESS RETAINER DRIVE SHAFT INPUT SHAFT BRACKET (P/O PL 8.28 Item 1) IDLER BRACKET IDLER BRACKET BELT SPRING BELT

Parts List

PL 8.28

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Revision DocuPrint 180F Service Manual

PL 8.29 IFS HORIZONTAL TRANSPORT COMPONENTS (2 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14

– 55K4713 117S23170 3E2741 125E420 – 32P1726 22K11292 9E6360 22K12292 31E1401 12E2200 –

15 16 17 18 19 20 21

30K23840 413W15155 12E4530 409W1369 409W3094 29P4240 130K40412

22 23 24 25

30E62752 3E3990 30K34092 30K34080

IFS HORIZONTAL TRANSPORT ASSEMBLY (P/O PL 8.27 Item 1) FRAME (P/O PL 8.29 Item 1) PIVOT BAFFLE WIRE HINGE BRUSH ROLLER (P/O PL 8.29 Item 9) GUIDE ROLLER ASSEMBLY SPRING ROLLER YOKE LINK TRAY 3 OVERSIZE NIP RELEASE SOLENOID (SOL852) BRACKET BEARING LINK SPRING SPRING PIVOT TRAY 3 HORIZONTAL TRANSPORT SENSOR (Q854) BRACKET HANDLE HANDLE BRACKET PIVOT BRACKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 8.29

PL 8.30 REGISTRATION TRANSPORT ASSEMBLY (1 OF 3) Item

Part

Description

1

22K59400

2 3 4 5

50K34720 50K22620 26P20800 –

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

31K1650 3E3990 3E524 3E531 22K16940 409W1513 14E3321 49E6350 32E621 125E420 116P1750 117S23170 68K6390 19E1971 30E4842 55K8820

22 23 24

19E3621 31K5120 55E34250

REGISTRATION TRANSPORT ASSEMBLY UPPER TRAY RIGHT TRAY SOCKET FLAT HEAD SCREW LOWER TRAY (P/O PL 8.30 Item 21) CROSS ROLL IDLER HANDLE HINGE HINGE SERVO IDLER ROLLER COMPRESSION SPRING LIFT BLOCK SERVO NIP BRACKET GUIDE STATIC BRUSH TERMINAL GROUND WIRE SPRING BRACKET SPRING CLIP BAFFLE SUPPORT LOWER RIGHT BAFFLE ASSEMBLY FLAT SPRING PASSIVE IDLER (SKI) PAPER BAFFLE

PL 8.3

PL 8.31

Parts List

PL 8.30

11/00 5-108

Revision DocuPrint 180F Service Manual

PL 8.31 REGISTRATION TRANSPORT ASSEMBLY (2 OF 3) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14

50K19510 419W201 19E1110 30K51670 1K46540 130E342 127K17911 6K13290 423W60650 409W3185 22K16990 19E3390 55K403

15 16 17

9E9281 62S1792 38K9530

REGISTRATION TRANSPORT ASSEMBLY (P/O PL 8.30 Item 1) LOWER TRAY CABLE CLAMP SPRING CLIP FRONT SUPPORT TRANSPORT STRIP SENSOR SERVO MOTOR/ENCODER SERVO SHAFT BELT (106T) EXTENSION SPRING IDLER BRACKET RETAINER CLIP TURN BAFFLE ASSEMBLY (W/ TAG P-163) SPRING REFLECTOR REGISTRATION GUIDE

Revision DocuPrint 180F Service Manual

PL 8.4

11/00 5-109

Parts List

PL 8.31

PL 8.32 REGISTRATION TRANSPORT ASSEMBLY (3 OF 3) Item

Part

Description

1

--

2 3 4 5 6 7 8 9

32P1726 125E420 – – – 9P4437 121K8250 121K8280

10 11 12 13

31K5000 31K4980 – –

14 15 16 17 18 19

– 419W201 123K690 122P523 30K54370 –

20

–

REGISTRATION TRANSPORT ASSEMBLY (P/O PL 8.30 Item 1) GUIDE STATIC BRUSH PINCH SHAFT IDLER BRACKET BRUSH BRACKET SPRING SOLENOID ASSEMBLY (SOL862) DUAL LIFT SOLENOID ASSEMBLY (SOL861) CROSS ROLLS IDLER CROSS ROLLS IDLER BRACKET (P/O PL 8.32 Item 9) DUAL IDLER LINK (P/O PL 8.32 Item 9) BRACKET (P/O PL 8.32 Item 8) CLAMP LIGHT ASSEMBLY LAMP LAMP SUPPORT NIP RELEASE SOLENOID (REFER PL 8.10) IDLER BRACKET (REFER PL 8.11)

PL 8.5

PL 8.10

PL 8.11

PL 8.30

Parts List

PL 8.32

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Revision DocuPrint 180F Service Manual

PL 8.33 CROSS ROLLS DRIVE ASSEMBLY Item

Part

Description

1

–

2 3 – 4

1K64610 127E9532 127K14462 600K7301

5 6 7 8 9

6K13390 6K13380 6K661 6K671 –

10

–

11 12

22K37810 –

13 14 15 – 16 17 18 19 20 21 22 – 23

9E58240 19E4150 423W61550 423W61950 423W60650 423W63750 423W56950 702W933 600K24530 600K23050 409W2218 409W3216 20E23191

CROSS ROLLS DRIVE ASSEMBLY U CHANNEL FRAME AC MOTOR (50HZ) AC MOTOR (60HZ) CROSS ROLLS KIT (3 PER KIT)(ORDER 2 KITS) SHAFT (NO. 1) SHAFT (NO. 1A) SHAFT (NO. 2) SHAFT (NO. 3) IDLER ROLL (P/O PL 8.33 Item 1 AND PL 8.33 Item 20) IDLER ROLLS (P/O PL 8.33 Item 1 AND PL 8.33 Item 21) FIXED IDLER EXTENSION SPRING (P/O PL 8.33 Item 1, PL 8.33 Item 20 AND PL 8.33 Item 21) EXTENSION SPRING RETAINER CLIP BELT (115T)(60HZ) BELT (119T)(50HZ) BELT (106T) BELT (137T) BELT (69T) CAPACITOR (C861) IDLER REPAIR KIT (1 PER KIT) IDLER REPAIR KIT (1 PER KIT) EXTENSION SPRING (60HZ) EXTENSION SPRING (50HZ) PULLEY (32T)(50HZ)

Revision DocuPrint 180F Service Manual

PL 8.7

11/00 5-111

Parts List

PL 8.33

PL 9.1 PR MODULE ASSEMBLY AND DRAWER ASSEMBLY Item

Part

Description

1

64K1470

2 3 4

1R538 117K3661 50K7152

PR MODULE ASSEMBLY (TAG P317) PHOTORECEPTOR BELT RIBBON CABLE DRAWER ASSEMBLY

Parts List

PL 9.1

11/00 5-112

Revision DocuPrint 180F Service Manual

PL 9.2 PR MODULE COMPONENTS (1 OF 4) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15 16

30K17310 130K29910 55K8010 9P5213 2E2621 22K7893 2P11063 – 33E1420 55K8120 – 26E10930 9E24611 –

17

–

18

15E16110

PR MODULE ASSEMBLY (P/O PL 9.1 Item 1) PR MODULE FRAME (P/O PL 9.2 Item 1) BRACKET BELT HOLE LED (CR901) LIGHT SHIELD LEAF SPRING BEARING HOUSING CLEANER ZONE ROLL HOUSING BEARING SCREW (P/O PL 9.2 Item 1) CAM BLADE LIGHT SHIELD SCREW (P/O PL 9.2 Item 1) SCREW SPRING REAR BRACKET (P/O PL 9.2 Item 1) FRONT BRACKET (P/O PL 9.2 Item 1) RAMP

Revision DocuPrint 180F Service Manual

PL 9.2

11/00 5-113

Parts List

PL 9.2

PL 9.3 PR MODULE COMPONENTS (2 OF 4) Item

Part

Description

1

--

2

–

3 4 5 6 7 8

22K10860 28E1812 22K16741 32E83 2E37450 –

9

146K262

10 11 12 13 14 15 16 17 18 19

28E3930 25K592 29E25490 130K29920 28E4710 26E7930 2E36950 122K391 110P2823 62K5310

20 21 22

33E2400 35E12920 600K88610

23

600K88270

PR MODULE ASSEMBLY (P/O PL 9.1 Item 1) PR MODULE FRAME (P/O PL 9.3 Item 1) PR DRIVE ROLL SHOULDER WASHER STRIPPER ROLL GUIDE REAR HOUSING PR DRIVE COUPLING (P/O PL 9.3 Item 1, PL 9.3 Item 22, PL 9.3 Item 23) MACHINE CLOCK SENSOR (Q401) BEARING RETAINER STRIPPER FINGER ASSEMBLY KEY (3X3X8) POP SENSOR (Q904) WAVE WASHER SHAFT FRONT SUPPORT PRETRANSFER LAMP (DS901) LAMP TEST SWITCH (S901) PRETRANSFER LAMP REFLECTOR (P/O PL 9.3 Item 1) 5 MIL SEAL GASKET PR CONSTANT VELOCITY DRIVE KIT (TAG P-317) CONSTANT VELOCITY DRIVE REPAIR KIT (TAG P-317)

Parts List

PL 9.3

11/00 5-114

Revision DocuPrint 180F Service Manual

PL 9.4 PR MODULE COMPONENTS (3 OF 4) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10

– 122K391 2E36950 62K5310 19E4991 – 22K7893 9E1560 2E28100

–

2E28110

–

2E28120

–

2E28130

– –

802E17850 802E17860

–

802E17870

–

802E17880

–

802E17890

–

802E17900

– 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

2E2621 600K25820 11K1700 11K1710 68E9000 – 409W3330 – 35E12920 30E28321 30E24800 29E5960 116P20301 140K9561 – 600K75880 152K3568 600K71401

PR MODULE ASSEMBLY (P/O PL 9.1 Item 1) FRAME (P/O PL 9.4 Item 1) PRECHARGE LAMP (DS902) FRONT SUPPORT REFLECTOR OCCLUDER ROLL CAM (P/O PL 9.4 Item 1) DEVELOPER ZONE ROLL DEVELOPER SPRING BEARING HSG (YELLOW, MINUS 1)(TAG P-488) BEARING HSG (VIOLET, MINUS 2)(TAG P-488) BEARING HSG (BROWN, PLUS 1)(TAG P-488) BEARING HSG (GRAY, PLUS 2)(TAG P-488) BEARING HSG (IB WHITE) (MICR) BEARING HSG (IB YELLOW) (MICR) BEARING HSG (IB VIOLET) (MICR) BEARING HOUSING (OB BROWN) (MICR) BEARING HSG (OB GRAY) (MICR) BEARING HSG (OB WHITE) (MICR) BEARING HSG (WHITE, 0) MECHANICAL SUPPORT KIT LEVER ARM LEVER LATCH BRACKET LABEL (P/O PL 9.4 Item 1) SPRING NUT (P/O PL 9.4 Item 11) GASKET BRACKET BRACKET RETAINER PIN STANDOFF DISCHGE LAMPS PWB, (PS902) REAR CAP (P/O PL 9.4 Item 1) BEARING HSG KIT (MICR ONLY) BELT MODULE HARNESS TRIMBAR KIT (TAG P-488)

Revision DocuPrint 180F Service Manual

PL 9.6

PL 9.4 Item 27

PL 9.16 Item 3

11/00 5-115

Parts List

PL 9.4

PL 9.5 PR MODULE COMPONENTS (4 OF 4) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14

30K14341 30K14351 32E150 9E43230 32K310 12K140 22S5602 32E892 3K1341 – 12E470 30K7320

PR MODULE ASSEMBLY (P/O PL 9.1 Item 1) PR MODULE FRAME (P/O PL 9.5 Item 1) RIGHT BRACKET PULLEY SPRING GUIDE PR TENSION SPRING PR EDGE GUIDE PR TENSION CABLE PR TENSION ROLL PR EDGES GUIDES PR TENSION RELEASE HANDLE BRACKET (P/O PL 9.5 Item 1) CONNECTING ROD BRACKET

Parts List

PL 9.5

11/00 5-116

Revision DocuPrint 180F Service Manual

PL 9.6 DRAWER ASSEMBLY COMPONENTS (1 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7

20E1470 29E8921 30K22841 30E44731 12K1510 –

8 9 10 11 12

14E15140 32E2240 30K22821 – –

13

–

14

–

15 16 17 18 19 20

– – 6K3291 30E47690 10K1660 10K1631

DRAWER ASSEMBLY (P/O PL 9.1 Item 4) PULLEY PIN ARM LOCK PUSH ARM ARM DRAWER LATCH CABLE MANIFOLD BRACKET (P/O PL 9.6 Item 1) SPACER PLATE GUIDE PIVOT ARM BRACKET (P/O PL 9.6 Item 1) DRAWER FRAME (P/O PL 9.6 Item 1) AIR MANIFOLD BRACKET (P/O PL 9.6 Item 1) EXTENSION SPRING (P/O KIT PL 9.4 Item 11) LINK (P/O KIT PL 9.4 Item 11) PAWL (P/O KIT PL 9.4 Item 11) SHAFT BRACKET RH SLIDE SLIDE

Revision DocuPrint 180F Service Manual

11/00 5-117

Parts List

PL 9.6

PL 9.7 DRAWER ASSEMBLY COMPONENTS (2 OF 2) Item

Part

Description

1

--

2

130K45660

3 4 5 6 7 8 9 10 11

9E16610 115E2200 130K49300 50K7171 30K31641 30K17330 30K25251 30E44490 –

12

–

13

–

14

–

15 16 17 18 19

– 120E500 152K3577 130K59360 32E2240

DRAWER ASSEMBLY (P/O PL 9.1 Item 4) WASTE BOTTLE FULL SENSOR (Q906) SPRING PR GROUND BRUSH BELT HOLE SENSOR (Q901) BLADE CAM RECEPTACLE BRACKET BRACKET HANDLE BRACKET DRAWER FRAME (P/O PL 9.7 Item 1) SENSOR BRACKET (P/O PL 9.7 Item 1) ARM LOCK LATCH (P/O PL 9.7 Item 1) TONER LEVEL BRACKET (P/O PL 9.7 Item 1) IRD BRACKET (P/O PL 9.7 Item 1) CABLE TIE HARNESS IRD PLATE GUIDE

Parts List

PL 9.7

11/00 5-118

Revision DocuPrint 180F Service Manual

PL 9.8 ENVIRONMENTAL COMPONENTS Item

Part

Description

1 2 2A 2B

53E950 – 127K6321 –

3 4

702W9822 702W229

5 6 7 7A

702W1529 30E15840 119K190 600K24340

8 9 10 11 12

120P562 – – – 114K281

13 14

114K271 114K261

15 – 16 17 –

117K6371 117K28350 419W3250 35E13720 –

18

117K27730

CAVITY COOLING FILTER CABLE ADAPTER KIT CAVITY COOLING FAN (MOT105) CABLE ADAPTER (P/O PL 9.8 Item 2) CAPACITOR BOOT OZONE BLOWER CAPACITOR (C901) CAPACITOR BRACKET BRACKET OZAC DUCT (TAG P-287) OZAC REPAIR KIT (CLAMP, 2 ORINGS, SPLIT SHELL HOSE)(NOT SHOWN) CABLE TIE BRACKET BUMPER MOUNT BRACKET CONNECTOR (CHARGE 1) CONNECTOR (CHARGE 2) CONNECTOR (PRECLEAN) CONNECTOR (DETACK) CONNECTOR (TRANSFER) HVDC SPIDER CABLE HVD SPIDER CABLE CLAMP O-RING GASKET O-RING GASKET KIT (6 PER ORDER) OZAC HARNESS ASSEMBLY

PL 9.9

PL 1.7

Revision DocuPrint 180F Service Manual

11/00 5-119

Parts List

PL 9.8

PL 9.9 OZONE FILTER ASSEMBLY Item

Part

Description

1 2 3

53K861 110E1130 127E2801

4 5

53K72 –

OZONE FILTER ASSEMBLY OZONE VACUUM SWITCH (S902) OZONE BLOWER MOTOR (MOT904) OZONE FILTER GROMMET (P/O PL 9.9 Item 1)

Parts List

PL 9.9

11/00 5-120

Revision DocuPrint 180F Service Manual

PL 9.10 DICOROTRONS Item

Part

Description

1 2 3 4

55K10310 52E5590 130K54110 48K78750

5

48K56790

6 7 8

1K45620 – –

DICOROTRON SHIELD AIR FITTING PATCH GENERATOR CHG 1 DICOR (NO WIRE) CHG 2 DICOR (NO WIRE) PRECLEAN DICOR (NO WIRE) DICOROTRON WIRE REPLACEMENT CHARGE SUPPORT (TAG P-287) SCREW STOP SCREW

Revision DocuPrint 180F Service Manual

PL 1.7

11/00 5-121

Parts List

PL 9.10

PL 9.11 TRANSFER ASSIST DEVICE AND DETACK DICOROTRON Item

Part

Description

1

802K19830

2 3 4

– 55K10310 33K3010

– – –

33K2261 33K2291 33K3440

–

33K3360

5

33K2280

–

33K2250

–

33K2270

6

32E3440

DETACK DICOR, TRANSFER DICOR (NO WIRE) DETACK GUIDE DICOROTRON SHIELD TRANSFER BLADE (60HZ ONLY)(FX) TRANSFER BLADE (60HZ ONLY) TRANSFER BLADE (50HZ ONLY) TRANSFER BLADE (50HZ)(TAG P-318) TRANSFER BLADE (60HZ)(TAG P-318) TRANSFER ASSIST DEVICE (60HZ)(FX) TRANSFER ASSIST DEVICE (60HZ) TRANSFER ASSIST DEVICE (50HZ) TRANSFER BLADE TOOL

Parts List

PL 9.11

11/00 5-122

Revision DocuPrint 180F Service Manual

PL 9.12 TRANSFER ASSIST DEVICE COMPONENTS Item

Part

Description

1

--

2

–

3 4

3E11310 –

5

–

6

–

7

–

8 9 10

117K22930 120E500 130E500

11 12 13

9E23900 9E23910 –

14 15

– 121K5041

16

–

17 18

– 121K9911

19 20

16E6381 14E17262

TRANSFER ASSIST DEVICE (P/O PL 9.11 Item 5) ACTUATOR LEVER (P/O PL 9.12 Item 1) KNOB SOLENOID BRACKET (P/O PL 9.12 Item 1) SOLENOID CLIP (P/O PL 9.12 Item 1) SOLENOID CLIP (P/O PL 9.12 Item 1) STOP BRACKET (P/O PL 9.12 Item 1) GROUND WIRE CABLE TIE TRANSFER BLADE SENSOR (Q907) COMPRESSION SPRING COMPRESSION SPRING SOLENOID PLUNGER (P/O PL 9.12 Item 15) SOLENOID (P/O PL 9.12 Item 15) TRANSFER 2 SOLENOID ASSEMBLY (SOL905) TRANSFER 3 SOLENOID ASSEMBLY (SOL906) TRANSFER 4 SOLENOID ASSEMBLY (SOL904) SOLENOID PLUNGER (P/O PL 9.12 Item 18) SOLENOID (P/O PL 9.12 Item 18) TRANSFER 1 SOLENOID ASSEMBLY (SOL903) PIVOT BUSHING PIVOT BLOCK

Revision DocuPrint 180F Service Manual

11/00 5-123

Parts List

PL 9.12

PL 9.13 DEVELOPER ASSEMBLY Item

Part

Description

1

600K53635

–

600K71952

2

–

3 4 5 6 –

52E5490 54E2050 – 94K1212 94K3052

7 8 9 10 11

2E36140 50E4621 – 93K310 3E5380

DEVELOPER ASSEMBLY KIT (TAG P-315) DEVELOPER ASSEMBLY KIT (MICR ONLY)(TAG P-315) DEVELOPER HOUSING (P/O PL 9.13 Item 1) EXHAUST TUBE VACUUM MANIFOLD TONER BOTTLE TONER DISPENSER ASSEMBLY TONER DISPENSER (MICR ONLY) ROLL COVER DEVELOPER CATCH TRAY CLAMP DEVELOPER DUMP TRAY DEVELOPER CRANK

Parts List

PL 9.13

11/00 5-124

Revision DocuPrint 180F Service Manual

PL 9.14 DEVELOPER HOUSING ASSEMBLY (1 OF 5) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

– 152K21681 15E9820 7E7221 8E2660 7K461 5K651 7K441 7K3721 419W201 7E2211 7E2231 55E5280 7K2371 116E3780 15E9810 15E11110 16E4650

DEVELOPER ASSEMBLY (P/O PL 9.13 Item 1) DEVELOPER HOUSING (P/O PL 9.14 Item 1) BUSHING (P/O PL 9.14 Item 1) HARNESS ROLLS 1 @ 2 BIAS PLATE GEAR (31T) CAM GEAR (40T) CAM FOLLOWER GEAR (54T) GEAR (54T/17HEX) CLAMP GEAR (31T) GEAR (40T) GEAR GUARD GEAR (40/59T) CONTACT BIAS WIRE TRIM BAR BIAS PLATE ROLL 3 BIAS PLATE SPACER

Revision DocuPrint 180F Service Manual

11/00 5-125

Parts List

PL 9.14

PL 9.15 DEVELOPER HOUSING ASSEMBLY (2 OF 5) Item

Part

Description

1

--

2

–

3 –

19K800 19K5130

4 5 6 7 – 8 9 10 –

19E5700 5K1790 35K2220 15K46190 15K25942 22K59551 13K1681 22K59970 22K64590

11 12 13 14

22K59960 22K53381 35K4130 --

15

--

16

--

DEVELOPER ASSEMBLY (P/O PL 9.13 Item 1) DEVELOPER HOUSING (P/O PL 9.15 Item 1) REAR BEARING CLAMP REAR BEARING CLAMP (MICR ONLY) ROLL 3 REAR BEARING CLAMP CLUTCH PR GROUND CLEANER TOP PLATE (MICR ONLY) TOP PLATE BRD ROLL OUTBOARD BEARING DEVELOPER ROLL 3 DEVELOPER ROLL 3 (MICR ONLY) DEVELOPER ROLL 2 DEVELOPER ROLL 1 SEAL SET (OUTBOARD) OUTBOARD SEAL NO. 1 (P/O PL 9.15 Item 7, PL 9.15 Item 13) OUTBOARD SEAL NO. 2 (P/O PL 9.15 Item 7, PL 9.15 Item 13) OUTBOARD SEAL NO. 3 (P/O PL 9.15 Item 7, PL 9.15 Item 13)

Parts List

PL 9.15

PL 9.15

PL 9.15 PL 9.15

11/00 5-126

PL PL 9.15

Revision DocuPrint 180F Service Manual

PL 9.16 DEVELOPER HOUSING ASSEMBLY (3 OF 5) Item

Part

Description

1

--

2

–

3

–

4 5 6 7 8 9

25E10 413W21054 21K2030 21E1780 94K3360 7E7301

DEVELOPER ASSEMBLY (P/O PL 9.13 Item 1) DEVELOPER HOUSING (P/O PL 9.16 Item 1) TRIM BAR CAP (P/O PL 9.4 Item 27) TRIMMER BAR BEARING REAR AUGER CAP BEARING CAP MIXING AUGER GEAR (29T)

Revision DocuPrint 180F Service Manual

11/00 5-127

Parts List

PL 9.16

PL 9.17 DEVELOPER HOUSING ASSEMBLY (4 OF 5) Item

Part

Description

1

--

2

–

3 4 5 6

35S3731 2K8451 – 35E59720

7

3K2851

DEVELOPER ASSEMBLY (P/O PL 9.13 Item 1) DEVELOPER HOUSING (P/O PL 9.17 Item 1) DOOR SEAL DUMP DOOR REAR PLATE (P/O PL 9.17 Item 1) INBOARD SEAL (BEAD CARRYOUT SEAL) LATCH

Parts List

PL 9.17

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PL 9.18 DEVELOPER HOUSING ASSEMBLY (5 OF 5) Item

Part

Description

1

--

2

–

3

600K59282

4 – 5

33K3390 33K3380 –

6 7

7E2221 –

8

--

9 10 11 12 13

– 21E1800 5E14860 – –

DEVELOPER ASSEMBLY (P/O PL 9.13 Item 1) DEVELOPER HOUSING (P/O PL 9.18 Item 1) PADDLE WHEEL SHAFT KIT (TAG P-315) PADDLE WHEEL (TAG P-315) PADDLE WHEEL (ALTERNATE) PADDLE WHEEL SHAFT (P/O PL 9.18 Item 3) GEAR (86T) CAP BEARING (P/O PL 9.18 Item 3) CAP MAGNET (P/O PL 9.18 Item 3) AUGER (P/O PL 9.18 Item 3) REAR CAP DRIVE COUPLING DRIVE KEY (P/O PL 9.18 Item 3) KEY HOLDER SPRING (P/O PL 9.18 Item 3)

PL 9.18 PL 9.18

PL 9.18

PL 9.18 PL Item 9.18

PL 9.18

PL 9.18 Item 11 Common

PL 9.18 Item 9 PL 9.18 Item 8 PL 9.18 Item 7 PL 9.18

Revision DocuPrint 180F Service Manual

PL 9.18 PL 9.18

Common

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Parts List

PL 9.18

PL 9.19 TONER DISPENSER ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6

94K1202 – 35P3365 130S947 127K6180

7 8

4K21 –

9 10 11

– 103P347 107P280

DISPENSER ASSEMBLY (P/O PL 9.13 Item 6) M-PACK HARNESS (P/O PL 9.19 Item 1) SENSOR SEAL LOW TONER SENSOR (Q903) TONER DISPENSER MOTOR (MOT902) TONER THUMPER ASSEMBLY TONER THUMPER SOLENOID (SOL901)(P/O PL 9.19 Item 7) BRACKET (P/O PL 9.19 Item 7) RESISTOR DIODE

Parts List

PL 9.19

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PL 9.20 TONER FILTER ASSEMBLY (1 OF 2) Item

Part

Description

1

127K4882

2 – 3 4 5 – 6

20E12730 20E13880 20E13250 55E13330 435W1252 435W1352 127E4090

TONER FILTER BLOWER MOTOR (MOT905) PULLEY (50HZ) PULLEY (60HZ) PULLEY BLOWER PULLEY GUARD O RING BELT (60HZ) O RING BELT (50HZ) TONER FILTER BLOWER

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Parts List

PL 9.20

PL 9.21 TONER FILTER ASSEMBLY (2 OF 2) Item

Part

Description

1 2 3

50E4720 19E9662 53K1190

4

–

5 6 7 8 9 10 11

35E7060 – – 53K753 2K18050 – –

RECEPTACLE CLIP TONER FILTER HOUSING ASSEMBLY TONER FILTER HOUSING (P/O PL 9.21 Item 3) GASKET BRACKET DIRT BOX ADAPTER TONER FILTER BAG FILTER BOX COVER ASSEMBLY GROMMET (P/O PL 9.21 Item 9) FASTENER (P/O PL 9.21 Item 9)

Parts List

PL 9.21

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PL 9.22 CLEANER ASSEMBLY Item 1 2 3 4

Part

Description

42K518 93K460 91P44901 –

CLEANER MODULE ASSEMBLY WASTE BOTTLE LABEL LABEL (P/O PL 9.22 Item 2)

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Parts List

PL 9.22

PL 9.23 WASTE TONER DUCT ASSEMBLY Item

Part

Description

1 2 3 4

50K7421 30K24460 50K7411 127K3791

5 6 7 8

19E11640 52K1270 54E610 23E3330

9 10 11 12 13 14 15

16K500 30E41113 2E22930 52K1291 52K1280 9E19760 30K18213

16 17 18

54K1183 9E24440 –

UPPER WASTE TONER DUCT SLIDE LOWER WASTE TONER DUCT WASTE COMPACTOR MOTOR (MOT903) CLAMP MANIFOLD DUCT COUPLING DEVELOPER EXHAUST DUCT WASTE COMPACTOR DRIVE BELT EXHAUST ADAPTER BRACKET WASTE COMPACTOR SHIELD CLEANER EXHAUST DUCT EXHAUST DUCT COUPLING AGITATOR SPRING WASTE COMPACTOR MOTOR BRACKET WASTE CAPACITOR AUGER AGITATOR WIRE CLAMP

Parts List

PL 9.23

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PL 9.24 CLEANER ASSEMBLY COMPONENTS (1 OF 2) Item

Part

Description

1 2

42K518 –

3 4 5

4R57 2K16483 –

6

–

7

–

8

–

9 10 11 12

7E10290 2K16321 1K11670 –

13 14 15

600K14331 22K11721 600K22221

16 17 18

– – 54K1271

19

25K280

CLEANER MODULE CLEANER HOUSING (P/O PL 9.24 Item 1) CLEANER BRUSH FRONT COVER ASSEMBLY SHOULDER SCREW (P/O PL 9.24 Item 4) ARBOR SHAFT (P/O PL 9.24 Item 4) FRONT ARBOR (P/O PL 9.24 Item 4) COMPRESSION SPRING (P/O PL 9.24 Item 4) AUGER GEAR AUGER GEAR HOUSING PRECLEAN DICOROTRON RAIL FRONT COVER (P/O PL 9.24 Item 4) CLEANER BLADE KIT CLEANER AUGER DICOROTRON SPACER KIT (2 PER KIT) SPACER (P/O PL 9.24 Item 15) TUBE CAP (P/O PL 9.24 Item 1) CLEANER MANIFOLD ASSEMBLY (INCLUDES HOSE) FLICKER BAR

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Parts List

PL 9.24

PL 9.25 CLEANER ASSEMBLY COMPONENTS (2 OF 2) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9

7E10262 7E10272 7K11700 15K5116 15K5106 22K10960 –

10 11 12

152K21661 – 116E2970

13 14 15 16 17 18 19 20 21 22

6K6250 27E1410 3E9520 3E10710 409W1017 3E12190 600K22221 – 600K31860 --

CLEANER MODULE (P/O PL 9.24 Item 1) CLEANER HOUSING (P/O PL 9.25 Item 1) GEAR (22T) GEAR (25T) GEAR (27T) REAR PLATE FRONT PLATE DETONER ROLL BOTTOM BAFFLE (P/O PL 9.25 Item 1) WIRING HARNESS BRACKET (P/O PL 9.25 Item 1) CONTACT STRIP (P/O PL 9.25 Item 1) SHAFT LOCK NUT LATCH LATCH SPRING ANCHOR SPACER KIT (2 PER KIT) SPACER (P/O PL 9.25 Item 19) CLEANER SUPPORT REPAIR KIT PRECLEAN RAIL (SEE PL 9.24 Item 11)

Parts List

PL 9.25

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PL 9.26 PR SPOTS BLADE Item 1 2 3 4 – 5 6

Part

Description

30K37060 15K8700 15K8690 33K2750 33K3190 6E22450 30E77630

SPOTS BLADE BRACKET FRONT SPOTS BLADE GUIDE REAR SPOTS BLADE GUIDE SPOTS BLADE SPOTS BLADE (MICR ONLY) SHAFT SPOTS BLADE TOOL

PL 9.26

PL 9.26

PL 9.2

PL 9.26 PL 9.26

PL 9.26 PL 9.22 PL 9.24 PL 9.25

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Parts List

PL 9.26

PL 9.27 POWERED VENT DUCT Item 1 2 3 4 5 6 7 8

Part

Description

127E5850 152K34241 152K35450 52E10950 35E8610 35E7230 118P658 152K34250

BLOWER VENT FAN HARNESS VENT EXTENSION HARNESS FLEX HOSE (152MM) GASKET GASKET GROMMET VENT EXTENSION HARNESS

TAG TAG IFS/ P-241

Parts List

PL 9.27

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PL 10.1 FUSER ASSEMBLY Item

Part

Description

1 –

126K4474 126K13051

2

110K3530

3 4 5 6 7 8 9 10 11 12 – 13 14 15

117K5770 15E11680 120P2239 29P4809 – 2E20210 30E2441 68E21620 – 21K730 21K740 93K251 – –

FUSER ASSEMBLY (TAG P-312) FUSER ASSEMBLY (MICR) (TAG P-312) FUSER INTERLOCK SWITCH (S1001) LATCHING BRACKET LATCH PLATE SNAP IN CABLE TIE CLAMP PIN SWITCH BRACKET DRIP PAN BRACKET WIRE BRACKET DUST COVER CAP ASSEMBLY (60HZ ONLY) CAP ASSEMBLY (50HZ ONLY) FUSER AGENT RESERVOIR LABEL (P/O PL 10.1 Item 12) CAP (P/O PL 10.1 Item 12)

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Parts List

PL 10.1

PL 10.2 FUSER COMPONENTS (1 OF 4) Item

Part

Description

1

--

2

2K17833

3

2K17823

4 5 6

12K2120 2K17140 –

7 8 9

27E30 5E222 –

10 11 12 13

– – 3E550 –

14 15 16 17 18 19

10E1084 16E160 1K10281 10E195 5E2730 –

FUSER ASSEMBLY (P/O PL 10.1 Item 1) FRONT CAMMING ARM ASSEMBLY REAR CAMMING ARM ASSEMBLY PUSH ROD ASSEMBLY LOADING ARM PIN (P/O PL 10.2 Item 2 AND PL 10.2 Item 3) COUPLING NUT COUPLING SCREW BEARING SLEEVE (P/O PL 10.2 Item 2 AND PL 10.2 Item 3) SPRING (P/O PL 10.2 Item 4) PUSH ROD (P/O PL 10.2 Item 4) BEARING RETAINER HOUSING ARM (P/O PL 10.2 Item 2 AND PL 10.2 Item 3) LEFT DRAWER SLIDE LOCATING BUSHING FUSER FRAME RIGHT DRAWER SLIDE PIN BEARING (P/O PL 10.2 Item 4)

Parts List

PL 10.2

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PL 10.3 FUSER COMPONENTS (2 OF 4) Item

Part

Description

1

126K4474

2 3

33E1680 –

4 5 6

14E37010 5E2140 127K7101

–

127K7091

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

7K120 7K1700 28E2000 30E30890 1K10281 3K43 6E3020 – 30E17340 9E9320 30E51830 – – 30K8560 28E5120 2E15210 5K2410 –

FUSER ASSEMBLY (P/O PL 10.1 Item 1) COOLING FAN CAMMING MOTOR (MOT1004) (P/ O PL 10.3 Item 6) SPACER COUPLING SLIDER FUSER CAMMING MOTOR ASSEMBLY (50HZ) FUSER CAMMING MOTOR ASSEMBLY (60HZ) FUSER GEAR DRIVE GEAR LOCKWASHER ACTUATOR BRACKET FUSER FRAME FUSER LATCH ASSEMBLY SHAFT CLAMP (P/O PL 10.3 Item 12) BRACKET SPRING ARM LEVER (P/O PL 10.3 Item 12) BEARING (P/O PL 10.3 Item 12) HANDLE WASHER COUPLING COVER COUPLING HUB FLAT SPRING (P/O PL 10.3 Item 1)

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Parts List

PL 10.3

PL 10.4 FUSER COMPONENTS (3 OF 4) Item

Part

Description

1

--

2 3 4 5 6 7

30E25440 125P493 30K17580 55K5300 22K6941 –

8 9

– 130P225

10 11 –

30E59210 130K56330 130K64820

12 13

9E1842 –

14 15

19E13700 –

16

–

17

48K27291

18 19 20 21

3E10730 30K21382 49E32480 –

FUSER ASSEMBLY (P/O PL 10.1 Item 1) BRACKET SUPPORT STATIC BRUSH BRACKET FUSER ENTRANCE BAFFLE PRESSURE ROLL CABLE CLAMP (P/O PL 10.4 Item 1) LATCH (P/O PL 10.4 Item 1) FUSER ROLL THERMOSTAT (THS1002) THERMOSTAT BRACKET THERMISTOR (RT1001) (RT1003) THERMISTOR (RT1001) (RT1003)(MICR) THERMISTOR SPRING MIRROR BRACKET (P/O PL 10.4 Item 1) CLAMP CABLE CLAMP (P/O PL 10.4 Item 1) FUSER FRAME (P/O PL 10.4 Item 1) METERING ASSEMBLY (TAG P312) FUSER ROLL LATCH MIRROR BRACKET THERMISTOR BRACKET CABLE CLAMP (P/O PL 10.4 Item 1)

Parts List

PL 10.4

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PL 10.5 FUSER COMPONENTS (4 OF 4) Item

Part

Description

1

126K4474

2 3

30E29170 130S3210

4 5 6 7 8 9 10 11 12

1K13422 5K2410 8E261 – – – 162K8122 54K1301 52E1301

FUSER ASSEMBLY (P/O PL 10.1 Item 1) SENSOR BRACKET CAM-IN AND CAM-OUT SENSOR (Q1002, Q1003) CAM SHAFT ASSEMBLY COUPLING HUB SENSOR CAMMING FLAG TUBE REPAIR KIT TUBE (P/O PL 10.5 Item 7) CLAMP (P/O PL 10.5 Item 7) FUSER HARNESS ASSEMBLY STRIPPER ASSEMBLY AIR TUBE

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Parts List

PL 10.5

PL 10.6 STRIPPER COMPONENTS Item

Part

Description

1

--

2 3 4 5

91P40691 52E4990 52E1920 –

6 7

121K5500 –

8 9

54K660 –

10 11 12 13 14 15 16 17 18 19

52E6870 30K26660 1E14670 55K6502 130E3750 9E32340 30K26670 19S21202 55E13920 3E11770

STRIPPER ASSEMBLY (P/O PL 10.5 Item 11) CAUTION LABEL AIR TUBE FITTING CABLE CLAMP (P/O PL 10.6 Item 1) AIR KNIFE SOLENOID (SOL1001) STRIPPER PIVOT SHAFT (P/O PL 10.6 Item 1) AIR KNIFE MANIFOLD LOCATING SHAFT (P/O PL 10.6 Item 1) MALE FITTING MIRROR BRACKET SIDE PLATE VACUUM FUSER SENSOR (Q1010) SPRING SENSOR BRACKET STRIPPER FINGER FINGER GUARD HANDLE

Parts List

PL 10.6

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PL 10.7 FUSER ROLL ASSEMBLY Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9

126E1400 3E4751 22K53281 3E50510 35E50560 7E34470 –

FUSER ASSEMBLY (P/O PL 10.1 Item 1) FUSER ROLL AND HEATER ASSEMBLY HEAT ROD (HTR1001) HANDLE FUSER ROLL ASSEMBLY HEAT ROD HOLDER SPACER FUSER GEAR BEARING (P/O PL 10.7 Item 5)

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Parts List

PL 10.7

PL 10.8 METERING ASSEMBLY (1 OF 2) Item

Part

Description

1

48K27291

2

130P225

3

130E7810

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

– 22K9162 33E1110 9E20220 9E20230 802K21500 19E8710 9E14380 30E30850 30K21260 30E47110 6E10740 30E50130 120E500 126E390

19 20

30E2670 30E47120

METERING ASSEMBLY (P/O PL 10.4 Item 17) METERING ROLL THERMOSTAT (THS1001) METERING ROLL THERMISTOR (RT1002) FUSER WICK METERING ROLL METERING BLADE TORSION SPRING TORSION SPRING HOUSING CLIP SPRING BRACKET SUPPORT BLADE SUPPORT BRACKET CLAMP SHAFT THERMISTOR BRACKET CABLE TIE METERING ROLL HEATER (HTR1002) THERMOSTAT BRACKET BRACKET CLAMP

Parts List

PL 10.8

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PL 10.9 METERING ASSEMBLY (2 OF 2) Item

Part

Description

1

--

2 3 4 5

94K2330 21E250 52K2260 –

6

–

7 8

94K2030 –

9 10

– –

11 12

6E15640 31K2970

13 14 15 16

9E18510 – 52K2270 –

17

31K3390

18 19 20

22K27670 12K1910 –

21

–

22 23 24

152K17325 52E8030 –

25 26

– –

27

19E21710

METERING ASSEMBLY P/O PL 10.4 Item 17) PUMP ASSEMBLY CAP CAP ASSEMBLY COMPRESSION SPRING (P/O PL 10.9 Item 12 AND PL 10.9 Item 17) CAMMING STOP (P/O PL 10.9 Item 12 AND PL 10.9 Item 17) PUMP SOLENOID (SOL1004) FLAT SPRING (P/O PL 10.9 Item 12 AND PL 10.9 Item 17) LATCH PIN (P/O PL 10.9 Item 1) COMPRESSION SPRING (P/O PL 10.9 Item 1) SHAFT FRONT CAM BRACKET ASSEMBLY SPRING LINK (P/O PL 10.9 Item 12) TUBING ASSEMBLY FUSER AGENT FILTER (P/O PL 10.9 Item 4) REAR CAM BRACKET ASSEMBLY DONOR ROLL LINK FRONT CAM LOADING ARM (P/O PL 10.9 Item 12) REAR CAM LOADING ARM (P/O PL 10.9 Item 17) HARNESS INLET TUBE RETURN TUBE (P/O PL 10.9 Item 4) TUBE BRACE (P/O PL 10.9 Item 2) TUBE FITTING (P/O PL 10.9 Item 15) CLAMP

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Parts List

PL 10.9

PL 10.10 AIR SYSTEMS COMPONENTS (1 OF 2) Item

Part

Description

1

53K911

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

53E450 52K560 52K1550 33K960 53E871 – 33K970 – 52E1950 27E500 4E1860 – – 52E6470 52E6490

PRESSURE REGULATOR ASSEMBLY REGULATOR (P/O PL 10.10 Item 1) AIR GAUGE TUBING TUBING BLADE AIR FILTER MIM COMPRESSOR (MOT1002) BLADE BRACKET (P/O PL 10.10 Item 8) FITTING LOCK NUT SHOCK MOUNT BRACKET FAN GRILLE FITTING FITTING

Parts List

PL 10.10

PL 10.11 Item 6

PL 10.11 PL 10.11 Item 14

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PL 10.11 AIR SYSTEMS COMPONENTS (2 OF 2) Item

Part

Description

1 2 2A

52K580 53K1910 600K31070

3 4 5 6 7

52K1640 52K1630 52K600 52E2050 121K4340

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

53K601 102E2630 52E6740 52E3630 51E10 435W3250 52K1571 52E1940 116E3020 52E6280 52K1560 52E2090 – 52E6480 52E6470 52E4570

TUBING MOISTURE TRAP AIR FILTER ELEMENT FILTER ONLY KIT (NOT SHOWN) TUBING TUBING TUBING 4 PORT FITTING BLEED OFF SOLENOID (SOL1003) RELIEF VALVE CAPACITOR FITTING FITTING ACCUMULATOR TANK O-RING TUBING ASSEMBLY FITTING TERMINAL FITTING TUBING FITTING TUBING (P/O PL 10.11 Item 14) FITTING FITTING FITTING

PL 9.10

PL 10.6

PL 10.8

PL 10.11 Item 9

PL 10.10 Item 8 PL 10.9 Item

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Parts List

PL 10.11

PL 10.12 DECURLER ASSEMBLY Item

Part

Description

1

–

2 3

30K2350 30K2340

DECURLER ASSEMBLY REPAIR KIT BRACKET BRACKET

Parts List

PL 10.12

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PL 10.13 DECURLER COMPONENTS Item

Part

Description

1

–

2 3

55K150 –

4 5

11K130 –

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

6K950 16E6820 6E22200 55E12760 4P778 16P1623 19E1310 – – 409W3187 16E6520 409W3110 6K8330 3E4390 28P20111 35P3112 20K4140

DECURLER ASSEMBLY (P/O PL 10.12 Item 1) DECURLER EXIT BAFFLE RETAINER PLATE (P/O PL 10.13 Item 1) ADJUSTING LEVER DECURLER FRAME (P/O PL 10.13 Item 1) IDLER SHAFT SUPPORT BLOCK BEND SHAFT PIVOT BAFFLE BUMPER PIVOT BUSHING CLAMP DECURLER BELT KIT DECURLER BELT (5/KIT) EXTENSION SPRING MOUNTING BUSHING EXTENSION SPRING DRIVE SHAFT ASSEMBLY KNOB PLASTIC WASHER SEAL PULLEY

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Parts List

PL 10.13

PL 10.14 POSTFUSER TRANSPORTS MODULE Item 1 2 3

Part

Description

22K48700 22K11231 22K44890

TOP TRANSPORT ASSEMBLY EXIT TRANSPORT ASSEMBLY DUPLEX INVERTER ASSEMBLY

Parts List

PL 10.14

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PL 10.15 TOP TRANSPORT ASSEMBLY (1 OF 5) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

29P4231 409W3184 22K16980 409W3185 23E5531 23E5511 23E5521 23E5571 22K16450 6K960 31E1540 5E10870 6K711 19E3660 6K890 6K720 –

20 21 22 23 24 25 26 27 28

20K612 20K460 20K451 20K360 6K701 413W15355 50P1997 22K16990 6K8141

TOP TRANSPORT ASSY (P/O PL 10.14 Item 1) TOP TRANSPORT FRAME (P/O PL 10.15 Item 1) DUPLEX GATE PIVOT EXTENSION SPRING BELT IDLER EXTENSION SPRING REAR SLIP SHAFT DRIVE BELT FRONT SLIP SHAFT DRIVE BELT MAIN DRIVE SHAFT BELT TOP TRANSPORT DRIVE BELT ROLLER TURN SHAFT INVERTER ARM SLIP CLUTCH SLIP SHAFT CLIP DRIVE SHAFT MAIN DRIVE SHAFT STUB SHAFT (P/O PL 10.15 Item 28) PULLEY (24T) PULLEY (72T) CLUTCH NIP PULLEY ONE WAY PULLEY SHAFT SPLIT BEARING DUPLEX GATE BELT IDLER STUB SHAFT ASSEMBLY

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Parts List

PL 10.15

PL 10.16 TOP TRANSPORT ASSEMBLY (2 OF 5) Item

Part

Description

1

--

2

121K24820

3 4 5 6 7

30E9630 12E720 125E420 9P4980 –

8 9 10

409W1529 115E861 –

11 12 13 14 15 16 17 18 19 20 21 22 23

30E4930 22K16450 9P4437 – 413W15355 31K3691 31K3680 10K520 57K30 14E16010 14E16030 14E16020 6K7931

TOP TRANSPORT ASSY (P/O PL 10.14 Item 1) DUPLEX GATE SOLENOID (SOL1002) SOLENOID BRACKET SOLENOID ACTUATOR GROUNDING BRUSH SPRING TOP TRANSPORT FRAME (P/O PL 10.16 Item 1) SPRING GROUND STRIP GUIDE BLOCK (P/O PL 10.16 Item 1) SHAFT SUPPORT ROLLER SPRING SHAFT (P/O PL 10.16 Item 23) SPLIT BEARING LIFT ARM PIVOT ARM PLUNGER INSULATOR TOP FRONT LATCH BLOCK BOTTOM FRONT LATCH BLOCK BOTTOM REAR LATCH BLOCK NIP SHAFT ASSEMBLY

Parts List

PL 10.16

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PL 10.17 TOP TRANSPORT ASSEMBLY (3 OF 5) Item

Part

Description

1

--

2

–

3

130K17224

4 5 6 7 8 9 10 11 12 13 14

30K26600 6E3550 115E861 30E4930 9P4437 22K16450 – 125P493 55K3157 3E3990 130K36062

15 16 17 18 19 20 21 22 23

55K7891 3E13610 55K7882 9E22150 6E20311 3E13620 413W15355 6E20321 –

24 25 26

120K731 6K7931 29E13120

TOP TRANSPORT ASSY (P/O PL 10.14 Item 1) TOP TRANSPORT FRAME (P/O PL 10.17 Item 1) TOP TRANSPORT SENSOR (Q1012) MAGNET BRACKET PIVOT SHAFT GROUND STRIP SHAFT SUPPORT SPRING ROLLER SHAFT (P/O PL 10.17 Item 25) STATIC ELIMINATOR BRUSH JAM ACCESS BAFFLE HANDLE DECURLER SENSOR ASSEMBLY (Q1011) INNER BAFFLE ASSEMBLY RIGHT HANDLE INNER BAFFLE COMPRESSION SPRING SHORT LATCH SHAFT LEFT HANDLE SPLIT BEARING LONG LATCH SHAFT DECURLER SENSOR (Q1011) (P/ O PL 10.17 Item 14) SENSOR ACTUATOR NIP SHAFT ASSEMBLY IDLER PIN

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Parts List

PL 10.17

PL 10.18 TOP TRANSPORT ASSEMBLY (4 OF 5) Item

Part

Description

1

--

2

–

3 4 5

– 3E2741 –

6 7 8 9 10 11 12 13 14 15 16

22K16450 – 9P4437 30E4930 115E861 6K7931 14E12990 – 16E7200 6K10040 146E760

17

–

TOP TRANSPORT ASSY (P/O PL 10.14 Item 1) TOP TRANSPORT FRAME (P/O PL 10.18 Item 1) BAFFLE (P/O PL 10.18 Item 1) HINGE GROUND WIRE (P/O PL 10.18 Item 1) ROLLER SHAFT (P/O PL 10.18 Item 11) SPRING BRACKET IDLER GROUND STRIP NIP SHAFT ASSEMBLY SPACER PD CABLE (P/O PL 10.18 Item 1) GROMMET NIP SHAFT ASSEMBLY ORIENTATION SHAFT INDICATOR SHAFT (P/O PL 10.18 Item 15)

Parts List

PL 10.18

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PL 10.19 TOP TRANSPORT ASSEMBLY (5 OF 5) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13

55K2331 413W15355 9E8170 9E8160 6E3550 6K7931 – 22K16450 9P4437 30E4930 115E861

TOP TRANSPORT ASSEMBLY (P/ O PL 10.14 Item 1) TOP TRANSPORT FRAME (P/O PL 10.19 Item 1) PIVOT BAFFLE SPLIT BEARING REAR TORSION SPRING FRONT TORSION SPRING PIVOT SHAFT SHAFT ASSEMBLY SHAFT (P/O PL 10.19 Item 8) ROLLER SPRING BRACKET IDLER GROUND STRAP

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Parts List

PL 10.19

PL 10.20 EXIT TRANSPORT ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7

9P4437 55K1136 409W3184 22K16980 55S3805 –

8 9

125P493 –

10 11 12 13

115E861 20K370 6K701 –

14 15 16 17 18 19 20

30E4930 6K7931 22K16450 – 55S4038 3E2741 –

21 22

125E420 –

23 24 25 26

– 12K1771 14E12990 23E5501

EXIT TRANSPORT ASSEMBLY (P/ O PL 10.14 Item 2) SPRING BAFFLE SPRING IDLER BRACKET BAFFLE BRUSH GUARD (P/O PL 10.20 Item 1) STATIC ELIMINATOR BRUSH EXIT TRANSPORT FRAME (P/O PL 10.20 Item 1) GROUND STRIP BYPASS PULLEY SHAFT STIFFENER BAR (P/O PL 10.20 Item 1) SHAFT SUPPORT PINCH SHAFT ASSEMBLY ROLLER SHAFT (P/O PL 10.20 Item 15) BAFFLE HINGE GROUND WIRE (P/O PL 10.20 Item 1) BRUSH WIRE ASSEMBLY (P/O PL 10.20 Item 1) CLIP (P/O PL 10.20 Item 1) PD CABLE SPACER EXIT TRANSPORT DRIVE BELT

Parts List

PL 10.20

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PL 10.21 DUPLEX INVERTER ASSEMBLY COMPONENTS (1 OF 4) Item

Part

Description

1

--

2

–

3

–

4

110K3503

5 6

30E7362 –

7 8

28E2990 6K6200

9 10

130K30391 –

11 12

130E4130 3E4390

DUPLEX INVERTER ASSEMBLY (P/O PL 10.14 Item 3) DUPLEX INVERTER FRAME (P/O PL 10.21 Item 1) LOWER INPUT BAFFLE (P/O PL 10.21 Item 1) DUPLEX TAKEAWAY ROLL SENSOR (Q842) SENSOR BRACKET UPPER EXIT BAFFLE (P/O PL 10.21 Item 1) BEARING RETAINER DUAL DRIVE ROLL SHAFT ASSEMBLY DUPLEX SHEET SENSOR (Q841) SENSOR BRACKET (P/O PL 10.21 Item 1) CAUTION LABEL KNOB

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Parts List

PL 10.21

PL 10.22 DUPLEX INVERTER ASSEMBLY COMPONENTS (2 OF 4) Item

Part

Description

1

--

2

–

3 4

6K8250 –

5 6

125E420 –

7 8

6K7490 –

9

–

10

–

11 12 13 14 15

413W15555 6K6221 6K6191 28E2990 9E20210

DUPLEX INVERTER ASSEMBLY (P/O PL 10.14 Item 3) DUPLEX INVERTER FRAME (P/O PL 10.22 Item 1) IDLER SHAFT UPPER INPUT BAFFLE (P/O PL 10.22 Item 1) GROUND BRUSH LIFT BRACKET (P/O PL 10.22 Item 1) SHAFT REAR HINGE (P/O PL 10.22 Item 1) FRONT HINGE (P/O PL 10.22 Item 1) OUTER TURN BAFFLE (P/O PL 10.22 Item 1) SLEEVE BEARING FORWARD REVERSE SHAFT EXIT SHAFT BEARING RETAINER TORSION SPRING

Parts List

PL 10.22

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PL 10.23 DUPLEX INVERTER ASSEMBLY COMPONENTS (3 OF 4) Item

Part

Description

1

--

2

–

3 4

3E11300 –

5 6 7

50K8312 9E18042 –

8 9

– –

10 11 12 13

125E420 6K8250 9E20210 –

14 15

409W1443 –

16 17

– –

18

–

19 20 21 22 23 24

26E8441 32K1251 3E13551 9E18032 – –

25 – 26

29E3600 366W103 8E3480

DUPLEX INVERTER ASSEMBLY (P/O PL 10.14 Item 3) DUPLEX INVERTER FRAME (P/O PL 10.23 Item 1) CATCH SPLIT BEARING (P/O PL 10.23 Item 1) GATE TORSION SPRING RIGHT LATCH SHAFT (P/O PL 10.23 Item 1) HINGE (P/O PL 10.23 Item 1) FRONT PLATE (P/O PL 10.23 Item 1) GROUND BRUSH IDLER SHAFT TORSION SPRING JAM CLEARANCE BAFFLE (P/O PL 10.23 Item 1) COMPRESSION SPRING LEFT LATCH SHAFT (P/O PL 10.23 Item 1) PIN (P/O PL 10.23 Item 1) LEFT LINK LATCH (P/O PL 10.23 Item 1) RIGHT LINK LATCH (P/O PL 10.23 Item 1) SHOULDER SCREW LATCH GUIDE HANDLE TORSION SPRING SCREW (P/O PL 10.23 Item 1) PIVOT SHAFT (P/O PL 10.23 Item 1) CLIP ALTERNATE CAM

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Parts List

PL 10.23

PL 10.24 DUPLEX INVERTER ASSEMBLY COMPONENTS (4 OF 4) Item

Part

Description

1

--

2

–

3 4 5

31K3561 409W3216 7K8440

6 7 8 9 10

118E7550 – 22K16450 22K16990 –

11 – 12 13 14

423W64950 23E21030 20K451 30K25921 423W58450

15 16

30K25911 409W3229

DUPLEX INVERTER ASSEMBLY (P/O PL 10.14 Item 3) DUPLEX INVERTER FRAME (P/O PL 10.24 Item 1) PIVOT ARM EXTENSION SPRING INVERTER GEAR BOX ASSEMBLY FORWARD CLUTCH (CL841) REVERSE CLUTCH (CL842) EDGE PROTECTOR IDLER BRACKET (NOT SPARED) BEARING IDLER DRAG BRAKE (P/O PL 10.24 Item 11) GEAR BOX DRIVE BELT DRIVE BELT (151T) (50HZ ONLY) ONE WAY CLUTCH IDLER ASSEMBLY FORWARD REVERSE DRIVE BELT IDLER BRACKET EXTENSION SPRING

Parts List

PL 10.24

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PL 11.1 PREREGISTRATION AND BLOWER ASSEMBLIES Item

Part

Description

1

–

2

127K15201

–

127K15211

3 4 5 6 7 8

423W67650 9E42920 – 91P4419 702W11833 702W11433

9

702W11633

10 11

600K71510 –

12 13 14 15 16 17 18 19

127K30160 127K12490 127K6783 23E6361 20E4840 20K4161 3E50450 –

20 21

52E18290 419W22850

22

–

23 24

54K15640 600K32560

PREREGISTRATION TRANSPORT STACKER MAIN DRIVE MOTOR (60HZ)(MOT1110) STACKER MAIN DRIVE MOTOR (50HZ)(MOT1110) SYNCH BELT SPRING BELT IDLER (P/O PL 11.1 Item 24) CAUTION LABEL BYPASS RUN CAPACITOR (15NF) INVERTER RUN CAPACITOR (10NF), BYPASS START CAPACITOR (10NF) INVERTER MAIN RUN CAPACITOR (12.5NF), INVERTER MAIN START CAPACITOR (12.5NF) TONER STICKING KIT BLOWER BASE PLATE (P/O PL 11.1 Item 10) BLOWER ASSEMBLY AC MOTOR (50/60HZ) BLOWER O-RING DRIVE BELT O-RING PULLEY PULLEY BLOWER PLUG BLOWER/MOTOR BRACKET (P/O PL 11.1 Item 12) AIR HOSE HOSE CLAMP (P/O PL 11.1 Item 10) JUMPER HARNESS (P/O PL 11.1 Item 10) MANIFOLD BELT IDLER REPAIR KIT

Revision DocuPrint 180F Service Manual

PL 11.2

11/00 5-163

Parts List

PL 11.1

PL 11.2 PREREGISTRATION TRANSPORT ASSEMBLY Item

Part

Description

1

–

2 3 4 5 6 7 8

1K27451 28E2990 409W2198 22K14780 7K4362 12E2232 6K10590

9 10

30E36691 130K52641

11 12 13 14 15

– 130E1440 423W66350 55K7172 –

16 17 18 19 20 21 22

55K10170 22E3321 6E8311 9E21030 27P1160 117S23175 –

23 24

6E31960 413W15455

REG OUTPUT ASSY (P/O PL 11.1 Item 1) TRANSPORT FRAME RETAINER SPRING BELT IDLER DRIVE PULLEY FLEXIBLE DRIVE SHAFT PRESTACKER DRIVE ROLL SHAFT BRACKET POST INVERTER SENSOR (Q1156) ACTUATOR (P/O PL 11.2 Item 1) PRESTACKER SENSOR (Q1158) BELT BAFFLE ASSEMBLY REGISTRATION HOUSING ASSEMBLY (REFER PL 11.3) BAFFLE ROLL ROLL SHAFT ROLL SPRING LOCK NUT WIRE PIVOT BAFFLE (P/O PL 11.2 Item 1)(REFER PL 11.4) PIVOT SHAFT BEARING

Parts List

PL 11.2

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PL 11.3 PREREGISTRATION HOUSING ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7 8 9

2E22741 6K6101 28E1770 423W8050 6K6111 6K6070 22K56250 28E2781

BAFFLE ASSEMBLY (P/O PL 11.2 Item 14) HOUSING LOWER SHAFT RETAINER BELT CENTER SHAFT DRIVE SHAFT CORRUGATOR ROLLS RETAINER

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Parts List

PL 11.3

PL 11.4 PREREGISTRATION PIVOT BAFFLE ASSEMBLY Item

Part

Description

1

–

2 3 4 5 6 7 8 9 10 11 12 13 14 15

3E3990 30K46060 12E5670 413W15455 3E19601 6K10970 125E420 9E6360 22K11292 – 32P1726 9E44470 55K14241 6K11000

PIVOT BAFFLE ASSEMBLY (P/O PL 11.2 Item 22) HANDLE HANDLE BRACKET LINK SLEEVE BEARING HANDLE LATCH SHAFT BRUSH SPRING ROLLER ASSEMBLY ROLLER (P/O PL 11.4 Item 10) GUIDE SPRING TOP TURN BAFFLE HANDLE SHAFT

Parts List

PL 11.4

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PL 11.5 STACKER OFFSET ASSEMBLY Item

Part

Description

1 2 – 3 4

– 22K32351 22K32341 48K53530 102E3010

5

127K5161

–

127K5571

6

48K50310

BACK GUIDE ASSEMBLY RIGHT GUIDE ASSEMBLY (50HZ) RIGHT GUIDE ASSEMBLY (60HZ) FRONT GUIDE FRONT TAMPER MOTOR CAPACITOR (C1106) FRONT TAMPER MOTOR (60HZ) (MOT1107) FRONT TAMPER MOTOR (50HZ) (MOT1107) BACK GUIDE

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Parts List

PL 11.5

PL 11.6 BACK GUIDE ASSEMBLY (1 OF 2) Item

Part

Description

1

–

2

127K5271

–

127K8091

3 4

152K37532 102E3010

5 6 7 8 9 10 11 12 13

30K25762 30E52403 30K43841 10K982 2E32472 423W9050 120E4940 162K28340 130K18870

14 15 16 17 18 19 20 21 22 23 24

48K50310 2E32380 23E4140 30K45111 127K5281 409W3187 6K5963 15K10290 30K27084 30K44620 30K44630

BACK GUIDE ASSEMBLY (P/O PL 11.5 Item 1) BACK TAMPER MOTOR, (MOT1108)(60HZ) BACK TAMPER MOTOR, (MOT1108)(50HZ) OFFSET AC HARNESS BACK TAMPER MOTOR CAPACITOR, (C1107) BRACKET SENSOR BRACKET BASE PLATE SLIDE RH LEAD MOUNT BELT CABLE HOLDER OFFSET SIGNAL HARNESS BACK GUIDE HOME SENSOR, (Q1133) BACK GUIDE BEARING CAP BELT IDLER BRACKET BACK GUIDE MOTOR, (MOT1104) EXTENSION SPRING LEAD SCREW DRIVE PLATE OFFSET BRACE RH OFFSET SUPPORT LH OFFSET SUPPORT

Parts List

PL 11.6

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PL 11.7 BACK GUIDE ASSEMBLY (2 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10

2E22844 6E23261 9E46410 12K1561 31K4340 9E44420 8E4230 6K5872 –

11 12 13 14

2E23831 19K2820 – –

15 16 17

6K14050 130K40140 48E36500

BACK GUIDE ASSEMBLY (P/O PL 11.5 Item 6) HOUSING TAMPER SHAFT SPRING RETRACT LINK TAMPER ARM SPRING CAM FOLLOWER DRIVE SHAFT BEARING CAP (P/O PL 11.7 Item 1) CLUTCH BEARING CAP FINGER ASSEMBLY SPRING (P/O PL 11.7 Item 12) FINGER HOUSING (P/O PL 11.7 Item 12) CLUTCH SHAFT BACK TAMPER SENSOR (Q1134) MOUNTING BRACKET

Com mon

PL 11.7

Com mon

Revision DocuPrint 180F Service Manual

PL 11.7

PL 11.7

11/00 5-169

Parts List

PL 11.7

PL 11.8 FRONT GUIDE ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10

2E22844 6E23261 9E46410 12K1561 31K4340 9E44420 8E4230 5E4381 –

11 12 13 14

2E23831 19K2820 – –

15 16 17

6K14050 6K6622 –

18

–

19

–

FRONT GUIDE ASSEMBLY (P/O PL 11.5 Item 3) HOUSING TAMPER SHAFT SPRING RETRACT LINK TAMPER ARM SPRING CAM FOLLOWER OFFSET COUPLING BEARING CAP (P/O PL 11.8 Item 1) CLUTCH BEARING CAP FINGER ASSEMBLY SPRING (P/O PL 11.8 Item 12) FINGER HOUSING (P/O PL 11.8 Item 12) CLUTCH SHAFT DRIVE SHAFT SWITCH BEARING CAP (P/O PL 11.8 Item 1) FRONT TAMPER SENSOR (Q1135)(P/O PL 11.8 Item 1) DEFLECTOR (NOT SPARED)

Parts List

PL 11.8

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PL 11.9 RIGHT GUIDE ASSEMBLY Item

Part

Description

1

--

2

127K5281

3 4 5 6 7 8

30K45111 423W15550 130K18870 6K13350 6K13330 127K12600

–

127K12680

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

13E9150 120E8110 20K3592 10K1191 152K67570 12E4431 38E7674 30K43431 30E61171 2E63860 48K14752 409W3200 120E3660 14E26690 28E1770

RIGHT GUIDE ASSEMBLY (P/O PL 11.5 Item 2) RIGHT GUIDE MOTOR (MOT1105) TENSIONER IDLER BELT SENSOR (Q1132) SHORT LEAD SCREW LONG LEAD SCREW RIGHT GUIDE TAMPER MOTOR (60HZ)(MOT1113) RIGHT GUIDE TAMPER MOTOR (50HZ)(MOT1113) BLOCK BEARING CABLE HOLDER WHEEL SLIDE CHASSIS TAMPER HARNESS TAMPER LINK MOVING WALL SUPPORT BRACKET SLIDE BRACKET TRAIL EDGE GUIDE TRAIL EDGE HOUSING EXTENSION SPRING WIRE MOUNTING SUPPORT BLOCK RETAINER

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Parts List

PL 11.9

PL 11.10 BYPASS TRANSPORT ASSEMBLY Item

Part

Description

1

55K21860

–

55K6375

2

22K37610

– 3

22K44920 36K254

PURGE TRANSPORT TOP BAFFLE ASSEMBLY (FS) BYPASS TRANSPORT TOP BAFFLE ASSEMBLY (IFS/ MID MOD) BYPASS TRANSPORT ASSY (IFS)(MID MOD) PURGE TRANSPORT ASSY (FS) COUNTER BALANCE

Parts List

PL 11.10

11/00 5-172

Revision DocuPrint 180F Service Manual

PL 11.11 BYPASS TRANSPORT COMPONENTS Item

Part

Description

1

--

2 3 4 5 6 7 8

– 7E14102 2K19564 22K14780 409W3211 – –

9 10

3E3990 –

11 12

– –

13 14 15 16 17

30K40532 6K6301 28E1970 7E15501 121E7000

18 19 20 21 22 23 24 25 26

12K1300 29K680 30K25311 6K11231 6K6293 55K13490 130E4440 55K8695 –

BYPASS TRANSPORT ASSEMBLY (IFS)(P/O PL 11.10 Item 2) FRAME (P/O PL 11.11 Item 1) TELESCOPIC DRIVE SHAFT FRONT HOUSING IDLER SPRING BELT (P/O PL 11.11 Item 1) PULLEY (P/O PL 11.11 Item 14 AND PL 11.11 Item 22) HANDLE RIGHT DRIVES COVER (P/O PL 11.11 Item 1) SYNCH BELT LEFT DRIVES COVER (P/O PL 11.11 Item 1) COVER MOUNTING BRACKET SHAFT RETAINER GEAR BYPASS TRANSPORT GATE SOLENOID, (SOL1104) CABLE PIN BRACKET B5 SHAFT LEFT DRIVE SHAFT BYPASS LEAD IN BAFFLE SENSOR (Q1106) TRAIL EDGE ASSIST BAFFLE IDLER SHAFT (NOT SPARED)

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Parts List

PL 11.11

PL 11.12 PURGE TRANSPORT COMPONENTS (1 OF 2) Item

Part

Description

1

--

2 3 4 5

– 6K14880 1K47890 –

6 7 8 9 10

125E420 14E17312 130E1440 55K13480 –

PURGE XPORT ASSEMBLY (P/O PL 11.10 Item 2) FRAME (P/O PL 11.12 Item 1) PURGE OUTPUT DRIVE SHAFT TOP PURGE FRAME ASSY RETAINING RING (P/O PL 11.12 Item 4) GROUND BRUSH SPACER SENSOR (Q1164) PURGE LEAD IN BAFFLE IDLER SHAFT (NOT SPARED)

Parts List

PL 11.12

11/00 5-174

Revision DocuPrint 180F Service Manual

PL 11.13 PURGE TRANSPORT COMPONENTS (2 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10

– 7E14102 2K19564 22K14780 409W3211 – – 3E3990 –

11 12 13 14 15 16 17 18 19 20 21

423W65350 30K54310 30K40532 6K6301 28E1970 7E15501 6K11231 6K6293 29K680 12K1300 121E7000

22 23

30K25311 –

24 25

130E4440 22K45410

PURGE TRANSPORT ASSEMBLY (FS) (P/O PL 11.10 Item 2) FRAME (P/O PL 11.13 Item 1) TELESCOPIC DRIVE SHAFT FRONT HOUSING IDLER SPRING BELT (P/O PL 11.13 Item 1) PULLEY HANDLE RIGHT DRIVES COVER (P/O PL 11.13 Item 1) BELT (153T) LEFT DRIVES COVER COVER MOUNTING BRACKET SHAFT RETAINER GEAR B5 SHAFT LEFT DRIVE SHAFT PIN CABLE BYPASS TRANSPORT GATE SOLENOID, (SOL1104) BRACKET SYNCH BELT (P/O PL 11.13 Item 1) SENSOR (Q1106) IDLER ROLLER

Revision DocuPrint 180F Service Manual

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Parts List

PL 11.13

PL 11.14 BYPASS TRANSPORT, MIDDLE MODULE BYPASS TRANSPORT AND PURGE TRANSPORT COMPONENTS Item

Part

Description

1

--

2 3 4 5 6 7 8

– 16E2460 130K50512 9E24521 22K11360 55K9614 –

9

–

10 11 12 13 14 15 16 – 17 18 19 20 21 22 23 24 25 26 27

55K8695 125E420 32E621 – 14E18823 50E8110 152K48423 152K48413 413W17355 9E6360 130E4440 22K14780 409W3211 117S23175 6K10720 30K42112 14E18752 – –

BYPASS TRANSPORT ASSEMBLY (P/O PL 11.10 Item 2) FRAME (P/O PL 11.14 Item 1) BUSHING REFLECTIVE SENSOR (Q1167X) SPRING ROLLER STACKER LEAD IN BAFFLE TE ASSIST BELT (P/O PL 11.14 Item 1) TE ASSIST BELT (P/O PL 11.14 Item 1) BAFFLE BRUSH IDLER GUIDE IDLER ROLL (P/O PL 11.14 Item 1) REAR BLOCK BYPASS TRANSPORT GATE PURGE HARNESS BYPASS HARNESS SPLIT BEARING SPRING DISK SHEET SENSOR (Q1106) ROLLER SPRING WIRE IDLE SHAFT SENSOR BRACKET BEARING BLOCK DISK GATE (P/O PL 11.14 Item 1) ROLLER (P/O PL 11.14 Item 23)

Parts List

PL 11.14

11/00 5-176

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PL 11.15 BYPASS TRANSPORT AND MIDDLE MODULE BYPASS TRANSPORT TOP BAFFLE Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11

– 30E56951 117S23176 30K28472 30E53931 9E6360 125E420 22K11292 32P1726 –

MID MOD, BYPASS TRANSPORT TOP BAFFLE ASSEMBLY (P/O PL 11.10 Item 1) FRAME (P/O PL 11.15 Item 1) BRACKET WIRE CHANNEL BRACKET SPRING BRUSH ROLLER ASSEMBLY GUIDE ROLLER (P/O PL 11.15 Item 9)

Revision DocuPrint 180F Service Manual

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Parts List

PL 11.15

PL 11.16 PURGE TRANSPORT TOP BAFFLE Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14

– 125P552 117S23176 30E53931 30K28472 125E420 22K45161 9E6360 22K11292 32P1726 – 30K56941 30K56951

PURGE TRANSPORT TOP BAFFLE ASSEMBLY (P/O PL 11.10 Item 1) FRAME (P/O PL 11.16 Item 1) BRUSH WIRE BRACKET CHANNEL BRUSH SLIP NIP ROLLER SPRING ROLLER ASSEMBLY GUIDE ROLLER (P/O PL 11.16 Item 10) LH BRACKET RH BRACKET

Parts List

PL 11.16

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Revision DocuPrint 180F Service Manual

PL 11.17 STACKER ELEVATOR ASSEMBLY (1 OF 3) Item

Part

Description

1

–

2 3 4 5 6 – 7 8 9 10 11 12 13 14 15 16

10K763 10K753 22E9761 3K5153 9E46410 409W3079 413W15455 3K5292 – 9E24041 – 29E12420 30K36141 1K14575 50K10806 1K14583

STACKER ELEVATOR ASSEMBLY (50HZ)(60HZ) RIGHT SLIDE LEFT SLIDE ROLLER PALLET LATCH SPRING SPRING BEARING HANDLE ASSEMBLY HANDLE (P/O PL 11.17 Item 8) SPRING SHAFT (P/O PL 11.17 Item 8) LOCATING STUD BRACKET PALLET LIFT FRAME MAIN PALLET ASSEMBLY PALLET BASE

Revision DocuPrint 180F Service Manual

11/00 5-179

Parts List

PL 11.17

PL 11.18 STACKER ELEVATOR ASSEMBLY (2 OF 3) Item

Part

Description

1

–

2 3 4

19E7100 – –

5

130E1420

6 7 8 9 10

23E2350 19P3681 6K8101 13P2505 130K40921

11

702W11533

12 13

110E1250 710W2042

14

130E1440

15 16 17 18

2E37610 27P506 27K110 –

STACKER ELEVATOR ASSEMBLY (P/O PL 11.17 Item 1) CABLE CLIP BRACKET (P/O PL 11.18 Item 1) STACKER EMPTY SENSOR EMITTER (P/O PL 11.18 Item 5) STACKER EMPTY SENSOR (Q1130) BELT CLAMP LEAD SCREW ASSEMBLY BEARING CONTAINER SIZE SENSORS (Q1126, Q1127, Q1128) STACKER ELEVATOR CAPACITOR, (C1105) DRAWER IN SWITCH, (S1129) STACKER OVERTRAVEL UP SWITCH, (S1140) STACKER OVERTRAVEL DOWN SWITCH, (S1141) STACKER ELEVATOR DOWN SENSOR, (Q1125) PULLEY COVER NUT ANTIBACKLASH NUT PULLEY/BEARING (P/O PL 11.18 Item 8)

Parts List

PL 11.18

Common Common

Com mon

11/00 5-180

Revision DocuPrint 180F Service Manual

PL 11.19 STACKER ELEVATOR ASSEMBLY (3 OF 3) Item

Part

Description

1

–

2

–

3

127K8872

–

127K9081

4

–

5

130K18870

6 7 8 9 10

9E46990 30K36102 30K35864 30K35221 130K29890

11 12 13

19E7100 152K15826 –

STACKER ELEVATOR ASSEMBLY (P/O PL 11.17 Item 1) STACKER ELEVATOR MOTOR ASSEMBLY STACKER ELEVATOR MOTOR (60HZ)(MOT1106) STACKER ELEVATOR MOTOR (50HZ)(MOT1106) MOTOR PLATE (P/O PL 11.19 Item 2) STACKER ELEVATOR MOTOR ENCODER SENSOR, (Q1124) SPRING IDLER BRACKET BRACKET MAIN PALLET LATCH SENSOR (Q1149) CABLE CLIP STACKER HARNESS AC STACKER HARNESS (P/O PL 11.19 Item 1)

Revision DocuPrint 180F Service Manual

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Parts List

PL 11.19

PL 11.20 PALLET ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 –

50K11063 3E15060 3K5461 3E14862 30E66202 22E9761 409W3110 9E23851 30E71641 3E15430 50K18991 50K19001

PALLET ASSEMBLY (P/O PL 11.17 Item 15) PALLET RELEASE BUTTON HANDLE STACKER PALLET LATCH SUPPORT ROLLER SPRING LATCH SPRING BRACKET BUTTON CONTAINER (A4) CONTAINER (A3)

Com mon

Parts List

PL 11.20

11/00 5-182

Revision DocuPrint 180F Service Manual

PL 11.21 STACKER INNER COVERS Item 1 2 3 4 5

Part

Description

2E26732 2E26712 2E32073 2E26722 2E26702

ELEVATOR BASE COVER RIGHT SIDE INNER COVER REAR DRIVES INNER COVER REAR INNER COVER LEFT SIDE INNER COVER

Revision DocuPrint 180F Service Manual

11/00 5-183

Parts List

PL 11.21

PL 11.22 POST INVERTER AND INVERTER TRANSPORTS Item

Part

Description

1 2

30K57090 127K22060

3

30E24370

4 – 5

22K44711 22K44721 127K15190

–

127K15180

6 – 7 8 9

423W62150 423W61950 409W2198 22K14780 22K44930

10 11

29E14150 29E5880

INVERTER FAN BRACKET INVERTER MOTOR COOLING FAN INVERTER FRONT MOUNTING BRACKET INVERTER ASSEMBLY (60HZ) INVERTER ASSEMBLY (50HZ) INVERTER MAIN DRIVE MOTOR (50HZ)(MOT1112) INVERTER MAIN DRIVE MOTOR (60HZ)(MOT1112) BELT (50HZ) BELT (60HZ) SPRING IDLER POST INVERTER TRANSPORT ASSEMBLY PIN LOCATOR PIN LOCATOR

Parts List

PL 11.22

11/00 5-184

Revision DocuPrint 180F Service Manual

PL 11.23 INVERTER COMPONENTS (1 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12

50E8471 9E21850 22K5411 32P1726 125E420 3E3930 413W10355 28E1721 22K32480 29E4350 –

13

14E21060

INVERTER ASSEMBLY (P/O PL 11.22 Item 11) INVERTER ACTIVE GATE SPRING ROLLER GUIDE GROUNDING BRUSH CATCH BEARING (M6) BEARING RETAINER PIVOTING ASSEMBLY HINGE PIN INVERTER FRAME (P/O PL 11.23 Item 1) SPACER

Revision DocuPrint 180F Service Manual

PL 11.24

11/00 5-185

Parts List

PL 11.23

PL 11.24 INVERTER COMPONENTS (2 OF 2) Item

Part

Description

1

--

2 3

3E5301 121E2830

4 5 6 7

12P1397 29E15440 9E11140 –

8 9

28E1770 6K2681

–

6K2941

10 – 11

423W7350 423W7550 127K14850

12

130E1440

13

–

14

–

15

–

INVERTER ASSEMBLY (P/O PL 11.22 Item 11) TOP HINGE INVERTER GATE SOLENOID (SOL1108) LINK GATE PIVOT RETURN SPRING BOTTOM HINGE (P/O PL 11.24 Item 1) BEARING RETAINER BOTTOM DRIVE SHAFT (60HZ ONLY) BOTTOM DRIVE SHAFT (50HZ ONLY) SYNCHRON BELT (73T) (50HZ) SYNCHRON BELT (73T) (60HZ) INVERTER MOTOR ASSEMBLY (MOT1111) INVERTER ENTRANCE SENSOR (Q1155) INVERTER MOTOR (MOT1111) (P/ O PL 11.24 Item 11) INVERTER MOTOR PULLEY (P/O PL 11.24 Item 11) INVERTER FRAME (P/O PL 11.24 Item 1)

Parts List

PL 11.24

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PL 11.25 PIVOTING ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13

6K2861 6K1931 28E1710 50E2436 55K16360 32P1726 22K5411 9E21850 125E420 9E16211 28E1721 –

14 15 16 17 18

9E13582 16E1780 3K2841 – –

19

–

20 21

– –

22

–

23

–

PIVOTING ASSEMBLY (P/O PL 11.23 Item 10) TOP SHAFT MIDDLE SHAFT BEARING RETAINER PASSIVE GATE BAFFLE GUIDE ROLLER SPRING GROUNDING BRUSH GATE FLAT SPRING BEARING RETAINER PIVOT FRAME (P/O PL 11.25 Item 1) PASSIVE GATE CENTER SPRING PIVOT BUSHING INVERTER LATCH ASSEMBLY HANDLE (P/O PL 11.25 Item 16) HANDLE BRACKET (P/O PL 11.25 Item 16) LATCH MOUNT (P/O PL 11.25 Item 16) BEARING (P/O PL 11.25 Item 16) SPLIT BEARING (P/O PL 11.25 Item 16) LATCH RETURN SPRING (P/O PL 11.25 Item 16) LATCH (P/O PL 11.25 Item 1)

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Parts List

PL 11.25

PL 11.26 POST INVERTER TRANSPORT COMPONENTS (1 OF 2) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

28E2990 130E1440 55K13390 29E14310 30K43560 409W2376 423W8950 22K14890 6K10580 6K14910 28E3740 423W12150 6K14920 6K14900 125P552

POST INVERTER XPORT ASSEMBLY (P/O PL 11.22 Item 9) POST INVERTER FRAME (P/O PL 11.26 Item 1) BEARING RETAINER SAMPLE TRAY SENSOR, (Q1157) PIVOT BAFFLE ASSEMBLY PIN REVERSING GEAR BRACKET GEAR BRACKET SPRING INVERTER DRIVE BELT STATIONARY IDLER ROLLER STUB SHAFT LOWER SHAFT BEARING RETAINER BELT DRIVE SHAFT SHAFT STATIC BRUSH

Parts List

PL 11.26

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PL 11.27 POST INVERTER TRANSPORT COMPONENTS (2 OF 2) Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15

50K12671 413W15355 30K56921 30K56931 12E4841 22K45161 9E46510 22K6381 29E14240 413W15155 9E2210 29K1120 121E2830

POST INVERTER XPORT ASSEMBLY (P/O PL 11.22 Item 9) POST INVERTER FRAME (P/O PL 11.27 Item 1) SAMPLE TRAY GATE BEARING LH BRACKET RH BRACKET SOLENOID LINK SLIP NIP ROLLER SPRING IDLER GATE ACTUATOR BEARING RETURN SPRING ACTUATOR SAMPLE TRAY GATE SOLENOID, (SOL1110)

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Parts List

PL 11.27

PL 11.28 POST INVERTER TRANSPORT PIVOT BAFFLE ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7

55K13400 9E6360 31E4860 6E22001 11E3730 121E1610

8 9 10 11 12 13 14

125E420 3E3990 30K42231 3E17420 9E32551 26E18751 6K9931

PIVOT BAFFLE ASSEMBLY (P/O PL 11.26 Item 5) PIVOT BAFFLE IDLER PINCH SPRING YOKE CLEVIS SHAFT CLEVIS INVERTER A3 NIP RELEASE SOLENOID, (SOL1111) BRUSH HANDLE BRACKET LATCH SPRING STUD IDLER ROLL SHAFT

Parts List

PL 11.28

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PL 11.29 IFS, FS, AND MM DISK MODULE WELDMENT ASSEMBLY Item

Part

Description

1

1K56342

–

1K56352

2 3 4 5 6 7 8 9 10 11 12

423W65850 55K13291 30K25951 30K25960 3E16810 30K42780 – 130K51110 3K5850 423W88550 127K15201

–

127K15211

13

702W11433

14

702W11833

IFS DISK MODULE ASSY (TAG IFS/FS-64) FS DISK MODULE ASSY (TAG IFS/FS-64) BELT BAFFLE ASSEMBLY BRACKET BRACKET GATE STOP SENSOR BRACKET ASSEMBLY BRACKET (P/O PL 11.29 Item 7) STACK HEIGHT SENSOR (Q1122) STOP BELT BYPASS MOTOR (60HZ) (FS)(MM) BYPASS MOTOR (50HZ) (FS)(MM) BYPASS START CAPACITOR (10NF) BYPASS RUN CAPACITOR (15NF)

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Parts List

PL 11.29

PL 11.30 IFS DISK MODULE WELDMENT Item

Part

Description

1

--

2 3 4 5 6 7

– 6K6311 6K6321 6K18330 5E6910 127K18572

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

5E4433 22K16980 22K14850 409W3212 2K19575 423W59550 28P20116 68E5281 130K18870 28E1970 125E420 8K1221 26E13090 30K36963 9E24521 130K51420

24 25 26

15E32280 6K6331 130E1440

27 28 29 30 31 32

62K2120 152K37495 22K6381 5P3810 26E31620 102E3010

IFS DISK MODULE (P/O PL 11.29 Item 1) (TAG IFS/FS-64) FRAME (P/O PL 11.30 Item 1) SHAFT SHAFT DISK SHAFT (TAG IFS/FS-64) COUPLING DISK MOTOR (MOT1103) (TAG IFS/FS-64) DISK IDLER IDLER EXTENSION SPRING REAR HOUSING BELT WASHER SENSOR BRACKET DISK HOME SENSOR, (Q1121) RETAINER BRUSH CAM FOLLOWER STUD BRACKET SENSOR CLIP DISK LEAD EDGE SENSOR, (Q1166) REAR PLATE EXIT SHAFT BYPASS TRANSPORT SENSOR, (Q1107) REFLECTOR STACKER HARNESS IDLER COUPLING SHOULDER SCREW CAPACITOR (C1106)

Parts List

PL 11.30

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PL 11.31 FS AND MM DISK MODULE WELDMENT Item

Part

Description

1

--

2 3 4 5 6 7

– 6K6311 6K6321 6K18330 5E6910 127K18572

8 9 10 11 12 13 14 15 16 17 18 19 20

5E4433 22K16980 22K14850 409W3212 2K19575 28P20116 28E1970 125E420 8K1221 26E13090 30K36963 9E24521 130K51420

21 22 23 24 25 26 27 28 29

15E32280 152K37495 22K6381 5P3810 68E5281 130K18870 62K2120 26E31620 102E3010

FS/MM DISK MODULE (P/O PL 11.29 Item 1) (TAG IFS/FS-64) FRAME (P/O PL 11.31 Item 1) ENT SHAFT CHUTE SHAFT DISK SHAFT COUPLING DISK MOTOR, (MOT1103) (TAG IFS/FS-64) DISK BELT IDLER ROLLER EXTENSION SPRING REAR HOUSING WASHER BEARING RETAINER BRUSH CAM FOLLOWER STUD BRACKET SENSOR CLIP DISK LEAD EDGE SENSOR, (Q1166) REAR PLATE STACKER HARNESS IDLER DISC COUPLING SENSOR BRACKET DISK HOME SENSOR, (Q1121) REFLECTOR SHOULDER SCREW CAPACITOR (C1106)

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Parts List

PL 11.31

PL 11.32 CHUTE BAFFLE Item

Part

Description

1

55K13291

2

–

3 4 5 6 7 8 9

117S23175 22K11292 9E6360 125E420 117S23171 125E1250 32P1726

CHUTE BAFFLE ASSY (SHOWN ON PL 11.29) TOP BAFFLE (P/O PL 11.32 Item 1) WIRE ROLLER ASSEMBLY SPRING BRUSH WIRE BRUSH GUIDE

Parts List

PL 11.32

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PL 11.33 BTM BYPASS TRANSPORT ASSEMBLIES Item

Part

Description

1

22K37610

2

55K14321

3

55K14870

4

55K16100

BYPASS TRANSPORT ASSEMBLY PURGE TRANSPORT TOP BAFFLE ASSEMBLY BYPASS TRANSPORT TOP BAFFLE ASSEMBLY BYPASS TRANSPORT ENT BAFFLE ASSEMBLY

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Parts List

PL 11.33

PL 11.34 BTM BYPASS TRANSPORT (1 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10

– 7E14102 2K19564 22K14780 409W3212 423W59550 – 3E3990 –

11

–

12

–

13 14 15 16 17

30K40532 6K6301 28E1970 7E15501 121E7000

18 19 20 21 22 23 24 25

12K1300 29K680 30K25311 6K11231 6K6293 55K13480 130E4440 –

BYPASS XPORT ASSEMBLY (P/O PL 11.33 Item 1) FRAME (P/O PL 11.34 Item 1) TELESCOPIC DRIVE SHAFT FRONT HOUSING IDLER BRACKET SPRING BELT GEAR (P/O PL 11.34 Item 1) HANDLE RIGHT DRIVE COVER (P/O PL 11.34 Item 1) SYNCH BELT (P/O PL 11.34 Item 1) LEFT DRIVE COVER (P/O PL 11.34 Item 1) COVER MOUNTING BRACKET SHAFT RETAINER GEAR SOLENOID BYPASS GATE (S0L1104) CABLE PIN BRACKET TEA SHAFT LEFT DRIVE SHAFT BYPASS LEADING BAFFLE SENSOR (Q1106) IDLER SHAFT

Parts List

PL 11.34

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PL 11.35 BTM BYPASS TRANSPORT (2 OF 2) Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11

– 16E2460 22K11360 19E7100 – – 55K8695 125E420 32E621 –

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

50E8110 413W17355 9E6360 22K14780 409W3212 117S23175 – 55K9614 6K10720 – 130E4440 – 152K48413 30K42112 14E18823 14E18752 9E24521 130K50512

BYPASS XPORT ASSEMBLY (P/O PL 11.33 Item 1) FRAME (P/O PL 11.35 Item 1) BUSHING ROLLER CABLE CLIP BELT (P/O PL 11.35 Item 1) BELT (P/O PL 11.35 Item 1) LOWER BAFFLE BRUSH IDLER GUIDE IDLER SHAFT (P/O PL 11.35 Item 1) BYPASS TRANSPORT GATE BEARING SPRING IDLER BRACKET SPRING GROUND HARNESS DISK GATE (P/O PL 11.35 Item 1) STACKER LEADING BAFFLE IDLER SHAFT ROLLER (P/O PL 11.35 Item 20) SENSOR (Q1106) ROLLER (P/O PL 11.35 Item 1) WIRE HARNESS BRACKET REAR BLOCK BEARING BLOCK SPRING REFLECTIVE SENSOR (Q1167)

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Parts List

PL 11.35

PL 11.36 BTM PURGE TRANSPORT TOP BAFFLE Item

Part

Description

1

--

2

–

3

–

4 5 6 7 8 9 10 11 12 13

117S23176 30E53931 30K28472 125E420 – 9E6360 22K11291 32P1726 12K2630 125P552

PURGE TRANSPORT TOP BAFFLE ASSEMBLY (P/O PL 11.33 Item 2) BAFFLE FRAME (P/O PL 11.36 Item 1) IDLER BRACKET (P/O PL 11.36 Item 1) GROUND WIRE BRACKET CHANNEL ROLL BRUSH ROLLER SHAFT PINCH SPRING S ROLLER ASSEMBLY GUIDE SAFETY CABLE STATIC BRUSH

Parts List

PL 11.36

11/00 5-198

Revision DocuPrint 180F Service Manual

PL 11.37 BTM BYPASS TRANSPORT TOP BAFFLE ASSEMBLY Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10

22K11292 32P1726 125E420 30K28472 117S23176 9E6360 30E53931 30E56951

BYPASS TRANSPORT TOP BAFFLE ASSEMBLY (P/O PL 11.33 Item 3) BAFFLE FRAME (P/O PL 11.37 Item 1) S ROLLER ASSEMBLY GUIDE GROUND BRUSH CHANNEL WIRE HARNESS PINCH SPRING BRACKET SNAP BRACKET

Revision DocuPrint 180F Service Manual

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Parts List

PL 11.37

PL 11.38 BTM BYPASS TRANSPORT ENT BAFFLE ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7

– 6E32990 19E7100 22E12480 50E8951 –

8 9 10 11 12 13 14 15 16

121E2340 125E420 130E4440 6K11030 12K2790 29K1200 55K14680 413W10355 –

17

–

18 19 20 21

409W3091 152K56750 68E67250 6K10720

BYPASS TRANSPORT ENT BAFFLE ASSEMBLY (P/O PL 11.33 Item 4) BAFFLE (P/O PL 11.38 Item 1) SHAFT CABLE CLIP IDLER ROLL GATE SOLENOID BRACKET (P/O PL 11.38 Item 1) LINEAR SOLENOID GROUND BRUSH SENSOR SHAFT CABLE SOLENOID PIN TOP BAFFLE BEARING CABLE SPRING (P/O PL 11.38 Item 1) RETAINING RING (P/O PL 11.38 Item 1) EXTENSION SPRING PURGE GATE XPORT HARNESS IDLER BRACKET IDLER SHAFT

Parts List

PL 11.38

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Revision DocuPrint 180F Service Manual

PL 11.39 BTM ASSEMBLIES Item

Part

Description

1

22K27371

2

22K27363

3 4 5 – 6

15E31030 30K47221 423W34850 423W65350 127K17273

–

127K17283

7

91P4419

TRANSITION MODULE VERTICAL TRANSPORT TRANSITION MODULE PAPER TRANSPORT VERTICAL PLATE BRACKET LOWER PLATE BRACKET SYNCHRON BELT (60HZ) BELT (153T)(50HZ) TRANSITION MODULE MAIN DRIVE MOTOR (60HZ) (MOT1301) TRANSITION MODULE MAIN DRIVE MOTOR (50HZ) (MOT1301) CAUTION LABEL

Revision DocuPrint 180F Service Manual

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Parts List

PL 11.39

PL 11.40 BTM VERTICAL TRANSPORT ASSEMBLY Item

Part

Description

1

--

2

–

3 4 5 6 7 8 9 10 11 12 13 14 15

55K3923 55K3934 6K11270 6K4282 6K4293 22K11292 6K11280 9P4437 409W3094 125E420 – 23E3770 –

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

6E10461 22K14780 22K14810 409W3338 6E10471 30K47900 12E2310 6E10481 413W10555 413W15355 9P4417 3E3990 15E7131 413W10355 6E10040 32E1471 28E3100 13E6150 117S23171 117S23172 22K16450 15K11950 423W63050

BTM VERTICAL XPORT ASSEMBLY (P/O PL 11.39 Item 1) VERTICAL XPORT FRAME (P/O PL 11.40 Item 1) UPPER PIVOT BAFFLE LOWER PIVOT BAFFLE SHAFT SHAFT SHAFT ROLLER SHAFT EXTENSION SPRING EXTENSION SPRING GROUND BRUSH PAD SLIDE BELT (297T) IDLER PLATE (P/O PL 11.40 Item 1) LATCH SHAFT ROLLER ROLLER EXTENSION SPRING CATCH SHAFT LATCH BRACKET REAR LINK BAFFLE SHAFT SPLIT BEARING SPLIT BEARING TORSION SPRING HANDLE PLATE SHAFT BEARING PIVOT SHAFT UPPER GUIDE RETAINING BEARING IDLER PULLEY WIRE HARNESS WIRE HARNESS ROLLER IDLER PLATE BELT

Parts List

PL 11.40

11/00 5-202

Revision DocuPrint 180F Service Manual

PL 11.41 BTM PAPER TRANSPORT ASSEMBLY Item

Part

Description

1

--

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

– 55K14721 13E6150 – 6K11260 28E2601 26E8520 22K5411 125E420 9E6360 32P1726 22K14810 22K27410 409W3338 15K11950 15K11940 423W60550 423W65550 125P475 130E1440

22 23 24 25 26 27 28 29 30 31 32 33 34

6E34071 9E11661 15E7131 6E10471 12K1683 12E2310 3E3990 6E34060 413W10355 413W10555 413W15355 117S23175 117S23176

BTM PAPER TRANSPORT ASSEMBLY (P/O PL 11.39 Item 2) PAPER TRANSPORT FRAME LOWER BAFFLE PULLEY BEARING SHAFT RETAINER BEARING RETAINER ROLLER GROUND BRUSH PINCH SPRING IDLER GUIDE ROLLER IDLER EXTENTION SPRING IDLER PLATE IDLER PLATE BELT BELT STATIC BRUSH PAPER TRANSPORT SENSOR (Q1384) LATCH SHAFT LATCH SPRING PLATE SHAFT LATCH SPRING REAR LINK HANDLE BAFFLE SHAFT BEARING BEARING SPLIT BEARING WIRE HARNESS WIRE HARNESS

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Parts List

PL 11.41

PL 24.1 CONNECTORS PIN AND SOCKET HOUSING (1 OF 2) Item 1 2 3 4 5 6 7 8 9

Part

Description

– – – – – – – – 713W42020

PLUG HOUSING RECEPTACLE HOUSING RECEPTACLE HOUSING CONNECTOR RECEPTACLE HOUSING PLUG HOUSING PLUG HOUSING SOCKET HOUSING 20 POS HSG W/O LATCH

Parts List

PL 24.1

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Revision DocuPrint 180F Service Manual

PL 24.2 CONNECTORS PIN AND SOCKET HOUSING (2 OF 2) Item

Part

Description

1 2 3 4

– – – 713W31231

5 6

– –

PIN HOUSING SOCKET HOUSING PIN HOUSING 12 PINS SINGLE ROW RECEPTACLE HOUSING PLUG HOUSING SOCKET HOUSING

Revision DocuPrint 180F Service Manual

11/00 5-205

Parts List

PL 24.2

PL 24.3 CONNECTORS PINS AND SOCKETS Item

Part

Description

1 2 3 4 5 6 7

– – – – – – 113E27710

8

113E27720

9 10 11 12 13 14

713W40120 – – – – –

SOCKET PIN PIN SOCKET PIN SOCKET SOCKET CONT 14-16 AWG CRIMP METRI-MATE PIN CONTACT 14-16 AWG CRIMP METRI-MATE SOCKET CONT 24-20 AWG PIN SOCKET SOCKET PIN SOCKET

Parts List

PL 24.3

11/00 5-206

Revision DocuPrint 180F Service Manual

PL 24.4 TERMINALS Item

Part

Description

1

716W10503

2 3 4

– – 716W793

18-14 AWG STRAIGHT FEM QUICK CONNECT BARE CRIMP PLAIN RING FASTON TERMINAL POLARIZING KEY

Revision DocuPrint 180F Service Manual

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Parts List

PL 24.4

PL 24.5 ELECTRICAL MISCELLANEOUS ITEMS Item

Part

Description

1 – – – – – 2 3 – – – 4 5 6 7

420W10201 420W10301 420W10701 420W11001 420W10901 420W30101 – 419W101 419W201 419W1401 19P80473 – – – –

8 9 10 11 12 13 14 15

– – – – – 120E1340 – 107P280

CABLE TIE (95.3MM) CABLE TIE (137.2MM) CABLE TIE (203.2MM) CABLE TIE (281.4MM) CABLE TIE (102.6MM) CABLE TIE (96.5MM) CABLE BLOCK NYLON P CLAMP (D.115) NYLON P CLAMP (D.172) NYLON P CLAMP (D.297) GROUND CLAMP (D.375) RETAINER STANDOFF CATERPILLAR GROMMET FUSE (1AMP TYPE 1 QUICK ACTING) SHIELD BATTERY BUSHING SCREW LOCK (FEMALE) CONNECTOR SHUNT CABLE HOLDER TWIST TIE DIODE W/ CONNECTOR

Parts List

PL 24.5

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PL 25.1 FIELD TOOLS AND SPECIAL TOOLS

PL 25.2 CONSUMABLES

Item

Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

600T80026 600T80025 18E620 82E4161 32E3440 32E2071 53K880 600S7321 – 600K2060 600K2070 600K71181 600K71192 600T2008 30E77630 130K44671 50K25070 50K25081 93E690 93E700 600K70990 600K71000 600K71010 600S1858 600K71100

26 27 28

600K71210 600K71220 600K25814

8X COMPARITOR CLEARWAVE POSITION AND DIMENSION GAUGE GAUGE TOOL IMAGE QUALITY SYSTEM INSERTER GUIDE (9.11) INSTALLATION GUIDE (8.2) MANOMETER (7.15) METRIC HARDWARE KIT MOLEX MINI SOCKET MOLEX WIRE KIT (F) MOLEX WIRE KIT (M) OZONE BLOWER KIT (50HZ)(TAG P-490) OZONE BLOWER KIT (60HZ)(TAG P-490) P/R DRIVE COUPLING ALIGNMENT TOOL SET UP BRACKET (9.26) TRANSFER BLADE TIMING TOOL VACUUM CLEANER KIT (60HZ) VACUUM CLEANER KIT (50HZ) WRENCH (9.5MM, 16MM, 22MM)(7.15) WRENCH (9.5MM, 11.5MM, 15MM)(7.15) AIR LINE REPAIR KIT (O-RING 23E16990) AIR LINE REPAIR KIT (O-RING 23E17000) AIR LINE REPAIR KIT (O-RING 23E17010) CONNECTOR CAP KIT (116H251) RELIB CONNECTOR KIT (43E170 116H251 120E500 713W3123 713W13123) CABLE TIES KIT (120E500) TIN METRIMA KIT (117P20615 713W20823 713W21623) 2M SM KIT

Revision DocuPrint 180F Service Manual

1 2 3 4 5 6 7 8 9 10 – 11

Part

Description

99P3211 99E3270 8R2955 43P81 70P31 99P3044 130E2290 93K450 93K460 43E170 43E500 95E14850

CHALK POUCH DISPOSAL BAGS FUSER AGENT (SEE CAUTION) LENS/MIRROR CLEANER LUBRICANT SOLDER TEMP. TAPE KIT TONER WASTE BOTTLE (50HZ) TONER WASTE BOTTLE (60HZ) DEOXIDIZER CLEANER ALTERNATE PHOTORECEPTOR BELT BAG

NOTE: CAUTION. DO NOT USE FUSER SHIELD IN MICR PRINTERS. PRINT QUALITY DEFECTS WILL OCCUR FROM USE OF FUSER SHIELD.

11/00 5-209

Parts List

PL 25.1, PL 25.2

Common Hardware A-MA Item

Part

Description

A B C D E F G H J K L M N P R S T U V W X Y Z AA AB AC AD AE AF AG AH AK AL AM AN AP AR AS AT AU AV AW AX AY AZ BA BB BC BD

102W6255 102W6355 102W6455 102W6555 102W10255 102W10355 102W10455 102W10555 102W10755 103W16502 103W19502 103W19802 103W22701 103W22802 103W23001 103W28801 112W410 112W510 112W2410 112W2503 112W4503 112W5154 112W5155 112W5255 112W5354 112W5355 112W5455 112W5655 112W5755 112W5855 112W5955 112W7254 112W7255 112W7354 112W7355 112W7356 112W7455 112W7456 112W7655 112W7755 112W7855 112W8055 112W8155 112W11355 112W11455 112W11655 112W11755 112W13755 112W16309

SCREW (M3 X 6) SCREW (M3 X 8) SCREW (M3 X 10) SCREW (M3 X 12) SCREW (M4 X 6) SCREW SCREW (2.9 X 13) SCREW (M4 X 12) SCREW SCREW (4-40 X 5/16) SCREW (6-32 X 5/16) SCREW (6-32 X 1/2) SCREW (8-32 X 7/16) SCREW (8-32 X 1/2) SCREW (8-32 X 5/8) SCREW (10-32 X 1/2) SCREW (4-40 X 1/4) SCREW (4-40 X 5/16) SCREW (4-40 X 1/4) SCREW (4-40 X 5/16) SCREW (4-40 X 5/16) SCREW (M3 X 6) SCREW (M3 X 6) SCREW (M3 X 8) SCREW (M3 X 10) SCREW (M3 X 10) SCREW (M3 X 12) SCREW (M3 X 16) SCREW (M3 X 20) SCREW (M3 X 25) SCREW (M3 X 30) SCREW (M4 X 8) SCREW (M4 X 8) SCREW (M4 X 10) SCREW SCREW (M4 X 10) SCREW (M4 X 12) SCREW (M4 X 12) SCREW (M4 X 16) SCREW (M4 X 20) SCREW (M4 X 25) SCREW (M4 X 35) SCREW (M4 X 40) SCREW MACH HEX SCREW (M6 X 12) SCREW (M6 X 16) SCREW (M6 X 20) SCREW (M8 X 20MM) SCREW (4-40 X 3/16)

Parts List

Common Hardware A-MA

BE BF BG BH BJ BK BL BM BN BP BR BS BT BU BV BW BX BY BZ CA CB CC CD CE CF CG CH CJ CK CL CM CN CP CR CS CT CU CV CW CX CY CZ DA DB DC DD DE DF DG DH DJ DK 11/00 5-210

112W19409 112W22809 112W24503 112W24510 112W24610 112W25155 112W25355 112W25455 112W26410 112W26510 112W26603 112W26610 112W27255 112W27310 112W27355 112W27455 112W27655 112W27851 112W35853 112W36053 112W39510 113W6055 113W6155 113W6255 113W6355 113W6455 113W6555 113W6755 113W6855 113W6955 113W8255 113W10155 113W10255 113W10355 113W10455 113W10555 113W10655 113W10755 113W10855 113W10955 113W13402 113W16202 113W16302 113W16402 113W16502 113W16802 113W17202 113W19303 113W19402 113W19404 113W19501 113W19502

SCREW (6-32 X 1/4) SCREW (8-32 X 1/2) SCREW (6-32 X 5/16) SCREW (6-32 X 5/16) SCREW (6-32 X 3/8) SCREW SCREW (M3 X 10) SCREW SCREW (6-32 X 1/4) SCREW (6-32 X 5/16) SCREW (6-32 X 3/8) SCREW (6-32 X 5/16) SCREW (M4 X 8) SCREW (6-32 X 1) SCREW (M4 X 10) SCREW (M4 X 12) SCREW M4 SCREW SCREW SCREW SCREW (8/32 X .312) SCREW (M3 X 4) SCREW (M3 X 5) SCREW (M3 X 6) SCREW (M3 X 8) SCREW (M3 X 10) SCREW (M3 X 12) SCREW (M3 X 16) SCREW (M3 X 20) SCREW (M3 X 25) SCREW (M3 X 6) SCREW (M3 X 4) SCREW (M4 X 6) SCREW (M4 X 8) SCREW (M4 X 10) SCREW (M4 X 12) SCREW (M4 X 14) SCREW (M4 X 16) SCREW (M4 X 20) SCREW (M4 X 25) SCREW (2-56 X 1/4) SCREW (4-40 X 1/8) SCREW (4-40 X 1/16) SCREW (4-40 X 1/4) SCREW (4-40 X 5/16) SCREW (4-40 X 1/2) SCREW (4-40 X 3/4) SCREW (6-32 X 1/16) SCREW (6-32 X 1/4) SCREW (6-32 X 1/4) SCREW (6-32 X 5/16) SCREW (6-32 X 5/16) Revision DocuPrint 180F Service Manual

DL DM DN DP DR DS DT DU DV DW DX DY DZ EA EB EC ED EE EF EH EJ EK EL EM EN EP ER ES ET EU EV EW EX EY EZ FA FB FC FD FE FF FG FJ FK FL FM FP FR FS FT FV FW

113W19602 113W19701 113W19802 113W20002 113W20202 113W20402 113W22502 113W22602 113W22702 113W22802 113W23002 113W23202 113W25802 113W28402 113W29602 113W35858 113W36057 121W10255 121W10455 121W30255 121W30355 121W30455 121W30555 121W30655 121W30856 121W50355 121W70655 131W4053 131W4253 131W4653 131W7053 131W7153 131W7253 131W7353 131W7553 131W7653 131W7753 131W8053 131W13253 131W13353 131W13553 131W10353 131W16553 131W16653 131W16853 131W17253 131W19453 131W20653 131W34253 131W37753 132W553 132W753

SCREW (6-32 X 3/8) SCREW (6-32 X 7/16) SCREW (6-32 X 1/2) SCREW (6-32 X 5/8) SCREW (6-32 X 3/4) SCREW (6-32 X 7/8) SCREW (8-32 X 5/16) SCREW (8/32 X 3/8) SCREW (8-32 X 7/16) SCREW (8-32 X 1/2) SCREW (8-32 X 5/8) SCREW (8-32 X 3/4) SCREW (10-24 X 1/2) SCREW SCREW (10-32 X 1) SCREW M4 SCREW SETSCREW (M3 X 4) SETSCREW (M3 X 6) SCREW SET SETSCREW (M4 X 5) SETSCREW (M4 X 6) SETSCREW (M4 X 8) SCREW SETSCREW (M4 X 16) SET SCREW SCREW (M6 X 10) SCREW (M3 X 6) SCREW (M3) SCREW (M3 X 20) SCREW (M4 X 6) SCREW (M4 X 8) SCREW (M4 X 10) SCREW (M4 X 12) SCREW (M4 X 16) SCREW (M4 X 20) SCREW (M4 X 25) SCREW SCREW (M6 X 10) SCREW (M6 X 12) SCREW (M6 X 16) SCREW SCREW (M8 X 16) SCREW (M8 X 20) SCREW (M8 X 30) SCREW (M8 X 50) SCREW MACH. SCREW (M10 X 20) SCREW SCREW CAPSCREW (M3 X 12) CAPSCREW (M3 X 16)

Revision DocuPrint 180F Service Manual

FX FY FZ GA GB GC GD GE GG GH GJ GK GL GM GN GP GR GS GT GU GV GW GX GZ HA HB HC HD HE HF HG HH HJ HK HL HM HN HP HR HS HT HU HV HW HX HY HZ JA JB JD JE JF 11/00 5-211

132W853 132W3253 132W3353 132W3453 132W3553 132W3653 132W3753 132W3853 132W10953 132W13153 134W11050 134W12550 136W5050 136W32050 136W32550 136W34050 136W36050 136W38050 136W40050 136W42050 136W46050 136W50050 136W33550 153W13451 153W13452 153W13453 153W13653 153W13702 153W13751 153W13851 153W13853 153W13951 153W17551 153W17552 153W17751 153W18251 153W23852 156W13352 156W13452 156W13552 156W13852 156W13952 156W15452 156W15552 156W15652 156W17452 156W17552 156W17652 156W17752 156W23555 156W27555 158W15353

SCREW (M3 X 20) CAPSCREW (M4 X 6) CAPSCREW (M4 X 8) CAPSCREW (M4 X 10) CAPSCREW (M4 X 12) SCREW (M4 X 14) CAPSCREW (M4 X 16) SCREW (M4 X 20) SCREW (M6 X 25) SCREW (M8 X 35) SCREW (8 X 30) SHOULDER SCREW (10 X 12MM) SCREW (M3 X 5) SCREW (M4 X 2) SCREW (M4 X 2.5) SCREW (M4 X 4) SCREW (M4 X 6) SCREW SCREW (M4 X 10) SCREW (M4 X 12) SCREW (M4 X 16) SCREW (M4 X 20) SHOULDER SCREW SCREW (M4 X 9.5) SCREW (2.9 X 9.5) SCREW THREAD SCREW THREAD SCREW SCREW (M4 X 19) SCREW (3.5 X 6.5) SCREW HEX SCREW (2.9 X 25) SCREW (4.2 X 13) SCREW (4.2 X 13) SCREW (4.2 X 19) SCREW (4.2 X 45) SCREW (2.9 X 22) SCREW (2.9 X 4.5) SCREW (2.9 X 9.5) SCREW (2.9 X 13) SCREW (2.9 X 22) SCREW (25) SCREW (3.5 X 9.5) SCREW SCREW (3.5 X 16) SCREW (4.2 X 9.5) SCREW (4.2 X 13) SCREW (4.2 X 16) SCREW (4.2 X 19) SCREW SCREW SCREW (M3 X 5) Parts List

Common Hardware A-MA

JG JH JJ JK JL JM JN JR JS JT JU JV JW JX JY JZ KA KB KC KD KE KF KG KH KJ KK KL KM KN KP KR KS KT KU KV KW KX KY KZ LA LB LC LD LE LF LG LH LJ LK LL LM LN

158W17352 158W17452 158W17552 158W17652 158W17752 158W17852 158W17952 158W21452 158W21652 158W21752 158W21852 158W21952 158W22052 158W31352 158W31452 158W31552 158W40452 181W10351 183W10351 190W30452 201W355 201W455 201W655 201W755 201W3455 201W11302 215W10350 215W10450 215W10650 215W10750 215W12450 220W350 220W450 220W550 220W650 232W20652 232W20752 232W21252 235W10402 235W11402 235W20402 235W20502 236W4351 236W4551 236W12003 240W450 251W10355 251W10356 251W10455 251W10456 251W10555 251W10655

SCREW (M4 X 6) SCREW (M4 X 8) SCREW (M4 X 10) SCREW (M4 X 12) SCREW (M4 X 16) SCREW (M4 X 20) SCREW (M4 X 20) SCREW (M6 X 8) SCREW (M6 X 12) SCREW (M6 X 16) SCREW (M6 X 20) SCREW (M6 X 20) SCREW (M6 X 30) SCREW (M3 X 6) SCREW (M3 X 8) SCREW (M3 X 10) SCREW (M4 X 8) WELD STUD STUD WELD STUD (M4 X 10) NUT (M3) NUT (M4) NUT (M6) NUT (M8) NUT (M4) NUT NUT (M3) NUT (M4) NUT (M6) NUT (M8) NUT (M4) NUT (M3) NUT (M4) NUT-HEXAGON NUT (M6) NUT (M3) NUT NUT (M4) NUT (1.59MM) NUT NUT (M3) NUT (M3) SCREW NUT (4MM) NUT (.112) NUT WELD WASHER (M3) WASHER (M3) WASHER (M4) WASHER (M4) WASHER WASHER (|6)

Parts List

Common Hardware A-MA

LP LR LS LT LU LV LW LX LY LZ

11/00 5-212

251W10656 251W10755 251W10855 251W10856 251W16455 251W16555 251W16655 251W16755 251W16855 251W16955

WASHER (M6) WASHER (M8) WASHER (M10) WASHER (M8) WASHER (M4) WASHER (M5) WASHER (M6) WASHER (M8) WASHER (M10) WASHER

Revision DocuPrint 180F Service Manual

Common Hardware MA-BAN Item

Part

Description

MA MB MC MD ME MF MG MH MJ MK ML MM MN MP MR MS MT MU MV MW MX MY MZ NA NB ND NE NF NG NH NJ NK NL NM NN NP NR NS NT NU NV NW NX NY NZ PA PB PC PD

251W18855 251W21301 251W80201 252W10901 252W11101 252W12501 256W20354 256W20454 256W20654 256W20754 256W20854 256W20954 259W10502 259W11102 259W30251 259W30351 259W30551 265W450 265W550 265W650 265W850 265W1050 265W1450 271W3652 271W3752 286W2454 286W3654 286W4054 287W12053 287W16953 287W31253 287W31454 287W31654 287W42054 287W63854 301W2550 301W4350 301W5050 301W6450 301W6550 301W9350 301W10150 350W12251 350W12651 351W3903 351W10451 351W10651 351W10751 351W10851

WASHER (M10) WASHER (M4) WASHER WASHER (NO. 6) WASHER (N0. 8) WASHER (.260MM) LOCKWASHER (M3) LOCKWASHER (M4) LOCKWASHER (M6) LOCKWASHER (M8) LOCKWASHER (M10) WASHER,LOCK SPR WASHER (M4) WASHER WASHER (M3) LOCKWASHER (M4) LOCKWASHER (M4)(6) WASHER SPRING WASHER (5) WASHER (M6) WASHER (M8) WASHER (M10) WASHER (M14) PIN M3 X 16) PIN (3 X 20MM) SPRING PIN (M12) SPRING PIN (M16) SPRING PIN PIN (6 X 20MM) PIN (M7 X 20) PIN (9 X 12MM) PIN (3 X 14MM) PIN (3 X 16MM) PIN (4 X 20MM) PIN (6 X 38MM) KEY (2 X 16MM) KEY (3 X 12MM) KEY (3 X 28MM) KEY SHAFT KEY (4 X 16MM) KEY (5 X 5 X 12) KEY (5 X 5 X 32) RETAINING RING (22MM) RETAINING RING (26MM) RETAINING RING (10MM) RETAINING RING (M4) RETAINING RING (M6) RETAINING RING (M7) RETAINING RING (M8)

Revision DocuPrint 180F Service Manual

PE PF PG PH PJ PK PL PM PN PP PR PS PT PU PV PW PX PY PZ RA RB RC RD RE RF RG RH RJ RK RL RM RN RP RR RS RT RU RV RW RX RY RZ SA SB SC SD SE SF SG SH SJ SK 11/00 5-213

351W10951 351W11051 351W11251 351W11651 351W11851 351W12551 351W12751 351W13151 354W355 354W555 354W855 354W20452 354W20552 354W20652 354W20752 354W20852 354W20952 354W21052 354W21152 354W21252 354W21352 354W21452 354W21552 354W21652 354W21752 354W21852 354W24251 356W5002 356W10453 356W10553 356W10653 356W10853 356W11053 357W3103 358W11803 357W3703 360W2503 360W3103 362W7502 362W10002 366W91702 366W92902 366W94302 158W40652 259W30751 153W12653 359W1203 153W27552 287W31653 351W13551 156W23455 131W34153

RETAINING RING (M9) RETAINING RING (M10) RETAINING RING (M12) RETAINING RING (M16) RETAINING RING (M18) RETAINING RING (M25) RETAINING RING (M28) RETAINING RING (M30) CLIP-RET KL CLIP-RET KL CLIP-RET KL E-RING (2-2.5MM) E-RING (2.5-3MM) E-RING (3-4MM) E-RING (4-5MM) E-RING (5-7MM) E-RING (6-8MM) E-RING (7-9MM) E-RING (8-11MM) E-RING (9-12MM) E-RING (10-14MM) E-RING (11-15 MM) E-RING (13-18MM) RETAINING RING E-RING (20-31MM) RETAINING RING (M24) ALTERNATE RETAINING RING (1/2) RETAINING RING (4MM) RING RETAINR RETAINING RING (6MM) RETAINING RING (8MM) RETAINING RING (10MM) RETAINING RING (.312) RETAINING RING (1.188) RETAINING RING RETAINING RING RETAINING RING RETAINING RING RETAINING RING RETAINING RING RETAINING RING RETAINING RING SCREW (M4 X 12) WASHER (M4) SCREW (M3 X 13) RETAINING RING SCREW PIN RETAINING RING SCREW SCREW Parts List

Common Hardware MA-BAN

SL SM SN SP SR SS ST SU SV SW SX SY SZ TA TC TE TF TG TH TJ TK TL TM TN TP TR TS TU TW TX TY TZ UA UC UD UF UG UH UJ UL UN UP UR UW UY UZ VA VB VC VD VE VF

131W37353 153W11453 153W17452 153W17652 153W27952 153W62353 156W17555 113W13801 201W10302 158W31652 158W13553 153W15451 136W35050 131W34053 287W62554 158W40552 112W27755 112W7458 153W13651 131W37053 121W30755 287W21053 131W7953 201W22002 251W23201 113W36058 153W12253 251W10556 113W36258 233W12102 252W12301 113W11155 286W2254 220W850 236W451 158W35752 134W10550 286W3854 158W31752 251W16355 158W40752 112W11855 251W22601 158W26505 153W13253 259W30451 258W12702 256W11902 201W22102 158W40852 131W31802 113W23802

SCREW SCREW SCREW (4.2 X 9.5) SCREW (4.2 X 16) SCREW (4.2 X 25) ROUND SCREW SCREW SCREW NUT SCREW SCREW SCREW SCREW SCREW PIN SCREW (M4 X 10) SCREW (M4 X 20) SCREW (M4 X 12) SCREW SCREW SETSCREW PIN SCREW NUT WASHER SCREW (M4 X 10) SCREW WASHER SCREW (M4 X 12) NUT WASHER SCREW SPRING PIN NUT PUSH ON NUT SCREW SHOULDER SCREW SPRING PIN SCREW WASHER SCREW (M4 X 16) SCREW (M6 X 25) WASHER SCREW, PAN HD SCREW LOCKWASHER LOCKWASHER LOCKWASHER NUT SCREW SCREW SCREW

Parts List

Common Hardware MA-BAN

VG VH VJ VL VM VN VP VR VS VT VU VV VW WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WU WV WW WX WY WZ XA XB XC XD XE XF XG XH XJ XK XL XM XN XP XR XS 11/00 5-214

201W10902 121W10255 121W50555 232W21152 256W11802 259W11502 190W30752 201W11702 217W1852 271W1852 351W11351 351W11551 158W35452 153W13551 136W2550 131W6355 158W40352 112W36610 153W11253 134W10450 251W10901 112W40010 131W17453 251W23602 271W652 301W2750 141W30852 153W14753 220W20450 301W2250 112W25755 121W10655 131W7853 220W20350 112W25655 113W3255 112W25255 191W22301 259W10902 158W6156 220W10450 112W92555 112W92755 112W96555 113W11055 113W36658 156W13455 113W56755 158W19552 121W30855 156W17455 141W30452

NUT SETSCREW SETSCREW NUT LOCKWASHER LOCKWASHER STUD NUT NUT PIN RETAINING RING RETAINING RING SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW WASHER SCREW SCREW WASHER PIN KEY SETSCREW SCREW NUT RETAINING RING SCREW SETSCREW SCREW NUT SCREW SCREW SCREW STANDOFF WASHER SCREW NUT SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW (M5X10) SCREW (M4X12) SCREW SCREW Revision DocuPrint 180F Service Manual

XT XV XW XX XY XZ YA YB YC YD YF YG YH YJ YK YL YN YR YS YT YU YX YY YZ ZB ZC ZD ZE ZF ZG ZH ZJ ZK ZL ZM ZN ZP ZR ZS ZU ZV ZW ZX ZY ZZ AAA AAB AAC AAD AAE AAF AAH

112W7358 156W17755 112W13204 256W20554 132W6453 351W4312 131W13953 220W10650 259W24250 121W30457 251W23502 251W22301 105W24602 112W27955 113W28302 153W23452 153W23552 131W37553 102W13555 236W651 153W23752 112W13855 131W14253 156W27455 112W810 112W2610 112W22609 112W27110 112W36510 112W36810 112W39610 112W39810 112W39811 112W57810 112W66610 112W66710 158W36610 190W28701 201W10702 201W11902 220W10904 220W11304 220W11504 251W23202 252W10601 259W10302 153W42353 153W12753 153W41253 215W12650 153W27554 121W30955

SCREW SCREW SEM SCREW LOCK WASHER CAP SCREW RETAINING RING SCREW (M6X35) NUT (M6) LOCK WASHER SET SCREW WASHER WASHER RND HD SCREW SCREW PAN SCREW SCREW SCREW SCREW SCREW SPEED NUT SCREW SCREW SCREW SCREW SCREW SCREW SEMS SCREW SCREW SEMS SCREW SEMS SCREW SCREW SEMS SCREW SEMS SCREW SEMS SCREW SEMS SCREW SEMS SCREW SCREW STUD NUT NUT NUT NUT NUT WASHER WASHER LOCK WASHER SCREW SCREW SCREW LOCKNUT SCREW (M4 X 13) SETSCREW

Revision DocuPrint 180F Service Manual

AAJ AAK AAL AAM AAN AAP AAR AAS AAU AAV AAW AAZ ABA ABB ABC ABD ABE ABF ABG ABH ABJ ABK ABL ABM ABN ABP ABR ABS ABT ABU ABV ABW ABX ABY ABZ ACA ACB ACC ACD ACE ACF ACG ACH BAF BAG BAH BAJ BAK BAL BAM BAN

11/00 5-215

112W610 SCREW (4-40) – SCREW 112W19501 SCREW 112W37110 SCREW 112W39710 SCREW 112W63810 HEX SEMS SCREW 131W22602 SCREW 220W10504 LOCKNUT 112W54610 SEMS SCREW 113W35859 MACH ROUND SCREW 201W11302 NUT 251W21302 WASHER 256W10302 LOCK WASHER 113W16801 SCREW 113W26059 SCREW 153W27552 SELF TAPPING (M4) 131W9255 SCREW 271W12452 DOWEL PIN 252W11601 WASHER 113W21202 SCREW (6-32 X 1-3/4) 354W20652 RETAINING RING 201W10502 HEX NUT 232W11502 NUT 259W30351 LOCK WASHER (M4) 112W27010 SCREW 220W10704 NUT 258W10702 WASHER 112W29455, 113W16602 SCREW 113W25658 PAN HEAD SCREW 102W8356 MACH SCREW FLAT 112W26810 SEMS SCREW 113W19804 SCREW 203W10701 NUT 256W10502 LOCK WASHER 113W54555 PAN HEAD SCREW 112W25960 MACH PAN SCREW 153W1799 SCREW 158W40457 THREAD ROLL SCREW 258W11502 LOCK WASHER 134W10750 SCREW 102W8355 MACHINE SCREW 256W10702 LOCKWASHER 220W20850 SELF LOCK HEX NUT 301W2950 KEY 301W3050 KEY 301W7050 KEY 301W9950 KEY 287W21453 HEADED PIN 366W403 HITCH PIN CLIP 112W25855 SCREW 112W27555 SCREW (M4)

Parts List

Common Hardware MA-BAN

Part Number Index

Table 1 Part Number Index Table 1 Part Number Index

Part Number

Part List

2K8451

PL 9.17

Part Number

Part List

2E8490

PL 8.12

1R538

PL 9.1

2E9981

PL 7.3

1K1110

PL 8.4

2P11063

PL 9.2

1K7722

PL 8.7

2P11924

PL 7.2

1K10281

PL 10.2

2E12191

PL 7.3

PL 10.3

2P13126

PL 7.7

1K10896

PL 4.10

2E15210

PL 10.3

1K11670

PL 9.24

2K15311

PL 4.3

PL 9.25

2K15384

PL 4.3

1K13422

PL 10.5

2S15742

PL 7.7

1K14575

PL 11.17

2K16321

PL 9.24

1K14583

PL 11.17

2P16449

PL 7.10

1E14670

PL 10.6

2K16483

PL 9.24

1K14842

PL 4.10

2K17140

PL 10.2

1K16770

PL 4.22

2K17593

PL 4.3

PL 4.23

2K17803

PL 4.8

PL 4.22

2K17823

PL 10.2

PL 4.23

2K17833

PL 10.2

1E17060

PL 4.9

2K17952

PL 4.3

1K27451

PL 11.2

2K18040

PL 4.4

1K31860

PL 4.26

2K18050

PL 9.21

1E39400

PL 4.10

2E18971

PL 4.8

1K45620

PL 9.10

2K19564

PL 11.11

1K46540

PL 8.31

1K47890

PL 11.12

1K54080

PL 4.10

1K54090

PL 4.10

1K54100

1K16780

PL 11.13 PL 11.34 2K19575

PL 11.30

PL 4.10

2K19622

PL 4.7

1K54380

PL 4.26

2E20210

PL 10.1

1K54390

PL 4.26

2E20311

PL 4.8

1K56342

PL 11.29

2E20920

PL 7.13

PL 11.30

2E20930

PL 7.13

1K56352

PL 11.29

2E22741

PL 11.3

PL 11.31

2E22844

PL 11.7

1K64610

PL 8.33

2E2621

PL 9.2

2E22930

PL 9.23

PL 9.4

2E23831

PL 11.7

2K4692

PL 4.17

2E6220

PL 7.1

2K24142

PL 4.20

2K8310

PL 7.13

2K24790

PL 4.7

Parts List

Part Number Index

PL 11.31

PL 11.8

PL 11.8

11/00 5-216

Revision DocuPrint 180F Service Manual

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

2K26160

PL 8.9

2E39450

PL 4.10

2E26673

PL 4.14

2E39610

PL 4.10

2E26702

PL 11.21

2K39610

PL 4.2

2E26712

PL 11.21

2E40360

PL 7.14

2E26722

PL 11.21

2K54211

PL 4.25

2E26732

PL 11.21

2E62080

PL 2.5

2E28100

PL 9.4

2E63860

PL 11.9

2E28110

PL 9.4

3K43

PL 10.3

2E28120

PL 9.4

3E460

PL 4.22

2E28130

PL 9.4

3E470

PL 4.22

2K28182

PL 4.12

3E524

PL 8.3

2K28192

PL 4.12

2K28481

PL 4.15

3E531

PL 8.3

PL 8.30

2K28500

PL 4.15

2K28510

PL 4.11

3E550

PL 10.2

PL 4.14

3K1341

PL 9.5

PL 4.15

3K1520

PL 7.11

PL 4.25

3P2502

PL 4.12

PL 4.26

3E2741

PL 8.22

PL 8.30

PL 4.27

PL 8.26

2E28570

PL 4.17

PL 8.29

2K28691

PL 4.15

PL 10.18

2E32073

PL 11.21

2E32200

PL 4.11

3K2841

PL 4.15

3K2851

PL 9.17

PL 4.25

3K3262

PL 7.3

PL 4.26

3E3930

PL 11.23

PL 4.27

3E3990

PL 8.3

3E3990

PL 8.17

2E32380

PL 11.6

2E32472

PL 11.6

PL 10.20 PL 11.25

PL 8.6

2K32771

PL 4.10

PL 8.19

2E34650

PL 4.8

PL 8.21

2E34660

PL 4.8

PL 8.26

2E36140

PL 9.13

PL 8.29

2E36950

PL 9.3

PL 8.30

PL 9.4

PL 10.17

2E37450

PL 9.3

PL 11.4

2E37610

PL 11.18

PL 11.11

2K38431

PL 1.11

PL 11.13

2E38920

PL 4.7

PL 11.28

2E38930

PL 4.7

PL 11.34

Revision DocuPrint 180F Service Manual

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Parts List

Part Number Index

Table 1 Part Number Index Part Number

Table 1 Part Number Index

Part List

Part Number

Part List

PL 11.40

3E14171

PL 4.11

PL 11.41

PL 4.13

3E4390

PL 10.13

3E14191

PL 4.13

PL 10.21

3E14862

PL 11.20

3K4650

PL 2.1

3E15060

PL 11.20

3E4751

PL 10.7

3E15430

PL 11.20

3K4781

PL 7.3

3E16810

PL 11.29

3E4980

PL 7.3

3E17420

PL 11.28

PL 7.15

3E19601

PL 11.4

3K5153

PL 11.17

3P25202

PL 1.4

3E5230

PL 7.3

PL 1.8

3E5240

PL 7.3

PL 1.16

3K5292

PL 11.17

PL 1.17

3E5301

PL 11.24

PL 1.19

3E5380

PL 9.13

PL 1.21

3K5461

PL 11.20

3K5480

PL 4.1

PL 4.28 3E25870

PL 4.1

3E39541

PL 4.14

PL 4.5

3K5530

PL 4.5

3K5850

PL 11.29

3S6255

PL 4.1

3K6941

PL 4.11

3E45890

PL 4.12

PL 4.13

3E50450

PL 11.1

PL 4.25

3E50510

PL 10.7

3E8491

PL 8.9

4K21

PL 9.19

3E9520

PL 9.25

4P101

PL 1.4

3E10710

PL 9.25

3E10730

PL 10.4

3E11300

PL 10.23

4E300

3E11310

PL 9.12

4P778

PL 10.13

3E11770

PL 10.6

4P820

PL 4.1

3E12190

PL 9.25

4E1860

PL 10.10

3E13010

PL 4.1

4E2100

PL 4.6

PL 4.5

4E2240

PL 4.26

PL 4.11

4E2801

PL 2.5

PL 4.13

4E3060

PL 4.13

PL 4.14

4E5240

PL 4.14

PL 4.25

5E222

PL 10.2

3E13300

PL 2.5

5E330

PL 4.16

3E13551

PL 10.23

5E370

PL 8.1

3E13610

PL 10.17

5E420

PL 8.1

3E13620

PL 10.17

5E510

PL 4.17

Parts List

Part Number Index

PL 4.24

PL 4.12 PL 8.26

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PL 8.26

Revision DocuPrint 180F Service Manual

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

5E520

PL 4.18

6K1751

PL 8.1

5E640

PL 4.17

6E1924

PL 8.2

5K651

PL 9.14

6K1931

PL 11.25

5K830

PL 4.17

6K2100

PL 8.9

5K840

PL 4.20

6K2681

PL 11.24

5E1533

PL 4.19

6K2861

PL 11.25

PL 8.15

6K2920

PL 7.17

PL 4.19

6K2941

PL 11.24

5K1790

PL 9.15

6K2970

PL 8.13

5E1812

PL 8.1

6E3020

PL 10.3

5E2140

PL 10.3

6K3291

PL 9.6

5E2233

PL 2.2

6E3550

PL 10.17

5K2410

PL 10.3 PL 10.5

6K4033

PL 8.23

5K2550

PL 4.17

6K4243

PL 8.19

5E2730

PL 10.2

6K4272

PL 8.17

5P3378

PL 7.11

6K4282

PL 11.40

5P3810

PL 11.30

6K4293

PL 8.17 PL 8.25

5E1722

PL 10.19

PL 11.31

PL 11.40

5E4381

PL 11.8

6K5013

5E4433

PL 11.30

6K5113

PL 11.31 5E6910

PL 8.21 PL 8.28

PL 11.30

6K5123

PL 8.21

PL 11.31

6K5872

PL 11.7

5E7481

PL 8.13

6K5963

PL 11.6

5E10870

PL 10.15

6K6070

PL 11.3

6K300

PL 8.9

6K6101

PL 11.3

6K601

PL 8.1

6K6111

PL 11.3

6K651

PL 8.7

6K6191

PL 10.22

6K661

PL 8.7

6K6200

PL 10.21

PL 8.33

6K6221

PL 10.22

6K671

PL 8.7

6K6250

PL 9.25

PL 8.33

6K6293

PL 11.11

6K701

PL 10.15

PL 11.13

PL 10.20 6K711

PL 10.15

6K720

PL 10.15

6K890

PL 10.15

6K950

PL 10.13

6K960

PL 10.15

6E1040

PL 4.22

Revision DocuPrint 180F Service Manual

PL 11.34 6K6301

PL 11.11 PL 11.13 PL 11.34

6K6311

PL 11.30 PL 11.31

6K6321

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PL 11.30 Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index Part List

Part Number

Part List

PL 11.31

6E10740

PL 10.8

6K6331

PL 11.30

6K10970

PL 11.4

6K6622

PL 11.8

6K11000

PL 11.4

6K7490

PL 10.22

6K11030

PL 11.38

6K7510

PL 7.11

6K11112

PL 8.10

6E7571

PL 7.12

6K11231

PL 11.11

Part Number

6E7590

PL 7.13

6K7640

PL 7.11

6K7931

PL 10.16

6K11260

PL 11.41

PL 10.17

6K11270

PL 11.40

PL 10.18

6K11280

PL 11.40

PL 10.19

6K13290

PL 8.4

PL 11.13 PL 11.34

PL 10.20

PL 8.31

6K7961

PL 8.21

6K13330

PL 11.9

PL 8.28

6K13350

PL 11.9

6E8051

PL 7.10

6K13380

PL 8.33

6K8101

PL 11.18

6K13390

PL 8.33

6K8141

PL 10.15

6K14050

PL 11.7

6K8250

PL 10.22 PL 10.23

6K14880

PL 11.12

PL 8.26

6K14900

PL 11.26

PL 11.2

6K14910

PL 11.26

6K8330

PL 10.13

6K14920

PL 11.26

6K9931

PL 11.28

6K14930

PL 4.19

6E10040

PL 8.18

6K15130

PL 8.17

PL 8.19

6K15140

PL 8.17

PL 11.40

6K15150

PL 8.17

6K10040

PL 10.18

6E15640

PL 10.9

6E10461

PL 8.17

6K18330

PL 11.30

6E8311

PL 11.8

PL 11.40

PL 11.31

6K10470

PL 8.1

6E20311

PL 10.17

6E10471

PL 8.17

6E20321

PL 10.17

PL 11.40

6E21280

PL 7.1

PL 11.41

6E21700

PL 8.23

6E10481

PL 8.17

6E22001

PL 11.28

PL 11.40

6E22200

PL 10.13

6K10580

PL 11.26

6E23261

PL 11.7

6K10590

PL 11.2

6K10720

PL 11.14

6E24730

PL 4.27

PL 11.35

6E31960

PL 11.2

PL 11.38

6E32990

PL 11.38

Parts List

Part Number Index

PL 11.8

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Table 1 Part Number Index Part Number

Part List

6E34060

PL 11.41

6E34071

Table 1 Part Number Index Part Number

Part List

PL 11.41

9K740

PL 7.16

7K120

PL 10.3

9P1366

PL 1.2

7K441

PL 9.14

7K461

PL 9.14

7K1401

PL 4.16

9E1560

PL 9.4

7K1700

PL 10.3

9P1609

PL 1.4

7E2211

PL 9.14

7E2221

PL 9.18

7E2231

PL 9.14

7K2371

PL 9.14

7K2900

PL 11.8

PL 1.3 PL 4.4

PL 1.5 PL 1.6 9P1698

PL 7.5

PL 4.17

9E1842

PL 10.4

7K3721

PL 9.14

9E2210

PL 11.27

7E4350

PL 4.19

9E2760

PL 4.17

7K4362

PL 11.2

9P3470

PL 4.18

7E6500

PL 8.6

9E3620

PL 7.11

7E6510

PL 8.6

9E3630

PL 4.17

7E7221

PL 9.14

9P4398

PL 7.13

7E7301

PL 9.16

9P4413

PL 4.16

7K8320

PL 4.16

9P4417

PL 8.18

7K8440

PL 10.24

7K9570

PL 4.17

7E10262

PL 9.25

9P4422

PL 7.4

7E10272

PL 9.25

9P4437

PL 8.5

7E10290

PL 9.24

PL 8.11

7K11700

PL 9.25

PL 8.18

7E14102

PL 11.11

PL 8.32

PL 11.13

PL 10.16

PL 11.34

PL 10.17

PL 11.11

PL 10.18

PL 11.13

PL 10.19

PL 11.34

PL 10.20

7E15501

PL 7.6

PL 8.19 PL 11.40

7E34470

PL 10.7

8K961

PL 8.8

9P4631

8K1221

PL 11.30

9P4694

PL 7.12

PL 11.31

9P4858

PL 7.11

8E2660

PL 9.14

9P4889

PL 8.8

8R2955

PL 25.2

9P4945

PL 7.7

8E3210

PL 8.8

9P4952

PL 7.3

8E3480

PL 10.23

9P4980

PL 10.16

8E4230

PL 11.7

9P5167

PL 4.18

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PL 11.40

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PL 7.2

Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part List

Part Number

Part List

9P5213

PL 9.2

9E18510

PL 10.9

9P5450

PL 4.16

9E19760

PL 9.23

9E6270

PL 4.16

9E20210

PL 10.22

9E6360

PL 8.29 PL 11.4

9E20220

PL 10.8

PL 11.14

9E20230

PL 10.8

PL 11.15

9E21030

PL 11.2

PL 11.16

9E21850

PL 11.23

PL 11.32

9E22150

PL 10.17

PL 11.35

9E23851

PL 11.20

PL 11.36

9E23900

PL 9.12

PL 11.37

9E23910

PL 9.12

PL 11.41

9E24041

PL 11.17

9E7170

PL 4.19

9E24101

PL 4.14

9E8160

PL 10.19

9E8170

PL 10.19

9E24440

PL 9.23

9E8490

PL 2.4

9E24521

PL 11.14

9E8520

PL 1.8

PL 11.30

PL 1.16

PL 11.31

PL 10.23

PL 11.28

PL 11.25

PL 4.24

9E8640

PL 8.6

9E8670

PL 4.20

9E24611

PL 9.2

9E9281

PL 8.4

9E24900

PL 8.15

PL 8.31

9E32340

PL 10.6

9E9320

PL 10.3

9E32551

PL 11.28

9E9350

PL 7.8

9E42550

PL 4.17

9E11140

PL 11.24

9E42920

PL 11.1

9E11661

PL 8.17

9E43230

PL 9.5

PL 11.41

9E43350

PL 4.17

PL 4.16

9E44420

PL 11.7 PL 11.4

9E12220

PL 11.35

9E12320

PL 8.15

9E13582

PL 11.25

9E44470

9E14380

PL 10.8

9E44720

PL 7.15

9E14420

PL 8.26

9E46410

PL 11.7

9E15100

PL 4.1

PL 11.8

PL 11.8 PL 11.17

PL 4.5 9E16211

PL 11.25

9E46510

PL 11.27

9E16610

PL 9.7

9E46990

PL 11.19

9E17910

PL 4.1

9E58240

PL 8.33

9E18032

PL 10.23

9E79660

PL 8.1

9E18042

PL 10.23

10E195

PL 10.2

Parts List

Part Number Index

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Table 1 Part Number Index Part Number

Part List

10K520

PL 10.16

10K714

PL 7.18

Table 1 Part Number Index Part Number

Part List

12K2630

PL 4.14

PL 11.41

10K724

PL 7.18

10K753

PL 11.17

10K763

PL 11.17

12E2661

PL 8.26

10K982

PL 11.6

12K2790

PL 11.38

10E1084

PL 10.2

12E3481

PL 8.25

10K1191

PL 11.9

12K3562

PL 8.15

10K1631

PL 9.6

12E4431

PL 11.9

10K1660

PL 9.6

12E4530

PL 8.21

10E4530

PL 7.1

10E4540

PL 7.1

12E4610

PL 8.20

11K130

PL 10.13

12E4841

PL 11.27

11E250

PL 4.22

12E5670

PL 11.4

11K1700

PL 9.4

13K1681

PL 9.15

11K1710

PL 9.4

13P2505

PL 7.5

11E3730

PL 11.28

12K140

PL 9.5

12E470

PL 9.5

13E5260

PL 7.17

12E720

PL 10.16

13E6150

PL 11.40

12K971

PL 8.6

12E1160

PL 8.6

13E9150

PL 11.9

12K1300

PL 11.11

14K1603

PL 8.25

PL 11.13

14K2700

PL 8.15

PL 11.34

14E3321

PL 8.3

PL 4.24 PL 11.36

PL 8.29

PL 7.6 PL 11.18

PL 11.41

12P1397

PL 11.24

12K1510

PL 9.6

14E5040

PL 2.4

12K1561

PL 11.7

14E12990

PL 10.18

12K1561

PL 11.8

12K1683

PL 8.17

14E14590

PL 2.4

PL 11.41

14E15140

PL 9.6

12K1771

PL 10.20

14E16010

PL 10.16

12K1792

PL 8.10

14E16020

PL 10.16

12K1910

PL 10.9

14E16030

PL 10.16

12E2120

PL 8.6

14E16151

PL 7.1

12K2120

PL 10.2

14E17262

PL 9.12

12K2150

PL 8.10

14E17312

PL 11.12

12E2200

PL 8.29

14E17540

PL 7.4

12E2232

PL 11.2

14E17550

PL 7.4

12E2310

PL 8.18

14E18752

PL 11.14

PL 8.30

PL 10.20

PL 11.40 Revision DocuPrint 180F Service Manual

PL 11.35

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Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

14E18823

PL 11.14

15E15740

PL 4.11

PL 11.35

PL 4.15

14E19721

PL 7.16

PL 4.26

14E21060

PL 11.23

14E23400

PL 4.26

15E16110

PL 9.2

14E26690

PL 11.9

15E16140

PL 4.12

14E37010

PL 10.3

15K24790

PL 4.14

15K535

PL 8.2

15E3910

PL 8.9

15K25942

PL 9.15

15K4761

PL 8.8

15E31030

PL 11.39

15K5050

PL 7.4

15E31230

PL 8.9

15K5060

PL 7.4

15E31720

PL 4.14

15K5106

PL 9.25

15K5116

PL 9.25

15E32280

PL 11.30

15K5790

PL 4.16

15E7131

PL 8.17

15E37060

PL 2.3

PL 11.40

15E40000

PL 8.13

PL 11.41

15K46190

PL 9.15

15S7516

PL 8.8

16E160

PL 10.2

15E7860

PL 4.1

16E380

PL 4.7

15E7870

PL 4.1

16K500

PL 9.23

15K8401

PL 4.11

16P1623

PL 10.13

PL 4.13

16E1780

PL 11.25

PL 4.25

16E2270

PL 4.3

PL 4.27

PL 4.24

PL 4.24 PL 11.31

15K8690

PL 9.26

PL 4.8

15K8700

PL 9.26

PL 4.15

15K8761

PL 7.14

PL 4.25

15K9290

PL 4.13

PL 4.27

PL 4.14 15K9310

16E2280

PL 4.2

16E2460

PL 11.14

PL 4.14

PL 4.7

PL 4.24 15E9810

PL 9.14

15E9820

PL 9.14

16E4491

PL 2.2

15K10290

PL 11.6

16E4650

PL 9.14

15E11110

PL 9.14

16E6381

PL 9.12

15E11680

PL 10.1

16E6520

PL 10.13

15K11940

PL 11.41

16E6820

PL 10.13

15K11950

PL 11.40

16E7150

PL 4.27

PL 11.41

16E7200

PL 10.18

15K12030

PL 4.25

17K202

PL 4.21

15K12090

PL 4.25

17K213

PL 4.21

Parts List

Part Number Index

PL 11.35

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Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

17E963

PL 4.22

19E9662

PL 9.21

PL 4.23

19E11191

PL 7.13

17K1561

PL 4.26

19E11320

PL 6.1

17E4162

PL 4.22

19E11640

PL 9.23

PL 4.23

19E13060

PL 4.17

18P371

PL 7.1

19E13700

PL 10.4

18E620

PL 25.1

19E13710

PL 4.9

19K800

PL 9.15

19E14411

PL 6.1

19E1110

PL 8.4

19E20740

PL 7.15

PL 8.31

19S21202

PL 10.6

19E1310

PL 10.13

19E21710

PL 10.9

19E1971

PL 8.3

19P80473

PL 24.5

PL 8.30

19P80487

PL 2.4

19E2450

PL 2.2

20K240

PL 4.17

19E2700

PL 1.4

20K300

PL 4.18

19K2820

PL 11.7

20K320

PL 8.15

PL 11.8

20K360

PL 10.15

PL 8.4

20K370

PL 10.20

PL 8.31

20K451

PL 10.15 PL 10.15

19E3390 19E3450

PL 6.1

19E3621

PL 8.3

20K460

PL 8.30

20K612

PL 10.15

19E3660

PL 10.15

20K681

PL 7.12 PL 4.17

19P3681

PL 10.24

PL 7.17

20K970

PL 11.18

20K980

PL 4.20

19P3686

PL 7.2

20K1101

PL 7.11

19E4150

PL 8.7

20K1110

PL 7.10

PL 8.33

20K1240

PL 7.5

19P4310

PL 7.6

19E4991

PL 9.4

19K5130

PL 9.15

20K1413

PL 4.19

19E5260

PL 8.13

20E1470

PL 9.6

19E5590

PL 4.19

20K1530

PL 4.17

19E5700

PL 9.15

20K1660

PL 4.19

19E7100

PL 11.18

20K1860

PL 4.18

PL 11.19

20E2010

PL 7.10

PL 11.35

20K2280

PL 8.15

PL 11.38

20P3448

PL 7.8

19E8710

PL 10.8

20S3449

PL 7.8

19E9321

PL 2.2

20E3560

PL 7.18

19E9440

PL 7.13

20K3592

PL 11.9

Revision DocuPrint 180F Service Manual

PL 7.6 PL 7.7

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Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

20S3683

PL 7.12

22K6381

PL 11.27

20S3684

PL 7.12

20K4140

PL 10.13

20K4161

PL 11.1

22K6781

PL 8.13

20K4520

PL 4.17

22K6924

PL 8.20

20K4590

PL 4.17

20E4840

PL 8.15

PL 11.30 PL 11.31

PL 8.21 PL 8.22

PL 11.1

22K6933

PL 8.20

20K5070

PL 4.18

20K5080

PL 4.16

22K6941

PL 10.4

20K7610

PL 8.1

22K7245

PL 8.16

20E12730

PL 9.20

20E13250

PL 9.20

22K7893

PL 9.2

20E13410

PL 4.19

20E13880

PL 9.20

22K8695

PL 8.24

20E23191

PL 8.7

PL 8.23

PL 8.19 PL 9.4 PL 8.25

PL 8.33

PL 8.26

21E250

PL 10.9

21K730

PL 10.1

21K740

PL 10.1

21P744

PL 8.26

22K9162

PL 10.8

21E1240

PL 4.17

22E9761

PL 11.17

21E1250

PL 4.17

21E1780

PL 9.16

22K10860

PL 9.3

21E1800

PL 9.18

22K10960

PL 9.25

21K2030

PL 9.16

22K11231

PL 10.14

21E2440

PL 2.2

21E5040

PL 4.16

22K11291

PL 11.36

21E7360

PL 4.1

22K11292

PL 8.18

22K2720

PL 7.10

PL 8.19

PL 7.12

PL 8.22

PL 8.26

PL 8.23

PL 11.2

PL 8.26

22P4018

PL 7.12

PL 8.29

22K4871

PL 8.13

PL 11.4

22K5411

PL 11.23

PL 11.15

PL 11.25

PL 11.16

PL 11.41

PL 11.32

22S5602

PL 9.5

PL 11.37

22P5606

PL 7.11

22P5987

PL 7.12

22E3321

Parts List

Part Number Index

22K9074

PL 8.27 PL 8.28 PL 8.29

PL 11.20

PL 10.20

PL 11.40 22K11360

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Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

22K11360

PL 11.35

22K16741

PL 9.3

22K11721

PL 9.24

22K16940

PL 8.3

22K12292

PL 8.29

22E12480

PL 11.38

22K16980

PL 10.15

22K14502

PL 8.8

PL 10.20

PL 8.9

PL 11.30

22K14780

PL 8.30

PL 8.14

PL 11.31

PL 8.18

22K16990

PL 11.2

PL 8.4

PL 11.11

PL 8.31

PL 11.13

PL 10.15

PL 11.14

PL 10.24

PL 11.22

22K17670

PL 8.11

PL 11.34

22K17830

PL 8.22

PL 11.35 22K14810

PL 4.19

PL 8.28

PL 11.40

22S24511

PL 7.13

PL 8.18

22S24821

PL 7.10

PL 11.40

22K27363

PL 11.39

22K27371

PL 11.39 PL 11.41

PL 11.41

PL 11.41

22K14830

PL 8.22

22K14850

PL 8.25

22K27410

PL 11.30

22K27670

PL 10.9

PL 11.31

22K27680

PL 4.26

22K14890

PL 11.26

22K32341

PL 11.5

22K15011

PL 7.10 22K32351

PL 11.5

22K32480

PL 11.23

22K37610

PL 11.10

PL 8.28

PL 11.40

PL 11.9

PL 7.11 PL 7.12

PL 11.9

PL 7.13 22K15101

PL 8.1

22K16450

PL 8.18

PL 11.25

PL 8.19

PL 11.11

PL 8.22

PL 11.14

PL 10.15

PL 11.33

PL 10.16

PL 11.34

PL 10.17

PL 11.35

PL 10.18

22K37810

PL 10.19

22K44711

PL 10.20

PL 11.24

PL 11.40 Revision

PL 11.22 PL 11.23

PL 10.24

DocuPrint 180F Service Manual

PL 8.33

22K44721

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Part Number Index

Table 1 Part Number Index Part Number

Table 1 Part Number Index

Part List

Part Number

Part List

PL 11.23

22K59970

PL 9.15

PL 11.24

22K64590

PL 9.15

PL 8.3

23E470

PL 4.17

PL 8.4

23E620

PL 4.18

PL 8.5

23E1320

PL 4.20

PL 10.14

23E1340

PL 7.10

PL 10.18

23P1346

PL 4.17

PL 10.22

23E1350

PL 7.10

PL 10.23

23E2350

PL 11.18

PL 10.24

23E3330

PL 9.23

PL 11.10

23E3770

PL 11.40

PL 11.12

23E4140

PL 11.6

PL 11.13

23E5501

PL 10.20

PL 11.14

23E5511

PL 10.15

PL 11.22

23E5521

PL 10.15

PL 11.26

23E5531

PL 10.15

PL 11.27

23E5571

PL 10.15

PL 11.16

23E5910

PL 8.22

PL 11.27

23E6361

PL 11.1

22K45410

PL 11.13

23E15120

PL 4.16

22K45480

PL 8.16

23E21030

PL 10.24

PL 8.17

25E10

PL 9.16

PL 8.18

25K160

PL 7.1

PL 10.14

25K280

PL 9.24

PL 10.15

25E313

PL 2.2

PL 10.16

25K592

PL 9.3

PL 10.17

25P868

PL 7.1

PL 10.19

26K780

PL 4.17

22K50890

PL 8.12

26P816

PL 1.8

22K53281

PL 10.7

26P1458

PL 1.16

22K53381

PL 9.15

26P1734

PL 1.4

22K55571

PL 4.17

22K56250

PL 8.25

22K44881

22K44890

PL 10.21

22K44920

22K44930

22K45161

22K48700

PL 4.19

PL 8.13

PL 1.16

PL 1.5 PL 1.6

PL 11.3

26P1885

PL 1.16

PL 8.30

26P2081

PL 1.2

PL 8.32

26E2750

PL 4.20

22K59551

PL 9.15

26E3510

PL 7.1

22K59960

PL 9.15

26E3772

PL 7.16

22K59400

PL 8.31

Parts List

Part Number Index

PL 1.3

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Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

26P3773

PL 4.16

26P20800

PL 8.3

PL 4.18

26P20802

PL 8.6

26P3796

PL 7.5

26E31620

PL 11.30

26P3797

PL 7.6

26P3798

PL 7.5

27E30

PL 10.2

26P3799

PL 7.6

27K110

PL 7.17

26P3913

PL 7.12

26P4036

PL 7.8

27E500

PL 10.10

26P4037

PL 7.8

27P506

PL 7.14

26P4098

PL 7.2

26P4114

PL 7.10

26E4180

PL 4.22

27E510

PL 1.7

PL 4.23

27P1126

PL 7.5

26P4221

PL 7.5

26P4222

PL 7.5

27P1160

PL 8.26

26E4230

PL 4.3 PL 4.8

27P1205

PL 7.5

PL 4.2

27E1410

PL 9.25

PL 4.7

28P497

PL 4.4

PL 4.11

28P778

PL 7.12

PL 4.15

28P859

PL 1.4

PL 4.17

26E4240

26E4360

PL 8.30

PL 11.31

PL 11.18

PL 8.12 PL 11.18

PL 7.6 PL 11.2

PL 4.25

PL 1.5

PL 4.27

PL 1.6

PL 4.21

PL 1.8 PL 1.16

PL 4.22 26P4453

28P1127

PL 7.4

PL 1.4

26E4730

PL 4.4

PL 1.5

26E5111

PL 2.2

PL 1.6

26E6590

PL 4.22

PL 1.8

26E7930

PL 9.3

26E7970

PL 4.7

PL 1.16 28P1183

PL 1.2

26E8441

PL 10.23

26E8520

PL 11.41

26E10930

PL 9.2

28P1709

PL 7.12

26E13090

PL 11.30

28E1710

PL 11.25

PL 11.31

28E1721

PL 11.23

28E1770

PL 11.3

PL 1.3 PL 4.4

26E17630

PL 7.16

26E18751

PL 11.28

26P20304

PL 7.4

PL 11.9

26P20307

PL 7.13

PL 11.24

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Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

28E1812

PL 9.3

28E5120

PL 10.3

28P1815

PL 7.10

28P20111

PL 10.13

PL 7.12

28P20116

PL 11.30

28P80090

PL 1.2

29K680

PL 11.11

PL 7.13 28P1818

PL 7.10

28P1866

PL 7.12

28E1970

PL 11.11

PL 11.31

PL 7.11

PL 1.3 PL 11.13

PL 11.13

PL 11.34

PL 11.30

29K1120

PL 11.27

PL 11.31

29K1200

PL 11.38

PL 11.34

29E3600

PL 10.23

28E1990

PL 7.10

29P4231

PL 10.15

28E2000

PL 10.3

29P4240

PL 8.21

28E2601

PL 11.41

28E2680

PL 4.2

PL 8.26 PL 8.29

PL 4.3

29E4350

PL 11.23

PL 4.7

29P4809

PL 10.1

PL 4.8

29E4830

PL 4.16

PL 4.11

29E5880

PL 11.22

PL 4.15

29E5960

PL 9.4

PL 4.25

29E8690

PL 4.1

29E8701

PL 4.1

PL 4.27 28E2781

PL 11.3

28E2990

PL 4.19

PL 4.2 PL 4.2

PL 10.21

PL 4.13

PL 10.22

29E8921

PL 9.6

PL 11.2

29E9220

PL 4.1

PL 8.18

29E10710

PL 8.19

PL 8.19

29E12420

PL 11.17

PL 8.21

29E12820

PL 4.5

PL 8.22

29E13120

PL 10.17

PL 8.23

29E14150

PL 11.22

PL 8.25

29E14240

PL 11.27

PL 8.28

29E14310

PL 11.26

PL 11.40

29E15440

PL 11.24

28E3740

PL 11.26

29E25440

PL 4.17

28E3930

PL 9.3

29E25450

PL 4.17

28E4710

PL 9.3

29E25490

PL 9.3

28E4730

PL 4.7

30K701

PL 8.8

PL 4.2

PL 11.26 28E3100

Parts List

Part Number Index

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Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

30K1953

PL 8.8

30K14341

PL 9.5

30E2030

PL 8.9

30K14351

PL 9.5

30K2340

PL 10.12

30K15110

PL 1.7

30K2350

PL 10.12

30K15572

PL 1.17

30E2441

PL 10.1

30E2670

PL 10.8

30E15840

PL 9.8

30K3331

PL 8.1

30K16000

PL 7.12

30E4652

PL 1.5

30K16101

PL 7.16

PL 1.6

30K16602

PL 8.6

PL 8.3

30K16730

PL 8.6

PL 8.30

30E17223

PL 1.9

30E4853

PL 8.3

30K17310

PL 9.2

30E4930

PL 10.16

30K17330

PL 9.7

PL 10.17

30E17340

PL 10.3

PL 10.18

30K17461

PL 7.1

PL 10.19

30K17530

PL 1.15

PL 10.20

30K17580

PL 10.4

PL 7.12

30K18213

PL 9.23

30K6862

PL 7.12

30K19421

PL 1.7

30K7320

PL 9.5

30K19931

PL 4.9

30E7362

PL 10.21

30E19970

PL 4.17

30K7420

PL 4.1

30K20730

PL 8.6

30K7851

PL 1.7

30K21222

PL 7.17

30K8262

PL 1.9

30K21260

PL 10.8

30K8271

PL 1.9

30K21382

PL 10.4

30K8560

PL 10.3

30K21780

PL 8.26

30K9332

PL 7.3

30K22041

PL 1.7

30K9342

PL 7.3

30K22500

PL 7.8

30E9630

PL 10.16

30K22551

PL 4.3

30K9882

PL 7.3

30K22821

PL 9.6

30K9892

PL 7.3

30K22841

PL 9.6

30K10302

PL 7.3

30K23360

PL 8.15

30K10312

PL 7.3

30K23840

PL 8.29

30K11071

PL 4.18

30K24080

PL 8.1

30K11081

PL 4.18

30E24370

PL 11.22

30K11591

PL 7.15

30K24460

PL 9.23

30K12713

PL 4.1

30E24800

PL 9.4

PL 4.2

30K25251

PL 9.7

30K12723

PL 4.1

30K25311

30K13000

PL 8.3

PL 11.13

30K13940

PL 8.6

PL 11.34

30E4842

30K6851

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PL 11.11

Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part List

Part Number

Part List

30E25440

PL 10.4

30K34871

PL 4.12

30K25762

PL 11.6

30S34950

PL 7.6

30K25911

PL 10.24

30K34970

PL 8.20

30K25921

PL 10.24

30K34981

PL 4.12

30K25951

PL 11.29

30K35111

PL 8.21

30K25960

PL 11.29

30K26600

PL 10.17

30K35221

PL 11.19

30K26660

PL 10.6

30K35380

PL 7.5

30K26670

PL 10.6

30K35541

PL 4.8

30K26790

PL 8.2

30K35864

PL 11.19

30K27084

PL 11.6

30K36102

PL 11.19

30K27786

PL 8.13

30K36141

PL 11.17

30E28321

PL 9.4

30P36359

PL 7.9

30K28472

PL 11.15

30K36630

PL 4.14

PL 11.16

30E36691

PL 8.23

PL 8.28

PL 11.36

PL 8.25

PL 11.37

PL 11.2

30K29012

PL 4.14

30E36721

PL 8.26

30E29084

PL 4.13

30K36760

PL 7.5

30E29170

PL 10.5

30P36798

PL 7.6

30E29700

PL 8.17

30K36963

PL 11.30

30S29910

PL 7.13

30K37060

PL 9.26

30E30850

PL 10.8

30S37758

PL 7.1

30E30890

PL 10.3

30K38401

PL 8.20

30K31641

PL 9.7

30K31752

PL 8.2

30S39161

PL 7.5

30K31870

PL 4.9

30K40532

PL 11.11

30K32224

PL 7.16

30K32662

PL 4.13

30K32752

PL 4.23

30E41113

PL 9.23

30P33868

PL 7.6

30K41521

PL 8.12 PL 7.3

PL 8.19

PL 11.31

PL 8.27

PL 11.13 PL 11.34

PL 4.19

30S42059

PL 4.20

30S42060

PL 7.3

30K34080

PL 8.21

30K42112

PL 11.14

30K34092

PL 8.21

30K42231

PL 11.28

PL 8.29

30K42780

PL 11.29

30K34101

PL 8.21

30K42950

PL 4.15

PL 8.28

30K43431

PL 11.9

PL 7.11

30K43560

PL 11.26

30P33911

PL 11.35

PL 8.29

30P34644 Parts List

Part Number Index

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Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part List

Part Number

Part List

30K43630

PL 7.10

30K55200

PL 8.15

30K43841

PL 11.6

30K56921

PL 11.27

30E44490

PL 9.7

30K56931

PL 11.27

30K44620

PL 11.6

30K56941

PL 11.16

30K44630

PL 11.6

30E56951

PL 11.15

30E44731

PL 9.6

30K45111

PL 11.6

30K56951

PL 11.16

PL 11.9

30K57090

PL 11.22

30K46060

PL 11.4

30E59210

PL 10.4

30E46420

PL 4.1

30E60960

PL 8.1

PL 4.2

30E61060

PL 4.6

30E46430

PL 4.1

30E61171

PL 11.9

30E47110

PL 10.8

30E62752

PL 8.21

30E47120

PL 10.8

30K47221

PL 11.39

30E65131

PL 4.14

30E47690

PL 9.6

30E66202

PL 11.20

30K47900

PL 11.40

30E67993

PL 4.11

30K47920

PL 4.26

30E50130

PL 10.8

30E68570

PL 8.19

30K50220

PL 4.2

30E69241

PL 4.21

30S50752

PL 7.1

30E71641

PL 11.20

30K51670

PL 8.31

30E77630

PL 9.26

30S51752

PL 8.8

30E51830

PL 10.3

30E79891

PL 4.13

30E52403

PL 11.6

31K170

PL 4.17

30S52884

PL 7.1

31K370

PL 4.18

30S52885

PL 7.1

31E1401

PL 8.29

30S53073

PL 7.6

31E1540

PL 10.15

30S53082

PL 7.6

31K1650

PL 8.3

30S53096

PL 7.6

30S53097

PL 7.6

31K1700

PL 4.16

30K53681

PL 8.2

31K1720

PL 4.16

30K53691

PL 8.2

31K2970

PL 10.9

30K53701

PL 8.2

31K3011

PL 8.5

30E53931

PL 11.15

31P3205

PL 7.5

PL 11.16

31K3252

PL 8.10

PL 11.36

31K3390

PL 10.9

PL 11.37

PL 8.29

PL 4.13

PL 25.1

PL 8.30

PL 11.37

31K3561

PL 10.24

30K54310

PL 11.13

31K3680

PL 10.16

30K54370

PL 8.5

31K3691

PL 10.16

PL 8.32

31K4300

PL 4.16

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Parts List

Part Number Index

Table 1 Part Number Index Part Number

Part List

31K4310

PL 4.16

31K4340 31E4860 31K4980

Table 1 Part Number Index Part Number

Part List

PL 11.7

33K960

PL 10.10

PL 11.8

33K970

PL 10.10

PL 11.28

33E1110

PL 10.8

PL 8.32

33E1420

PL 9.2

31K5000

PL 8.32

33E1680

PL 10.3

31K5120

PL 8.30

33K2250

PL 9.11

PL 25.1

32E83

PL 9.3

32E150

PL 9.5

33K2261

PL 9.11

32K310

PL 9.5

33K2270

PL 9.11

32E621

PL 8.3 33K2280

PL 9.11

PL 11.14

33K2291

PL 9.11 PL 9.3

PL 9.12

PL 9.12

PL 8.11 PL 8.30

PL 9.12

PL 11.35

33E2400

32E892

PL 9.5

33K2750

PL 9.26

32K1251

PL 10.23

33K3010

PL 9.11

32E1471 32P1726

PL 8.18

33K3190

PL 9.26

PL 11.40

33K3360

PL 9.11

PL 8.5

33K3380

PL 9.18

PL 8.18

33K3390

PL 9.18

PL 8.19

33K3440

PL 9.11

PL 8.22

35E390

PL 8.14

PL 8.26

35K2220

PL 9.15

PL 8.29

35K3090

PL 4.7

PL 8.32

35P3112

PL 7.10

PL 8.23

32P1726

PL 8.15

PL 11.4

PL 7.12

PL 11.15

PL 10.13

PL 11.16

35P3365

PL 9.19

PL 11.23

35S3731

PL 9.17

PL 11.25

35E6090

PL 8.14

PL 11.36

35E7060

PL 9.21

PL 11.37

35E7230

PL 9.27

PL 11.41

35E8610

PL 9.27

32E2071

PL 8.2

35E10610

PL 4.9

PL 25.1

35E10620

PL 4.9

32E2240

PL 9.6

35E10630

PL 4.9

PL 9.7

35E12920

PL 9.3

PL 11.32

32E3440 Parts List

Part Number Index

PL 8.15

PL 9.11

PL 9.4

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Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part List

PL 10.7

48K45160

PL 7.3

35E59720

PL 9.17

48K45870

PL 4.13

36K254

PL 11.10

48K45890

PL 4.13

36K461

PL 4.5

48K45940

PL 4.14

36K471

PL 4.14

48K45960

PL 4.14

PL 4.24

48K45980

PL 4.14

38K1261

PL 7.2

48K46020

PL 4.10

38K1271

PL 7.2

48K46130

PL 4.11

38K2189

PL 8.4

48K46170

PL 2.4

38K2314

PL 7.16

48K46180

PL 2.4

38K6660

PL 7.13

48K46210

PL 2.5

38E6780

PL 7.2

48K46230

PL 2.5

38E7674

PL 11.9

48K46260

PL 4.5

38E7800

PL 7.2

48K47420

PL 6.1

38K8101

PL 7.16

48K47510

PL 4.27

38K9530

PL 8.31

48K47660

PL 6.2

38E9541

PL 8.13

48K47970

PL 4.25

38K9670

PL 7.16

48K47990

PL 4.25

38K11250

PL 8.4

48K48010

PL 4.25

42K518

PL 9.22

48K48030

PL 4.25

PL 9.24

48K50310

PL 11.5

Part Number

Part List

35E13720

PL 9.8

35E50560

PL 4.24

PL 9.25 43P81

PL 25.2

43E170

PL 25.2

PL 11.6 PL 11.7 48K53530

PL 11.5

43E500

PL 25.2

48K8180

PL 4.7

48K56790

PL 9.10

48K9590

PL 4.8

48K57090

PL 4.7

48K14752

PL 11.9

48K78750

PL 9.10

48K26540

PL 4.3

49E6350

PL 8.30

48K26780

PL 1.8

49E32480

PL 10.4

48K27291

PL 10.4

49E56190

PL 4.1

PL 10.8

49E56200

PL 4.1

PL 10.9

50P680

PL 1.4

PL 11.8

48E30820

PL 4.1

PL 1.8

48K32270

PL 7.3

PL 1.16

48K32280

PL 7.7

PL 1.17

48K43030

PL 4.2

48K43050

PL 4.6

50P1934

48K43250

PL 7.3

50P1997

PL 10.15

48K44901

PL 4.14

50P2096

PL 1.1

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PL 1.19

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PL 1.7

Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

50E2436

PL 11.25

PL 7.16

50E2710

PL 4.2

PL 7.17

Part Number

PL 4.3

Part List

PL 7.18

PL 4.11

50E17770

PL 7.15

PL 4.15

50K17880

PL 8.4

PL 4.26

50K18450

PL 4.26

PL 4.27

50K18991

PL 11.20

50E4621

PL 9.13

50K19001

PL 11.20

50E4720

PL 9.21

50K19510

PL 8.31

50K5282

PL 8.3

50K22620

PL 8.30

50K6104

PL 8.4

50K25070

PL 25.1

50K7152

PL 9.1

50K25081

PL 25.1

50K7152

PL 9.6

50K25570

PL 7.1

PL 9.7

PL 7.2

50K7171

PL 9.7

PL 7.3

50K7411

PL 9.23

PL 7.4

50K7421

PL 9.23

PL 7.5

50E7650

PL 4.15

PL 7.6

50E7660

PL 4.15

PL 7.7

50E8110

PL 11.14

PL 7.8

PL 11.35

50K31042

PL 8.3

50K8312

PL 10.23

50K32570

PL 4.5

50E8471

PL 11.23

50K34720

PL 8.30

50E8951

PL 11.38

50K52890

PL 8.3

50K10670

PL 7.2

51E10

PL 10.11

50K10690

PL 7.1

52K560

PL 10.10

PL 7.2

52K580

PL 10.11

PL 7.3

52K600

PL 10.11

PL 7.4

52K1270

PL 9.23

PL 7.5

52K1280

PL 9.23

PL 7.6

52K1291

PL 9.23

PL 7.7

52E1301

PL 10.5

PL 7.8

52K1550

PL 10.10

50K10806

PL 11.17

52K1560

PL 10.11

PL 11.20

52K1571

PL 10.11

50K11063

PL 11.20

52K1630

PL 10.11

50E12511

PL 4.14

52K1640

PL 10.11

PL 4.24

52E1920

PL 10.6

50K12671

PL 11.27

52E1940

PL 10.11

50K17382

PL 7.14

52E1950

PL 10.10

PL 7.15

52E2050

PL 10.11

Parts List

Part Number Index

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Table 1 Part Number Index Part Number

Part List

Part Number

Part List

52E2090

PL 10.11

54E2050

PL 9.13

52K2260

PL 10.9

54K15640

PL 11.1

52K2270

PL 10.9

55K150

PL 10.13

52E3630

PL 10.11

55K403

PL 8.4

52E4570

PL 10.11

52E4990

PL 10.6

55K1136

PL 10.20

52E5490

PL 9.13

55K1491

PL 8.8

52E5590

PL 9.10

55K2331

PL 10.19

52E6280

PL 10.11

55K3157

PL 10.17

52E6470

PL 10.10

55K3654

PL 8.23

PL 10.11

55K3674

PL 8.22

PL 10.11

55S3805

PL 10.20

52E6490

PL 10.10

55K3893

PL 8.19

52E6740

PL 10.11

55K3923

PL 8.18

52E6870

PL 10.6

52E8030

PL 10.9

55K3934

PL 8.18

52E6480

PL 8.31

PL 11.40

52E10950

PL 9.27

52E18290

PL 11.1

55S4038

PL 10.20

53K72

PL 9.9

55K4533

PL 8.26

53E450

PL 10.10

55K4713

PL 8.29

53K601

PL 10.11

55K5190

PL 8.26

53K753

PL 9.21

55E5280

PL 9.14

53K861

PL 9.9

55K5300

PL 10.4

53E871

PL 10.10

55K5390

PL 6.2

53K880

PL 25.1

55E5580

PL 8.19

53K911

PL 10.10

55K6375

PL 11.10

53E950

PL 9.8

53K1190

PL 9.21

55K6502

PL 10.6

53K1541

PL 4.7

55K7172

PL 11.2

53E1810

PL 1.10

53K1910

PL 10.11

55K7882

PL 10.17

53E2301

PL 2.3

55K7891

PL 10.17

54E180

PL 8.14

55K8010

PL 9.2

54K322

PL 8.14

55K8120

PL 9.2

54E610

PL 9.23

55K8370

PL 4.20

54K660

PL 10.6

55K8380

PL 4.20

54K980

PL 8.9

55K8695

PL 11.11

54K1183

PL 9.23

54K1271

PL 9.24

54K1301

PL 10.5

PL 11.40

PL 11.15

PL 11.3

PL 11.14 PL 11.35 55K8820

PL 8.30

PL 10.6 Revision DocuPrint 180F Service Manual

PL 8.3

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Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part List

Part Number

Part List

55K9421

PL 1.20

56S3078

PL 4.12

55K9614

PL 11.14

56S3200

PL 4.2

PL 11.35

56S3201

PL 4.1

55K10170

PL 11.2

56S3202

PL 4.1

55K10310

PL 9.10

56S3207

PL 4.11

PL 9.11

56S3208

PL 4.12

55E11230

PL 4.9

57K30

PL 10.16

55E12760

PL 10.13

60K270

PL 7.15

55K13291

PL 11.29

62S1792

PL 8.31

PL 11.32

62P1869

PL 7.4

55E13330

PL 9.20

62S1940

PL 7.4

55K13390

PL 11.26

62S1950

PL 7.4

PL 11.28

62K2120

PL 11.30

62K5310

PL 9.3

62K8023

PL 6.1

64K1470

PL 9.1

55K13400

PL 11.28

55K13480

PL 11.12

55K13490

PL 11.11

PL 11.31

PL 11.34

PL 9.4 PL 6.2

55E13920

PL 10.6

55K14241

PL 11.4

55K14321

PL 11.33

PL 9.2

PL 11.36

PL 9.3

55K14680

PL 11.38

PL 9.4

55K14721

PL 11.41

55K14870

PL 11.33

68K670

PL 4.11

PL 11.37

68E5281

PL 11.30

55K16100

PL 11.33 PL 11.38

68K6390

PL 8.30

55K16360

PL 11.25

68E6410

PL 4.14

55K19560

PL 8.26

68E9000

PL 9.4

55K21860

PL 11.10

68E14330

PL 8.26

PL 11.16

68E21620

PL 10.1

55E23370

PL 4.14

68E23580

PL 4.11

PL 4.24

68E48070

PL 7.15

55E34250

PL 8.3

68E59360

PL 8.3

PL 8.30

68E62990

PL 8.3

56E481

PL 2.4

68E63000

PL 8.3

56E490

PL 2.4

68E67250

PL 11.38

56K2450

PL 7.3

70P31

PL 25.2

56K2460

PL 7.3

73E11420

PL 4.5

PL 7.15

82E4161

PL 25.1

56S3077

PL 4.11

91P4419

PL 11.1

Parts List

Part Number Index

PL 9.5

PL 11.31

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Table 1 Part Number Index

Part List

Part Number

Part List

PL 11.39

93K310

PL 9.13

91P4728

PL 7.9

93K450

PL 25.2

91K10530

PL 4.12

93K460

PL 9.22

93E690

PL 7.15

93E700

PL 7.15

PL 7.15

PL 25.2

91E12020

PL 7.11

91E12040

PL 7.2

91E12050

PL 7.2

91E15201

PL 4.4

94K1202

PL 9.19

91E18071

PL 4.3

94K1212

PL 9.13

91E18092

PL 4.3

91P40691

PL 4.20

94K2030

PL 10.9

PL 10.6

94K2330

PL 10.9

91P41601

PL 7.11

94K3052

PL 9.13

91P41701

PL 7.13

91P41801

PL 7.13

94K3360

PL 9.16

91P41902

PL 7.3

95E14850

PL 25.2

91P42201

PL 4.4

96E72500

PL 7.3

91P42301

PL 4.4

96E72510

PL 7.3

91P42501

PL 4.4

96E72520

PL 7.15

91P44801

PL 4.4

96E76150

PL 4.5

91P44901

PL 9.22

96E80490

PL 4.12

91E45432

PL 7.15

96E80500

PL 4.12

91E56570

PL 7.2

96E80510

PL 7.15

91E56950

PL 4.5

96E80520

PL 7.15

91E59091

PL 4.13

96E80530

PL 4.12

91E59101

PL 4.13

97S1515

PL 4.28

91E59111

PL 4.13

98K2950

PL 8.15

91E59121

PL 4.11

99P3044

PL 25.2

91E59132

PL 4.11

99P3211

PL 25.2

91E59143

PL 4.11

99E3270

PL 25.2

91E59151

PL 4.12

101K760

PL 4.18

91E59161

PL 4.12

101P3030

PL 2.1

91E59171

PL 4.12

101K3825

PL 1.7

91E59181

PL 4.12

101K3986

PL 1.7

91E61730

PL 2.5

101K4105

PL 1.4

92E8980

PL 7.15

101E5200

PL 7.9

92E55580

PL 1.21

101K5875

PL 1.16

PL 4.26

101K25870

PL 1.16

92E55590

PL 4.26

101K25890

PL 1.16

93K251

PL 10.1

101K26070

PL 1.11

PL 25.1

PL 7.15

Revision DocuPrint 180F Service Manual

PL 25.1

PL 9.19

PL 9.19

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Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

101K26461

PL 1.14

108E4010

PL 1.3

101K26471

PL 1.14

108E4030

PL 1.3

101K26620

PL 1.16

109K82

PL 1.5

101K29930

PL 1.14

101K32701

PL 1.6

109E230

PL 1.2

109E241

PL 1.5

109E262

PL 1.5

109E340

PL 1.6

101K32711

PL 1.5

101K32720

PL 1.1

101K32730

PL 1.1

101K32760

PL 1.1

PL 1.6 PL 1.3

PL 1.3

PL 1.6

PL 1.3

102K110

PL 1.6

PL 1.2

PL 1.17

PL 1.5

PL 1.19

PL 1.6 102P630

PL 7.7

102E1340

PL 4.19

PL 1.21 109P397

PL 1.6

PL 4.20 102E2630

PL 10.11

102E3010

PL 11.5

PL 1.10 109E511

PL 1.2 PL 1.3

PL 11.6

PL 1.5

PL 11.30

109P645

PL 11.31 102E10380

PL 1.5

PL 1.17 PL 1.19

PL 4.19

PL 1.21

PL 4.20

109P662

PL 4.19

110E460

PL 8.12

PL 4.20

110E1130

PL 9.9

103P347

PL 9.19

110E1250

PL 7.14

103K380

PL 8.20 PL 8.27

110E1521

PL 4.3

103E521

PL 2.1

110E1740

PL 1.8

105K472

PL 1.7

PL 1.18

105E850

PL 1.2

PL 1.20

102E15690

PL 1.5

PL 11.18

PL 1.3

PL 1.21

105P859

PL 1.1

110K1896

PL 7.16

105K1385

PL 1.7

110P2340

PL 7.9

105E3600

PL 1.1

110P2407

PL 2.5

105K24530

PL 1.11

110P2441

PL 4.13

107P280

PL 9.19

110P2483

PL 2.1

PL 24.5

110P2542

PL 1.15

107E2571

PL 1.3

110K2653

PL 7.17

108E4000

PL 1.2

110K2690

PL 4.13

Parts List

Part Number Index

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Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

110P2823

PL 9.3

117K2450

PL 8.9

110K3503

PL 10.21

117K2990

PL 7.2

110K3530

PL 4.3

117K3000

PL 7.2

PL 4.5

117K3661

PL 9.1

PL 4.11

117K6371

PL 9.8

PL 4.12

117E6780

PL 8.13

PL 4.13

117K7950

PL 1.11

PL 4.25

117S8737

PL 7.2

PL 10.1

117K11300

PL 1.16

PL 7.6

117K14641

PL 1.21

117K15000

PL 1.4

110E6850 111P452

PL 1.15

112K163

PL 1.10

112K172

PL 1.10

112K184

PL 1.10

113K1040

PL 4.14

117K15020

PL 1.8

113E3020

PL 1.3

117K15030

PL 1.8

113E5520

PL 1.8

117K15040

PL 2.1

PL 1.16

117K15090

PL 1.4

PL 4.28 PL 1.8 PL 2.2

113E27710

PL 24.3

113E27720

PL 24.3

117K15110

PL 1.8

113P90064

PL 1.2

117K15130

PL 1.4

114K261

PL 9.8

117K15140

PL 1.4

114K271

PL 9.8

117K15160

PL 1.18

114K281

PL 9.8

115E861

PL 10.16

PL 1.18

PL 1.20 PL 1.21

PL 10.17

117K15170

PL 1.18

PL 10.18

117K15180

PL 1.16

PL 10.20

117K15190

PL 1.18

115E2200

PL 9.7

117K15200

PL 2.2

116E1440

PL 1.14

117K15210

PL 2.2

116P1750

PL 8.3

117K15870

PL 1.17

PL 8.30

117K15880

PL 1.16

116E2970

PL 9.25

117K15890

PL 1.21

116E3020

PL 10.11

117K16410

PL 8.3

116E3780

PL 9.14

117K17680

PL 2.2

116E7080

PL 1.14

117K22930

PL 9.12

116P20301

PL 1.1

117S23142

PL 7.5

117K1490

PL 2.3

117S23170

PL 4.23

117K2311

PL 1.8

PL 10.19

PL 1.20

PL 9.4

Revision DocuPrint 180F Service Manual

PL 7.7 PL 8.3

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Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part Number

Part List

PL 8.26

120P562

PL 9.8

PL 8.29

120K731

PL 10.17

PL 8.30

120P863

PL 1.5

Part List PL 8.22

117S23171

PL 10.8

PL 8.18

PL 1.6

PL 8.19

PL 1.17

PL 11.32

PL 1.19

PL 11.40

PL 1.21

117S23172

PL 8.18

120E1240

PL 11.40

120E1331

PL 7.17

117S23175

PL 11.2

120E1340

PL 1.11

PL 11.14

PL 7.15

PL 11.32

PL 7.16

PL 11.35 117S23176

PL 8.9

PL 24.5

PL 11.41

120P1361

PL 11.15

120P2239

PL 10.1

PL 11.16

120E3260

PL 4.1

PL 7.4

PL 11.36

PL 4.5

PL 11.37

PL 4.11 PL 4.25

PL 11.41 120E3660

PL 7.18

PL 2.1

120E4940

PL 11.6

117S24928

PL 2.2

120E5220

PL 1.1

117S25001

PL 2.1

120E6620

PL 4.16

117S25002

PL 2.1

120E8110

PL 11.9

117S25003

PL 2.1

120P20320

PL 7.7

117S25004

PL 2.1

120P20321

PL 7.7

117K27730

PL 9.8

121E1610

PL 7.17

117K28350

PL 9.8

117K33680

PL 2.2

121E2340

PL 11.38

118P658

PL 9.27

121E2830

PL 11.24

118P1502

PL 7.4

118E7550

PL 10.24

121K2844

PL 8.5

118E8080

PL 2.4

121K3380

PL 8.15

119K190

PL 9.8

121K4340

PL 10.11

120E200

PL 8.9

121E4450

PL 7.12

120K240

PL 7.3

121K5041

PL 9.12

120E500

PL 4.9

121K5500

PL 10.6

PL 9.7

121E6000

PL 8.10

PL 9.12

121E7000

PL 11.11

117P23978

PL 2.2

117S24927

PL 11.9

PL 2.3

Parts List

Part Number Index

PL 11.28

PL 11.27

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Table 1 Part Number Index

Part List

Part Number

Part List

PL 11.13

PL 11.4

PL 11.34

PL 11.12

121K8250

PL 8.32

PL 11.14

121K8280

PL 8.32

PL 11.15

121K9911

PL 9.12

PL 11.16

121K9960

PL 4.18

PL 11.23

121E11710

PL 2.3

PL 11.25

121E16460

PL 2.3

PL 11.28

121K24820

PL 10.16

PL 11.30

122K391

PL 9.3

PL 11.31

PL 9.4

PL 11.32

PL 8.5

PL 11.35

PL 8.20

PL 11.36

PL 8.27

PL 11.37

PL 8.32

PL 11.38

PL 8.5

PL 11.40

122P523

123K690

PL 8.32 123E791

PL 11.41

PL 2.4

125P475

PL 11.41

123E1010

PL 4.14

125P493

PL 10.4

123E1500

PL 2.1

123K1650

PL 8.20

PL 10.17 PL 10.20

PL 8.27 123K5890

PL 2.1

125E420

PL 8.3

125P552

PL 11.26 PL 11.36

PL 8.5

125E1250

PL 8.11

126E390

PL 10.8

PL 8.17

126E1400

PL 10.7

PL 8.18

126K4474

PL 10.1 PL 10.2

PL 8.21

PL 10.3

PL 8.22

PL 10.4

PL 8.23

PL 10.5 PL 10.7

PL 8.28

Revision DocuPrint 180F Service Manual

PL 11.32

PL 8.19

PL 8.25

125E420

PL 11.16

126K13051

PL 10.1

PL 8.29

PL 10.2

PL 8.30

PL 10.3

PL 8.32

PL 10.4

PL 10.16

PL 10.5

PL 10.20

PL 10.7

PL 10.22

127K1540

PL 7.18

PL 10.23

127K1570

PL 8.15

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Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part List

Part Number

Part List

127K2024

PL 8.15

127K15190

PL 11.22

127P2260

PL 1.11

127K15201

PL 11.1

PL 2.3

PL 11.29

127P2347

PL 8.9

127P2552

PL 7.7

127E2801

PL 9.9

127K17090

127K3791

PL 9.23

127K17100

PL 8.14

127K3820

PL 1.20

127K17273

PL 11.39

127E4090

PL 9.20

127K17283

PL 11.39

127K4882

PL 9.20

127K17911

127K4974

PL 8.15

127K5161

PL 11.5

127K5271

PL 11.6

127K5281 127K5571 127E5660

PL 1.10

127E5850

PL 4.9

127K6180

127K15211

PL 11.1 PL 11.29 PL 8.14

PL 8.4 PL 8.31

127K18572

PL 11.30

PL 11.6

127K22060

PL 11.22

PL 11.9

127K30160

PL 11.1

PL 11.5

130P225

PL 10.4

130E342

PL 8.4

PL 9.19

130E500

PL 9.12

127K6321

PL 9.8

130P811

PL 7.13

127K6783

PL 11.1

130S947

PL 9.19

127K7091

PL 10.3

130E1110

PL 8.6

127K7101

PL 10.3

130E1420

PL 11.18

127K8091

PL 11.6

130E1440

PL 11.2

127K8872

PL 11.19

PL 11.12

127K9081

PL 11.19

PL 11.18

127E9532

PL 8.7

PL 11.24

PL 8.33

PL 11.26

127E10433

PL 6.1

PL 11.30

127E11330

PL 4.18

PL 11.31

PL 10.8 PL 8.31

PL 9.27

PL 11.41

PL 4.20

130E2290

PL 25.2

PL 4.18

130S3210

PL 10.5

PL 4.20

130E3750

PL 10.6

127K12490

PL 11.1

130E4130

PL 10.21

127K12600

PL 11.9

130E4440

PL 11.11

127K12680

PL 11.9

PL 11.13

127K14462

PL 8.7

PL 11.14

PL 8.33

PL 11.34

127K14850

PL 11.24

PL 11.35

127K15180

PL 11.22

PL 11.38

127E11340

Parts List

Part Number Index

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Table 1 Part Number Index Part Number

Part List

Part Number

Part List

130E7810

PL 10.8

140K6001

PL 2.4

130K17224

PL 10.17

140K7391

PL 7.3

130K17476

PL 8.1

130K18870

PL 11.6

140K9561

PL 9.4

PL 11.9

140K11202

PL 4.12

PL 11.19

140K14840

PL 1.8

PL 11.30

140K15723

PL 1.10

PL 11.31

140K16591

PL 1.1

130S21011

PL 7.1

140K16825

PL 1.7

130K26120

PL 7.4

140K24311

PL 7.15

PL 7.16 130K26130

PL 1.21 PL 4.28

PL 7.2

140K26352

PL 1.4

PL 7.16

PL 1.7

PL 8.3

PL 1.17

PL 11.19

PL 1.18

130K29910

PL 9.2

PL 1.19

130K29920

PL 9.3

130K30391

PL 10.21

140K49480

130K36062

PL 10.17

142K690

PL 2.3

130K40412

PL 8.17

142K1500

PL 1.1

PL 8.19

142K1510

PL 1.1

PL 8.23

142K1520

PL 1.1

PL 8.25

142S10149

PL 2.3 PL 9.3

130K29890

PL 1.20 PL 1.21

PL 8.29

146K262

130K40921

PL 11.18

146E760

PL 10.18

130K42680

PL 8.9

152K3568

PL 9.4

130K44671

PL 25.1

152K3577

PL 9.7

130K45660

PL 9.7

152K6902

PL 7.11

130K49300

PL 9.7

152S10088

PL 1.7

130K50512

PL 11.14

152K12761

PL 1.11

PL 11.35

152K15754

PL 8.23

130K51110

PL 11.29

152K15764

PL 8.25

130K51420

PL 11.30

152K15774

PL 8.19

PL 11.31

152K15784

PL 8.17

130K52641

PL 11.2

152K15826

PL 11.19

130K52680

PL 8.12

152K17325

PL 10.9

130K54110

PL 9.10

152K20942

PL 7.2

130K56330

PL 10.4

152K21614

PL 8.28

130K59360

PL 9.7

152K21661

PL 9.25

130K64820

PL 10.4

152K21671

PL 1.7

140K5221

PL 1.7

152K21681

PL 9.14

Revision DocuPrint 180F Service Manual

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Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

152K30563

PL 4.12

162K28340

PL 11.6

152K32411

PL 4.9

366W103

PL 10.23

152K34241

PL 9.27

409W1017

PL 9.25

152K34250

PL 9.27

409W1249

PL 8.26

152K35450

PL 9.27

409W1369

PL 8.21

152K37495

PL 11.30 PL 11.31

409W1443

PL 10.23

152K37532

PL 11.6

409W1469

PL 8.1

152K48413

PL 11.14

409W1513

PL 8.3 PL 10.16

PL 8.29

PL 11.35

PL 8.30

152K48423

PL 11.14

409W1529

152K56750

PL 11.38

409W1765

PL 4.22

152K67570

PL 11.9

409W2198

PL 11.2

160K7873

PL 1.4 409W2218

PL 8.7

PL 1.21

409W2376

PL 11.26

160K8203

PL 1.4

409W3079

PL 11.17

160K23541

PL 1.11

409W3091

PL 11.38

160K23960

PL 1.8

409W3094

PL 8.18

160K23990

PL 1.4

PL 8.19

PL 1.8

PL 8.22

PL 1.17

PL 8.23

PL 1.18

PL 8.26

PL 1.20

PL 8.29

PL 11.22

PL 1.8 PL 1.17

PL 8.33

PL 1.21 160K24000

PL 1.18

160K24063

PL 2.2

PL 11.40 409W3110

PL 10.13

409W3184

PL 10.15

409W3185

PL 8.4

PL 1.20 160K28310

PL 1.4

160K33470

PL 4.19

160K40580

PL 1.11

160K43701

PL 1.11

160K49620

PL 2.1

160K53981

PL 1.11

160K71570

PL 11.20 PL 10.20 PL 8.31 PL 10.15 409W3187

PL 10.13

PL 2.2

409W3191

PL 8.14

160K79760

PL 1.4

409W3200

PL 11.9

162K8122

PL 10.5

409W3211

PL 11.11

162K17110

PL 1.11

162K23900

PL 6.1

162K23910

PL 6.1

Parts List

Part Number Index

PL 11.6

PL 11.13 PL 11.14 409W3212

11/00 5-246

PL 11.30 Revision DocuPrint 180F Service Manual

Table 1 Part Number Index

Table 1 Part Number Index Part Number

Part Number

Part List PL 11.31

PL 11.4

PL 11.34 409W3216

Part List PL 11.17

PL 11.35

413W15555

PL 10.22

PL 8.7

413W17355

PL 11.14

413W21054

PL 9.16

PL 8.33

PL 11.35

PL 10.24 409W3229

PL 10.24

409W3279

PL 4.26

413W35357

PL 8.6

409W3330

PL 9.4

419W101

PL 7.1

409W3338

PL 8.18

409W3338

PL 8.22

419W201

PL 8.5

PL 9.18

PL 24.5

PL 8.25

PL 8.31

PL 8.28

PL 8.32

PL 11.40

PL 9.14

PL 11.41 409W3503

PL 24.5

PL 8.6

419W1401

PL 7.13

413W456

PL 7.10

413W8205

PL 7.5

419W3250

PL 9.8

PL 7.6

419W22850

PL 11.1

413W10355

PL 8.17

419W22950

PL 8.14

PL 11.23

420W10201

PL 24.5

PL 11.38

420W10301

PL 24.5

PL 11.40

420W10701

PL 1.4

413W10555

PL 24.5

PL 11.41

PL 1.11

PL 8.17

PL 7.12

PL 11.40

PL 8.19 PL 24.5

PL 11.41 413W10714

PL 1.7

420W10901

PL 24.5

413W15155

PL 8.21

420W11001

PL 7.7

PL 8.29

420W30101

PL 24.5

PL 24.5

PL 8.26

413W15355

PL 11.27

423W50

PL 7.18

PL 8.17

423W148

PL 8.1

PL 10.15

423W899

PL 4.17

PL 10.16

423W6350

PL 7.7

PL 10.17

423W7350

PL 11.24

PL 10.19

423W7550

PL 11.24

PL 11.27

423W8050

PL 8.25

PL 11.41

423W8950

PL 11.26

PL 11.2

423W9050

PL 11.6

PL 11.3

PL 11.40 413W15455 Revision DocuPrint 180F Service Manual

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Parts List

Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

423W12150

PL 11.26

423W88550

PL 11.29

423W12351

PL 4.16

435W1252

PL 9.20

423W15550

PL 11.9

435W1352

PL 9.20

423W34850

PL 11.39

435W3250

PL 10.11

423W56950

PL 8.33

499W10009

PL 4.17

423W58450

PL 4.19

600S1858

PL 25.1

PL 10.24

600T2008

PL 25.1

PL 11.30

600K2060

PL 25.1

PL 11.34

600K2070

PL 25.1

423W59750

PL 8.4

600S6991

PL 8.1

PL 8.28

600K7301

PL 8.7

423W60550

PL 11.41

423W60650

PL 8.31

600S7321

PL 25.1

PL 8.33

600S7637

PL 7.10

423W61350

PL 4.16

600K8340

PL 8.13

423W61550

PL 8.7

600K9921

PL 1.20

PL 8.33

600K13537

PL 1.9

PL 8.7

600K23050

PL 8.7

PL 11.22

600K24340

PL 9.8

423W62150

PL 11.22

600K24530

PL 8.7

423W62850

PL 8.20

423W63050

PL 11.40

600K24744

PL 1.4

423W63750

PL 8.7

600K25814

PL 25.1

PL 8.33

600K29140

PL 4.19

423W64050

PL 8.28

600K31070

PL 10.11

423W64650

PL 8.14

600K31880

PL 4.17

423W64950

PL 10.24

600K32560

PL 11.1

423W65250

PL 7.8

600K34680

PL 8.2

423W65350

PL 11.13

600K36440

PL 7.18

PL 11.39

600K36990

PL 11.7

423W65550

PL 11.41

600K53203

PL 2.3

423W65850

PL 11.29

600K53635

PL 9.13

423W66350

PL 11.2

PL 9.14

423W67650

PL 11.1

PL 9.15

423W71850

PL 8.14

PL 9.16

423W73250

PL 4.16

423W78150

PL 8.20

600K53635

PL 8.24

600K54730

PL 8.1

PL 8.27

600K57550

PL 8.10

PL 8.18

600K58540

PL 6.1

423W59550

423W61950

PL 8.33

PL 8.33

423W80050 Parts List

Part Number Index

PL 8.33

PL 8.33

PL 9.17

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PL 9.18

Revision DocuPrint 180F Service Manual

Table 1 Part Number Index Part Number

Part List

600K59282

PL 9.18

600K59300

Table 1 Part Number Index Part Number

Part List

PL 1.14

702W4522

PL 7.7

600K59310

PL 1.14

702W9822

PL 4.19

600K62370

PL 4.20

600K67452

PL 6.1

600K70710

PL 1.9

600K70900

PL 1.1

PL 8.14

PL 1.14

PL 11.1

600K70990

PL 25.1

600K71000

PL 25.1

600K71010

PL 25.1

600K71100

PL 25.1

600K71181

PL 25.1

600K71192

PL 25.1

600K71210

PL 25.1

600K71220

PL 25.1

600K71401

PL 9.4

600K71510

PL 11.1

600K71952

PL 9.13

PL 9.8

PL 4.20 PL 9.8 702W11433

PL 1.21

PL 11.29 702W11533

PL 8.15

702W11633

PL 7.3

702W11833

PL 1.21

PL 11.18 PL 11.1 PL 11.1 PL 11.29 702W12233

PL 7.18

709W21304

PL 1.2

PL 8.14

PL 9.14

PL 1.3

PL 9.15

PL 1.17

PL 9.16

PL 1.19 PL 1.21

PL 9.17 PL 9.18

710W2025

PL 7.4

600K75230

PL 6.1

710W2042

PL 11.18

600K75880

PL 9.4

713W31231

PL 24.2

600T80025

PL 25.1

713W40120

PL 24.3

600T80026

PL 25.1

713W42020

PL 24.1

600K82470

PL 6.1

713W73230

PL 1.16

600K82680

PL 4.8

716W793

PL 24.4

600K82681

PL 4.8

716W10503

PL 24.4

600K88270

PL 4.17

802E17850

PL 9.4

PL 9.3

802E17860

PL 9.4

600K88510

PL 2.3

802E17870

PL 9.4

600K88530

PL 1.11

802E17880

PL 9.4

600K88610

PL 4.17

802E17890

PL 9.4

PL 9.3

802E17900

PL 9.4

702W229

PL 9.8

802K19830

PL 9.11

702W933

PL 8.7

802K21500

PL 10.8

PL 8.33

802K24480

PL 4.1

702W1529

PL 4.20

802K24500

PL 4.1

Revision DocuPrint 180F Service Manual

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Parts List

Part Number Index

Table 1 Part Number Index Part Number

Part List

802E36770

PL 4.1

891E82030

PL 2.4

892E27180

PL 7.3

892E27190

PL 7.3

892E27200

PL 7.15

962K610

PL 1.4

Parts List

Part Number Index

11/00 5-250

Revision DocuPrint 180F Service Manual

6. General Procedures and Information Controller Diagnostics GP 1 Remote Hand Held Device (RHHD)....................................................................... GP 2 Manometer Usage ................................................................................................. GP 3 Enter/Exit Lockout .................................................................................................. GP 4 EDN PWB .............................................................................................................. GP 5 Adjustable HFSI Procedure ................................................................................... GP 6 Occurrence Log Procedure.................................................................................... GP 7 Dual Lamp 14 Inch Diagnostic Procedure ............................................................. GP 8 Dual Lamp 11 Inch Diagnostic Procedure ............................................................. GP 1000 Diagnostic Programs and Procedures .............................................................

6-3 6-4 6-5 6-5 6-6 6-10 6-11 6-11 6-12

Diagnostics dC 1 Service Mode Entry Procedure............................................................................... dC 2 Service Mode Exit Procedure ................................................................................. dC 101 Floppy Disk Read/Write...................................................................................... dC 102 Software Upgrade............................................................................................... dC 103 Billing Read and Setup ....................................................................................... dC 105 Initial Setups ....................................................................................................... dC 106 Printer Options.................................................................................................... dC 107 Component Life Counters................................................................................... dC 108 Software Checksum Display............................................................................... dC 121 Error Log Threshold Modifier.............................................................................. dC 131 EDN NVM Read/Write 70.10 SW ....................................................................... dC 131 FSN1 NVM Read/Write 70.10 SW...................................................................... dC 131 FSN2 NVM Read/Write 70.10 SW...................................................................... dC 131 MIN NVM Read/Write 70.10 SW ........................................................................ dC 131 PHN NVM Read/Write 70.10 SW ....................................................................... dC 131 UIM NVM Read/Write 70.10 SW ........................................................................ dC 131 TMN NVM Read/Write 70.XX SW ...................................................................... dC 140 Analog Display.................................................................................................... dC 203 Stacker Tests And Exercisers ............................................................................ dC 226 Inverter/Stacker Paper Path Timing Diagnostics ................................................ dC 227 Inverter/Stacker Jam Bypass.............................................................................. dC 302 Rigid Disk Tests.................................................................................................. dC 303 Selftest Monitor................................................................................................... dC 304 Touch Screen Alignment and Test ..................................................................... dC 305 Keyboard and Touch Screen Sensor Tests........................................................ dC 313 System Simulation.............................................................................................. dC 314 Dicorotron Power Supply Calibration.................................................................. dC 315 Fault and Status Simulation................................................................................ dC 322 Rigid Disk Formatter (Floppy Disk Routine) ....................................................... dC 323 EDN Replacement Procedure ............................................................................ dC 324 Rigid Disk Validate (Floppy Disk Routine) .......................................................... dC 325 Save Critical Disk Files (Floppy Disk Routine) ................................................... dC 326 Restore Critical Disk Files (Floppy Disk Routine) ............................................... dC 327 Change Service Mode Access Code (Floppy Disk Routine) .............................. dC 328 Software Transform Utility (Floppy Disk Routine)...............................................

Revision DocuPrint 180F Service Manual

6-15 6-17 6-19 6-20 6-22 6-23 6-24 6-24 6-26 6-27 6-27 6-35 6-37 6-39 6-45 6-49 6-50 6-50 6-51 6-53 6-56 6-56 6-57 6-58 6-58 6-59 6-59 6-60 6-61 6-62 6-64 6-65 6-67 6-68 6-70

dC 330 Component Control............................................................................................. dC 350 Save Crash Data Files (Floppy Disk Routine) .................................................... dC 352 Park Rigid Heads Diagnostic Utility (Floppy Disk Routine)................................. dC 354 Range Check Validation ..................................................................................... dC 355 Bad Block Locator (Floppy Disk Routine) ........................................................... dC 357 Rigid Disk Check (Floppy Disk Routine)............................................................. dC 603 Magnification Setup ............................................................................................ dC 604 Registration Setups ............................................................................................ dC 606 Imaging Tests ..................................................................................................... dC 701 Fuser Setups ...................................................................................................... dC 702 Duplex Inverter Setup and HCF Elevator Exerciser ........................................... dC 703 Registration Servo and Transfer Blade Setups and Tests.................................. dC 726 Paper Path Timing Diagnostics .......................................................................... dC 727 Paper Path Jam Bypass ..................................................................................... dC 909 P/R Belt Seam Setup and Xerographic Tests..................................................... dC 910 High Voltage Fault Test ...................................................................................... dC 912 Photoreceptor Uniformity Test ............................................................................ dC 951 Automatic Xerographic Setup .............................................................................

6-72 6-73 6-75 6-76 6-77 6-78 6-80 6-80 6-81 6-82 6-84 6-84 6-86 6-89 6-89 6-91 6-91 6-92

Generic Raps GP 6-1 Generic Switch Rap ............................................................................................ GP 6-2 Generic Sensor Rap ........................................................................................... GP 6-3 Generic Solenoid/Clutch/Relay RAP...................................................................

6-93 6-93 6-94

Installation Specifications Installation Space Requirements.....................................................................................

6-97

Change Tags Change Tag Introduction.................................................................................................

11/00 6-1

6-99

Processor Tags ......................................................................................................... 6-101 IFS/FS Tags ................................................................................................................ 6-137 UI Tags......................................................................................................................... 6-153

General Procedures and Information

General Procedures and Information

11/00 6-2

Revision DocuPrint 180F Service Manual

GP 1 Remote Hand Held Device (RHHD) Purpose The purpose of the RHHD is to provide a remote extension of Component Control dC330 diagnostic functions. After selection of the desired Component Control dC330 is enabled at the IOT Monitor, the RHHD allows one to move to a remote area of the Printer System and exercise the selected component and observe/test the component operation.

Procedure

4.

NOTE: Refer to the end of this procedure for explanations of the functional operation of the RHHD Buttons and the RHHD LED's.

a.

To turn the LAST Output component ON, press the CONTINUE Button on the RHHD.

b.

To turn the LAST Output component OFF, press the STOP Button on the RHHD. Pressing the CONTINUE Button again will turn the LAST Output component back ON.

c.

To Stop ALL the Output components, select the DISABLE Button on the RHHD. This clears all the Output components selected Except the Last selection. Pressing the CONTINUE Button again will turn ON the Last Output component Only.

To Disable the RHHD, press the DISABLE and STOP Buttons simultaneously.

MONITOR AN INPUT: 1.

Select the desired dC330 Component Control Screen with the Input that is to be tested.

2.

Select [AUDIO & REMOTE LED].

1.

Open the Inverter Cover Door, connect the RHHD cable connector to plug P4074, located on the lower right corner of the IFS inner panel just above the lower Transport.

2.

Cheat the IFS Door Interlock switch.

3.

Select [RHHD].

3.

enter dC330 at the IOT Monitor.

4.

4.

Either an Output component can be selected and toggled or an Input can be monitored using the RHHD. Refer to one of the three (3) procedures that follow.

Move to the area of the Machine and toggle the Input device (i.e., activate and deactivate the Switch or Sensor). When the Input device changes state, the INPUT LED on the RHHD with blink.

5.

To Disable the RHHD, press the DISABLE and STOP Buttons simultaneously.

TOGGLE A SINGLE OUTPUT COMPONENT: 1.

Operation of the RHHD Buttons:

Select the dC330 OUTPUT that is to be toggled.

NOTE: Once the [RHHD] icon is selected the dC330 Screen is locked out. No additional selections can be made at the IOT Monitor until the RHHD is disabled. 2.

CLEAR ALL: Behaves identical to the Clear All function from the IOT Monitor.

Select [RHHD].

WARNING The selection of the CONTINUE Button on the RHHD will cause the Output component to cycle up. Ensure that you and anyone around the Machine is clear of the component prior to making the selection. 3.

4.

Turning the Output component ON and OFF: a.

To turn the Output component ON, press the CONTINUE Button on the RHHD.

b.

To turn the Output component OFF, press the STOP or CLEAR ALL Button on the RHHD.

To Disable the RHHD, press the DISABLE and STOP Buttons simultaneously.

Individually select and activate the desired dC330 Output components by selecting each Output, then pressing CONTINUE on the IOT Monitor.

NOTE: Once the [RHHD] icon is selected the dC330 Screen locked out. No additional selections can be made at the IOT Monitor until the RHHD is disabled. 2.

Select [RHHD].

WARNING The selection of the CONTINUE Button on the RHHD will cause the Output component to cycle up. Ensure that you and anyone around the Machine is clear of the component prior to making the selection. 3.

CONTINUE: Activates the LAST component selected in dC330 prior to selecting the RHHD icon. STOP: Deactivates operation of the LAST Output component selected within dC330 prior to entering the RHHD mode. Operation of the RHHD LED's:

TOGGLE AN OUTPUT COMPONENT WlTH OTHER COMPONENTS TURNED ON: 1.

DISABLE: Activated simultaneously with the STOP Button, deactivates the RHHD and turns control back over to the IOT Monitor.

The ENABLED state LED will turn ON when the RHHD icon is selected at the IOT Monitor. The LED will turn OFF when the RHHD mode is deactivated via the simultaneous actuation of the DISABLE and STOP Buttons on the RHHD. the OUTPUT state LED will mimic the LAST Output selected at the IOT Monitor within dC330 prior to selecting the RHHD icon. The OUTPUT state LED will turn ON when the selected Output icon has become active after pressing the CONTINUE Button on the RHHD. The LED will turn OFF when the selected Output icon has become inactive via either the initiation of any of the Stop commands or the Output has timed out. the INPUT state LED will alternately turn ON and OFF with each INPUT change of state to provide a visual indication of the Input Signal transition status, thereby eliminating the need to observe the IOT Monitor. The INPUT state LED will mimic the sound of the Audio Tone and the increment of the Input Counter as currently operating within dC330. The Audio & Remote LED icon must be selected prior to selecting the RHHD icon for the INPUT state LED to function.

Turning the Output component ON and OFF:

Preliminary Working Document No Product Name Assigned

0/0/00 ?-3

Section Name

GP 1

GP 2 Manometer Usage Purpose The purpose is to set up the manometer to measure the amount of air pressure in the Air Knife and the amount of vacuum in the Vacuum Transport Feeders.

Procedure 1.

Remove the Manometer from Tray 3. a.

Unwind the hose.

b.

Release the hose clamp.

c.

Lift the snap top.

NOTE: Moisten the tube with fluid to improve the accuracy of the readings. 2.

Calibrate the Manometer. a.

Move the reservoir up to its highest position in order to moisten the tube.

b.

The fluid level should be at the loser mark on the reservoir. If not, add fluid.

c.

Pressure is measured using the positive numbers on the right (+) scale.

d.

Vacuum is measured using the negative (+) numbers on the left scale.

e.

Move the reservoir down until the fluid level on the scale is at zero of the (+) scale to read the pressure or the (-) scale to read the vacuum.

f.

Measurements are read in millimeters of water and are written "+ or - mm. CAUTION

Close the manometer or the fluid will evaporate. 3.

Store the manometer. a.

Move the reservoir up to its highest position.

b.

Push the snap top down.

c.

Close the hose clamp.

d.

Rewind the hose.

e.

Store the manometer in Tray 3.

Figure 1 Manometer (T7001A)

Section Name

GP 2

0/0/00 ?-4

Preliminary Working Document No Product Name Assigned

GP 3 Enter/Exit Lockout

GP 4 EDN PWB

Procedure

Procedure

1.

Enter Privilege Service on the Sun workstation.

1.

2.

Type in the Password, then press ENTER.

If possible, enter Service Mode, enter dC101 and perform [Clean Disk Drive], [Floppy Disk Format], and [Save Setup Parameters] procedures; otherwise go to step 4.

2.

Record Meter A reading if different than the reading recorded during the Initial Actions of SCP, and exit Service Mode.

3.

Wait at least 30 seconds after exiting Service Mode, then go to the next step.

4.

Power off the printer.

The System is now in Lockout Mode. NOTE: Before exiting the UI Lockout Mode, ensure that the Printer is no longer in the Service Diagnostic Mode. 3.

To exit from the Lockout Mode type Privilege User, then press ENTER. The System has now exited from the Lockout Mode.

NOTE: Use the ESD Field Service Kit and proper procedures when handling PWBs. 5.

Use the EDN PWB removal procedure (REP 1-13) to remove the EDN PWB.

6.

Replace the EDN PWB.

7.

Restore printer power. Wait until Download is completed (at least 5 minutes). After download is complete either a message (Please Wait-Fuser Warming Up) or an 03-361 or 03362 Fault will be displayed.

8.

If an 03-361 fault is displayed, press [Clear] on the Printer Screen. The EDN PWB replacement is complete. If the message (Please Wait-Fuser Warming Up) is displayed, then proceed to step 9. If an 03-362 fault is displayed, go to step 10.

9.

Enter Service Mode at the Printer UI, enter dC323 and select [Initialize]. When the initialization is complete either an 03-203, 03-204, or 03-205 fault will be displayed. Clear these faults by pressing the R (reset) button on the Printer Control Panel and exit Service Mode. The EDN PWB replacement is complete.

10. Enter service mode at the Printer UI, enter dC131 and select [03-362 NVM Reset]. Wait for the red message (All machine setup procedures must be performed after NVM is reset). 11. Enter dC105, select [processor serial Number], and enter the correct processor serial number. 12. If the [Save Setup Parameters] procedure was performed in step 1, enter dC101, otherwise go to step 13. Insert the floppy disk with the saved setup Parameters into the floppy disk drive, select [Restore Setups-source Floppy], [confirm], and press the Continue button. When an 03-471 fault is displayed, press the R (reset) button on the Printer control Panel and exit service Mode. the EDN PWB replacement is complete. Report Meter change information to the appropriate organizations. 13. If the [Save Setup Parameters] procedure was not performed in step 1 and an 03-362 fault was not displayed, enter dC101, otherwise go to step 14. Select the [Restore Setup-source Rigid], [Confirm], and press the continue button. When an 03-471 fault is displayed, press the R (reset) button on the Printer Control Panel and exit Service Mode. The EDN PWB replacement is complete. Report Meter Change information to the appropriate organizations. 14. Perform all machine setup procedures. Report Meter Change information to the appropriate organization.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-5

Section Name

GP 3, GP 4

GP 5 Adjustable HFSI Procedure

Table 1 HFSI

Purpose

CODE

ITEM

THRESHOLD

NVM LOC.

NODE

The purpose is to enable the CSE to adjust the interval of the HFSI thresholds.

09-805

Post -Cleaner Blade

2000K

500

MIN

09-806

P/R Drive Coupling

4000K

492

MIN

09-807

Cleaner Blower O-Ring Drive Belts

2000K (10000K w/ P-194)

493

MIN

09-808

Cleaner Flicker Bar

2000K (4000K w/P224, 234)

494

MIN

Procedure 1.

Determine the HFSI threshold that is going to be adjusted. From Table 1 determine which NVM NODE and address will be accessed.

NOTE: Ensure that the correct NODE (EDN, PHN, MIN, FSN) is selected before making any changes.

09-809

POP Sensor

500K

501

MIN

09-815

Dicorotron Shields

500K

485

MIN

09-820

Charge 1

2000K

486

MIN

09-821

Charge 2

3000K

487

MIN

09-822

Preclean

1000K

488

MIN

NOTE: If a NODE is initialized, all the HFSI counters in that NODE will be reset to the default values. All the HFSI default intervals are listed in Table 1.

09-823

Transfer

2000K

489

MIN

09-824

Detack

1000K

490

MIN

3.

09-825

Developer

1000K

491

MIN

2.

enter dC131. Select the NODE for the HFSI threshold that is being adjusted. Enter the address for the HFSI that being adjusted. Enter the correct NVM value from Table 2 that will be used to adjust the HFSI to the desired threshold.

In order for the desired HFSI Screen selection to take affect, select the [Update Data] Icon on the SCP Screen or exit [Service Mode]. Table 1 HFSI

09-826

Cleaner housing, manifold hose 1000K (2000K w/P224, 234)

483

MIN

09-827

Developer, Tray 1, Tray 2 Drive Couplings

4000K

496

MIN

CODE

ITEM

THRESHOLD

NVM LOC.

NODE

01-801

Cleaner Filter

1000K

497

MIN

09-830

Bead Carryout Seal

4200K

502

MIN

01-802

LVPS Filters

500K

498

MIN

10-801

Metering Blade

1000K

493

PHN

03-801

IOT Monitor Filters

3000K

391

EDN

10-802

Wick and Agent Filter

1000K

494

PHN

03-802

Cooling Filter/Partiaculate Filter (DP180MX only)

2000K (w P-314)

492

PHN

10-803

Donor Roll (White)

1500K

495

PHN

10-803

Donor Roll (Brown)

8000K

495

PHN

03-803

Toner Cooling Filter

1000K

484

MIN

10-805

750K

501

PHN

08-802

Tray 1 Feed Belt

1000K

481

PHN

Prefuser and Fuser Jam Sensors

08-804

Tray 2 Feed Belt

1000K

483

PHN

10-806

499

PHN

Tray 3 Feed Belt

10000K

488

FSN

Pressure Roll and Stripper Finger

1500K

08-806-1 08-806-2

Tray 4 Feed Belt

10000K

489

FSN

10-811

Prefuser Transport Belts

6000K

497

PHN

Metering Roll

3000K

500

PHN PHN

08-806-3

Tray 5 Feed Belt

10000K

488

FSN2

10-812

08-806-4

Tray 5 Feed Belt

10000K

489

FSN2

10-813

Decurler Belts

15000K

489

PHN

10-814

Metering Assembly

1000K

503

PHN

FSN

10-815

Prefuser Transport Vacuum Holes

2000K

502

PHN

10-816

Fuser and PreFuser Drive Couplings

4000K

496

PHN

11-802-1

Disk Motor Coupling Element

10000K

486

FSN

11-802-2

Disk Motor Coupling Element

10000K

487

FSN

11-802-3

Stacker C Disk Motor Coupling

10000K

486

FSN2

11-802-4

Stacker D Disk Motor Coupling

10000K

487

FSN2

08-808

Vertical Transport Belts

3000K

485

08-810-1

Tray 3 Blower O Ring Drive Belt

9000K

490

08-810-2

Tray 4 Blower O Ring Drive Belt

9000K

491

FSN

08-810-3

Tray 5 Blower O Ring Drive Belt

9000K

490

FSN2

08-810-4

Tray 6 Blower O Ring Drive Belt

9000K

491

FSN2

08-816

Registration Cross Rolls

2000K

490

PHN

08-817

Registration Servo Shaft Rolls

3000K

491

PHN

08-818

System Cleaning

1000K

498

PHN

09-801

Cleaner Brush & Blades

1000K (2000K w/P224, 234)

481

MIN

09-802

Agitator Spring

7850K

482

MIN

09-803

Transfer Assist Blade

1000K

499

MIN

Section Name

GP 5

0/0/00 ?-6

Preliminary Working Document No Product Name Assigned

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

HFSI THRESHOLD

NVM VALUE

HFSI THRESHOLD

NVM VALUE

50K

.00

2,050K

40

100K

01

2,100K

41

150K

02

2,150K

42

200K

03

2,200K

43

250K

04

2,250K

44

300K

05

2,300K

45

350K

06

2,350K

46

400K

07

2,400K

47

450K

08

2,450K

48

500K

09

2,500K

49

550K

10

2,550K

50

600K

11

2,600K

51

650K

12

2,650K

52

700K

13

2,700K

53

750K

14

2,750K

54

800K

15

2,800K

55

850K

16

2,850K

56

900K

17

2,900K

57

950K

18

2,950K

58

1,000K

19

3,000K

59

1,050K

20

3,050K

60

1,100K

21

3,100K

61

1,150K

22

3,150K

62

1,200K

23

3,200K

63

1,250K

24

3,250K

64

1,300K

25

3,300K

65

1,350K

26

3,350K

66

1,400K

27

3,400K

67

1,450K

28

3,450K

68

1,500K

29

3,500K

69

1,550K

30

3,550K

70

1,600K

31

3,600K

71

1,650K

32

3,650K

72

1,700K

33

3,700K

73

1,750K

34

3,750K

74

1,800K

35

3,800K

75

1,850K

36

3,850K

76

1,900K

37

3,900K

77

1,950K

38

3,950K

78

2,000K

39

4,000K

79

Preliminary Working Document No Product Name Assigned

0/0/00 ?-7

Section Name

GP 5

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

HFSI THRESHOLD

NVM VALUE

HFSI THRESHOLD

NVM VALUE

4,050K

80

6,050K

120

4,100K

81

6,100K

121

4,150K

82

6,150K

122

4,200K

83

6,200K

123

4,250K

84

6,250K

124

4,300K

85

6,300K

125

4,350K

86

6,350K

126

4,400K

87

6,400K

127

4,450K

88

6,450K

128

4,500K

89

6,500K

129

4,550K

90

6,550K

130

4,600K

91

6,600K

131

4,650K

92

6,650K

132

4,700K

93

6,700K

133

4,750K

94

6,750K

134

4,800K

95

6,800K

135

4,850K

96

6,850K

136

4,900K

97

6,900K

137

4,950K

98

6,950K

138

5,000K

99

7,000K

139

5,050K

100

7,050K

140

5,100K

101

7,100K

141

5,150K

102

7,150K

142

5,200K

103

7,200K

143

5,250K

104

7,250K

144

5,300K

105

7,300K

145

5,350K

106

7,350K

146

5,400K

107

7,400K

147

5,450K

108

7,450K

148

5,500K

109

7,500K

149

5,550K

110

7,550K

150

5,600K

111

7,600K

151

5,650K

112

7,650K

152

5,700K

113

7,700K

153

5,750K

114

7,750K

154

5,800K

115

7,800K

155

5,850K

116

7,850K

156

5,900K

117

7,900K

157

5,950K

118

7,950K

158

6,000K

119

8,000K

159

Section Name

GP 5

0/0/00 ?-8

Preliminary Working Document No Product Name Assigned

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

HFSI THRESHOLD

NVM VALUE

HFSI THRESHOLD

NVM VALUE

8,050K

160

10,050K

200

8,100K

161

10,100K

201

8,150K

162

10,150K

202

8,200K

163

10,200K

203

8,250K

164

10,250K

204

8,300K

165

10,300K

205

8,350K

166

10,350K

206

8,400K

167

10,400K

207

8,450K

168

10,450K

208

8,500K

169

10,500K

209

8,550K

170

10,550K

210

8,600K

171

10,600K

211

8,650K

172

10,700K

212

8,700K

173

10,800K

213

8,750K

174

10,900K

214

8,800K

175

11,000K

215

8,850K

176

11,100K

216

8,900K

177

11,200K

217

8,950K

178

11,300K

218

9,000K

179

11,400K

219

9,050K

180

11,500K

220

9,100K

181

11,600K

221

9,150K

182

11,700K

222

9,200K

183

11,800K

223

9,250K

184

11,900K

224

9,300K

185

12,000K

225

9,350K

186

12,100K

226

9,400K

187

12,200K

227

9,450K

188

12,300K

228

9,500K

189

12,400K

229

9,550K

190

12,500K

230

9,600K

191

12,600K

231

9,650K

192

12,700K

232

9,700K

193

12,800K

233

9,750K

194

12,900K

234

9,800K

195

13,000K

235

9,850K

196

13,100K

236

9,900K

197

13,200K

237

9,950K

198

13,300K

238

10,000K

199

13,400K

239

Preliminary Working Document No Product Name Assigned

0/0/00 ?-9

Section Name

GP 5

Table 2 HFSI Service Interval Conversion Table for Adjustable Thresholds

GP 6 Occurrence Log Procedure Purpose

HFSI THRESHOLD

NVM VALUE

13,500K

240

13,600K

241

13,700K

242

13,800K

243

Procedure

13,900K

244

1.

14,000K

245

a.

Logs can be taken in standby or in print.

14,100K

246

b.

14,200K

247

The Occurrence log should be taken as soon as possible after the problem has been observed, and definitely before the following:

14,300K

248

14,400K

250

14,600K

251

14,700K

252

14,800K

253

15,000K

Section Name

GP 5, GP 6

The following tips are useful when taking an occurrence log:

•

249

14,500K

14,900K

The purpose is to enable the CSE to capture data that is stored continuously by the machine for debug purposes by Software Engineers. This procedure should be taken when a software problem is suspected.

c. 2.

254 255

the machine is powered off

•

diagnostics is entered

•

3 minutes have elapsed while the machine is delivering output

Any of the above three conditions may destroy relevant data.

The following information must be available with the floppy: a.

Log/SPAR number (if known).

b.

Machine serial number.

c.

Meter A reading.

d.

Date

e.

ESS Level

f.

IOT software level

g.

Complaint (one per write up; include the ESS PC code and task if applicable)

h.

Scenario (Job Command, when the log was taken, recovery action)

i.

Repeatability (not repeatable, repeatable in x tries, did not try to repeat)

3.

Obtain a formatted floppy and place it into the floppy drive.

4.

Press and hold the button for the digit "1", then press the "F1" button.

5.

Release both buttons.

6.

Press the "F1" button.

7.

The seven segment display will read "Log 1" and increment to "Log 7". When the occurrence data is written to the floppy, the seven segment display will read DONE.

8.

Press the "F4" button to exit the Occurrence Log Mode.

9.

Remove the floppy, and submit it with the problem report.

0/0/00 ?-10

Preliminary Working Document No Product Name Assigned

GP 7 Dual Lamp 14 Inch Diagnostic Procedure

GP 8 Dual Lamp 11 Inch Diagnostic Procedure

Purpose

Purpose

The purpose of this procedure is to enable the CSE to pulse the 14 inch segment of the Dual Lamp Fuser Rod. When directed to enter dC701 [Fuser Roll Temp] and observe the Fuser Rod the following procedure should be used.

The purpose is to enable the CSE to pulse the 11 inch segment of the Dual Lamp Fuser Rod. When directed to enter dC701 [Thermistor Cal] and observe the Fuser Rod the following procedure should be used.

Procedure

Procedure

To see additional information go to Fuser in the DocuPrint 180 Unique Components and Functions section.

To see additional information go to Fuser in the DocuPrint 180 Unique Components and Functions section.

NOTE: It may be helpful to remove the Fuser Inner Panel to enable better viewing of the fuser rod.

NOTE: It may be helpful to remove the Fuser Inner Panel to enable better viewing of the fuser rod.

1.

Ensure that the Fuser Drawer is closed. Enter dC701 the default is [Fuser Roll Temp].

1.

NOTE: There is a 3 to 5 second delay from the time that [Fuser Roll Temp] is selected until the time a signal is sent to pulse the 14 inch lamp segment of the dual lamp Fuser Rod.

NOTE: There is a 3 to 5 second delay from the time that [Thermistor Cal] is selected until the time a signal is sent to pulse the 11 inch lamp segment of the dual lamp Fuser Rod.

2.

The 14 inch segment of the fuser rod will pulse three (3) times.

2.

The 11 inch segment of the fuser rod will pulse three (3) times.

3.

While still in dC701 [Fuser Roll Temp] any time the fuser drawer is opened and then closed a signal will be sent to pulse the 14 inch segment of the dual lamp fuser rod three (3) times.

3.

While still in dC701 [Thermistor Cal] any time the fuser drawer is opened and then closed a signal will be sent to pulse the 11 inch segment of the dual lamp fuser rod three (3) times.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-11

Ensure that the Fuser Drawer is closed. Enter dC701 the default is [Fuser Roll Temp]. select [Thermistor Cal].

Section Name

GP 7, GP 8

GP 1000 Diagnostic Programs and Procedures

Add the appropriate values based on system configuration and enter the resulting sum:

Purpose

Sample Tray

The purpose of this General Procedure is to provide a licensed Self-Service Customer with methods to perform Diagnostic programs or procedures which are not installed on the system. If you, as a licensed Self-Service Customer, encounter references to any diagnostic program or procedure in this Service Diagnostic Manual which does not appear in the installed Diagnostic Software, this General Procedure is to be used for the appropriate service action. 6.

Printer Diagnostics •

dC101 NVM Save and Restore Use dC325 and dC326 on Diagnostic Floppy to save and restore files to the rigid disk drive. To restore NVM to the EDN PWB perform dC 323 after restoring files to RDD via dC326.

Enter dC131, EDN

2.

To select system Features enter appropriate value into NVM EDN Loc 262.

3.

4.

1

add

2

Stacker B

add

4

Stacker C

add

8

Stacker D

add 16

Bypass Transport

add

Purge Tray

add 128

32

To enable the following system Features enter appropriate value into NVM. To enable ASIC2 Pwb

Set EDN loc 488 = 64

To enable 240 spi (w/240 SLB Pwb)

Set EDN loc 489 = 7

dC106 Job Exerciser Run sample Diagnostic Test forms as required to evaluate system performance and setups. Use the SAMPLE command on LPS Controller, the Print Test Patterns command on NPS Controller, and utilize the Diagnostic Samples pull down window on IPS Controller.

dC105 Printer Configuration Setup 1.

add

Stacker A

•

Test forms available are

Add the appropriate values based on system configuration to current value and enter:

Dimensional

(DIME.PS, DIMExx.FRM)

MICR

Xerographic

(XERO.PS, XEROxx.FRM)

add 2

Enable 7x10 inch Kit add 16

E Form

(EFOR.PS, EFORxx.FRM)

Enable JB5 paper

Halftone

(HALF.PS, HALFxx.FRM)

To select Market Region, Altitude, Transfer Blade type, and Input Power type enter appropriate value into NVM EDN Loc 264

Quadrile

(QUAD.PS, QUADxx.FRM)

MICR

(MICR.PS, MICRxx.FRM)

Add the appropriate values based on system configuration and enter the resulting sum:

Test

(TEST.FRM)

US Market, normal altitude, 60 Hz

add 0

White Dusting (DUST.PS, DUSTxx.FRM)

50 Hz

add 1

add 32

10-13 inch Transfer Blade

add 2

10.12-14.33 inch Transfer Blade

add 4

dC107 Component Life Counters

High altitude (above 3000 ft)

add 8

Keep a record of parts usage and life counts on paper.

Spain Market

add 16

Holland/Belgium Market

add 32

dC226 Finisher Timing Diagnostics

Japan Market

add 48

Run sample print jobs that stress problem area. Observe jammed sheets for tell tale timing info.

To select Input Configuration enter appropriate value into NVM EDN Loc 265. Add the appropriate values based on system configuration and enter the resulting sum: Tray 1

add 1

Tray 2

add 2

dC603 Magnification Setup

Tray 3

add 4

Tray 4

add 8

Run samples of Dimensional test pattern for evaluation. Input new value into NVM to effect change then re-evaluate.

Tray 5

add 16

Tray 6

add 32

•

Slow scan adjustment:

3rd Party Input add 64 5.

NVM Loc 183 = New Value

To select Output Configuration enter appropriate value into NVM EDN Loc 266

Section Name

GP 1000

Enter dC131, MIN

0/0/00 ?-12

Preliminary Working Document No Product Name Assigned

Fast scan adjustment: NVM Loc 33 = New Value

•

CHG1##SI: NVM Loc 116

•

CHG1##SV: NVM Loc 117

•

CHG2$$SV: NVM Loc 139

•

CHG2##SI: NVM Loc 118

dC604 Registration Setup

•

CHG2##SV: NVM Loc 119

Run samples of Dimensional test pattern for evaluation. Input new value into NVM to effect change then re-evaluate.

•

TRAN$$SI: NVM Loc 62

•

TRAN##SI: NVM Loc 66

•

TRAN##SV: NVM Loc 67

•

PCLN$$SI: NVM Loc 59

•

PCLN##SI: NVM Loc 68

•

Enter dC131, PHN Slow scan adjustment: NVM Loc 97 = New Value Enter dC131, MIN Fast scan adjustment: NVM Loc 151 = New Value dC606 Printer Test Pattern Generation

Evaluate image quality from sampled test patterns. Refer to the dC106 procedure.

•

PCLN##SV: NVM Loc 69

•

DTAC$$SI: NVM Loc 58

•

DTAC##SI: NVM Loc 70

•

DTAC##SV: NVM Loc 71

•

DEV1$$BV: NVM Loc 141

•

DEV1##VM: NVM Loc 120

•

DEV2$$BV: NVM Loc 142

•

DEV2##VM: NVM Loc 121

dC726 Paper Path Timing Diagnostic Run sample print jobs that stress problem area. Observe jammed sheets for tell tale timing info.

dC910 High Voltage Fault Test Enter dC131, MIN •

dC314 Dicor Power Supply Calibration

Enter appropriate value into Loc 146 and run sample job to stress problem area. For Normal Mode, enter Value 230.

Enter dC131, MIN

For Low Stress Mode, enter Value 210. For High Stress Mode, enter Value 250.

To change an AC Power Supply NVM value, use the data provided with the power supply to update the following NVM locations:

A fault code will appear if a problem exists.

•

COR$$ACV: NVM Loc 147

•

COR##ACV: NVM Loc 112

dC912 PR Uniformity and Timing Tests

•

COR##ACI: NVM Loc 113

Wait for a fault code to appear.

•

CLNR$$BV: NVM Loc 57

•

CLNR##VM: NVM Loc 63

Call History

•

RCLM$$BV: NVM Loc 60

Keep information in a system log.

•

WAST$$BV: NVM Loc 61

•

WAST##VM: NVM Loc 65

HFSI

To change a DC Power Supply NVM value, use the data provided with the power supply to update the following NVM locations: •

CHG0$$SV: NVM Loc 148

•

CHGO##SI: NVM Loc 114

•

CHG0##SV: NVM Loc 115

•

CHG2$$SI: NVM Loc 140

Preliminary Working Document No Product Name Assigned

Keep information in a system log.

Fault History For a summary of faults that have occurred, use the Controller to print out the Printer Performance Report. To reset the Printer Fault History counters use the appropriate Controller command.

0/0/00 ?-13

Section Name

GP 1000

THIS PAGE INTENTIONALLY BLANK

Section Name

GP 1000

0/0/00 ?-14

Preliminary Working Document No Product Name Assigned

dC 1 Service Mode Entry Procedure Purpose The purpose is to provide instructions to enter the Service Mode.

Procedure Entry NOTE: For Third Party Technicians, refer to GP 1000, Diagnostic Programs and Procedures, for work-arounds if the diagnostic routine mentioned in the documentation is not located on the UI Screen. 1.

Select the Tool File Cabinet (Figure 1).

2.

Select [Service...]

3.

Enter the Service Access Code on the Keypad

4.

Select [Enter...]

Preliminary Working Document No Product Name Assigned

0/0/00 ?-15

Section Name

dC 1

Figure 1 Service Mode Entry Procedure

Section Name

dC 1

0/0/00 ?-16

Preliminary Working Document No Product Name Assigned

dC 2 Service Mode Exit Procedure Purpose The purpose is to provide instructions in order to exit from the Service Mode.

Procedure Entry 1.

Select the [SCP] file Cabinet.

2.

Select [Service Mode Exit].

Preliminary Working Document No Product Name Assigned

0/0/00 ?-17

Section Name

dC 2

Figure 1 Service Mode Exit Procedure

Section Name

dC 2

0/0/00 ?-18

Preliminary Working Document No Product Name Assigned

dC 101 Floppy Disk Read/Write

* High Frequency Service Items (HFSI) history.

Purpose

* Service Call Procedure information for the last two calls. Clean Disk Drive - Allows cleaning of the Floppy Disk Drive with the Disk Drive Cleaning Kit. It takes approximately 30 seconds to clean the Floppy Disk Drive.

The purpose is to save the Setup Parameters from NVM to the Floppy Disk, to restore the Setup Parameters from the Floppy or Rigid Disk to NVM, and to collect the System Data from NVM and the Rigid Disk to a Floppy Disk.

The Floppy Disk Drive must be cleaned before use. If the Floppy Disk Drive is not cleaned, there is a possibility that the Floppy Disk inserted may be damaged.

This program is also used to clean the Floppy Disk Drive and to format a Floppy Disk.

Restore Setup Parameters - Copies the setup parameters from a Floppy or Rigid Disk back to NVM on the SAN Core PWB.

Procedure

The setup parameters should be restored when the Rigid Disk or a SAN Core PWB has been replaced and if the NVM values have changed for an unknown reason and the machine is not performing properly.

NOTE: No copies can be made while in dC101. Entry

Floppy disk format - Erases the data from a previously used Floppy Disk, or prepares a new Floppy Disk to receive data.

1.

Enter dC101

It takes between four and five minutes to format a Floppy Disk.

2.

The options are:

The following functions are also available:

Specific directions and warnings are displayed within each selection.

Task Options - The ability to Confirm or Abort each of the options with the exception of the Disk Directory is available.

Disk Directory - When this is selected, the first file name of the Floppy Disk is displayed in the center box. This also allows scrolling through the file titles of the Floppy Disk. Next File Name - When this is selected, the next file on the Floppy Disk will be displayed. The files will be displayed in the same order as they are copied onto the Floppy Disk. Save Setup Parameters - Copies all of the machine's setup parameters to the Floppy Disk, that are stored in NVM on the SAN Core PWB. The setup parameters are as follows:

Confirm Allows running the selected option on the screen. Abort Will cancel the selected option on the screen. 3.

Insert the floppy disc and select the option to be performed.

4.

Select [Confirm].

5.

Press the Continue button.

Error Codes If an error is detected, one of the following codes will be shown on the digital display:

* ROS * Xerographics

F01

* Registration

This code will indicate that the disk is write protected, or that there is not a floppy in the drive. The Read/Write switch on the floppy is in the "Read Only" position. Place the switch in the "read/write" position. This means that the switch should be blocking the open window. If the window is open and not blocked, the switch is in the "Read Only" position. If a floppy was not inserted, insert a floppy into the drive.

* Paper Trays * Fuser * Feeder/Stacker CAUTION

F02

The setup parameters from only one machine should be copied to a single Floppy Disk. When saving the setup parameters, do not remove the Floppy Disk until all six files have been copied. As each file is copied, the message "File has been copied" will appear and the digital display will show a "1." When all six "1"s are displayed and the last "File has been copied" message has appeared, the Floppy Disk may be removed. Collect System Data - Copies the NVM data from the SAN Core PWB, along with additional portions of data from the Rigid Disk to the Floppy Disk. The system data information cannot be restored back into NVM. If it is, a message error will appear on the screen.

This code will indicate that the disk has not been formatted. Format the floppy before performing the write operation. F14 This code will indicate that the [Save Setup Parameters] command has timed out. No floppy has been inserted into the disk drive. F32 This code will indicate that the file has not been found. The file to be restored is not on the Floppy Disk. F33

The system data from several machines may be copied to the same Floppy Disk. A Floppy Disk can hold up to nine sets of system data information.

This code will indicate that the file is located on the disk but access to write to this file has been rejected.

The system data that is copied is as follows:

F34

* Last 50 Faults and Top 15 Faults

Preliminary Working Document No Product Name Assigned

0/0/00 ?-19

Section Name

dC 101

This code will indicate that the directory is full. There is no more space on the Floppy Disk. Insert a new Floppy Disk and repeat the command. F43 This code will indicate that the disk is an invalid disk. One of the following error codes may be shown on the digital display if there is a software error: F06

dC 102 Software Upgrade Purpose The purpose is to upgrade the system software on the Rigid Disk and/or to upgrade the User Interface Screen data. It also allows loading up to two languages (the primary and secondary language) and to enable or disable the secondary language.

Procedure

F07

Introduction

F38 F39

1.

Before performing a dC102, Software upgrade, go to dC101 and perform the Save Setup Parameters procedure.

2.

* Insert a new Floppy Disk.

If a full software upgrade is selected, first perform dC325, save critical disk files, using the diagnostic diskette to save the following information:

F40

a.

This code occurs in Save System Parameters when the software creates a new file and the floppy system fails to erase the old file. The system tries to store a new file over the existing file.

b.

the Initial screen information in SCP.

c.

the Last 50 faults in SCP.

d.

the Top 15 Actual and Almost faults in SCP.

* Use a new formatted floppy disc.

e.

the HFSI History information.

* If a new formatted floppy disc still fails replace the floppy drive.

f.

the Service Billing Credits.

g.

The Guarded Access Code.

Perform the following if there is a software error: * Repeat the selected operation.

One of the following error codes may be shown on the digital display if there is a hardware error: F03

The backup copy of the NVM located on the EDN Core PWB.

Entry 1.

F04

Enter dC102. a.

The following options are:

F05

Software change Full

F36

Software change Partial

F37

Language change Primary

F44

Language change Secondary

F45

Second language Enabled

Perform the following if there is a hardware error:

Second language Disabled

* Repeat the selected operation.

Full software upgrade requires a complete change to the software. It usually requires the loading of 7 Floppy Disks and takes approximately 1/2 hour to complete.

* Insert a new Floppy Disk. If problem continues, go to the 3-701, Floppy Disk Drive Failure RAP.

Partial software upgrade is anything less than a complete change to the software and only the differences are written to the Rigid Disk. Most software upgrades will be a partial upgrade. Since a partial upgrade does not completely rewrite the Rigid Disk, information from the Rigid Disk will not be lost. Current version is a window which indicates the software level that exists in the machine now. Floppy version is a window which indicates the software level that is going to be loaded in the software upgrade. Language change will upgrade the language software for either the Primary or Secondary language. It usually will require two Floppy Disks. Second language is a switch that will enable or disable the second language in the machine. b. Section Name

dC 101, dC 102

0/0/00 ?-20

The options are: Preliminary Working Document No Product Name Assigned

Task options - Read, Confirm or Abort the selection. Read selection is the command that will allow the software upgrade to begin by booting the number one Floppy Disk. This happens after Confirm has been selected and the Continue button is pressed. Confirm selection is the command that informs the MIN Core PWB to get ready for the software upgrade.

11. After the full software upgrade is completed, perform dC326, restore critical disk files using the diskette containing the new level of software. Information Display When a software upgrade is being performed, additional information can be obtained by pressing and holding the Information button.

Abort selection is the command that informs the MIN Core PWB that there is no software upgrade. 2.

Remove the software upgrade diskette #1 from the software upgrade kit.

3.

Insert the diskette #1 into the floppy disk drive.

4.

Select the option [Partial] or [Full].

5.

Select [Read].

6.

Select [Confirm].

7.

Press the Continue button.

dC102FC001 (Example of the information message) 0987654321 (LED position of information message) Table 2 INFORMATION MESSAGE DESCRIPTION ON DIGITAL DISPLAY LED POSITION #

4

This position indicates the status of the internal operations.

The machine will now reboot from the floppy Disk.

b.

As the upgrade begins, the digital display and the screen will go blank.

4

(blank)

c.

When the message "Full Upgrade" appears on the digital display, Press Continue.

4

C

sw upgrade is running

d.

The information on the floppy will begin to transfer to the EDN Core PWB and then the information will be transferred to the Rigid Disk.

4

D

sw upgrade is completed

e.

As the information is being transferred, the digital display will show the status of the software upgrade.

5

0987654321 (LED position of status message) Table 1 STATUS MESSAGE DESCRIPTION ON DIGITAL DISPLAY LED POSITION # 1, 2

f.

DESCRIPTION Number of the disk to be copied

3

Disk changing cue

4, 5, 6

Software revision level

7

L-Language Upgrade Indicator

8, 9

The System Activity Indicator

10

Error Indicator

5

F

full upgrade

5

p

partial upgrade

5

1

primary language upgrade

5

2

secondary language upgrade

5

(blank)

upgrade type is not yet determined

5

E

When the software upgrade diskette #1 has finished, a " d" will be flashing in the #3 LED position on the digital display. Also the next floppy to insert is indicated in the #1 and #2 LED positions on the digital display.

When an error message is displayed, always retry the software upgrade procedure. Many times the error will not occur the second time. If the error message is displayed a second time, use the information shown on the digital display in order to determine the corrective action. Ex1x033E01 (Example of error message) 0987654321 (LED position of error message)

Continue to insert the remainder of the software upgrade diskettes.

Table 3 ERROR MESSAGE DESCRIPTION ON DIGITAL DISPLAY LED POSITION #

The machine will reboot.

3

Disk changing cue Software revision level

7

0/0/00 ?-21

DESCRIPTION Number of disk with error

4, 5, 6 7

No Product Name Assigned

CODE

1, 2

10. When the last diskette has finished and the software level message appears, remove the diskette and then press the Continue button.

Preliminary Working Document

error has occurred These positions indicate which dC program is in operation.

Error Message

Insert the software upgrade diskette #2 into the floppy disk drive.

a.

revision # or sw revision level

This position indicates the type of sw being performed.

6, 7, 8, 9, 10

NOTE: With some of the software upgrade diskettes, the System Activity Indicator, in the #8 and #9 LED positions on the digital display, may cycle through more than one time. 9.

DESCRIPTION This is a 3 byte hex number and depends on what is displayed in LED position #4.

a.

E99L001d01 (Example of status message)

8.

CODE

1, 2, 3

Language upgrade (blank)

Language upgrade Section Name

dC 102

dC 103 Billing Read and Setup

Table 3 ERROR MESSAGE DESCRIPTION ON DIGITAL DISPLAY LED POSITION #

CODE

DESCRIPTION

7

L

Language upgrade

8

Purpose The purpose is to enable up to four meters that define the billing system. The meters you enable are displayed in the operator mode Tools and on the SCP Final screen.

Error Device Indicator

8

1

Floppy Disk problem

8

2

Rigid Disk problem

8

3

Language upgrade problem

9

(blank)

-

10

E

Error Indicator (Flashing E)

Procedure Entry

If an error message is shown on the digital display, go to the 3-703, Software Upgrade Problem RAP.

1.

Enter dC103.

2.

Meter A: Total good prints delivered (Always Selected).

3.

Select any of the three additional meters. Meter C: Total good, non - 7 pitch prints delivered (x100). Meter E: Total sheets delivered to sample tray (x100). Meter F: Total sheets delivered to purge tray (x100). Meter H: Total good duplex prints delivered (x100). Meter J: Total good service prints delivered (x100). Meter K: Total good prints delivered (x100). Meter M: Not used.

Section Name

dC 102, dC 103

0/0/00 ?-22

Preliminary Working Document No Product Name Assigned

dC 105 Initial Setups

a.

Feed Tray Selections

b.

Stacker Selections

c.

Transfer Blade Configuration

Select either [Tray 3], [Tray3/4], [Tray3/4/5], or [Tray3/4/5/6]

Purpose The purpose is to input information about the machine and the machine location into the memory.

Select either [Stackers A/B], [Stackers A/B/C], or [Stackers A/B/C/D]

Procedure

Select either [11 -14 inch] or [10 - 13 inch] d.

To see additional information go to Xerographics in the DocuPrint 180 Unique Components and Functions section 9. Entry

Select as required [Output Module], [Output Rotation Module], [Feeder Module] 6.

2.

3.

Select [Features]. Ensure the applicable features are selected: a.

[F2], 7 x 10 Option

b.

[F3], Variable RDR

Enter dC105. The Account Information will default to the following selections:

c.

[F4], MICR

Market Region - 1

d.

[F7], Digital Patch Generator

Line frequency - 60Hz

e.

[F8], Dual Lamp

Site Altitude - Below 3000 ft.

f.

[F9], Hi-C Fuser

Service Tone Volume - High

g.

[F12], Speed (180)

The options are:

h.

[F14], ROS VLD

Account Information

i.

[F15], ASIC1

Serial number and Service Phone number

j.

[F16], ASIC2

Configuration

k.

[F17], Precision Patch

Select [Account Information].

l.

[F18], 240 SPI (if applicable)

NOTE: No copies are run while in dC105. The Continue and Stop buttons are not used. 1.

Optional Device Selections

a.

Market Region Select the appropriate number [1], [2], [3], or [4]. The market region selection sets the point where the paper tray switches indicate the size of the paper in the tray.

b.

Line Frequency

c.

Site Altitude

Select either [60Hz] or [50Hz]. Select either [Below 3000 ft.] or [Above 3000 ft.]. d.

Service Tone Volume Select either [High] or [Low].

4.

Select [Serial number and Service telephone number]. a.

Service Telephone Number Enter the telephone information by using the number buttons on the control panel and the symbol selection at the bottom of the screen.

b.

Select [Enter]. This information will also appear on the Call For Service screen and on Tools screen.

c.

Printer Serial Number Enter the serial number information by using the number buttons on the control panel.

d.

Select [Enter]. This information will also appear on the Call For Service screen in Tools.

5.

Select [Configuration]

Preliminary Working Document No Product Name Assigned

0/0/00 ?-23

Section Name

dC 105

dC 106 Printer Options

dC 107 Component Life Counters

Purpose

Purpose

The purpose is to set up jobs, test patterns, and print quality for diagnostic purposes.

The purpose is to provide diagnostic counters indicating the number of events since the last replacement of specific components.

Procedure Procedure

Entry

Entry 1.

Enter dC106 (The default is JOB SETUP)

2.

Select [TEST PATTERNS AND PQ]

1.

Enter dC107

a.

2.

The options are:

The options for TEST PATTERNS are:

Current - The current screen displays the present number of events in the Component Life Counters.

Dimensional (Default) Xerographic

History - The history screen displays the previous five replacement intervals for the Component Life Counters.

Halftone E Form

3.

Quadratic b.

The default screen is Current and the options are:

The options for Prints Quality are:

Table 1

Table 1 ASIC1

ASIC2

Image ASIC1 Off

Print Nominal

PD3 Height Correction

Line Suppression

PD4 Height Correction

Print Lighter

DT135 Emulation

DT135 Emulation

Print Darker 1

Print Darker 1

Print Darker 2

Print Darker 2

Print Darker 3

Print Darker 3

Print Darker 4

Xero

F/S B

NOTE: If the Component Life Counters are blank, return to SCP Initial screen and Select [Update Data] then return to dC107. 4.

The default screen is Fuser and the counters are: Table 2

Print Darker 4 Print Darker 5

F/S A

Sheet

Image ASIC2 Off

Print Nominal

Fuser

Print Darker 5

c.

Select SET SIZE (Available only thru DC203 [Set ups],[GUIDES POSITION]).

d.

Use the number buttons on the control panel to select the number of prints.

Fuser Roll

(Print Hours)

Fuser System

(X 1000 Sheets)

Fuser dead cycles

(X 1000 Pitches

Pressure Roll

(X 1000 Sheets)

Air Knife Solenoid

(X 1000 Sheets)

Agent Pump Solenoid

(X 1000 Sheets)

Compressor Motor

(X 1000 Sheets)

5.

Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter.

6.

Select [Xero]. The options are: Table 3

Section Name

dC 106, dC 107

0/0/00 ?-24

Developer

(Print Hours)

P/R Belt

(X 1000 Pitches)

Cleaning Blades

(Print Hours)

Waste Bottle

(X 1000 Impressions)

Preliminary Working Document No Product Name Assigned

Table 6

Table 3 Developer

(Print Hours)

Tray 4

Polygon Motor

(Print Hours)

Back Guide

(X 100 Cycles)

ROS

(X 1000 Impressions)

Right Guide

(X 100 Cycles)

7.

Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter.

8.

Select [Sheet] the options are: Table 4

Offset Transport

(X 100 Cycles)

Stacking Disk

(X 1000 Cycles)

13. Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter. 14. Select [F/S C]. The options are:

IFS Inverter

(X 1000 Sheets)

Purge Tray

(X 1000 Sheets)

Table 7

Sample Tray

(X 1000 Sheets)

Tray 5

Stacker A

(X 1000 Sheets)

7 Pitch

(X 1000 Feeds)

Stacker B

(X 1000 Sheets)

3 Pitch

(X 1000 Feeds)

Unload

(X 100 Cycles)

Stacker C

(X 1000 Sheets) Stacker D

9.

(X 1000 Total Feeds)

(X 1000 Sheets)

Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter.

10. Select [F/S A]. The options are:

Back Guide

(X 100 Cycles)

Right Guide

(X 100 Cycles)

Offset Transport

(X 100 Cycles)

Stacking Disk

(X 1000 Cycles)

15. Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter.

Table 5 Tray 3

(X 1000 Total Feeds)

7 Pitch

(X 1000 Feeds)

3 Pitch

(X 1000 Feeds)

Unload

(X 1000 Total Feeds)

16. Select [F/S D]. The options are: Table 8

(X 100 Cycles)

Tray 6

(X 1000 Total Feeds)

Back Guide

(X 100 Cycles)

7 Pitch

(X 1000 Feeds)

Right Guide

(X 100 Cycles)

3 Pitch

(X 1000 Feeds)

Offset Transport

(X 100 Cycles)

Unload

(X 100 Cycles)

Stacking Disk

(X 1000 Cycles)

Back Guide

(X 100 Cycles)

Right Guide

(X 100 Cycles)

11. Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter. 12. Select [F/S B]. The options are: Table 6 (X 1000 Total Feeds)

7 Pitch

(X 1000 Feeds)

3 Pitch

(X 1000 Feeds)

Unload

(X 100 Cycles)

No Product Name Assigned

(X 100 Cycles)

Stacking Disk

(X 1000 Cycles)

17. Select the counters to be reset and Press [Reset counter to zero and update History] for each counter selected. This will reset each counter to zero and will update each History counter.

Tray 4

Preliminary Working Document

Offset Transport

0/0/00 ?-25

Section Name

dC 107

dC 108 Software Checksum Display

18. Select [History]. The options are:

Purpose

Table 9 Fuser

F/S A

Xero

F/S B

The purpose is to display the checksums (identification numbers) and linknames of the level of the software in the machine. This program can verify that the machine has the correct software installed.

Sheet

Procedure 19. The default screen is Fuser and the counters are the same as those in the current screen. The counters show the last 5 replacement intervals from most recent to least recent. NOTE: The following component life counters are also displayed in the [HFSI] counters: Developer (9-825) and Cleaning Blades (9-801) Resetting the respective HFSI counter will also reset the corresponding dC107 Component Life Counter and vice versa. The History counter will be updated automatically.

Entry NOTE: In order to interpret the checksums, refer to the System Program Description 6X's - 11 1.

Enter dC108.

2.

The following options are:

If the customer has been authorized to perform extended maintenance functions (PCT Trained Operators), resetting the [Guarded] [Tools] maintenance tasks counters will automatically reset their respective dC107 counters and related HFSI counters. In each case, the History counter will also be updated.

Section Name

dC 107, dC 108

0/0/00 ?-26

[Module/M.U.] selection allows you to select and verify checksums of [UIM] and [FSN 1]. [Node] selection allows you to select and verify checksums of [EDN], [MIN], and [PHN]. [HI/DOS/VE/Patterns] selection allows you to select and verify checksums of [Host Interface], [DOS], [Video Engine], and [Patterns].

Preliminary Working Document No Product Name Assigned

dC 121 Error Log Threshold Modifier

dC 131 EDN NVM Read/Write 70.10 SW

Purpose

Procedure

The purpose is to provide a means of modifying the NVM Jam and Fault Threshold values for each module.

Entry NOTE: These NVM Tables use 70.10 S/W as the base.

Procedure Entry

NOTE: Do not change any data unless directed to do so by a RAP or by other procedures. Ensure the correct node is being addressed before changing any data.

1.

Enter dC121

2.

The screen is broken down into two regions:

NOTE: Always refer to the IOT Software Release Document (IOT-21) for new or unique NVM values for the software level on this Machine.

3.

a.

Selection Threshold Area - which contains Threshold Area, Current Threshold, and the scroller icon.

b.

Threshold Adjustment - which contains the currently selected area and it's threshold value, Range and the digit area for entering the new threshold and an Enter icon.

1.

The following message will be displayed: SAVE SETUP PARAMETERS, dC101, before changing data. This message is a precaution to ensure having the latest NVM setup parameters in case any data entry is changed by accident.

Scroll to the desired threshold area. The yellow background indicates the selection.

4.

Enter New Data from the Keypad.

5.

Select the Enter icon

Enter dC131.

2.

The options are: Setups using the Address and Data section of the screen to read/write to the Rigid Disk. Guarded Access allows entering the operator Guarded mode without using the coded number. Usage Counters allows resetting the LPMS (Launch Performance Measurement System) counters in NVM. Initialize Node allows initializing the NVM setups to the default values for a selected node.

Setups 1.

Select the appropriate node.

2.

Enter the Address location by using the number buttons on the control panel. The address location number will appear on the bottom of the screen in the blue outline box.

3.

Select [Enter] in the Address section of the screen. (Pressing the F4 button will also perform the same function.) The address location number will now appear in the Address section of the screen. The data information for that address will now appear in the Data section of the screen. Scroll through the addresses by using the up or down arrows on the screen. Enter address locations from 0 to 511.

4.

Enter the new Data information by using the number buttons on the control panel.

5.

Select [Enter] in the Data section of the screen. (Pressing the F5 button will also perform the same function.) The new data information will now appear in the Data section of the screen. The following messages may be seen when using this part of the procedure. Address is out of range This means that the address location that was entered does not exist. Value is out of range This means that the value entered is either too high or too low for this location. It will not accept this number.

Preliminary Working Document No Product Name Assigned

0/0/00 ?-27

Section Name

dC 121, dC 131 EDN

Guarded Access

Table 1 EDN NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

09

--

Crash Array xxxxXXxxxx [crashArray2]

10

--

Crash Array xxxxxxXXxx [crashArray3]

11

--

Crash Array xxxxxxxxXX [crashArray4]

12

--

Host Interface Background state

16

4

Program Name

17

1

Program Name

18

3

Program Name

19

5

Program Name

20

136

SCP Jam Threshold for HCF1 (1st Byte)

21

19

SCP Jam Threshold for HCF1 (2nd Byte)

Enter dC131

22

136

SCP Jam Threshold for HCF2 (1st Byte)

Select the appropriate node in the Setups area of the screen.

23

19

SCP Jam Threshold for HCF2 (2nd Byte)

24

136

SCP Jam Threshold for HCF3 (1st Byte)

25

19

SCP Jam Threshold for HCF3 (2nd Byte)

26

136

SCP Jam Threshold for HCF4 (1st Byte)

27

19

SCP Jam Threshold for HCF4 (2nd Byte)

28

76

SCP Jam Threshold for Stacker A (1st Byte)

29

29

SCP Jam Threshold for Stacker A (2nd Byte)

30

76

SCP Jam Threshold for Stacker B (1st Byte)

31

29

SCP Jam Threshold for Stacker B (2nd Byte)

32

76

SCP Jam Threshold for Stacker C (2nd Byte)

33

29

SCP Jam Threshold for Stacker C (2nd Byte)

34

76

SCP Jam Threshold for Stacker D (2nd Byte)

35

29

SCP Jam Threshold for Stacker D (2nd Byte)

NOTE: The address location and the initial value (default value) is given in decimal.

36

64

SCP Jam Threshold Paper Handling Module 1 (1st Byte)

1.

37

31

SCP Jam Threshold Paper Handling Module 1 (2nd Byte)

38

76

SCP Jam Threshold Paper Handling Module 2 (1st Byte)

39

29

SCP Jam Threshold Paper Handling Module 2 (2nd Byte)

DESCRIPTION

40

100

SCP Jam Threshold Paper Handling Module 3 (1st Byte)

25

SCP Jam Threshold Paper Handling Module 3 (2nd Byte)

NOTE: Refer to the Operator Manual for more information. 1.

Select [One Time Access Code Bypass].

2.

Select [SCP].

3.

Select [Service Mode Exit].

4.

Select [Guarded Tools].

5.

Change password.

6.

Enter the new guarded access code by using the number buttons on the control panel.

7.

Select [Enter].

8.

To exit Guarded mode, Select [Printer Status].

Initialize Node 1. 2.

NOTE: When a node is initialized, all the setup parameters for that node are set to their initial values, with the exception of the counters for that node. Do not initialize any node unless requested to do so by a RAP or by other procedures. 3.

Select [Initialize Selected Node].

4.

Press the Continue button to confirm. The following message is displayed: NVM initialization completed.

Locations above 511 cannot be accessed in the Field; therefore, they are not shown in the following Tables.

The EDN NVM TABLE contains the initial values for the EDN node software . Table 1 EDN NVM TABLE (70.10 SW) LOC

INIT VALUE

00

170

NVM Battery Pattern 1

41

01

85

NVM Battery Pattern 2

42

4

SCP Jam Threshold for Xerographic Module (1st Byte)

0

SCP Jam Threshold for Xerographic Module (2nd Byte)

02

00

Boot ROM crash page (page where Boot ROM stores crash data)

43

03

00

Control System Crash Mode (00=System crashes but comes back and reports a crash code, 02 = System crashes and has to be powered off and back on (extended debug)

44

2

SCP Jam Threshold for Communication (1st Byte)

45

0

SCP Jam Threshold for Communication (2nd Byte)

46

6

SCP Jam Threshold for System (1st Byte)

04

--

One Byte Check Sum of NVM [checkSumNVM]

47

0

SCP Jam Threshold for System (2nd Byte)

05

00

Crash Data Retrieval Switch (00=no crash retrieval, 13=do crash retrieval) [retrieveData]

48

216

Feeder 1 Zone 1 (1st Byte)

49

92

Feeder 1 Zone 1 (2nd Byte)

50

132

Feeder 1 Zone 1 (3rd Byte)

51

205

Feeder 1 Zone 1 (4th Byte)

52

69

Feeder 1 Zone 1 (5th Byte)

06

00

Crash type (00=DOS crash, 01=Host Interface crash) [validCrash]

07

--

Crash Array XXxxxxxxxx [crashArray0]

08

--

Crash Array XXxxxxxx [crashArray1]

Section Name

dC 131 EDN

0/0/00 ?-28

Preliminary Working Document No Product Name Assigned

Table 1 EDN NVM TABLE (70.10 SW)

Table 1 EDN NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

DESCRIPTION

53

210

Feeder 2 Zone 1 (1st Byte)

94

164

Feeder 3 Zone 2 (2nd Byte)

54

164

Feeder 2 Zone 1 (2nd Byte)

95

36

Feeder 3 Zone 2 (3rd Byte)

55

36

Feeder 2 Zone 1 (3rd Byte)

96

77

Feeder 3 Zone 2 (4th Byte)

56

77

Feeder 2 Zone 1 (4th Byte)

97

74

Feeder 3 Zone 2 (5th Byte)

57

74

Feeder 2 Zone 1 (5th Byte)

98

216

Feeder 3 Zone 3 (1st Byte)

58

216

Feeder 1 Zone 3 (1st Byte)

99

40

Feeder 3 Zone 3 (2nd Byte)

59

40

Feeder 1 Zone 3 (2nd Byte)

100

133

Feeder 3 Zone 3 (3rd Byte)

60

133

Feeder 1 Zone 3 (3rd Byte)

101

141

Feeder 3 Zone 3 (4th Byte)

61

141

Feeder 1 Zone 3 (4th Byte)

102

82

Feeder 3 Zone 3 (5th Byte)

62

82

Feeder 1 Zone 3 (5th Byte)

103

216

Feeder 3 Zone 4 (1st Byte)

63

216

Feeder 1 Zone 4 (1st Byte)

104

144

Feeder 3 Zone 4 (2nd Byte)

64

144

Feeder 1 Zone 4 (2nd Byte)

105

133

Feeder 3 Zone 4 (3rd Byte)

65

133

Feeder 1 Zone 4 (3rd Byte)

106

13

Feeder 3 Zone 4 (4th Byte)

66

13

Feeder 1 Zone 4 (4th Byte)

107

89

Feeder 3 Zone 4 (5th Byte)

67

89

Feeder 1 Zone 4 (5th Byte)

108

176

Feeder 3 Zone 5 (1st Byte)

68

216

Feeder 2 Zone 1 (1st Byte)

109

93

Feeder 3 Zone 5 (2nd Byte)

69

92

Feeder 2 Zone 1 (2nd Byte)

110

4

Feeder 3 Zone 5 (3rd Byte)

70

132

Feeder 2 Zone 1 (3rd Byte)

111

219

Feeder 3 Zone 5 (4th Byte)

71

205

Feeder 2 Zone 1 (4th Byte)

112

69

Feeder 3 Zone 5 (5th Byte)

72

69

Feeder 2 Zone 1 (5th Byte)

113

164

Feeder 3 Zone 6 (1st Byte)

73

210

Feeder 2 Zone 2 (1st Byte)

114

165

Feeder 3 Zone 6 (2nd Byte)

74

164

Feeder 2 Zone 2 (2nd Byte)

115

68

Feeder 3 Zone 6 (3rd Byte)

75

36

Feeder 2 Zone 2 (3rd Byte)

116

90

Feeder 3 Zone 6 (4th Byte)

76

77

Feeder 2 Zone 2 (4th Byte)

117

74

Feeder 3 Zone 6 (5th Byte)

77

164

Feeder 2 Zone 2 (5th Byte)

118

176

Feeder 3 Zone 7 (1st Byte)

78

216

Feeder 2 Zone 3 (1st Byte)

119

41

Feeder 3 Zone 7 (2nd Byte)

79

40

Feeder 2 Zone 3 (2nd Byte)

120

5

Feeder 3 Zone 7 (3rd Byte)

80

133

Feeder 2 Zone 3 (3rd Byte)

121

155

Feeder 3 Zone 7 (4th Byte)

81

141

Feeder 2 Zone 3 (4th Byte)

122

82

Feeder 3 Zone 7 (5th Byte)

82

82

Feeder 2 Zone 3 (5th Byte)

123

176

Feeder 3 Zone 8 (1st Byte)

83

216

Feeder 2 Zone 4 (1st Byte)

124

145

Feeder 3 Zone 8 (2nd Byte)

84

144

Feeder 2 Zone 4 (2nd Byte)

125

5

Feeder 3 Zone 8 (3rd Byte)

85

133

Feeder 2 Zone 4 (3rd Byte)

126

27

Feeder 3 Zone 8 (4th Byte)

86

13

Feeder 2 Zone 4 (4th Byte)

127

89

Feeder 3 Zone 8 (5th Byte)

87

89

Feeder 2 Zone 4 (5th Byte)

128

00

DFA Input Profile data Valid

88

216

Feeder 3 Zone 1 (1st Byte)

129

00

89

92

Feeder 3 Zone 1 (2nd Byte)

DFA Input Profile (1st Byte) time from feed command to sheet entrance in MS

90

132

Feeder 3 Zone 1 (3rd Byte)

130

00

91

205

Feeder 3 Zone 1 (4th Byte)

DFA Input Profile (2nd Byte) time from feed command to sheet entrance in MS

92

69

Feeder 3 Zone 1 (5th Byte)

93

210

Preliminary Working Document No Product Name Assigned

Feeder 3 Zone 2 (1st Byte)

0/0/00 ?-29

131

00

DFA Profile (1st Byte) time to cycle up in MS

132

00

DFA Input Profile (2nd Byte) time to cycle up in MS

Section Name

dC 131 EDN

Table 1 EDN NVM TABLE (70.10 SW)

Table 1 EDN NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

DESCRIPTION

133

00

DFA Input Profile / Attributes

194

133

Feeder 4 Zone 4 (3rd Byte)

134

00

DFA Input Profile / Statuses supported

195

13

Feeder 4 Zone 4 (4th Byte)

135

00

DFA Input Profile feed signal adjust in MS

196

89

Feeder 4 Zone 4 (5th Byte)

146

00

DFA output profile data valid

197

176

Feeder 4 Zone 5 (1st Byte)

147

00

DFA output profile-(1st Byte) Time between sheets in MS

198

93

Feeder 4 Zone 5 (2nd Byte)

148

00

DFA output profile-(2nd Byte) Time between sheets in MS

199

4

Feeder 4 Zone 5 (3rd Byte)

149

00

DFA output profile-(1st Byte) Sheet jam time in MS

200

219

Feeder 4 Zone 5 (4th Byte)

150

00

DFA output profile-(2nd Byte) Sheet jam time in MS

201

69

Feeder 4 Zone 5 (5th Byte)

151

00

DFA output profile-(1st Byte) Time between sets in MS

202

164

Feeder 4 Zone 6 (1st Byte)

152

00

DFA output profile-(2nd Byte) Time between sets in MS

203

165

Feeder 4 Zone 6 (2nd Byte)

153

00

DFA output profile-(1st Byte) Set jam time in MS

204

68

Feeder 4 Zone 6 (3rd Byte)

154

00

DFA output profile-(2nd Byte) Set jam time in MS

205

90

Feeder 4 Zone 6 (4th Byte)

155

00

DFA output profile-(1st Byte) Time to cycle up in MS

206

74

Feeder 4 Zone 6 (5th Byte)

156

00

DFA output profile-(2nd Byte) Time to cycle up in MS

207

176

Feeder 4 Zone 7 (1st Byte)

157

00

DFA output profile-(1st Byte) Attributes

208

41

Feeder 4 Zone 7 (2nd Byte)

158

00

DFA output profile-(2nd Byte) Attributes

209

5

Feeder 4 Zone 7 (3rd Byte)

159

00

DFA output profile-(1st Byte) Statuses supported

210

155

Feeder 4 Zone 7 (4th Byte)

160

00

DFA output profile-(2nd Byte) Statuses supported

211

82

Feeder 4 Zone 7 (5th Byte)

161

00

DFA output profile-delivery signal type

212

176

Feeder 4 Zone 8 (1st Byte)

162

00

DFA output profile-(1st Byte) Delivery start adjust in MS

213

145

Feeder 4 Zone 8 (2nd Byte)

163

00

DFA output profile-(2nd Byte) Delivery start adjust in MS

214

05

Feeder 4 Zone 8 (3rd Byte)

164

00

DFA output profile-(1st Byte) Delivery end adjust in MS

215

27

Feeder 4 Zone 8 (4th Byte)

165

00

DFA output profile-(2nd Byte) Delivery end adjust in MS

216

89

Feeder 4 Zone 8 (5th Byte)

166

00

DFA output profile-Sheets after full

222

1

177

216

Feeder 4 Zone 1 (1st Byte)

Auxiliary Devices in Configuration (duplex=1, rotator=2, Bar Code Reader =3)

178

92

Feeder 4 Zone 1 (2nd Byte)

223

2

179

132

Feeder 4 Zone 1 (3rd Byte)

Diagnostic State (not in diagnostics=0, on line diagnostics=1, off line diagnostics=2

180

205

Feeder 4 Zone 1 (4th Byte)

224

00

Branch Code [branch code Byte 4]

225

00

Branch Code [branch code Byte 3]

226

00

Branch Code [branch code Byte 2]

227

00

Branch Code [branch code Byte 1]

229

1

(First Byte) Selected Billing Meters (A=1, C=2, E=4, F=8, H=16, J=32, K=64, M=128)

230

00

(Second Byte) Selected Billing Meters (A=1, C=2, E=4, F=8, H=16, J=32, K=64, M=128)

181 182 183

69 210 164

Feeder 4 Zone 1 (5th Byte) Feeder 4 Zone 2 (1st Byte) Feeder 4 Zone 2 (2nd Byte)

184

36

Feeder 4 Zone 2 (3rd Byte)

185

77

Feeder 4 Zone 2 (4th Byte)

186

74

Feeder 4 Zone 2 (5th Byte)

187

216

Feeder 4 Zone 3 (1st Byte)

231

00

Service Telephone Number [phone # byte 20]

188

40

Feeder 4 Zone 3 (2nd Byte)

232

00

Service Telephone Number [phone # byte 19]

189

133

Feeder 4 Zone 3 (3rd Byte)

233

00

Service Telephone Number [phone # byte 18]

190

141

Feeder 4 Zone 3 (4th Byte)

234

00

Service Telephone Number [phone # byte 17]

191

82

Feeder 4 Zone 3 (5th Byte)

235

00

Service Telephone Number [phone # byte 16]

192

216

Feeder 4 Zone 4 (1st Byte)

236

00

Service Telephone Number [phone # byte 15]

193

144

Feeder 4 Zone 4 (2nd Byte)

Section Name

dC 131 EDN

0/0/00 ?-30

Preliminary Working Document No Product Name Assigned

Table 1 EDN NVM TABLE (70.10 SW)

Table 1 EDN NVM TABLE (70.10 SW)

LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

DESCRIPTION

237

00

Service Telephone Number [phone # byte 14]

268

00

238

00

Service Telephone Number [phone # byte 13]

FSN1Stacker B Jam Bypass Switch Setting [stkAandBJamByPassSensors] (3S06=1, 3S07=2, 3S66=4, 3S67=8, 3S64=16)

239

00

Service Telephone Number [phone # byte 12]

269

00

240

00

Service Telephone Number [phone # byte 11]

241

00

Service Telephone Number [phone # byte 10]

FSN1 HCF 1 Jam Bypass Switch Setting [hcf1and2JamByPassSensors] (2S01=1, 2S02=2, 2S03=4, 3S04=8)

242

00

Service Telephone Number [phone # byte 9]

270

00

243

00

Service Telephone Number [phone # byte 8]

FSN1 HCF 2 Jam Bypass Switch Setting [hcf1and2JamByPassSensors] (3S01=1, 3S02=2, 3S03=4, 2S04=8)

244

00

Service Telephone Number [phone # byte 7]

271

00

245

00

Service Telephone Number [phone # byte 6]

PHN Jam Bypass Switch Setting [phnJamByPassSensors] (s1a=1, s2=2, s3=4, s4=8, s5=10, s8=20, s9=40, s11=80)

246

00

Service Telephone Number [phone # byte 5]

272

00

247

00

Service Telephone Number [phone # byte 4]

PHN Jam Bypass Switch Setting [phnJamByPassSensors] (s12=1, s14=2, s54=4)

248

00

Service Telephone Number [phone # byte 3]

273

00

249

00

Service Telephone Number [phone # byte 2]

Inverter Jam Bypass Switch Setting [invJamByPassSensors] (1S55=1, 1S56=2, 1S57=4, 1S58=8)

250

00

Service Telephone Number [phone # byte 1]

274

00

251

00

Service Serial Number [serial# byte 10]

TMN Jam Bypass Switch Setting Byte 1 [tmnJamBypassSensors] (5S76=1)

252

00

Service Serial Number [serial # byte 9]

276

00

FSN2Stacker C Jam Bypass Switch Setting [stkCandDJamBypassSensors] (2S06=1, 2S07=2, 2S66=4, 2S67=8, 2S64=16)

253

00

Service Serial Number [serial# byte 8]

277

00

254

00

Service Serial Number [serial# byte 7]

FSN2Stacker D Jam Bypass Switch Setting [stkCandDJamBypassSensors] (3S06=1, 3S07=2, 3S66=4, 3S67=8,3S64=16)

255

00

Service Serial Number [serial # byte 6]

278

00

256

00

Service Serial Number [serial# byte 5]

257

00

Service Serial Number [serial # byte 4]

FSN2 HCF 3 Jam Bypass Switch Setting [hcf3and4JamBypassSensors] (2S01=1, 2S02=2, 2S03=4, 2S04=8)

258

00

Service Serial Number [serial # byte 3]

279

00

259

00

Service Serial Number [serial # byte 2]

FSN2 HCF 4 Jam Bypass Switch Setting [hcf3and4Jam Bypass Sensors] (3S01=1, 3S02=2, 2S03=4, 2S04=8)

260

00

Service Serial Number [serial # byte 1]

280

262

00

Machine configuration (128=FSN Fixture, 64=Variable Internal Image Size RDR firmware, 32=JB5 paper handling enabled, 16=7X10 paper handling enabled, 8=Large paper, 4=Interposer, 2=MICR)

10 (LPS) 255 (NPS/IPS)

The number of ESS "no confirms" to IOT VideoHints permitted before the IOT cycles down IPS/NPS=255

281

216

Feeder 5 Zone 1 (1st Byte)

282

92

Feeder 5 Zone 1 (2nd Byte)

283

132

Feeder 5 Zone 1 (3rd Byte)

284

205

Feeder 5 Zone 1 (4th Byte)

285

69

Feeder 5 Zone 1 (5th Byte)

286

210

Feeder 5 Zone 2 (1st Byte)

287

164

Feeder 5 Zone 2 (2nd Byte)

288

36

Feeder 5 Zone 2 (3rd Byte)

289

77

Feeder 5 Zone 2 (4th Byte)

Feeders In Configuration (secondary=1. auxiliary=2, hcf1=4, hcf2=8. hcf3=16. hcf4=32) [feeders] Must power on/off to take effect.

290

74

Feeder 5 Zone 2 (5th Byte)

291

216

Feeder 5 Zone 3 (1st Byte)

292

40

Feeder 5 Zone 3 (2nd Byte)

Destinations In Configuration (sample=1. stackerA=2, stackerB=4, stackerC=8. stackerD=16, tmn=32), purgeBin=128) [destinations]- Must power on/off to take effect.

293

133

Feeder 5 Zone 3 (3rd Byte)

294

141

Feeder 5 Zone 3 (4th Byte)

295

82

Feeder 5 Zone 3 (5th Byte)

296

216

Feeder 5 Zone 4 (1st Byte)

263

264

265

266

267

00

00

Output device simulation / Enables running to output devices which are not in the configuration. (0=disabled) [outputSimulation] / must power off to take effect Market Region 0=60HXZ, normal altitude, US market, 1=50HZ, 2=10-13" transfer blade, 4=10.12-14.33 transfer blade, 8=HiAlt, 16= Spain, 32=Holland/Belgium, 48=Japan, Various values are added together for combinations. Must Power Off / Power On

15

135

00

FSN1Stacker A Jam Bypass Switch Setting [stkAandBJamByPassSensors] (2S06=1, 2S07=2, 2S66=4, 2S67=8),2S64=16)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-31

Section Name

dC 131 EDN

Table 1 EDN NVM TABLE (70.10 SW)

Table 1 EDN NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

DESCRIPTION

297

144

Feeder 5 Zone 4 (2nd Byte)

338

133

Feeder 6 Zone 4 (3rd Byte)

298

133

Feeder 5 Zone 4 (3rd Byte)

339

13

Feeder 6 Zone 4 (4th Byte)

299

13

Feeder 5 Zone 4 (4th Byte)

340

89

Feeder 6 Zone 4 (5th Byte)

300

89

Feeder 5 Zone 4 (5th Byte)

341

176

Feeder 6 Zone 5 (1st Byte)

301

176

Feeder 5 Zone 5 (1st Byte)

342

93

Feeder 6 Zone 5 (2nd Byte)

302

93

Feeder 5 Zone 5 (2nd Byte)

343

4

Feeder 6 Zone 5 (3rd Byte)

303

4

Feeder 5 Zone 5 (3rd Byte)

344

219

Feeder 6 Zone 5 (4th Byte)

304

189

Feeder 5 Zone 5 (4th Byte)

345

69

Feeder 6 Zone 5 (5th Byte)

305

69

Feeder 5 Zone 5 (5th Byte)

346

164

Feeder 6 Zone 6 (1st Byte)

306

164

Feeder 5 Zone 6 (1st Byte)

347

165

Feeder 6 Zone 6 (2nd Byte)

307

165

Feeder 5 Zone 6 (2nd Byte)

348

68

Feeder 6 Zone 6 (3rd Byte)

308

68

Feeder 5 Zone 6 (3rd Byte)

349

90

Feeder 6 Zone 6 (4th Byte)

309

90

Feeder 5 Zone 6 (4th Byte)

350

74

Feeder 6 Zone 6 (5th Byte)

310

74

Feeder 5 Zone 6 (5th Byte)

351

176

Feeder 6 Zone 7 (1st Byte)

311

176

Feeder 5 Zone 7 (1st Byte)

352

41

Feeder 6 Zone 7 (2nd Byte)

312

41

Feeder 5 Zone 7 (2nd Byte)

353

5

Feeder 6 Zone 7 (3rd Byte)

313

5

Feeder 5 Zone 7 (3rd Byte)

354

155

Feeder 6 Zone 7 (4th Byte)

314

155

Feeder 5 Zone 7 (4th Byte)

355

82

Feeder 6 Zone 7 (5th Byte)

315

82

Feeder 5 Zone 7 (5th Byte)

356

176

Feeder 6 Zone 8 (1st Byte)

316

176

Feeder 5 Zone 8 (1st Byte)

357

145

Feeder 6 Zone 8 (2nd Byte)

317

145

Feeder 5 Zone 8 (2nd Byte)

358

5

Feeder 6 Zone 8 (3rd Byte)

318

5

Feeder 5 Zone 8 (3rd Byte)

359

27

Feeder 6 Zone 8 (4th Byte)

319

27

Feeder 5 Zone 8 (4th Byte)

360

89

Feeder 6 Zone 8 (5th Byte)

320

89

Feeder 5 Zone 8 (5th Byte)

361

203

321

216

Feeder 6 Zone 1 (1st Byte)

Container Size Bytes-(1st Byte) [container Sizes (type1)width] US(203 X 267) RX(203 X254) FX(182 X 257)

322

92

Feeder 6 Zone 1 (2nd Byte)

362

00

Container Size Bytes-(2nd Byte) [containerSizes(type1)length]

323

132

Feeder 6 Zone 1 (3rd Byte)

363

11

Container Size Bytes-(1st Byte) [containerSizes(type1)length]

324

205

Feeder 6 Zone 1 (4th Byte)

364

1

Container Size Bytes-(2nd Byte) [containerSizes(type1)length]

325

69

Feeder 6 Zone 1 (5th Byte)

365

210

326

210

Feeder 6 Zone 2 (1st Byte)

Container Size Bytes-(1st Byte) [containerSizes(type2)width] All (210 X 297)

327

164

Feeder 6 Zone 2 (2nd Byte)

366

00

Container Size Bytes-(2nd Byte) [containerSizes(type2)lwidth]

367

41

Container Size Bytes-(1st Byte) [containerSizes(type2)length]

368

1

Container Size Bytes-(2nd Byte) [containerSizes(type2)length]

369

216

Container Size Bytes-(1st Byte) [containerSizes(type3)width] All (216 X 279)

370

00

Container Size Bytes-(2nd Byte) [containerSizes(type3)width]

371

23

Container Size Bytes-(1st Byte) [containerSizes(type3)length]

328

36

Feeder 6 Zone 2 (3rd Byte)

329

45

Feeder 6 Zone 2 (4th Byte)

330

74

Feeder 6 Zone 2 (5th Byte)

331

216

Feeder 6 Zone 3 (1st Byte)

332

40

Feeder 6 Zone 3 (2nd Byte)

333

133

Feeder 6 Zone 3 (3rd Byte)

334

141

Feeder 6 Zone 3 (4th Byte)

335

82

Feeder 6 Zone 3 (5th Byte)

336

216

Feeder 6 Zone 4 (1st Byte)

337

144

Feeder 6 Zone 4 (2nd Byte)

Section Name

dC 131 EDN

0/0/00 ?-32

372

1

Container Size Bytes-2nd Byte) [containerSizes(type3)length

373

216

Container Size Bytes-(1st Byte) [containerSizes(type4)width] All (216 X 330)

374

00

Container Size Bytes-(2nd Byte) [containerSizes(type4)width

Preliminary Working Document No Product Name Assigned

Table 1 EDN NVM TABLE (70.10 SW)

Table 1 EDN NVM TABLE (70.10 SW)

LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

DESCRIPTION

375

74

Container Size Bytes-(1st Byte) [containerSizes(type4)length]

413

210

Feeder 7 Zone 2 (1st Byte)

376

01

Container Size Bytes-2nd Byte) [containerSizes(type4)length]

414

164

Feeder 7 Zone 2 (2nd Byte)

377

216

Container Size Bytes-(1st Byte) [containerSizes(type5)width] All (216 X 356)

415

36

Feeder 7 Zone 2 (3rd Byte)

416

77

Feeder 7 Zone 2 (4th Byte) Feeder 7 Zone 2 (5th Byte)

378

00

Container Size Bytes-(2nd Byte) [containerSizes(type5)width

417

74

379

100

Container Size Bytes-(1st Byte) [containerSizes(type5)length

418

216

Feeder 7 Zone 3 (1st Byte)

380

01

Container Size Bytes-(2nd Byte) [containerSizes(type5)length

419

40

Feeder 7 Zone 3 (2nd Byte)

381

176

Container Size Bytes-(1st Byte) [container Sizes (type6)width] US(432 X 279) RX420 X297) FX(420 X 297)

420

133

Feeder 7 Zone 3 (3rd Byte)

421

141

Feeder 7 Zone 3 (4th Byte)

422

82

Feeder 7 Zone 3 (5th Byte)

423

216

Feeder 7 Zone 4 (1st Byte)

424

144

Feeder 7 Zone 4 (2nd Byte)

425

133

Feeder 7 Zone 4 (3rd Byte)

426

13

Feeder 7 Zone 4 (4th Byte)

427

89

Feeder 7 Zone 4 (5th Byte)

428

176

Feeder 7 Zone 5 (1st Byte)

429

93

Feeder 7 Zone 5 (2nd Byte)

430

4

Feeder 7 Zone 5 (3rd Byte)

Pitches Enabled Byte 2 (p8=1, p9=2, p10=4, p11=8, p12=16, p13=32, p14=64, p15=128) [pitches enabled]

431

219

Feeder 7 Zone 5 (4th Byte)

432

69

Feeder 7 Zone 5 (5th Byte)

UI Monitor Filter HFSI Due Threshold[hfsiThresholds]

433

164

Feeder 7 Zone 6 (1st Byte)

165

Feeder 7 Zone 6 (2nd Byte)

382

01

Container Size Bytes-(2nd Byte) [containerSizes(type6)width

383

23

Container Size Bytes-(1st Byte) [containerSizes(type6)length

384

01

Container Size Bytes-(2nd Byte) [containerSizes(type6)length

385

01

Container Size Bytes-(1st Byte) [containerSizes(type7)width] All (257 X 364)

386

01

Container Size Bytes-(2nd Byte) [containerSizes(type7)width

387

108

Container Size Bytes-(1st Byte) [containerSizes(type7)length

388

01

Container Size Bytes-(2nd Byte) [containerSizes(type7)length

389

248

Pitches Enabled Byte 1(p0=1, p1=2, p2=4, p3=8, p4=16, p5=32, p6=64, p7=128) [pitches enabled]

390 391

00 59

392

180

Prints Per Minute

434

393

119

Image Enhancement Off density 07, (ASIC1 & ASIC2)

435

68

Feeder 7 Zone 6 (3rd Byte)

Darker2M1= DT135 Emulation (ASIC1) Line Suppression (ASIC2)

436

90

Feeder 7 Zone 6 (4th Byte)

Darker1M2= Print Nominal (ASIC1), Emulation Template (ASIC2)

437

74

Feeder 7 Zone 6 (5th Byte)

Print Darker1 (ASIC1); DT135 Emulation (ASIC2)

438

176

Feeder 7 Zone 7 (1st Byte)

439

41

Feeder 7 Zone 7 (2nd Byte)

394 395 396

119 154/119 119

397

119

398

119

399 400 401

119 119 119

402

119

405

00

406

Print Darker2 (ASIC1), Print Lighter (ASIC2)

00

Print Darker3 (ASIC1), Print Normal (ASIC2)

440

5

Feeder 7 Zone 7 (3rd Byte)

PD3Ht Correction (ASIC1), Print Darker2 (ASIC2)

441

155

Feeder 7 Zone 7 (4th Byte)

Print Darker4 (ASIC1), Print Darker3 (ASIC2)

442

82

Feeder 7 Zone 7 (5th Byte)

PD4Ht Correction (ASIC1), Print Darker4 (ASIC2)

443

176

Feeder 7 Zone 8 (1st Byte)

Print Darker5 (ASIC1 & ASIC2)

444

145

Feeder 7 Zone 8 (2nd Byte)

Special Action Trigger: Set=0 trigers A and K meters to sync

445

5

Feeder 7 Zone 8 (3rd Byte)

Third Party Input Device Cycledown delay. Set between 0 to 20 (min)

446

27

Feeder 7 Zone 8 (4th Byte)

447

89

Feeder 7 Zone 8 (5th Byte)

Third Part Output Device Auto Restart (Enable=1)

448

216

Feeder 8 Zone 1 (1st Byte)

92

Feeder 8 Zone 1 (2nd Byte)

407

00

408

216

Feeder 7 Zone 1 (1st Byte)

449

409

92

Feeder 7 Zone 1 (2nd Byte)

450

132

Feeder 8 Zone 1 (3rd Byte)

410

132

Feeder 7 Zone 1 (3rd Byte)

451

205

Feeder 8 Zone 1 (4th Byte)

411

205

Feeder 7 Zone 1 (4th Byte)

452

69

Feeder 8 Zone 1 (5th Byte)

412

69

Feeder 7 Zone 1 (5th Byte)

453

210

Feeder 8 Zone 2 (1st Byte)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-33

Section Name

dC 131 EDN

Table 1 EDN NVM TABLE (70.10 SW)

Table 1 EDN NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

454

164

Feeder 8 Zone 2 (2nd Byte)

493

00

455

36

Feeder 8 Zone 2 (3rd Byte)

456

77

Feeder 8 Zone 2 (4th Byte)

457

74

Feeder 8 Zone 2 (5th Byte)

496

00

Average Belt Time Byte 1 [averageBeltTime]

458

216

Feeder 8 Zone 3 (1st Byte)

497

00

Average Belt Time Byte 2 [averageBeltTime]

459

40

Feeder 8 Zone 3 (2nd Byte)

498

460

133

Feeder 8 Zone 3 (3rd Byte)

461

141

Feeder 8 Zone 3 (4th Byte)

462

82

Feeder 8 Zone 3 (5th Byte)

463

216

Feeder 8 Zone 4 (1st Byte)

464

144

Feeder 8 Zone 4 (2nd Byte)

465

133

Feeder 8 Zone 4 (3rd Byte)

466

13

Feeder 8 Zone 4 (4th Byte)

467

89

Feeder 8 Zone 4 (5th Byte)

468

176

Feeder 8 Zone 5 (1st Byte)

469

93

Feeder 8 Zone 5 (2nd Byte)

470

4

Feeder 8 Zone 5 (3rd Byte)

471

219

Feeder 8 Zone 5 (4th Byte)

472

69

Feeder 8 Zone 5 (5th Byte)

473

164

Feeder 8 Zone 6 (1st Byte)

474

165

Feeder 8 Zone 6 (2nd Byte)

475

68

Feeder 8 Zone 6 (3rd Byte)

476

90

Feeder 8 Zone 6 (4th Byte)

477

74

Feeder 8 Zone 6 (5th Byte)

478

176

Feeder 8 Zone 7 (1st Byte)

479

41

Feeder 8 Zone 7 (2nd Byte)

480

05

Feeder 8 Zone 7 (3rd Byte)

481

155

Feeder 8 Zone 7 (4th Byte)

482

82

Feeder 8 Zone 7 (5th Byte)

483

176

Feeder 8 Zone 8 (1st Byte)

484

145

Feeder 8 Zone 8 (2nd Byte)

485

5

Feeder 8 Zone 8 (3rd Byte)

486

27

Feeder 8 Zone 8 (4th Byte)

487

89

Feeder 8 Zone 8 (5th Byte)

488

00

Xtra Config. Byte VLD ROS w/ASIC1=32, VLD ROS w/ASIC2=64

489

03 07

490

00

491 492

494

00

DESCRIPTION HSGR enable=1 Skip Before Offset Enable in 8 Pitch (Default=00, No Skip Before Offset)

32 w/ASIC1 VLD ROS 64 w/ASIC2

600spi & 300spi are enabled by default 600spi & 240spi are enabled. 240spi only is selectable through dC105. Product Code Byte 3 00

00

Section Name

dC 131 EDN

Product Code Byte 2 Product Code Byte 1

0/0/00 ?-34

Preliminary Working Document No Product Name Assigned

dC 131 FSN1 NVM Read/Write 70.10 SW

Table 1 FSN1 NVM TABLE (70.10 SW)

Procedure

LOC

INIT VALUE

DESCRIPTION

NVM Tables

81

00

Feeder 4 Actual feed time 5 pitch mode

82

163

Feeder 4 Actual feed time 6 pitch mode

83

00

Feeder 4 Actual feed time 6 pitch mode

84

178

Feeder 4 Actual feed time 7 pitch mode

The FSN1 NVM TABLE contains the initial values for the FSN1 node software. NOTE: These NVM Tables use 70.10 S/W as the base.

85

01

Feeder 4 Actual feed time 7 pitch mode

NOTE: Always refer to the IOT Software Release Document (IOT-21) for new or unique NVM values for the software level on this Machine.

86

96

Feeder 4 Actual feed time 8 pitch mode

87

01

Feeder 4 Actual feed time 8 pitch mode

NOTE: The address location and the initial value (default value) is given in decimal.

88

01

Feeder 7 Actual feed time 3 pitch mode

89

02

Feeder 7 Actual feed time 3 pitch mode

90

01

Feeder 7 Actual feed time 4 pitch mode

Table 1 FSN1 NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

91

02

Feeder 7 Actual feed time 4 pitch mode

0

69

Pattern

92

01

Feeder 7 Actual feed time 5 pitch mode

1

255

Local bus Configuration

93

02

Feeder 7 Actual feed time 5 pitch mode

16

00

FSN1 HDEX byte

94

01

Feeder 7 Actual feed time 6 pitch mode

19

255

Remembered Faults (Fault ID of First Fault Declared)

95

02

Feeder 7 Actual feed time 6 pitch mode

20

255

Remembered Faults (Fault ID of Second Fault Declared)

96

01

Feeder 7 Actual feed time 7 pitch mode

21

255

Remembered Faults (Fault ID of Third Fault Declared)

97

02

Feeder 7 Actual feed time 7 pitch mode

22

255

Remembered Faults (Fault ID of Fourth Fault Declared)

98

01

Feeder 7 Actual feed time 8 pitch mode

23

255

Remembered Faults (Fault ID of Fifth Fault Declared)

99

02

Feeder 7 Actual feed time 8 pitch mode

24

255

Remembered Faults (Fault ID of First Fault Declared)

100

16

Tray 3 3 Pitch Nominal Feed Time (First Byte)

25

255

Remembered Faults (Fault ID of Sixth Fault Declared)

101

01

Tray 3 3 Pitch Nominal Feed Time (Second Byte)

26

255

Remembered Faults (Fault ID of Eighth Fault Declared)

102

26

Tray 3 4 Pitch Nominal Feed Time (First Byte)

27

255

Remembered Faults (Fault ID of Ninth Fault Declared)

103

01

Tray 3 4 Pitch Nominal Feed Time (Second Byte)

28

255

Remembered Faults (Fault ID of Tenth Fault Declared)

104

26

Tray 3 5 Pitch Nominal Feed Time (First Byte)

64

16

Feeder 3 Actual feed time 3 pitch mode

105

01

Tray 3 5 Pitch Nominal Feed Time (Second Byte)

65

01

Feeder 3 Actual feed time 3 pitch mode

106

26

Tray 3 6 Pitch Nominal Feed Time (First Byte)

66

26

Feeder 3 Actual feed time 4 pitch mode

107

01

Tray 3 6 Pitch Nominal Feed Time (Second Byte)

67

01

Feeder 3 Actual feed time 4 pitch mode

108

26

Tray 3 7 Pitch Nominal Feed Time (First Byte)

68

26

Feeder 3 Actual feed time 5 pitch mode

109

01

Tray 3 7 Pitch Nominal Feed Time (Second Byte)

69

01

Feeder 3 Actual feed time 5 pitch mode

110

26

Tray 3 8 Pitch Nominal Feed Time (First Byte)

70

26

Feeder 3 Actual feed time 6 pitch mode

111

01

Tray 3 8 Pitch Nominal Feed Time (Second Byte)

71

01

Feeder 3 Actual feed time 6 pitch mode

112

19

Tray 4 3 Pitch Nominal Feed Time (First Byte)

72

26

Feeder 3 Actual feed time 7 pitch mode

113

02

Tray 4 3 Pitch Nominal Feed Time (Second Byte)

73

01

Feeder 3 Actual feed time 7 pitch mode

114

97

Tray 4 4 Pitch Nominal Feed Time (First Byte)

74

26

Feeder 3 Actual feed time 8 pitch mode

115

01

Tray 4 4 Pitch Nominal Feed Time (Second Byte)

75

01

Feeder 3 Actual feed time 8 pitch mode

116

237

Tray 4 5 Pitch Nominal Feed Time (First Byte)

76

19

Feeder 4 Actual feed time 3 pitch mode

117

00

Tray 4 5 Pitch Nominal Feed Time (Second Byte)

77

02

Feeder 4 Actual feed time 3 pitch mode

118

163

Tray 4 6 Pitch Nominal Feed Time (First Byte)

78

97

Feeder 4 Actual feed time 4 pitch mode

119

00

Tray 4 6 Pitch Nominal Feed Time (Second Byte)

79

01

Feeder 4 Actual feed time 4 pitch mode

120

178

Tray 4 7 Pitch Nominal Feed Time (First Byte)

80

237

Feeder 4 Actual feed time 5 pitch mode

121

01

Tray 4 7 Pitch Nominal Feed Time (Second Byte)

Preliminary Working Document No Product Name Assigned

0/0/00 ?-35

Section Name

dC 131

Table 1 FSN1 NVM TABLE (70.10 SW)

Table 1 FSN1 NVM TABLE (70.10 SW) LOC

INIT VALUE

DESCRIPTION

LOC

INIT VALUE

DESCRIPTION

122

96

Tray 4 8 Pitch Nominal Feed Time (First Byte)

289

00

Feeder 3 remaining number of Indexes

123

01

Tray 4 8 Pitch Nominal Feed Time (Second Byte)

290

--

Feeder 3 job modules for ordered stock

124

01

Tray 7 3 Pitch Nominal Feed Time (First Byte)

291

--

Feeder 3 current index of modules

125

02

Tray 7 3 Pitch Nominal Feed Time (Second Byte)

336

30

Feeder 4 feed clutch on time for paper width