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Xerox ColorQube 9303 Series Service Manual

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Table of Contents

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708P90290
February 2013
Xerox® ColorQube® 9303 Family Service Manual

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Summary of Contents for Xerox ColorQube 9303 Series

  • Page 1 708P90290 February 2013 Xerox® ColorQube® 9303 Family Service Manual...
  • Page 2 All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service per- sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or 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.

  • Page 3: Table Of Contents

    Introduction About This Manual ......................How To Use This Manual ....................Remote Control Panel ..................... Change History........................ Documentation Symbol ....................Mod/Tag Identification ..................... Voltages Resistances and Tolerances ................viii Safety Information ......................Health and Safety Incident Reporting................Translated Warnings ....................... Introduction February 2013 ColorQube®...
  • Page 4 Introduction February 2013 ColorQube® 9303 Family...

  • Page 5: About This Manual

    This section contains the detailed and illustrated spare parts list. Any part that is spared or that This manual is part of a multinational service documentation system that is structured in the must be removed to access a spared part is illustrated. standard Xerox service manual format. Section 6 General Procedures / Information Organization This section contains all other procedures, product specifications and general information.

  • Page 6: How To Use This Manual

    How To Use This Manual Remote Control Panel Always start with the Service Call Procedures, Section 1. Perform SCP 1 Initial Actions and The ColorQube 9303F machines with system software version 071.XXX.XX.XXX or higher are verify the problem, then follow the directions given. equipped with a remote control panel feature to allow remote user access to the UI.

  • Page 7: Change History

    Change History • Wiring Diagram 8.2 Media Path Driver PWB (2 of 5) • Wiring Diagram 9.8 Marking Unit Heater PWB This page gives information on major changes to the service manual. Please go to the relevant Bus Update June 2012 update.
  • Page 8 • RAP 71-101-00 to 71-161-00 Tray 1 Mis-Feed Jam • dC103 Billing Plan • RAP 72-101-00 to 72-161-00 Tray 2 Mis-Feed Jam • dC131 Table 3 • RAP 73-101-00 to 73-161-00 Tray 3 Mis-Feed Jam • dC131 Table 4 • RAP 74-101-00, 74-160-00 to 74-161-00 Bypass Tray 4 Mis-Feed •...

  • Page 9: Documentation Symbol

    Documentation Symbol Mod/Tag Identification This symbol is displayed in the service documentation: Figure 1, shows the Mod/Tag identification symbols. ESD Caution Symbol These with tag symbols are used to identify the components or configurations that are part of a machine change covered by this tag number.

  • Page 10: Voltages Resistances And Tolerances

    Voltages Resistances and Tolerances For AC power specifications, refer to GP 22 Electrical Power Requirements. Signal description (event that causes the signal level change) DC Voltage Levels and Tolerances DC Voltages should be measured between an available test point and a machine ground. Table 1 shows the range of the common voltages.
  • Page 11 The safety icons that follow are displayed on the machine: III. Objective Hot Surface Symbol This symbol indicates hot surfaces. Take care when servicing the machine. To enable prompt resolution of health and safety incidents involving Xerox products and to ensure Xerox regulatory compliance. IV. Definitions Incident: An event or condition occurring in a customer account that has resulted in injury, illness or property damage.
  • Page 12 Wasser zu beseitigen. Dadurch wird das Öl verteilt und es besteht eine noch VI. Appendices größere Rutschgefahr. The Health and Safety Incident Report involving a Xerox Product (Form # EH&S-700) is avail- AVISO: Absténgase de limpiar el aceite derramado a la manera convencional con una able in the locations that follow: fregona y agua, ya que ello sólo provocaría la extensión de la contaminación y aumen-...
  • Page 13 WARNING DANGER: Ne pas mettre la machine sous tension si un circuit de mise à la masse est déconnecté. Les circuits de mise à la masse permettent de garantir la sécurité de la Wear protective gloves when using solvents and cleaning agents, PL 26.10 Item 5 machine lors d'un incident.
  • Page 14 WARNING AVISO: Tenga cuidado al medir la tensión de la línea de alimentación de corriente alterna. La electricidad puede causar lesiones e incluso la muerte. Ensure that the electricity to the machine is switched off while performing tasks that do General Warnings not need electricity.
  • Page 15 comment déconnecter le module HCSS BM. not show the customer how to undock Tray 5. AVVERTENZA: Non sganciare il modulo HVF BM dalla macchina. Questo modulo non è DANGER: Attention à ne pas faire tomber le magasin 5. Le magasin 5 n’est pas stable stabile quando è...
  • Page 16 DANGER: Exécuter cette procédure avec précaution. Les moteurs peuvent devenir très booklet maker while the machine is powered on. The crease blade mechanism activates chauds en fonctionnement normal. quickly and with great force. AVVERTENZA: procedere con cautela durante questa procedura. I motori si riscaldano DANGER: Ne pas s'approcher du méchanisme de la lame de pliage lors d'une activité...
  • Page 17 1 Service Call Procedures SCP 1 Initial Actions......................SCP 2 Call Actions ......................SCP 3 Fault Analysis....................... SCP 4 Subsystem Maintenance..................SCP 5 Final Actions ......................Service Call Procedures February 2013 ColorQube® 9303 Family...
  • Page 18 Service Call Procedures February 2013 ColorQube® 9303 Family...

  • Page 19: Scp 1 Initial Actions

    SCP 1 Initial Actions SCP 2 Call Actions Use Service Call Procedures to find a problem with the machine. Use SCP 2 Call Actions during a service call. Always use SCP 1 Initial Actions to collect information on the machine performance. Do not Procedure skip Initial Actions.

  • Page 20: Scp 3 Fault Analysis

    SCP 3 Fault Analysis Use SCP 3 Fault Analysis to identify a fault. Procedure WARNING Isolate the machine from the customers network before performing tasks that do not need network access. Isolating the machine will prevent remote diagnostic access, If an error message or fault code appears, go to the relevant RAP. If necessary refer to OF 4 Status Codes and Messages RAP.
  • Page 21 GP 2 Fault Codes and History Files. HVF, HVF BM, Inserter and Tri-Folder Problems • Xerox extensible interface platform faults. Go to the OF 14 Xerox Extensible Interface • If the machine has a fault in the HVF or HVF BM, but with no fault code, perform the rele- Platform RAP.
  • Page 22 • GP 4 Machine Software • GP 47 Remote Diagnostics • GP 5 Customer Administration Tools • GP 48 How to Re-Enter Optional Feature Installation Keys • GP 6 Marking Unit Maintenance Positions • GP 49 USB Connection Mode • GP 7 System Grounding Verification •...

  • Page 23: Scp 4 Subsystem Maintenance

    SCP 4 Subsystem Maintenance Table 2 HFSI cleaning Use SCP 4 Subsystem Maintenance to maintain the machine. recommended cleaning Parts list Procedure Item Component Description frequency reference WARNING Drum fan Drum fan All sheets fed after last 500k feeds PL 94.20 Item 5 Ensure that the electricity to the machine is switched off while performing tasks that do shroud shroud...

  • Page 24: Scp 5 Final Actions

    SCP 5 Final Actions Use SCP 5 Final Actions to complete the service call. Procedure Perform the steps that follow: If necessary, perform an NVM Restore from service mode on the UI using dC361 Save and Restore. If necessary, perform GP 17 Network Clone Procedure.
  • Page 25 2 Status Indicator RAPs Chain 1 - Standby Power Chain 5 - DADH 01-505-00 Mid Left Door Open RAP ................05-250-00, 05-251-00 DADH Checksum Error RAP ............2-51 01-506-00 Upper Left Door Open RAP ................05-252-00 DADH Stepper Controller Communications Error.......... 2-51 01-510-00 Front Door Open RAP..................
  • Page 26 12-392-00-110, 12-393-00-110, 12-394-00-110 Front Tamper Move Failure RAP ..2-90 12-403-00-171, 12-413-00-171, 12-414-00-171 HVF BM Staple Head 2 and 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper Move Failure RAP ..2-91 Stapler Module RAP......................2-144 12-462-00-110 Bin 1 Movement Failure RAP ..............2-93 12-415-00-171 HVF BM Crease Roll Gate Home RAP ..........
  • Page 27 16-150-09 Cannot Send Registration Event RAP ............2-188 16-609-26 Fault Service Encountered Error RAP ............2-214 16-150-14 Unable to Obtain RPC Transport RAP............2-189 16-609-46 to 16-609-92 Invalid IPC Data Received RAP ..........2-215 16-150-19 Unable to Sync Peer RAP................2-189 16-610-00, 16-610-07 IPC Send Failure RAP..............
  • Page 28 16-646-26, 16-647-19, 16-647-26, 16-649-35, 16-650-35, 16-650-99 16-761-47 to 16-769-95 Other Network Faults 1 RAP ............ 2-248 Invalid Service Attribute RAP ..................2-234 16-770-09 to 16-779-95 Other Network Faults 2 RAP ............ 2-249 16-651-19, 16-651-35, 16-651-99, 16-652-38, 16-652-99, 16-653-38, 16-654-38, 16-780-00 to 16-789-47 Other Network Faults 3 RAP ............ 2-250 16-654-99, 16-655-38, 16-656-38 Register Failure RAP ..........
  • Page 29 22-330-06 ESS Scan to Distribution Service not Responding to List Jobs RPC Call RAP 2-290 74A Bypass Tray 4 Size Sensing Problems RAP ............2-320 22-350-01, 22-350-02 Software Detects Non-Valid Xerox SOK RAP ......2-290 75-101-00, 75-160-00 to 75-161-00 Tray 5 Mis-Feed RAP..........
  • Page 30 82-507-00, 82-508-00 Nip C and Nip D Release Solenoid Over Current RAP ....2-339 91-607-00, 91-608-00 Printhead to Drum Error RAP ............2-379 82-510-00 Trailer Slowdown Calculation Fail RAP ............2-339 91-610-00 to 91-613-00 Printhead Wave Amp Calibration Error RAP ......2-380 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 91-614-00 to 91-617-00 Printhead Data Error RAP ............
  • Page 31 94-611-00 Cleaning Unit Removal Pump Test Fail RAP..........2-468 93-520-00, 93-521-00, 93-522-00 Ink Melt Reservoir Thermal Error RAP...... 2-435 94-615-00 Non Xerox Cleaning Unit Detected RAP............2-469 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00, 93-533-00, 93-957-00 94-616-00 Cleaning Unit Low Oil Detected RAP.............
  • Page 32 2-487 OF 14 Extensible Interface Platform RAP ............... 2-615 99-394-00 to 99-413-00 PEST Error 13 RAP..............2-488 OF 15 Xerox Secure Access RAP .................. 2-616 99-414-00 to 99-428-00 PEST Error 14 RAP..............2-489 OF 16 POST Error RAP ....................2-618 99-429-00 to 99-443-00 PEST Error 15 RAP..............
  • Page 33 01-505-00 Mid Left Door Open RAP 01-506-00 Upper Left Door Open RAP 01-505-00 The mid door interlock switch detects that the mid left door is open. 01-506-00 The upper door interlock switch detects that the upper left door is open. Initial Actions Initial Actions WARNING...
  • Page 34 01-510-00 Front Door Open RAP 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload 01-510-00 The front door interlock switch detects that the front door is open. 01-525-00 An over current condition has been detected with the +24V, +12V, -12V or +5V sup- Initial Actions ply.
  • Page 35 Go to and follow the procedure for the media path driver PWB. Go to and follow the procedure for the drum driver PWB. Refer to 1.5. Disconnect PJDC4 from the power supply unit and check for a short circuit With PJDC3 still disconnected from the power supply unit, check for a short circuit between pin between pins 17 to chassis and from pin 18 to the chassis with the PJDC4 disconnected.
  • Page 36 01-530-00 +/- 50V Short Circuit and Overload RAP 01-530-00 An over current condition has been detected with the +50V or -50V supply. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 37 -50V Short Circuit Check 01-535-00 Power Interlock Failed: No Heater Requests RAP Procedure 01-535-00 The IME power interlock has failed because the AC power manager heater requests are not being updated. Switch off the machine, Refer to 1.4. Disconnect PJDC1 from the power supply unit and check for a short circuit Procedure...
  • Page 38 01-540-00, 01-544-00 +24V, +/-12V, +5V Failure RAP Switch off the machine, 14. Check pin 24 of PJ902 on the drum driver PWB. Pin is short circuit to ground. 01-540-00 The +24V, +12V, -12V and +5V supplies have shut down unexpectedly. Install a new power supply unit, PL 1.15 Item 01-544-00 The IME +24V, +12V, -12V and +5V supplies have failed to switch on.
  • Page 39 01-542-00, 01-546-00 50V Failure RAP Refer to WD 1.4 9.4. Check the red LED, Figure 1, is illuminated and the voltage on PJ902 pin 26 on the Drum driver PWB is greater than +2.5V. The LED is illuminated and the 01-542-00 The IME +50V or -50V supply has shutdown unexpectedly.
  • Page 40 01A AC Power Distribution RAP Power to the Power Supply Unit Check Procedure Use this RAP to diagnose faults with the AC power distribution throughout the machine. Check the green LED on top of the power supply, Figure 1. The green LED is lit. Initial Actions WARNING Check the customer AC supply.
  • Page 41 The ink reservoir heaters are good. If necessary, install a new Marking unit heater PWB, Registration / Pre-Heaters Check 92.10 Item 5. Perform SCP 5 Final Actions. Procedure Ink Melt Heaters Check Switch off the electricity to the machine, 14, and disconnect the power cord. Refer to 1.2.
  • Page 42 Finisher Supply Check Lower Umbilical Heater Check Procedure Procedure Verify that the machine is configured for a finisher and that the machine is ready to print. Refer Switch off the electricity to the machine, 14, and disconnect the power cord. Refer to WD 1.4 9.4.
  • Page 43 • Head 3 second half jetstack heater, pin 12 to pin 13. Expect a cold resistance of approxi- The head 2 heaters are good. If necessary, install a new marking unit heater PWB, PL 92.10 mately 495-505 ohms. Item • Check that pin 9 and pin 12 to the chassis is open circuit.
  • Page 44 01B +3.3V ESTAR Distribution RAP • Drum Driver PWB • Quad Wave Amp PWB Use this RAP to diagnose +3.3V ESTAR supply and distribution faults in the machine. This • Ink Load Entry PWB supply is used to power the IME logic circuits. This supply is not to be confused with the +3.3V supply, which is generated on the power distribution PWB.
  • Page 45 Marking Unit Driver PWB • If necessary, install a new printhead 1 or printhead 3 PL 91.25 Item 2 or install a new printhead 2 or printhead 4 PL 91.20 Item • To view the +3.3V ESTAR distribution from the IME controller PWB, refer to 9.7.
  • Page 46 01C +3.3V Distribution RAP – 5.1. – 5.2. Use this RAP to diagnose +3.3V supply and distribution faults. This supply is not to be con- • If necessary repair the wiring, 1.1. fused with the +3.3 ESTAR supply, which is generated in the power supply unit.
  • Page 47 01D +5V Distribution RAP NOTE: Many PWB’s have distribution fuses. Select the required PWB: Use this RAP to diagnose +5V supply and distribution faults. • IME Controller PWB NOTE: Refer to RAP 12A-171 to diagnose +5V supply and distribution faults on the HVF. Refer •...
  • Page 48 – Cleaning unit home sensor, PL 94.10 Item 17 3 Tray Module PWB – Post transfix sensor, PL 10.10 Item 6 • To view the +5V distribution from the media path driver PWB, refer to 8.2. • Repair the wiring as necessary, 1.1.
  • Page 49 DADH PWB • If necessary, install a new HVF PWB, PL 12.140 Item BM PWB (Booklet Maker) • Note: This PWB does not have an external +5V supply. +5V is generated on-board from the +3.3V supply, as shown in 5.2. •...
  • Page 50 01E +12V Distribution RAP • Single Board Controller PWB • Scanner PWB Use this RAP to diagnose +12V supply and distribution faults. • Full Width Array Procedure • UI PWB • Quad Wave Amp PWB WARNING • Printheads 1 to 4 Ensure that the electricity to the machine is switched off while performing tasks that do IME Controller PWB not need electricity.
  • Page 51 – Enclosure Fan, PL 1.15 Item – WD 1.7 – Marking unit cooling fan, PL 1.15 Item • Check for +12V on both sides of fuse F2 on the power distribution PWB. If +12V is not present, check the wiring between PJ8 pin 11 on the power distribution PWB and PJ920 –...
  • Page 52 01F -12V Distribution RAP Use this RAP to diagnose -12V supply and distribution faults. NOTE: Refer to RAP 12A-171 to diagnose -12V supply and distribution faults on the HVF. Refer to RAP 12D-110 to diagnose -12V supply and distribution faults on the LCSS. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 53 Drum Driver PWB 01G +17V Distribution RAP • To view the -12V distribution from the power supply unit, refer to 1.5. Use this RAP to diagnose +17V supply and distribution faults. • For -12V faults on the drum driver PWB, refer to 9.2.
  • Page 54 01H +24V Distribution RAP Switch off the machine, 14. Check pin 27 of PJ902 on the drum driver PWB. Pin 27 is short circuit to ground. Use this RAP to diagnose +24V supply and distribution faults. Install a new drum driver PWB, PL 1.15 Item NOTE: This supply is not to be confused with the +17V supply, which is shown in 1.5.
  • Page 55 • The marking unit driver PWB, PL 92.10 Item 4, is driven from +24V from the IME control- – WD 6.2 ler PWB • The components that follow are driven from +24V from the scanner PWB: • Repair the wiring as necessary, REP 1.1 –...
  • Page 56 – T1 feed / elevator motor MOT71-002, PL 81.25 Item – Transport motor 1 MOT12-223, PL 12.40 Item – T2 feed / elevator motor MOT72-001, PL 81.26 Item – SH1 motor MOT12-247, part of PL 12.55 Item – T3 feed motor MOT73-001, PL 81.30 Item –...
  • Page 57 – Staple head 1 motor MOT12-247, part of PL 12.110 Item – WD 12.22 – Stapler unit 1 motor MOT12-249, PL 12.110 Item • The components that follow are driven from +24V from the inserter PWB: – Ejector motor MOT12-236, part of PL 12.110 Item –...
  • Page 58 01J +50V Distribution RAP – WD 8.3 – WD 8.5 Use this RAP to diagnose +50V supply and distribution faults. • The +50V LED on this PWB is shown in 8.5. Procedure • The components that follow are driven from +50V from the media path driver PWB: –...
  • Page 59 01K -50V Distribution RAP Use this RAP to diagnose -50V supply and distribution faults. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14. Disconnect the power cord. Electricity can cause death or injury.
  • Page 60 Quad Wave Amp PWB • To view the -50V distribution from the IME controller PWB, refer to 9.5. • For -50V faults on quad wave amp PWB, refer to 9.13. • Repair the wiring as necessary, 1.1. • If necessary, install a new quad wave amp PWB, PL 92.10 Item Power supply unit Red LED...
  • Page 61 01L 0V Distribution RAP • LCSS PWB • HVF Control PWB Use this RAP to diagnose 0V faults. • BM PWB (Booklet maker) Procedure • Tri-folder PWB • Inserter PWB WARNING • OCT PWB Ensure that the electricity to the machine is switched off while performing tasks that do Power Supply Unit not need electricity.
  • Page 62 • Repair the wiring as necessary, 1.1. Cleaning Unit PWB • If necessary, install a new tray 5 control PWB PL 75.68 Item 8, or associated components. • Refer to WD 9.19 3 Tray Module PWB • Repair the wiring as necessary, 1.1.
  • Page 63 02-302-00, 02-306-00, 02-308-00 Flash Failure RAP 02-315-00 Service Registry Bad Data RAP 02-302-00 Flash rewrite failure. 02-315-00 Service registry bad or corrupted data 02-306-00 Flash erase failure. Procedure WARNING 02-308-00 Flash download failure. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 64 02-316-00, 02-317-00 SRS Error RAP 02-320-00 Data Time Out Error RAP 02-316-00 SRS returns to LUI invalid fields, invalid data or missing data. 02-320-00 UI does not receive requested data from the CCM within the specified time out win- dow. 02-317-00 LUI gets no response from SRS.
  • Page 65 02-321-00 XEIP Browser Dead RAP 02-380-00, 02-381-00 UI Communication Fault RAP 02-321-00 The user interface has detected that the EIP (Extensible Interface Platform) browser 02-380-00 Communication via H-H USB net path connection between SBC and UI panel is not does not respond, or is known to be not working. working Procedure 02-381-00 Communication via USB connection between SBC and UI panel is not working.
  • Page 66 02-390-00 Configurable Services RAP 02-390-00 During power up all configurable services have not achieved a stable state after 5 minutes from power up. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 67 03-316-00 CCM Cannot Communicate with IOT RAP 03-325-00 System Detects the Machine Clock Failed to Increment During Power On RAP 03-316-00 The communications between the single board controller PWB through the media path PWB and to the IME controller PWB have failed. 03-325-00 The software has detected that the machine clock has failed to increment within 1.5 seconds during the power on self test operation.
  • Page 68 03-331-00, 03-332-00 Main Controller and Network 03-338-00 The Main Controller on the SBC Has Reset RAP Controller on the SBC PWB Cannot Communicate RAP 03-338-00 System detects that the software in the single board controller PWB has been reset. This was due either to the watch dog timing out or the software writing to an illegal address. 03-331-00 Integral network communication error on the single board controller PWB.
  • Page 69 03-346-00 Unable To Communicate With UI RAP 03-347-00 Main Controller PWB Cannot Communicate with UI PWB RAP 03-346-00 Unable to re-establish communication with the UI after 30 seconds. 03-347-00 The single board controller PWB to UI control PWB communications have failed. Procedure WARNING Initial Actions...
  • Page 70 03-355-00 CCM POST Failure Detected RAP 03-362-00 CCS Power Fault RAP 03-355-00 The software has detected a CCM POST failure during the NVM integrity test/NVM 03-362-00 The single board controller software has failed to exit from a timer loop and has battery failure.
  • Page 71 03-397-00 System Configuration Recovery Attempt RAP 03-398-00, 03-399-00 SIM Card Fault RAP 03-397-00 System configuration is lost and an attempted recovery made (from SIM). 03-398-00 SIM card serial number mismatch between the option and the machine Initial Actions 03-399-00 SIM card data cannot be processed by the machine. WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 72 03-401-00, 03-403-00 Fax Not Detected RAP 03-417-00 Incompatible Fax Software RAP 03-401-00 The basic fax module has not been detected or confirmed. 03-417 The fax software version supplied at power up is not compatible with the image pro- cessing software. 03-403-00 Extended fax PWB has not been confirmed or detected.
  • Page 73 03-777-00 Power Loss Detected RAP 03-788-00 CCS Runtime Could Not Enter Power Saver Mode S3 RAP 03-777-00 This fault code in the fault history file indicates that the system has previously detected a power input loss. 03-788 The copy control software could not enter power save mode. The copy control software was unable to update its parameters from the UI, when the machine previously came out of Procedure sleep mode.
  • Page 74 03-790-00 Timezone Cannot Be Set RAP 03A Foreign Device PWB Fault RAP 03-790-00 At power up the Timezone is not valid due to NVM corruption, or OS file system Use this RAP when the foreign interface device is not detected. problem.
  • Page 75 05-250-00, 05-251-00 DADH Checksum Error RAP 05-252-00 DADH Stepper Controller Communications Error 05-250-00 The DADH flash memory is corrupted. A kernel checksum error has been detected. 05-252-00 DADH PWB to stepper motors communications have failed. 05-251-00 The DADH flash memory is corrupted. An application checksum error has been Initial Actions detected.
  • Page 76 05-253-00, 05-254-00 DADH Communications Error RAP 05-255-00 Late Pre Scan Message RAP 05-253-00 The DADH PWB to single board controller PWB communications have failed. 05-255-00 The DADH pre scan status message was not received in time. 05-254-00 The DADH PWB to single board controller PWB communications are out of Procedure sequence.
  • Page 77 05-256-00 Eject Count Error RAP 05-257-00 Unknown Document Size RAP 05-256-00 The number of ejections from the DADH did not match the number of feeds. 05-257-00 The DADH has failed to detect the document size during pre-feed. Procedure Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 78 Refer to 5.1. Check Q05-204. References: DADH width sensor • GP 11 How to Check a Sensor. Q05-095 • P/J184, DADH PWB. • +5V Distribution RAP. • 0V Distribution RAP. Install new components as necessary: • DADH feed sensor, PL 5.15 Item •...
  • Page 79 05-258-00, 05-307-00 DADH Cover Interlock Open RAP Actuator 05-258-00 The DADH cover interlock switch detects that the top cover is open during initializa- tion. 05-307-00 The DADH cover interlock switch detects that the top cover is open. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 80 05-259-00, 05-260-00 DADH Active Line or Standby Error 05-300-00 DADH Open RAP 05-300-00 The platen down sensor detects that the DADH is open during run. 05-259-00 The DADH active line is in the wrong state during the scan Initial Actions 05-260-00 The DADH is not in standby at the start of the job.
  • Page 81 05-310-00 Document Too Short RAP 05-330-00, 05-331-00 DADH Feed Sensor Failure RAP 05-310-00 The DADH detects a document that is shorter than 110mm. 05-330-00 The DADH feed sensor does not detect the lead edge of the document within the correct time after the feed motor runs. Initial Actions 05-331-00 The DADH feed sensor does not detect the trail edge of the document within the WARNING...
  • Page 82 Go to the DADH Motor Failure RAP. Clip While MOT 05-074 runs, stack the code 05-062 to energize the DADH feed clutch, CL05-062. NOTE: The feed clutch disengages after 30 seconds. The feed motor stops after 3 minutes. CL05-062 energizes, the nudger rolls and the feed rolls rotate. Perform the steps that follow: Feed yoke and •...
  • Page 83 05-335-00 DADH TAR Sensor Failure RAP 05-335-00 The DADH TAR sensor does not detect the lead edge of the document within the CVT motor MOT 05-099 correct time. Top cover interlock switch Initial Actions WARNING Feed motor Ensure that the electricity to the machine is switched off while performing tasks that do MOT05-074 not need electricity.
  • Page 84 • Make sure that the takeaway roll idlers are clean and rotate freely, refer to 5.4. 05-340-00 DADH Pre Registration Sensor Failure RAP • Check the takeaway roll static eliminator and ground harness, PL 5.35 Item 05-340-00 The DADH pre registration sensor does not detect the lead edge of the document •...
  • Page 85 05-345-00, 05-346-00 DADH Exit Sensor Failure RAP Go to the Final Checkout. 05-345-00 The DADH exit sensor does not detect the lead edge of the document within the correct time in the forward mode. This fault can be caused by the DADH feed motor running too slowly in reverse. Refer to the DADH Motor Failure RAP.
  • Page 86 NOTE: The exit roll idlers remain lowered for 30 seconds. Final Checkout Perform the steps that follow: Enter dC330 code 05-100 to energize the DADH duplex solenoid, SOL05-100, PL 5.30 Item to lower the exit roll idlers PL 5.30 Item 6.
  • Page 87 05-350-00, 05-352-00 DADH CVT Sensor Failure RAP Go to the Final Checkout. 05-350-00 The DADH CVT sensor does not detect the lead edge of the document within the correct time in the forward mode. NOTE: The exit roll idlers remain lowered for 30 seconds. 05-352-00 The DADH CVT sensor does not detect the lead edge of the document within the Enter dC330...
  • Page 88 05A DADH Other Faults RAP 05B DADH Document Sensor Failure RAP This RAP gives the additional information on common DADH problems. Perform the RAP for Initial Actions all current fault codes before this RAP is performed. • Remove all documents from the DADH. •...
  • Page 89 05C DADH Motor Failure RAP 05D DADH Feed Clutch Failure RAP Procedure Use this RAP when the DADH feed clutch does not operate correctly. WARNING Also use this RAP if the feed clutch energizes at the wrong time in duplex mode, which causes: Ensure that the electricity to the machine is switched off while performing tasks that do •...
  • Page 90 05E Damaged Documents RAP Use this RAP if the documents get damaged by the DADH. Baffle assembly Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14. Disconnect the power cord. Electricity can cause death or injury.
  • Page 91 05F Platen Down Failure RAP Use this RAP when the platen down sensor does not respond to opening and closing the DADH. Procedure Go to 05-300-00 DADH Open RAP. Status Indicator RAPs February 2013 ColorQube® 9303 Family 2-67...
  • Page 92 Status Indicator RAPs February 2013 2-68 ColorQube® 9303 Family...
  • Page 93 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00, • If glossy media is used, instruct the customer to feed the media from the bypass tray and select glossy for the media type. 10-148-00 Post Transfix Jam RAP 10-110-00 Timing sensor 11 detects that the sheet is too long. Procedure Refer to Figure...
  • Page 94 Install new components as necessary: dC625 Registration / Preheat Calibration. If the fault persists, check the following: • Roller drive J, PL 10.10 Item • Post transfix sensor (11), PL 10.10 Item • Roller drive L, PL 10.10 Item • Drum driver PWB, PL 1.15 Item •...
  • Page 95 10-140-00 to 10-146-00, 10-149-00 to 10-151-00 Exit Jam Enter dC330 code 83-006 exit duplex diverter solenoid, SOL83-006, PL 10.15 Item 14. Press Start. SOL83-006 energizes. 10-140-00 Timing sensor 15 detects that the sheet is too long. Refer to 8.1. Check SOL83-006. Refer to: •...
  • Page 96 • Belt 3 mm (112T), PL 10.15 Item 10-500-00 to 10-540-00 Transfix Error RAP • Belt 3 mm (92T), PL 10.15 Item 10-500-00 Insufficient force is detected by the front transfix flexure encoder. • Pulley 3 mm (21T one way), PL 10.15 Item •...
  • Page 97 Switch off the machine, 14. Use a screwdriver to manually rotate the transfix gear, Figure • PJ401, Drum driver PWB. 2. This action will move the transfix roller. Move the transfix roller onto, then off the drum. Per- • +50V Distribution RAP. form the action at the front and rear.
  • Page 98 10-545-00 Drum Position Error for Transfix RAP 10-545-00 The drum was not at the correct position to start the transfix operation. Rear transfix motor and encoder Initial Actions WARNING Rear transfix flexure Ensure that the electricity to the machine is switched off while performing tasks that do encoder not need electricity.
  • Page 99 10-550-00 Drum Stall During Transfix RAP 10-555-00 Post Transfix Motor (M4) Over Current RAP 10-550-00 The drum stalled during transfix. 10-555-00 The post transfix motor M4 is taking too much current. Initial Actions Procedure Check that the print media loaded into all of the trays matches the UI display for each tray. If WARNING necessary correct the settings or load the correct media.
  • Page 100 10-560-00, 10-565-00 Transfix Motor Over Current RAP 10-560-00 Front transfix motor over current. Roller drive J 10-565-00 Rear transfix motor over current. Procedure Post transfix motor Refer to the 10-500-00 to 10-540-00 Transfix Error RAP. Roller drive L Figure 1 Component location Status Indicator RAPs February 2013 10-555-00, 10-560-00, 10-565-00...
  • Page 101 10-570-00 Stripper Solenoid Over Current RAP 10-570-00 Stripper solenoid over current. Stripper blade lock Detent in shaft (Front and rear) Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 102 10-571-00, 10-572-00 Stripper Latch Sensor Error RAP • Drum driver PWB, PL 1.15 Item 10-571-00 Stripper latch sensor time out. Check all components in the stripper system for damage, 10.10. Pay special attention to: • Front latchfork, PL 10.10 Item 11 10-572-00 Stripper latch bad sensor state.
  • Page 103 12-701-00-65 Offset Catch Tray Failure RAP 12-701 The offset catch tray (OCT) fails to offset the paper stack. Sensor actuator Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 104 Status Indicator RAPs February 2013 12-701-00-65 2-80 ColorQube® 9303 Family...
  • Page 105 12-024-00-110, 12-025-00-110 Paddle Roll Failure RAP • P/J310, LCSS PWB. • 12D-110 LCSS Power Distribution RAP 12-024-00-110 The paddle is not at the home position. • 0V Distribution RAP 12-025-00-110 The paddle fails to rotate. Install new components as necessary: •...
  • Page 106 12-043-00-110, 12-046-00-110 Hole Punch Operation Failure Enter dC330 code 12-194 to actuate the punch head home sensor Q12-194, PL 12.20 Item The display changes. 12-043-00-110 The hole punch fails to perform a punch cycle. Go to 12.2, check Q12-194. Refer to: 12-046-00-110 The hole punch is not at the home position.
  • Page 107 12-127-00-110 Sheet Late to Hole Punch RAP 12-151-00-110, 12-152-00-110 Sheet Late to Bin 1 RAP 12-127-00-110 Sheet late at the punch sensor. 12-151-00-110 The trailing edge of the sheet is late to the compile exit sensor, Q12-106. Initial Actions 12-152-00-110 The leading edge of the sheet is late to the compile exit sensor, Q12-106. WARNING Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 108 • 10, How to check a motor. Install new components as necessary: • P/J309, LCSS PWB. • Transport motor 1, PL 12.40 Item • 12D-110 LCSS Power Distribution RAP. • LCSS PWB, PL 12.75 Item • 0V Distribution RAP. If the fault is still present, perform 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper Install new components as necessary:...
  • Page 109 12-171-00-110, 12-172-00-110 Paper Exiting to Bin 0 RAP Refer to: • 12G-110 LCSS PWB Damage RAP. 12-171-00-110 The leading edge of the sheet is late to the top exit sensor. • 10, How to Check a Motor. 12-172-00-110 The trailing edge of the sheet is late from the top exit sensor. •...
  • Page 110 • 12D-110 LCSS Power Distribution RAP. 12-199-00-110 Unexpected Sheet at Finisher Entry RAP • 0V Distribution RAP. 12-199-00-110 The leading edge of the sheet detected at finisher entry, without first receiving a Install new components as necessary: paper at IOT exit sensor command. •...
  • Page 111 12-310-00-110, 12-312-00-110, 12-313-00-110 Interlocks 12-312-00-110 Top Cover Interlock RAP Check the top cover interlock switch S12-197, PL 12.75 Item 6, as follows: • Check the switch actuator. 12-310-00-110 The docking interlock is open during run mode. • Enter dC330 code 12-197, actuate the top cover interlock switch. If the display does not change, refer to: 12-312-00-110 The top cover interlock is open during run mode.
  • Page 112 12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector Refer to: • 12G-110 LCSS PWB Damage RAP. Movement Failure RAP • GP 11 How to Check a Sensor. 12-340-00-110 The ejector is not at the home position. • P/J304, LCSS PWB. 12-341-00-110 The ejector is not at the out position. •...
  • Page 113 12-371-00-110, 12-372-00-110, 12-378-00-110 Staple Head • Figure 1, Component location. • 12D-110 LCSS Power Distribution RAP. Unit Movement Failure RAP • 0V Distribution RAP 12-371-00-110 The staple head unit fails to move. Install new components as necessary: • Stapler traverse assembly, PL 12.55 Item 12-372-00-110 The staple head unit is not at the home position.
  • Page 114 12-392-00-110, 12-393-00-110, 12-394-00-110 Front Tamper Move Failure RAP 12-392-00-110 Front tamper fails to move from the home position. 12-393-00-110 Front tamper fails to return to the home position. 12-394-00-110 Front tamper does not return to the away home position. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 115 Enter dC330 codes 12-226 and 12-228 alternately. The front tamper moves between the 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper home and inboard positions. Move Failure RAP Go to 12.3. Check the front tamper motor, MOT12-226, PL 12.45 Item 12-396-00-110 Rear tamper fails to move from the home position. Refer to: 12-397-00-110 Rear tamper fails to return to the home position.
  • Page 116 Procedure • 11, How to Check a Sensor. • P/J312, LCSS PWB. NOTE: All LCSS interlocks must be made to supply +24V to the motors. • 12D-110 LCSS Power Distribution RAP. NOTE: With reference to WD 12.3 component control codes; •...
  • Page 117 12-462-00-110 Bin 1 Movement Failure RAP Remove the LCSS rear cover. Enter dC330 code 12-192, bin 1 motor encoder sensor Q12-192 PL 12.30 Item 11, then slowly rotate the encoder disk by hand. The display changes. 12-462-00-110 Bin 1 failed to leave the bin 1 upper level sensor during stacking or failed to ini- tialise correctly.
  • Page 118 • GP 13 How to Check a Switch. 12-492-00-110 to 12-494-00-110 IME to Finisher Failure RAP • P/J315, LCSS PWB. 12-492-00-110 CDI Communications failure with the finisher. • 12D-110 LCSS Power Distribution RAP. • 0V Distribution RAP 12-493-00-110 The finisher failed to cycle up. Install new components as necessary: 12-494-00-110 The finisher failed to return a prep time to the IME within 1 second.
  • Page 119 12-762-00-110, 12-764-00-110, 12-765-00-110 IME to 12-950-00 IME Delivers Sheet Too Early RAP Finisher Communication Failure RAP 12-950-00 IME delivers sheet to finisher before the finisher preparation time has expired. 12-762-00-110 Communications failure between the IME and the finisher. Procedure 12-764-00-110 The IME cannot detect a finisher plugged in. WARNING Ensure that the electricity to the machine is switched off while performing tasks that do 12-765-00-110 The IME has detected an incompatible / unknown finisher.
  • Page 120 12A-110 Pause To Unload (PTU) Fault RAP 12B-110 Bin 1 Overload RAP Use this RAP when the pause to unload (PTU) feature fails to operate. Use this RAP to resolve a fault on the bin 1 90% full sensor. Initial Actions Procedure WARNING WARNING...
  • Page 121 12C-110 LCSS Initialization Failure RAP • Rear tamper not at home, refer to 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper Move Failure RAP.- When an initialization command is received from the machine, the units are initialized in two • Paddle not at home, refer to 12-024-00-110, 12-025-00-110 Paddle Roll Failure RAP.
  • Page 122 12D-110 LCSS Power Distribution RAP WARNING Do not install a fuse of a different type or rating. Installing the wrong type or The LCSS has an integral power supply providing +24V and +5V supplies to the LCSS PWB. rating of fuse can cause overheating and a risk of fire. The AC power for the LCSS power supply comes from the LVPS and base module of the machine.
  • Page 123 12E-110 LCSS Paper Entry RAP Disconnect P/J300. +5V is available at P/J300 between pins 4 and 6, also between The leading edge of the sheet is late to the entry sensor Q12-077, PL 12.70 Item pins 7 and 8 on the end of the harness. Initial Actions Loosen the 4 screws and lift the power supply module away from the LCSS frame.
  • Page 124 12F-110 LCSS PWB DIP Switch Settings RAP 12G-110 LCSS PWB Damage RAP To show the correct settings for the DIP switches on the LCSS PWB. Use this RAP to determine the cause of damage to the LCSS PWB, so that the cause can be repaired before a new LCSS PWB is installed.
  • Page 125 Table 1 LCSS PWB Drive Components LCSS PWB Driven Normal resistance Spared part and component component measurement +/- 10% references Transport PJ305 pin 1 to 3 = 2.8 ohms. Transport motor 1, PL 12.40 motor 1 PJ305 pin 1 to 4 = 2.8 ohms. Item 12-171-00-110, 12- PJ305 pin 2 to 5 = 2.8 ohms.
  • Page 126 12H-110 Copy Damage in the LCSS RAP 12J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP Use this RAP to identify and correct the causes of copy damage in the LCSS. Use this RAP to identify and correct the causes of mis-registration in stapled sets, resulting in Procedure staples missing some sheets in the set, or poorly registered non-stapled sets.
  • Page 127 12K-110 LCSS Poor Stacking RAP 12L-110 Stapling Prime Failure RAP Use this RAP to find the cause of poor stacking in the LCSS. Use this RAP when the staples in the stapling head are not primed. Procedure Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 128 NOTE: If the SH1 priming sensor does not see staples in the primed position, the staple head cycles a number of times to prime the staple head. This occurs when the LCSS interlocks are made. Follow the customer instruction label inside the LCSS front door to remove the staple cartridge, slide out the top sheet of staples from the cartridge, to expose a fresh sheet of staples on the top of the stack.
  • Page 129 12M-110 Staple Head Operation Failure RAP Use this RAP when the staple head fails to cycle or the staple head is not at the home position. NOTE: The home position is with the jaws of the staple head fully open. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 130 Install new components as necessary: 12N-110 Chad Bin Present and Bin Full RAP • Staple head unit, PL 12.55 Item Use this RAP when there is a false indication of a missing or full chad bin. • LCSS PWB, PL 12.75 Item Initial Actions Perform SCP 5...
  • Page 131 12-024-00-171, 12-025-00-171 HVF Paddle Roller Position 12-024-00-171 The paddle roller has failed to return to the home position. Pusher 12-025-00-171 The paddle roller has failed to move from the home position. Paddle roll home sen- Initial Actions Q12-186 WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 132 12-044-00-171 to 12-047-00-171 HVF Punch Head Position • GP 10 How to Check a Motor. • 12A-171 HVF Power Distribution RAP. • 0V Distribution RAP 12-044-00-171 The punch head has failed to return to the home position within the required time. Install new components as necessary: 12-045-00-171 The punch head has failed to move from the home position within the required •...
  • Page 133 12-056-00-171, 12-057-00-171 Inserter Bottom Plate RAP 12-061-00-171, 12-416-00-171 HVF BM Crease Blade Fault 12-056-00-171 The inserter bottom plate has failed to return to the home position. 12-061-00-171 The crease blade has failed to clear the crease blade home sensor. 12-057-00-171 The inserter bottom plate has failed to lift. Initial Actions 12-416-00-171 The crease blade has failed to return to the home position.
  • Page 134 • 12A-171 HVF Power Distribution RAP. 12-062-00-171 HVF BM Crease Roll Motor Failure RAP • 0V Distribution RAP 12-062-00-171 The HVF BM crease roll motor has failed to run. Install new components as necessary: Initial Actions • BM PWB, PL 12.175 Item Clear any paper jam in the area of the crease rolls.
  • Page 135 12-063-00-171, 12-411-00-171 HVF BM Staple Unit 1 Failure Enter dC330, code 12-254 to run the BM SH1 motor. The staple head cycled. Go to WD 12.16 12.19. Check the wiring and connectors. 12-063-00-171 The HVF BM staple unit 1 has failed to leave the home position. The wiring and connectors are good.
  • Page 136 12-065-00-171, 12-383-00-171 HVF BM Backstop Motor Install new components as necessary: • BM backstop motor, PL 12.160 Item Fault RAP • BM PWB, PL 12.175 Item 12-065-00-171 The HVF BM backstop motor fails to move. Enter dC330 code 12-259 to energize the BM stack hold solenoid, SOL12-259, PL 12.165 Item 12-383-00-171 The HVF BM backstop is not at the home position.
  • Page 137 12-066-00-171, 12-384-00-171, 12-419-00-171, 12-420-00- 12-083-00-171, 12-440-00-171 to 12-444-00-171 HVF Paper 171 HVF BM Tamper Fault RAP Pusher Fault RAP 12-066-00-171 The HVF BM tamper has failed to clear the home sensor. 12-083-00-171 The paper pusher motor has stalled. 12-384-00-171 The HVF BM tamper is not at the home sensor. 12-440-00-171 The paper pusher has failed to return to the home, (upper) position.
  • Page 138 Enter dC330, code 12-092. Manually actuate the paper pusher upper sensor, Q12-092, 12-113-00-171, 12-114-00-171, 12-190-00-171, 12-192-00-171 12.115 Item 16. The display changes. HVF BM Entry RAP Go to 12.9. Check Q12-092. 12-113-00-171 The paper leading edge is late arriving at the HVF booklet exit sensor. Refer to: 12-114-00-171 The paper trailing edge is late leaving the HVF booklet exit sensor.
  • Page 139 Enter dC330, code 12-263 to run the bypass feed motor, MOT12-263, Figure 1. The motor • 0V Distribution RAP runs. Install new components as necessary: • BM paper present sensor, PL 12.185 Item Go to 12.8. Check the bypass feed motor, MOT 12-263. •...
  • Page 140 12-125-00-171, 12-126-00-171 HVF Entry Sensor RAP 12-125-00-171 The entry sensor is not turned on within a specified time. BM entry sensor Q12-089 12-126-00-171 The paper trailing edge is late leaving the entry sensor. Initial Actions BM compiler motor, WARNING MOT12-251 Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 141 12-141-00-171, 12-142-00-171 HVF Buffer Path Sensor RAP Install new components as necessary: • Buffer motor, PL 12.120 Item 12-141-00-171 The paper trailing edge is late leaving the buffer path sensor. • HVF PWB, PL 12.140 Item 12-142-00-171 The paper leading edge is late arriving at the buffer path sensor. Check the buffer feed motor belt, PL 12.120 Item 9.
  • Page 142 12-151-171, 12-152-171 HVF Compiler Exit Sensor RAP Install new components as necessary: • Transport motor 2, PL 12.120 Item 12-151-00-171 The paper trailing edge is late leaving the compiler exit sensor. • HVF PWB, PL 12.140 Item 12-152-00-171 The paper leading edge is late arriving at the compiler exit sensor. Check the transport motor 2 drive belt.
  • Page 143 12-157-00-171, 12-158-00-171 HVF Buffer Position Sensor Go to 12.8. Check MOT12-263. Refer to: 12-157-00-171 The paper leading edge is late arriving at the buffer position sensor. • GP 10 How to Check a Motor. • 12A-171 HVF Power Distribution RAP 12-158-00-171 The paper trailing edge is late leaving the buffer position sensor.
  • Page 144 12-166-00-171 HVF BM Compiler Exit Jam RAP Unlatch the entrance baffle assembly, PL 12.150 Item 22. Run again MOT12-251. The entry roll rotates. 12-166-00-171 The trail edge is late leaving the BM compiler exit sensor. Check the following components: Initial Actions •...
  • Page 145 12-171-00-171, 12-172-00-171 HVF Top Tray Exit Sensor Fault RAP 12-171-00-171 The paper leading edge is late arriving at the top exit sensor. BM entry roll 12-172-00-171 The paper trailing edge is late leaving the top exit sensor. Initial Actions WARNING BM compiler motor, Ensure that the electricity to the machine is switched off while performing tasks that do MOT12-251...
  • Page 146 • 0V Distribution RAP 12-181-00-171, 12-182-00-171 HVF BM Exit Jam RAP Install new components as necessary: 12-181-00-171 The lead edge is late arriving at the BM exit sensor. • Transport motor 2, PL 12.120 Item • HVF PWB, PL 12.140 Item 12-182-00-171 The trail edge is late leaving the BM exit sensor.
  • Page 147 Enter dC330 code 12-213. Actuate the BM exit sensor, Q12-213, Figure 2. The display Refer to: changes. • GP 10 How to Check a Motor. • 12A-171 HVF Power Distribution RAP. Go to 12.18. Check Q12-213. • 0V Distribution RAP Refer to: Install new components as necessary: •...
  • Page 148 BM crease roll gate motor, MOT12-273 BM crease blade motor encoder sensor, Q12-215 BM exit sensor, Q12-213 BM crease blade motor, MOT12-252 Figure 2 Component location BM crease roll motor, MOT12-253 BM crease roll motor encoder, Q12-216 Figure 1 Component location Status Indicator RAPs February 2013 12-181-00-171, 12-182-00-171...
  • Page 149 12-183-00-171, 12-184-00-171 HVF BM Paper Jam RAP • 12A-171 HVF Power Distribution RAP. • 0V Distribution RAP 12-183-00-171 The BM PWB has detected an unexpected sheet in the booklet maker paper Install new components as necessary: path. • BM PWB, PL 12.175 Item 12-184-00-171 The BM PWB has detected a stray sheet in the booklet maker paper path after •...
  • Page 150 BM entry sensor, Q12-089 BM exit sensor, Q12-213 Figure 2 Component location BM paper present sensor, Q12-170 Figure 1 Component location Status Indicator RAPs February 2013 12-183-00-171, 12-184-00-171 2-126 ColorQube® 9303 Family...
  • Page 151 12-185-00-171 to 12-187-00-171 Tri-Folder Exit Sensor and Assist Sensor RAP 12-185-00-171 The lead edge is late arriving at the tri-folder exit sensor. 12-186-00-171 The trail edge is late leaving the tri-folder exit sensor. 12-187-00-171 The lead edge is late arriving at the tri-folder assist gate sensor. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 152 Install new components as necessary: Go to WD 12.19 12.20. Check SOL12-267. • BM crease roll motor, PL 12.175 Item Refer to: • BM PWB, PL 12.175 Item • GP 12 How to Check a Solenoid or Clutch. • 12A-171 HVF Power Distribution RAP.
  • Page 153 Tri-folder exit sensor, Q12-166 Figure 2 Component location BM crease roll motor, MOT12-253 Figure 3 Component location Status Indicator RAPs February 2013 12-185-00-171 to 12-187-00-171 ColorQube® 9303 Family 2-129...
  • Page 154 12-191-00-171, 12-193-00-171, 12-194-00-171, 12-196-00- • 0V Distribution RAP Install new components as necessary: 171 Inserter Paper Jam RAP • Inserter TE sensor, PL 12.310 Item 12-191-00-171 The leading edge is late arriving at the inserter standby sensor. • Inserter PWB, PL 12.310 Item •...
  • Page 155 Refer to: • GP 12 How to Check a Solenoid or Clutch. Inserter clutch, Inserter pickup sensor • 12A-171 HVF Power Distribution RAP. CL12-260 Q12-315 • 0V Distribution RAP Inserter TE sensor Install new components as necessary: Q12-084 • Inserter clutch, PL 12.310 Item Inserter LE Sensor •...
  • Page 156 12-198-00-171, 12-199-00-171 HVF Paper Jam RAP Install new components as necessary: • Buffer path sensor, PL 12.135 Item 12-198-00-171 A stray sheet was detected in the finisher, after a jam clearance. • HVF PWB, PL 12.140 Item 12-199-00-171 An unexpected sheet has been detected in the finisher. Enter dC330, code 12-106.
  • Page 157 12-288-00-171, 12-289-00-171 HVF Nip Split RAP 12-288-00-171 The nip split has failed to operate. 12-289-00-171 The nip split has failed to return to the home position. Top tray exit sensor Q12-107 Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 158 Install new components as necessary: 12-310-00-171, 12-312-00-171, 12-313-00-171 HVF Docking • Nip split sensor, PL 12.135 Item and Interlocks RAP • HVF PWB, PL 12.140 Item 12-310-00-171 The finisher was detected to be undocked in the run mode. Perform SCP 5 Final Actions.
  • Page 159 • If necessary, install a new front door interlock switch, PL 12.115 Item 12-316-00-171, 12-319-00-171 Inserter Interlocks RAP 12-316-00-171 The inserter top cover interlock was detected open in the run mode. 12-319-00-171 The inserter left hand door was detected open in the run mode. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 160 12-317-00-171, 12-318-00-171 Tri-folder Interlocks RAP 12-317-00-171 The tri-folder top cover interlock was detected open during a run. 12-318-00-171 The tri-folder front door interlock was detected open during a run. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 161 12-367-00-171, 12-368-00-171, 12-380-00-171 HVF Punch Go to WD 12.19 12.20. Check the wiring and repair as necessary, 1.1. Unit Paper Edge Detect RAP Check the tri-folder top cover interlock sensor, Q12-210. Refer to: • GP 11 How to Check a Sensor. 12-367-00-171 The punch unit failed to detect the edge of the A4 LE feed paper.
  • Page 162 Install new components as necessary: • Transport motor 1, PL 12.120 Item • HVF PWB, PL 12.140 Item Check the transport motor 1 drive belt, PL 12.120 Item 7. The drive belt is good. Install a new transport motor 1 drive belt, PL 12.120 Item Enter dC330, code 12-245 punch unit motor, to check that the motor runs.
  • Page 163 12-369-00-171 to 12-377-00-171 HVF Stapler Position and • 12A-171 HVF Power Distribution RAP. • 0V Distribution RAP Priming RAP Install new components as necessary: 12-369-00-171 The stapler return end home failure. • Stapler assembly, PL 12.110 Item • HVF PWB, PL 12.140 Item 12-370-00-171 The stapler end home failure.
  • Page 164 Go to 12.14. Check MOT12-247. Refer to: Go to 12.10, check for a change in signal level at PJ301 pin 12, while code 12-247 is running. The signal level changes. • GP 10 How to Check a Motor. • 12A-171 HVF Power Distribution RAP.
  • Page 165 Stapler unit mid home sensor, Q12-176 Paper pusher Stapler gate safety switch, S12-319 Figure 1 Component location Stapler unit home sensor, Q12-135 Figure 2 Component location Status Indicator RAPs February 2013 12-369-00-171 to 12-377-00-171 ColorQube® 9303 Family 2-141...
  • Page 166 12-392-00-171 to 12-395-00-171 HVF Front Tamper Fault Stack the dC330 code 12-182, tamper front away sensor, Q12-182. Move the tamper using the control codes 12-226 and 12-228. The display changes. 12-392-00-171 The front tamper did not move from the home position. Go to 12.15.
  • Page 167 12-396-00-171 to 12-399-00-171 HVF Rear Tamper Fault Go to 12.11. Check the wiring and repair as necessary, 1.1. Check Q12-183. Refer to: 12-396-00-171 The rear tamper tray did not move from the home position. • GP 11 How to Check a Sensor. •...
  • Page 168 12-403-00-171, 12-413-00-171, 12-414-00-171 HVF BM Install new components as necessary: • BM staple head 2, PL 12.185 Item Staple Head 2 and Stapler Module RAP • BM PWB, PL 12.175 Item 12-403-00-171 The booklet maker staple head 2 motor has failed to move. Enter dC330, code 12-275 to run the BM SH2 motor.
  • Page 169 12-415-00-171 HVF BM Crease Roll Gate Home RAP 12-415-00-171 The crease roll gate is not at the home position. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 170 12-417-00-171, 12-418-00-171 HVF BM Flapper RAP 12-417-00-171 The booklet maker flapper did not return to the home position. 12-418-00-171 The booklet maker flapper did not move from the home position. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 171 12-450-00-171, 12-456-00-171 to 12-459-00-171 HVF Ejector • HVF PWB, PL 12.140 Item Module RAP Exit diagnostics mode, selecting the re-boot option. This returns the ejector module to the 12-450-00-171 The ejector module motor has stalled home position. Enter the dC330 code, 12-185, ejector out sensor, Q12-185.
  • Page 172 12-451-00-171 to 12-455-00-171 HVF Ejector Roll and Lower Paddle Fault RAP 12-451-00-171 The ejector roll motor has stalled. 12-452-00-171 The ejector roll did not return to the home position. 12-453-00-171 The ejector roll did not move from the home position. 12-454-00-171 The lower paddle has failed to return to the home position.
  • Page 173 Install new components as necessary: • Ejector assembly, PL 12.110 Item • HVF PWB, PL 12.140 Item Go to 12.11. Check the wiring and repair as necessary, 1.1. Check the ejector roll motor encoder sensor, Q12-097. Refer to: • GP 11 How to Check a Sensor.
  • Page 174 Ejector paper Rotate paddle 1 present sensor, complete turn Q12-202 Figure 3 Component location Ejector lower paddle home sensor, S12- RIGHT UNDER-SIDE VIEW OF EJECTOR Figure 2 Component location Status Indicator RAPs February 2013 12-451-00-171 to 12-455-00-171 2-150 ColorQube® 9303 Family...
  • Page 175 12-460-00-171 to 12-462-00-171 HVF Bin 1 Position RAP • HVF PWB, PL 12.140 Item 12-460-00-171 Bin 1 motor has stalled. If the tray is not at the lower limit, enter the dC330 code 12-191, bin 1 lower limit switch. Manually actuate the switch, Figure 1.
  • Page 176 Enter the dC330 code 12-187, bin 1 90% full sensor. Actuate the sensor using a piece of paper. The display changes. Go to 12.13. Check the wiring and repair as necessary. Check Q12-187. Refer to: • GP 11 How to Check a Sensor. •...
  • Page 177 12-463-00-171, 12-464-00-171 HVF BM +24V Failure RAP If a inserter is installed, go to PJ703. +24V is available between PJ703 pin 1 and PJ111 pin 1. 12-463-00-171 The booklet maker control PWB has failed to detect +24V at the input from the HVF.
  • Page 178 12-465-00-171 to 12-468-00-171 Paddle Unit Position RAP 12-465-00-171 The paddle unit has failed to return to the upper position. 12-466-00-171 The paddle unit has failed to move from the upper position. 12-467-00-171 The paddle unit has failed to return to the lower position. 12-468-00-171 The paddle unit has failed to move from the lower position.
  • Page 179 12-473-00-171 to 12-478-00-171 Support Finger Position Go to 12.9. Check Q12-175. Refer to: 12-473-00-171 The pressing and support motor does not return to initial position within the • GP 11 How to Check a Sensor. required time. • 12A-171, HVF Power Distribution RAP. •...
  • Page 180 Enter the dC330 code 12-171 pressing and support B sensor, Q12-171. Turn the gear wheel to extend the support fingers approximately 25 mm (1 inch). The display changes. Go to 12.12. Check Q12-171. Refer to: • GP 11 How to Check a Sensor. •...
  • Page 181 12-479-00-171 Inserter Paper Length Fault RAP 12-479-00-171 A shorter than expected sheet has been fed from the inserter. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 182 Install new components as necessary: Install new components as necessary: • Inserter paper length sensor 3, PL 12.300 Item • Inserter unit motor, PL 12.315 Item • Inserter PWB, PL 12.310 Item • Inserter PWB, PL 12.310 Item • HVF PWB, PL 12.140 Item •...
  • Page 183 12-492-00-171 to 12-494-00-171 IME To Finisher Failure 12-762-00-171, 12-764-00-171, 12-765-00-171 IME To Finisher Communication Failure RAP 12-492-00-171 CDI Communications failure with the finisher. 12-762-00-171 Communications failure between the IME and the finisher 12-493-00-171 The finisher failed to cycle up. 12-764-00-171 The IME cannot detect a finisher plugged in. 12-494-00-171 The finisher failed to return a prep time to the IME within 1 second.
  • Page 184 12A-171 HVF Power Distribution RAP Install a new HVF power supply module, PL 12.140 Item The HVF has an integral power supply providing +24V and +5V supplies to the HVF PWB and HVF BM PWB. The AC power for the HVF power supply comes from the LVPS and base mod- Check the in-line fuse, F1 (10A), and as necessary install a new fuse, PL 12.140 ule of the machine.
  • Page 185 Check the connectors and harness between PJ553 and PJ601. Repair the harness • LED 8 - red, steady. This indicates that the HVF top cover, front door and docking inter- as necessary, 1.1. locks are all closed and +24V is available at the HVF module. •...
  • Page 186 12B-171 HVF BM to Machine Communications Interface and BM Present RAP A communication fault exists between the HVF BM and the machine. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 187 12C-171 HVF BM Bin 2 Failure RAP • BM PWB, PL 12.175 Item Bin 2 fails to remove the finished booklets from the exit area of the booklet maker. The fault may be intermittent, check for damaged wiring or bad connectors, 1.1.
  • Page 188 12D-171 Booklet Quality RAP Examine the booklets for defects. Refer to the following: • Top and Bottom Edge Alignment. Use this RAP to identify and correct the causes of poor booklet quality in the HVF BM. • Open Side Edge Alignment.
  • Page 189 If the top and bottom edge alignment does not conform to the specification in Table 2, check If the open side edge alignment does not conform to the specification in Table 3, check the the operation of the BM tampers, refer to the 12-066-00-171, 12-384-00-171, 12-419-00-171, operation of the BM stack hold solenoids, refer to the 12-065-00-171, 12-383-00-171...
  • Page 190 ADJ 12.9-171 Booklet Marker Skew. Check the BM back stop assembly for damage. If necessary, install a new BM back stop assembly, PL 12.165 Item Booklet Crease is Off Centre Figure 4, open out the booklet at the centre page and press it onto a flat surface. Measure the position of the booklet crease.
  • Page 191 If the booklet crease position does not conform to the specification in Table 5, perform 12.7-171 Booklet Crease Position. Booklet Staple Position is Not On The Fold Figure 5, open out the booklet at the centre page and press it onto a flat surface. Measure the position of the booklet staple from the crease line.
  • Page 192 12E-171 Copy Damage in the HVF BM RAP 12F-171 Mis-Registration in Stapled and Unstapled Sets Use this RAP to identify and correct the causes of copy damage in the HVF BM. Use this RAP to identify and correct the causes of mis-registration in stapled sets, resulting in Procedure staples missing some sheets in the set, or poorly registered non-stapled sets.
  • Page 193 12G-171 HVF BM Poor Stacking RAP 12H-171 Pause to Unload (PTU) RAP Use this RAP to find the cause of poor stacking in the HVF BM. Use this RAP to diagnose pause to unload problems. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 194 12J-171 Inserter Paper Sensing and +5V Supply RAP Go to 12.13, WD 12.21 WD 12.22 and check the inserter paper width sensor 2. Use this RAP to find the cause of inserter empty, inserter paper width and +5v supply prob- Refer to: lems.
  • Page 195 Inserter paper width sensor Inserter unit empty sensor, 1, (Q12-081) Q12-082 Inserter paper width sensor 2, (Q12-169) Inserter Pickup Inserter acceleration sensor (Q12-315) sensor (Q12-316) Figure 1 Component location Figure 2 Component location Status Indicator RAPs February 2013 12J-171 ColorQube® 9303 Family 2-171...
  • Page 196 12K-171 HVF Initialization Failure RAP • Staple head not at home, refer to 12-369-00-171 to 12-377-00-171 HVF stapler Position and Priming RAP. When an initialization command is received from the machine, the HVF is initialized with the • Ejector not at home, refer to 12-450-00-171, 12-456-00-171 to 12-459-00-171 HVF Ejec- following actions:...
  • Page 197 12L-171 Tri-Folder Not Detected RAP 12M-171 Buffer Path Clamp Problems RAP Use this RAP when the machine fails to detect the tri-folder module. Use this RAP when having problems with the buffer path clamp on the HVF. Problems in this area result in paper jams at the exit and poor compiling.
  • Page 198 12N-171 Chad Bin Present and Bin Full RAP Use this RAP when there is a false indication of a missing or full chad bin. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 199 Chad bin level sensor, (Q12-193) Chad bin present sensor, (Q12-118) UNDERSIDE VIEW Figure 1 Component location Status Indicator RAPs February 2013 12N-171 ColorQube® 9303 Family 2-175...
  • Page 200 Status Indicator RAPs February 2013 12N-171 2-176 ColorQube® 9303 Family...
  • Page 201 16-000-00 to 16-000-26 Cannot Create RPC With ENS RAP 16-001-09 to 16-001-90 Unable to Synchronize Startup RAP 16-000-00 Format services non shutdown ESS faults 16-001-09 Unable to do startup synchronization 16-000-01 ENS service non shutdown ESS faults 16-001-14 Unable to do startup synchronization 16-000-09 Cannot create RPC connection with ENS 16-001-19 Unable to do startup synchronization 16-000-14 Cannot create RPC connection with ENS...
  • Page 202 16-002-09 to 16-002-19 Unable to Register as RPC RAP 16-003-09 to 16-003-90 Too Many IPC Handles RAP 16-002-09 Unable to Register as an RPC server 16-003-09 Too many IPC handles 16-002-14 Unable to Register as an RPC server 16-003-14 Too many IPC handles 16-002-19 Unable to Register as an RPC server 16-003-19 Too many IPC handlers 16-002-26 Unable to Register as an RPC server...
  • Page 203 16-004-14 to 16-005-92 RPC Failure to Register RAP 16-006-09, 16-006-19 Cannot Register for Events RAP 16-004-14 RPC call failure to ESS registration service 16-006-09 Cannot register for events 16-004-19 RPC connect failure to ESS registration service 16-006-19 Cannot register for events 16-004-26 RPC connect failure to ESS registration service Procedure WARNING...
  • Page 204 16-007-92 to 16-010-99 Invalid IPC / RPC Data RAP 16-013-14, 16-014-14 Copier Synchronization Error RAP 16-007-92 Invalid RPC data received 16-013-14 Digital copier ENS synchronization error 16-009-09 Invalid IPC data received 16-014-14 Digital copier ENS synchronization error 16-010-14 Unable to send IPC Procedure WARNING 16-010-99 IPC open, create, signal queue failed...
  • Page 205 16-015-14, 16-015-19 Data Store Variable Not Set RAP 16-016-14, 16-016-19 Data Store Initialization Failed RAP 16-015-14 SESS data store environmental variable not set 16-016-14 Data store initialization failed 16-015-19 SESS data store environmental variable not set 16-016-19 Data store initialization failed Procedure Procedure WARNING...
  • Page 206 16-017-19 to 16-021-26 Send Event Failure / Could Not Get 16-021-46 Unable to Get Host Name RAP Host Name RAP 16-021-46 Unable to get Host Name 16-017-19 Send event failure. Unable to send event to ESS ENS Procedure 16-021-19 ESS PM registration connect error WARNING Ensure that the electricity to the machine is switched off while performing tasks that do 16-021-26 Service could not get Host name...
  • Page 207 16-023-09, 16-023-26 RPC Call Failure RAP 16-026-09 to 16-026-92 Memory Allocation Error RAP 16-023-09 RPC call failure to ENS 16-026-09 Memory allocation failure 16-023-26 RPC call failure to ENS 16-026-14 Malloc error Procedure 16-026-46 Memory allocation failure WARNING 16-026-90 Malloc error Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 208 16-027-90 Unable to Obtain Queue ID RAP 16-028-09, 16-028-90 Unable to Complete RPC Call / Invalid Range RAP 16-027-90 Unable to obtain well known queue ID 16-028-09 Unable to complete RPC call Procedure WARNING 16-028-90 Invalid range string Ensure that the electricity to the machine is switched off while performing tasks that do Procedure not need electricity.
  • Page 209 16-030-19 Unable to Obtain Client RAP 16-031-09 Invalid Event Notification RAP 16-030-19 Unable to obtain client RPC handle to EJS 16-031-09 Invalid event notification received Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 210 16-032-19, 16-039-00 NVM Connection Failure / Pthread 16-040-92 Semaphore Fault RAP Create Error RAP 16-040-92 Semaphore fault 16-032-19 NVM connection failure Procedure 16-039-00 Pthread create error WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Procedure not need electricity.
  • Page 211 16-048-09 Unable to Set Binding RAP 16-048-14, 16-048-90 Cannot Set ESS Client Binding RAP 16-048-09 Unable to set binding 16-048-14 Cannot set ESS client binding Procedure 16-048-90 Cannot set ESS client binding WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 212 16-048-99 Unable to Set Client Binding RAP 16-150-09 Cannot Send Registration Event RAP 16-048-99 Unable to set client binding 16-150-09 Cannot send Registration Event Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 213 16-150-14 Unable to Obtain RPC Transport RAP 16-150-19 Unable to Sync Peer RAP 16-150-14 Unable to obtain RPC transport 16-150-19 Unable to sync peer (within ESS) infrastructure services Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 214 16-150-26 Fault Service Failed to Write Log RAP 16-150-90 Invalid IPC Request Destination RAP 16-150-26 Fault Service Failed to write log 16-150-90 Invalid IPC request destination Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 215 16-150-92 Consumer Interface Fault RAP 16-151-09 to 16-151-19 Invalid IPC Command / SNMP Reg Failure RAP 16-150-92 Consumer interface fault 16-151-09 Invalid IPC command Procedure WARNING 16-151-14 SNMP event registration failed Ensure that the electricity to the machine is switched off while performing tasks that do 16-151-19 Invalid IPC command not need electricity.
  • Page 216 16-151-26 Fault Service Failed to Get a Log RAP 16-151-90 Environment Variable Failure RAP 16-151-26 Fault service failed to get a log handle 16-151-90 Put environment variable failure Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 217 16-152-09 Internal IPC Failure RAP 16-152-14 Empty Internal Event Failure RAP 16-152-09 Internal IPC failure 16-152-14 Empty internal event received by ENS Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 218 16-152-19 Unable to Send Request to SESS RAP 16-152-26 Unable to Send Request to SESS RAP 16-152-19 Unable to send request to SESS 16-152-26 Unable to send request to SESS Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 219 16-153-09 Unable to Obtain IPC Queue RAP 16-153-14 Unable to Initialize Event List RAP 16-153-09 Unable to obtain IPC queue 16-153-14 Can not initialize internal event list Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 220 16-153-19 NVM Save Failure RAP 16-154-09 ESS Registration Configuration Error RAP 16-153-19 NVM save failure 16-154-09 ESS Registration service configuration error Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 221 16-154-14 Cannot Create Internal Event Queue RAP 16-154-19 NVM Read Failure RAP 16-154-14 Cannot create internal event 16-154-19 NVM read failure Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 222 16-155-19 ESS Failed to Boot from Alternate Disk RAP 16-156-19 Service Run Loop Failed RAP 16-155-19 ESS failed to boot from alternate disk partition 16-156-19 Service run loop failed Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 223 16-160-09 ESS Reg Service Process Death RAP 16-161-09, 16-164-09 Cannot Send Reg Event / List Access Failure RAP 16-160-09 ESS Registration Service Process Death 16-161-09 Cannot send registration event Procedure WARNING 16-164-09 List access failure (create, add, find, delete) Ensure that the electricity to the machine is switched off while performing tasks that do Procedure not need electricity.
  • Page 224 16-162-09 to 16-163-09 Cannot Send Reg Event / ESS 16-429-00, 16-431-00 Unable to Write to Data Store / Get Services Failure RAP System Time RAP 16-162-09 ESS platform manager services process death 16-429-00 Unable to write to data store 16-163-09 ESS DM agent services process death 16-431-00 Unable to get system time Procedure Procedure...
  • Page 225 16-432-00 Unknown Scheduler Received RAP 16-433-00 RPC Call Failed RAP 16-432-00 Unknown scheduler received 16-433-00 RPC call failed Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 226 16-434-00 Unable to Change Scheduler RAP 16-600-07 to 16-600-67 Cannot Create RPC Connection 16-434-00 Unable to change scheduler received 16-600-07 Cannot create RPC connection to ENS Procedure WARNING 16-600-35 Cannot create RPC connection to ENS Ensure that the electricity to the machine is switched off while performing tasks that do 16-600-46 Cannot create RPC connection to ENS not need electricity.
  • Page 227 16-601-26 to 16-601-46 Queue Setup / System Control 16-601-47 Diagnostics Service Failed IPC Queue Setup Failed / Invalid UI Info RAP 16-601-26 Fault Service Failed IPC Queue Setup 16-601-47 Diagnostics service failed IPC queue setup 16-601-35 System control initialization Failed Procedure WARNING 16-601-46 Invalid UI information (RPC data) returned...
  • Page 228 16-601-66, 16-601-67 Unable to Do Start Up Sync RAP 16-601-68 Unable to Start Up and Sync RAP 16-601-66 Unable to do start up synchronization 16-601-68 Unable to start up & synchronize with SC 16-601-67 Unable to do start up synchronization Procedure WARNING Procedure...
  • Page 229 16-601-105 Unable Synchronize At Start Up RAP 16-602-07 to 16-602-105 RPC Service Registration Failure 16-601-105 Unable to do start up synchronization 16-602-07 RPC service registration failure Procedure WARNING 16-602-09 Unable to unregistered as RPC service during shutdown Ensure that the electricity to the machine is switched off while performing tasks that do 16-602-11 RPC server register failed not need electricity.
  • Page 230 16-603-11, 16-603-28 Replace Handler Call Failed RAP 16-603-46 to 16-603-67 Too Many IPC Handlers RAP 16-603-11 Replace handler call failed 16-603-46 Too many IPC handlers 16-603-28 Replace handler call failed 16-603-66 Too many IPC handlers Procedure 16-603-67 Too many IPC handlers WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 231 16-603-68, 16-604-105 Replace Handler Call Failed / Data 16-603-105, 16-604-14 RPC Call Failure to NC Reg Service Store Variable Not Set RAP 16-603-68 Replace handler call failed 16-603-105 RPC call failure to network controller registration service. 16-604-105 SESS data store environmental variable not set 16-604-14 Unable to unregister as RPC service during shutdown.
  • Page 232 16-604-38 to 16-605-07 Could Not Register With Reg 16-605-14, 16-605-105 Unable to Unregister As RPC Service RAP Service / RPC Call Failure RAP 16-604-38 Could not register with registration service 16-605-14 RPC call failure to ESS registration service 16-604-99 Could not register with registration service 16-605-105 Unable to unregister as RPC service during shutdown 16-605-07 Unable to register with registration service Procedure...
  • Page 233 16-605-26 Fault Service Timed Out Registering RAP 16-605-35 to 16-605-67 RPC Call Failure to ESS RAP 16-605-26 Fault service timed out registering with registration service 16-605-35 RPC call failure to ESS registration service Procedure 16-605-47 RPC call failure to ESS registration service (to register with) WARNING 16-605-66 RPC call failure to ESS registration service Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 234 16-606-07 Cannot Register For Events RAP 16-606-35 to 16-606-99 Cannot Register For Events RAP 16-606-07 Cannot register for events 16-606-35 Cannot register for events Procedure 16-606-46 Cannot register for events WARNING 16-606-99 Cannot register for events Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 235 16-606-105 OS Problem RAP 16-607-19 to 16-608-14 Invalid RPC Data / Unable to Free Resources RAP 16-606-105 OS problem 16-607-19 Invalid RPC data received Procedure WARNING 16-607-46 Invalid RPC data received Ensure that the electricity to the machine is switched off while performing tasks that do 16-607-47 Invalid RPC disk diagnostic data received not need electricity.
  • Page 236 16-608-26 Fault Service Failed to Unbind RAP 16-608-28 to 16-608-67 Unable to Free IPC Resources RAP 16-608-26 Fault service failed to unbind with SC 16-608-28 IPC unregister fail Procedure 16-608-35 Unable to free IPC resources WARNING 16-608-38 Unable to unregister as IPC server Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 237 16-608-105 Unable Build UI SVC Obtain Client Failed RAP 16-609-07 Unknown Message Received RAP 16-608-105 Unable build UI SVC obtain client failed 16-609-07 Unknown message received from DM agent Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 238 16-609-19, 16-609-105 Too Many IPC Handlers / Invalid 16-609-26 Fault Service Encountered Error RAP RPC Data RAP 16-609-26 Fault service encountered error trying to get IPC message 16-609-19 Invalid RPC data received Procedure 16-609-105 Too many IPC handlers WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Procedure not need electricity.
  • Page 239 16-609-46 to 16-609-92 Invalid IPC Data Received RAP 16-610-00, 16-610-07 IPC Send Failure RAP 16-609-46 Invalid IPC data received 16-610-00 IPC send failure to ESS triple A service for queue command authorization 16-609-47 Invalid IPC data received. Get SC diagnostics handle failed; 16-610-07 IPC send failure to DM agent 16-609-92 Invalid IPC data received Procedure...
  • Page 240 16-610-09 Cannot Send IPC Message RAP 16-610-11 to 16-610-90 Unable to Send IPC Message RAP 16-610-09 Cannot send IPC message to ESS platform manage 16-610-11 IPC communication failed Procedure 16-610-19 Unable to send IPC message WARNING 16-610-26 Unable to send IPC message Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 241 16-610-92 Failure to Send Queue Status RAP 16-610-99 Unable to Send IPC Message RAP 16-610-92 Failure to send queue status 16-610-99 Unable to send IPC message Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 242 16-611-07, 16-611-38 Client Removal Failed RAP 16-611-19 to 16-611-47 Unable to Remove RPC Connection 16-611-07 Client removal failure 16-611-09 Unable to remove RPC connection 16-611-38 Client removal failure 16-611-14 Unable to remove RPC connection Procedure WARNING 16-611-19 Unable to remove RPC connection Ensure that the electricity to the machine is switched off while performing tasks that do 16-611-26 Unable to remove RPC connection not need electricity.
  • Page 243 16-611-66 to 16-611-99 Unable to Remove RPC Connection 16-612-09 to 16-612-68 Unable to Do Shutdown Sync RAP 16-612-09 Unable to do shutdown synchronization 16-611-66 Unable to remove RPC connection 16-612-14 Unable to do shutdown synchronization 16-611-67 Unable to remove RPC connection 16-612-35 Unable to do shutdown synchronization 16-611-99 Unable to remove RPC connection 16-612-46 Unable to do shutdown synchronization...
  • Page 244 16-613-09 to 16-614-19 DC Sync / Comms Error RAP 16-614-47 Invalid Software Upgrade RAP 16-613-09 DC registration synchronization error 16-614-47 Invalid SW upgrade file 16-613-14 DC ENS synchronization error Procedure WARNING 16-613-19 DC sys mgr sync error Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 245 16-615-35, 16-615-46 Data Store Variable Not Set RAP 16-615-47 Multiple Software Upgrade File RAP 16-615-35 SESS data store environmental variable not set 16-615-47 Multiple SW upgrade files in directory 16-615-46 SESS data store environmental variable not set Procedure WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 246 16-615-66 Data Store Variable Not Set RAP 16-615-67, 16-615-90, 16-616-38, 16-616-46 SESS Data Store Environmental Variable RAP 16-615-66 SESS data store environmental variable not set 16-615-67 SESS data store environmental variable not set. Procedure WARNING 16-615-90 Corrupt environment variable, configuration script error. Ensure that the electricity to the machine is switched off while performing tasks that do 16-616-35 SESS Faults 206 or 207.
  • Page 247 16-616-47 IPC Message Failure RAP 16-616-67 Submission Of E-mail OR IFax Job Failed RAP 16-616-47 IPC message failure. 16-616-67 Submission of e-mail or IFax job failed. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 248 16-617-19 RPC Information Corrupt RAP 16-617-47 TAR Extraction Failure RAP 16-617-19 Invalid event information or data. ENS failure, system RPC information corrupt. 16-617-47 TAR extraction failure Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 249 16-618-47 DLM SPI Extraction Failure RAP 16-619-14 to 16-619-93 Cannot Unregister From Registration Service RAP 16-618-47 DLM SPI Extraction failure 16-619-14 Registration service failed to respond in time. Procedure WARNING 16-619-19 Registration service failed to respond in time. Ensure that the electricity to the machine is switched off while performing tasks that do 16-619-26 Could not register with Registration Service.
  • Page 250 16-620-07 to 16-620-90 Registration Service Failed RAP 16-620-92, 16-620-93, 16-620-99 Unable to Register With Network Controller Registration Service RAP 16-620-07 Registration Service failed. 16-620-92 Unable to unregister with network controller registration service due to registration 16-620-14 Registration Service failed. service failure. 16-620-19 Registration Service failed.
  • Page 251 16-621-00, 16-621-07, 16-621-11, 16-621-28, 16-621-35, 16- 16-622-07, 16-622-09, 16-622-11, 16-622-14, 16-622-19, 16- 621-38, 16-621-47, 16-621-66, 16-621-67, 16-621-93, 16-621- 622-26, 16-622-28, 16-622-35, 16-622-38, 16-622-46, 16-622- 99 Unable to Obtain Host Name RAP 47 Corrupt RPC Table RAP 16-621-00 Unable to get host name. Configuration error. 16-622-07 Corrupt O/S RPC table.
  • Page 252 16-622-66, 16-622-67, 16-622-68 Unable to Register RPC 16-623-35, 16-623-47, 16-624-46 ENS Service Failed to Service RAP Respond In Time RAP 16-622-66 Unable to unregister as RPC service during shutdown. 16-623-35 ENS Service failed to respond in time. 16-622-67 Unable to register as RPC service during shutdown. 16-623-47 ENS service failed to respond in time.
  • Page 253 16-625-35, 16-625-46, 16-625-66, 16-625-67, 16-625-90 16-626-00, 16-626-11, 16-626-38, 16-626-47, 16-626-67 Invalid IPC Type RAP Memory Leak RAP 16-625-35 Unknown message received. Software version mismatch. 16-626-00 Memory leak, software bug memory corrupt. Virtual memory exhausted. Process size exceeding system limits. 16-625-46 Software version mismatch. 16-626-11 Memory leak, software bug memory corrupt.
  • Page 254 16-628-07, 16-628-35, 16-628-46, 16-628-66, 16-628-67 16-628-09, 16-629-11, 16-629-26, 16-629-46, 16-629-67, 16- Range Environment Variable RAP 629-68, 16-629-92, 16-629-93 No Acknowledgment For RPC Message RAP 16-628-07 Range environment variable not set. Set to invalid numeric string. 16-628-09 Unable to complete RPC call. 16-628-35 Range environment variable not set.
  • Page 255 16-630-09, 16-630-26, 16-630-35, 16-630-38, 16-630-46, 16- 16-631-19, 16-631-46, 16-631-19, 16-633-19, 16-634-46, 16- 630-47, 16-630-66, 16-630-67, 16-630-68, 16-630-99 Corrupt 635-07, 16-635-35, 16-635-46, 16-635-99-16-636-35, 16-636- RPC RAP 99 XDR Data Error RAP 16-630-09 Corrupt O/S RPC table. 16-631-19 Software error in the ENS service or in the service generating the fault. 16-630-26 Corrupt system configuration.
  • Page 256 16-637-11, 16-637-26, 16-637-38, 16-637-47, 16-637-66, 16- 16-638-66, 16-638-67, 16-639-38, 16-639-46, 16-640-28, 16- 637-67, 16-637-93, 16-637-95 File Error RAP 640-35, 16-640-46, 16-641-00, 16-641-26, 16-641-46 O/S Failure RAP 16-637-11 Failed to open system jobs file. 16-638-66 Unable to initialize with queue library. 16-637-26 Failed to open system jobs file.
  • Page 257 16-642-46, 16-642-47, 16-643-19, 16-643-26, 16-643-47, 16- 16-644-11, 16-644-26, 16-644-46, 16-644-47, 16-644-66, 16- 644-11 Unable To Close File RAP 644-67, 16-645-11, 16-645-26, 16-645-46, 16-645-47, 16-645- 66, 16-645-67 Unable To Read From File RAP 16-642-46 Software error. 16-644-11 Common logging utility failed to get log size. 16-642-47 Software error.
  • Page 258 16-646-26, 16-647-19, 16-647-26, 16-649-35, 16-650-35, 16- 16-651-19, 16-651-35, 16-651-99, 16-652-38, 16-652-99, 16- 650-99 Invalid Service Attribute RAP 653-38, 16-654-38, 16-654-99, 16-655-38, 16-656-38 Register Failure RAP 16-646-26 Failed to delete system jobs file. 16-651-19 IPC, OS, SESS or SC operation. 16-647-19 Lynx OS not responding 16-651-35 IPC and OS failure.
  • Page 259 16-658-07, 16-659-11, 16-659-28, 16-659-93, 16-659-95, 16- 16-662-11, 16-662-28, 16-662-93, 16-662-95, 16-663-28, 16- 660-95, 16-660-99, 16-661-95 Parser Utility Open Failure 663-93, 16-663-95 Parser Utility Template Failed To Parse 16-658-07 Unable to get host name. Configuration error. 16-662-11 Parser utility template failed to parse. 16-659-11 Parser utility open failure.
  • Page 260 16-664-11, 16-664-28, 16-664-93, 16-664-95, 16-665-95 16-666-11, 16-666-28, 16-666-93, 16-666-95 Parser Utility Parser Utility Closing Failure RAP Invocation Failed RAP 16-664-11 Parser utility parser closing failed. 16-666-11 Parser utility invocation failed. 16-664-28 Parser utility parser closing failed. 16-666-28 Parser utility invocation failed. 16-664-93 Parser utility parser closing failed.
  • Page 261 16-667-11, 16-667-28, 16-667-95, 16-668-47 Parser Utility 16-668-93, 16-668-95 Unable To Determine Local File Set Status Failure RAP Statistics RAP 16-667-11 Parser utility set status failed. 16-668-93 Unable to determine local file statistics. 16-667-28 Parser utility set status failed. 16-668-95 Unable to determine local file statistics. 16-667-95 Parser utility set status failed.
  • Page 262 16-669-28, 16-669-93, 16-669-95, 16-670-00 Unable To Write 16-670-11, 16-670-28, 16-670-47, 16-670-93, 16-671-00, 16- Job Template RAP 671-47 Unable To Decode Template File RAP 16-669-28 Unable to write job template to network controller disk. 16-670-11 Unable to decode template file. 16-669-93 Unable to write job template to network controller disk. 16-670-28 Unable to decode template file.
  • Page 263 16-617-93, 16-671-95, 16-672-09, 16-672-95, 16-673-95, 16- 16-674-09, 16-675-00, 16-700-00, 16-701-00, 16-701-99, 16- 674-00, 16-674-09, 16-675-00, 16-6700-00, 16-700-35 File 702-00, 16-702-95, 16-707-00, 16-709-00 XSA Database Error RAP Failure RAP 16-671-93 Unable to encode template file. 16-674-09 RPC server not responding. 16-671-95 Unable to encode template file. 16-675-00 Database server not responding.
  • Page 264 16-710-00, 16-710-35, 16-716-00, 16-728-00, 16-730-00, 16- 16-742-19 Hard Disk ODIO Failure RAP 730-28, 16-730-35, 16-730-66, 16-740-19, 16-750-07, 16-750- 16-742-19 Hard disk ODIO failure 09, 16-750-11 Unable To Create Client Handle RAP Procedure 16-710-00 Service being communicated to is dead. System resource corrupted. WARNING 16-710-35 Service trying to communicate to is dead.
  • Page 265 16-750-14, 16-750-19, 16-750-26, 16-750-35, 16-750-38, 16- 16-750-92, 16-750-93, 16-750-95, 16-751-00, 16-751-07, 16- 750-46, 16-750-47, 16-750-66, 16-750-67, 16-750-90 Invalid 751-09, 16-751-11, 16-751-14, 16-751-19, 16-751-26 Request RAP Database Error RAP 16-750-14 Too many messages sent to SESS system control. 16-750-92 Unable to open bit map captured to disk. bad or full disk. 16-750-19 Invalid request data from calling service.
  • Page 266 16-751-28, 16-751-35, 16-751-38, 16-751-46, 16-751-66, 16- 16-752-00, 16-753-00 File Cabinet Application Registration 751-67, 16-751-92, 16-751-93 Unknown Attribute RAP Error RAP 16-751-28 Templates attributes are invalid, or syntax error. 16-752-00 File cabinet application registration error 16-751-35 Invalid queue ID. 16-753-00 File cabinet application un-registration error 16-751-38 Unknown attribute returned for completed job list.
  • Page 267 16-752-07, 16-752-09, 16-752-14, 16-752-19, 16-752-26, 16- 16-752-66, 16-752-67, 16-752-92, 16-752-93, 16-752-95, 16- 752-28, 16-752-35, 16-752-46, 16-752-47 Invalid File Details 753-09, 16-753-14, 16-753-19, 16-753-26, 16-753-28 Scan to FAX Registration Error RAP 16-752-07 Data store error. 16-752-66 Scan to FAX services registration error. 16-752-09 Configuration control problem.
  • Page 268 16-753-35, 16-753-46, 16-753-47, 16-753-66, 16-753-67, 16- 16-754-14, 16-754-19, 16-754-26, 16-754-28, 16-754-35, 16- 753-90, 16-753-92, 16-753-93, 16-753-95, 16-753-09 Data 754-46, 16-754-47, 16-754-66, 16-754-67, 16-754-68 OS Store Read Failure RAP Error RAP 16-753-35 Unable to change EJS status to offline. 16-754-14 Receipt is not there. Failure on ENS side. 16-753-46 Invalid table row.
  • Page 269 16-754-90, 16-754-92, 16-754-92, 16-754-93, 16-754-95, 16- 16-755-35, 16-755-46, 16-755-47, 16-755-67, 16-755-90, 16- 755-00, 16-755-09, 16-755-14, 16-755-19, 16-755-26, 16-755- 755-93, 16-755-99, 16-756-09, 16-756-14 Request Error RAP 28 Fault Service Error RAP 16-755-35 OS corrupt. Software corrupt. Data store corrupt. 16-754-90 Software bug. 16-755-46 Mismatched data type during object write.
  • Page 270 16-756-35, 16-756-46, 16-756-47, 16-756-66, 16-756-67, 16- 16-757-35, 16-757-46, 16-757-47, 16-757-66, 16-757-67, 16- 756-93, 16-757-09, 16-757-14, 16-757-19, 16-757-26 NVM 757-93, 16-758-09, 16-758-14, 16-758-19, 16-758-26 Unable Corrupt RAP to Write NVM Value RAP 16-756-35 OS corrupt. Software error. NVM error. 16-757-35 OS corrupt. Software error. NVM corrupt. 16-756-46 Poll select failed.
  • Page 271 16-758-35, 16-758-46, 16-758-47, 16-758-66, 16-758-67, 16- 16-759-46, 16-759-47, 16-759-66, 16-759-67, 16-759-93, 16- 758-93, 16-759-09, 16-759-14, 16-759-19, 16-759-26 Service 760-09, 16-760-14, 16-760-19, 16-760-26, 16-760-46 Fail to Run Loop Failed RAP Enable Process RAP 16-758-35 Unable to change EJS state to offline. 16-759-46 Process no in correct state, O/S failure.
  • Page 272 16-760-47, 16-760-67, 16-760-68, 16-760-93, 16-760-99, 16- 16-761-47 to 16-769-95 Other Network Faults 1 RAP 761-09, 16-761-14, 16-761-19, 16-761-26, 16-761-46 File 16-761-47 Failed to initialize. Files needed for software verify. Error RAP 16-761-67 Failed to retrieve public list. 16-760-47 Found incorrect checksum partition 1 during software verify check. Bad disk and 16-761-68 Login gets no response from SRS.
  • Page 273 16-765-67 Failed to retrieve recipient list. 16-770-09 to 16-779-95 Other Network Faults 2 RAP 16-765-93 Unable to access data store. 16-770-09 Software error. Check fault log for more specific reasons. 16-766-09 Adobe process failure. Check faults log for more specific reasons. 16-770-19 SESS/DM job command not processed.
  • Page 274 16-776-46 TCPIP invalid interface. 16-780-00 to 16-789-47 Other Network Faults 3 RAP 16-780-00 Power save request time out. 16-776-95 Cannot clean up after job completion. 16-780-09 Software error. Check fault log for more specific reasons. 16-777-09 Software error. Check fault log for more specific reasons. 16-780-19 Power saver request time out.
  • Page 275 16-785-19 UI does not respond to upgrade prep command. 16-790-09 to 16-799-47 Other Network Faults 4 RAP 16-790-09 Software error. Check fault log for more specific reasons. 16-785-46 TCPIP resolve file failure. 16-790-19 Option load failure software. 16-785-47 SESS diagnostic failure. 16-790-47 SESS diagnostic failure.
  • Page 276 16-800-09 to 16-809-47 Other Network Faults 5 RAP 16-807-09 Job log service unavailable. 16-800-09 List access failure (create, add, find, delete.) 16-807-19 State change failed. 16-800-19 Option not supported. 16-807-47 SESS diagnostic failure. 16-800-46 Unable to connect to device when setting up IP over Ethernet. 16-808-00 Job tracker death error.
  • Page 277 16-810-00 to 16-16-819-47 Other Network Faults 6 RAP 16-820-47 to 16-829-47 Other Network Faults 7 RAP 16-810-00 Scan to distribution death error. 16-820-47 SESS diagnostics failure. 16-810-09 Scan service available. 16-821-47 SESS diagnostics failure. 16-810-19 Failed to remove accounting. 16-822-47 SESS diagnostics failure. 16-810-47 SESS diagnostic failure.
  • Page 278 16-830-47 to 16-839-47 Other Network Faults 8 RAP 16-840-47 to 16-849-47 Other Network Faults 9 RAP 16-830-47 Unable to get the default router for the device. 16-840-47 Corrupt OS, software error. 16-831-47 Unable to get the subnet mask for the device. 16-841-47 Corrupt file system.
  • Page 279 16-850-47 to 16-859-47 Other Network Faults 10 RAP 16-860-47 to 16-869-47 Other Network Faults 11 RAP 16-850-47 Failed adding stream to stream editor array. 16-860-47 No machines responded to an ICMP echo request. 16-851-47 Failed on call to stream editor. 16-861-47 Failed setting up monitor routine with registration service.
  • Page 280 16-870-47 to 16-879-47 Other Network Faults 12 RAP 16-880-47 to 16-890-47 Other Network Faults 13 RAP 16-870-47 SESS NETBIOS test illegal name number. 16-880-47 SESS PCI test failed on put message call. 16-871-47 SESS NETBIOS test cannot find name or no answer. 16-881-47 SESS PCI test invalid argument.
  • Page 281 16-891-00, 16-892-00 Edge Server Auto Registration Failed 16-900-19 to 16-909-19 Other Network Faults 14 RAP 16-900-19 Failed to open SMC driver. 16-891-00 Edge server auto registration failed 16-901-19 Failed to make ioctl call using SMC driver. 16-892-00 Edge server communication failed 16-902-19 Address specified is invalid.
  • Page 282 16-910-19 to 16-919-19 Other Network Faults 15 RAP 16-920-19 to 16-929-19 Other Network Faults 16 RAP 16-910-19 Failed untar file. 16-920-19 ELT daemon start failed. 16-911-19 Error changing directory. 16-922-19 NVM store failed. 16-912-19 Install script did not execute. 16-923-19 Failed saving persistent data. 16-913-19 Write failure to file.
  • Page 283 16-930-19 to 16-939-19 Other Network Faults 17 RAP 16-940-19 to 16-949-19 Other Network Faults 18 RAP 16-930-19 Failed to remove jobs. 16-940-19 Auto-upgrade failed. Machine in diagnostics mode. 16-931-19 Failed to close on SMC driver. 16-941-19 Auto-upgrade failed. Network controller cannot communicate with main controller. 16-932-19 NVM write failure.
  • Page 284 16-950-19 to 16-959-19 Other Network Faults 19 RAP 16-960-19 to 16-969-19 Other Network Faults 20 RAP 16-950-19 Scan to email image processing hardware not available. 16-960-19 Failed to install SMTP. 16-951-19 Internet fax image processing hardware not available. 16-961-19 Failed to remove kerberos. 16-952-19 Scan to email memory size error.
  • Page 285 16-975-19 to 16-979-35 Other Network Faults 21 RAP 16-980-00 to 16-989-35 Other Network Faults 22 RAP 16-975-19 Failed to install immediate image overwrite. 16-980-00 DM request handle NULL. Null data received from DM. 16-980-19 Network controller PM failed to install G4. Option load failure software. 16-976-19 Failed to install immediate image overwrite.
  • Page 286 16-985-19, 16-986-19 Network Scanning Application 16-987-19, 16-988-19 Server Fax Application Registration Registration Error RAP Error RAP 16-985-19 Network scanning application registration error 16-987-19 Server Fax application registration error 16-986-19 Network scanning application un-registration error 16-988-19 Server Fax application un-registration error Procedure Procedure WARNING...
  • Page 287 16-989-19 Disk Encryption Operation Failed RAP 16-990-00 to 16-999-35 Other Network Faults 23 RAP 16-989-19 Disk encryption operation failed 16-990-00 Promote response from DM received with errors. Software error. 16-990-35 Promote response from DM received with errors. Software error. Procedure 16-991-00 Request to DM to promote job failed.
  • Page 288 Administrator. If the customer does not have a System Administrator, they should Ensure that the machine is configured for scan to file: contact the Customer Support Centre or request a Xerox analyst troubleshoot their network which will be subject to a charge.
  • Page 289 Check. Changes were made to the customers System Administrator, they should contact the Customer Support Centre or settings. request a Xerox analyst troubleshoot their network which will be subject to a charge. Escalate the fault to the system Administrator. If the customer does not have a...
  • Page 290 System Administrator. If the customer does not have a System Administrator, they should contact the Customer Support Centre or request a Xerox analyst troubleshoot their network which will be subject to a charge.
  • Page 291 Check the network name listed next to SSID on the configuration report. If the network name does not match the customer’s wireless network, ask the cus- Use this RAP when the customer reports wireless network failures when using the Xerox wire- tomer to configure the wireless network setup before continuing.
  • Page 292 Status Indicator RAPs February 2013 2-268 ColorQube® 9303 Family...
  • Page 293 19-300-00 to 19-310-00 Image Disk (HDD) Failure RAP 19-401-00, 19-402-00 Stress Out of Memory RAP 19-300-00 Unable to read or write data from the image disk. 19-401-00 Out of memory caused by a stress document. 19-301-00 Unable to write data to the image disk. 19-402-00 Out of memory caused by a stress job.
  • Page 294 19-403-00 EPC Out of Memory RAP 19-409-00 Job Integrity Failure RAP 19-403-00 Out of memory with greater than one job in EPC. 19-409-00 Video determines that it cannot guarantee the integrity of the job being processed. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 295 19-410-00 to 19-410-13 Image Structure Failure RAP 19-750-00 EPC Memory Change Detected RAP 19-410-00 The system has detected a mark output time-out. 19-750-00 The system detects that the EPC memory size configuration has changed during the power on sequence. 19-410-01 The system has detected a mark output time-out. Procedure 19-410-02 The system has detected a compress image time-out.
  • Page 296 19-752-00 Image Rotation Detected RAP 19-754-00 Image Disk Change RAP 19-752-00 The system detects that the image rotation configuration has changed during the 19-754-00 The system detects that the Image disk configuration (present vs. not present) has Power On sequence. changed during the power on sequence.
  • Page 297 20-302-00, 20-303-00 Fax Reset Failure RAP 20-305-00 Fax System Low Memory Unrecoverable RAP The fax card will automatically reset itself. The fax card will automatically reset itself. 20-302-00 Unexpected reset fault due to fax card hardware or software error. 20-305-00 Unrecoverable fax system low memory due to fax card hardware or software error 20-303-00 Unrecoverable fault due to fax card hardware or software error.
  • Page 298 20-320-00 Fax Fault Not Cleared by Reset RAP 20-322-00 Non-Volatile Device not Installed RAP 20-320-00 After five instances of an unrecoverable fax fault and has not been cleared by a 20-322-00 The non-volatile device has not been installed on the embedded fax card. card reset.
  • Page 299 20-323-00, 20-324-00 Fax System Memory Low RAP 20-331-00, 20-338-00, 20-339-00, 20-341-00, 20-345-00 Fax Network Line 1 Fault RAP 20-323-00 The fax system memory is low, less than 6Mb. 20-331-00 No communication via the PSTN 1 port. 20-324-00 There is not enough memory to use the fax service. 20-338-00 Fax Communication Error at power up or reboot.
  • Page 300 20-332-00, 20-340-00 Fax Network Line 2 Fault RAP 20-342-00 Fax File Integrity Fault RAP 20-332-00 No communication via the PSTN 2 port. 20-342-00 An error has occur when accessing the file on a non-volatile device. 20-340-00 Fax port 2 modem failure. Initial Actions WARNING Initial Actions...
  • Page 301 20-701-00 Fax Phone Book Download Failed RAP 20-710-00, 20-711-00 Image Overwrite Error RAP 20-701-00 The fax phone book download failed. 20-710 Immediate image overwrite error has occurred on the fax card when overwriting the job. Initial Actions 20-711 On demand image overwrite error has occurred on the fax card when overwriting the WARNING memory.
  • Page 302 20A Fax Entry RAP 20B Unable To Send A Fax RAP Use this RAP to isolate components which contribute to Fax communications failure. Use this RAP to isolate components which contribute to a send failure. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 303 The Fax only dials once and hangs up or the busy tone has unusual timing, frequency or 20C Unable To Send A Fax To Some Machines RAP level. The busy tones are recognized. Use this RAP to isolate components which contribute to a failure to send a Fax to some machines.
  • Page 304 20D Unable To Receive A Fax RAP Install new components as necessary: • Fax module, PL 20.05 Item Use this RAP to isolate components which contribute to the fax not received from the machine. The Fax is working correctly. Send a three page test Fax to a known good Fax machine. Initial Actions Print a Protocol Report and check for errors.
  • Page 305 20E Fax Will Not Print RAP 20F Fax Tab Not Available RAP Use this RAP to solve fax printing problems. Use this RAP to isolate the problem when the Fax tab is not available or greyed out. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 306 20G Fax Module Checkout 20H Fax Problems on Digital Networks RAP Use this RAP to check for problems with the fax module. Use this RAP to isolate the problem when using digital networks. Initial Actions The Fax option was designed as an analogue Group 3 device. This will have the best perfor- mance when connected to a dedicated analog phone PSTN (Public Switched Telephone Net- WARNING work) line or POTS (Plain Old Telephone system).
  • Page 307 22-300-05 to 22-309-04 Other Network Faults 24 RAP 22-310-04 to 22-318-04 Other Network Faults 25 RAP 22-300-05 Image complete not received from video. 22-310-04 Pages received from extended job service out of sequence. 22-300-10 Failed to transfer image due to decoding error. 22-314-04 Module registration error.
  • Page 308 22-315-04 One or More Modules Did Not Respond RAP 22-319-04 IOT Integrity Problem While Printing a Job RAP 22-315-04 One or more modules did not respond with completion message. 22-319-04 Integrity problem while printing a job. The IOT cycles down and up 10 times without printing a page within the same job causing the fault.
  • Page 309 22-321-00 SM Failed to Remove Scan to File RAP 22-321-04 Proposal Response Time Out Error RAP 22-321-00 SM failed to remove the scan to file. 22-321-04 Proposal response time out error - RS422 configuration mismatch. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 310 22-325-01 Cleaning Unit Extended Life Mode Entered RAP 22-328-00 Incomplete System Information RAP 22-325-01 Cleaning unit extended life mode entered (CU snooze mode). 22-328-00 Incomplete system information. The accounting service data has been corrupted. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 311 22-330-00 Page Pack PIN Entry Locked RAP 22-330-01 List Jobs Request Timed Out Between UI and Copy Controller RAP 22-330-00 An incorrect page pack PIN has been entered more than 3 times and entry is now locked for 24 hours. Only one retry is now possible every 24 hours. 22-330-01 List jobs request timed out between UI and copy controller.
  • Page 312 22-330-02 List Jobs Request Timed Out Between Copy 22-330-03 List Jobs Request Timed Out Between Copy Controller and ESS Print Service RAP Controller and Scan to File Service RAP 22-330-02 List jobs request timed out between copy controller and ESS print service. 22-330-03 List jobs request timed out between copy controller and scan to file service.
  • Page 313 22-330-04 List Jobs Request Timed Out Between Copy 22-330-05 List Jobs Request Timed Out Between Queue Controller and Scan to Fax Service RAP Utility and DC Job Service RAP 22-330-04 List jobs request timed out between copy controller and scan to Fax service. 22-330-05 List jobs request timed out between queue utility and DC job service.
  • Page 314 22-330-06 ESS scan to distribution service not responding to list RPC call. 22-350-01 Software detected non-valid Xerox SOK 1. Procedure 22-350-02 Software detected non-valid Xerox SOK 2 or 3. WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 315 22-351-01 to 22-351-03 SOK Write Failure RAP 22-352-00 Serial Number Missing RAP 22-351-01 SOK 1 write failure. 22-352-00 Serial number has been lost. 22-351-02 SOK 2 write failure. Initial Actions WARNING 22-351-03 SOK 3 write failure. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 316 22-360-00 Service Plan Mismatch RAP 22-371-00, 22-372-00 Fax Application Registration Error 22-360-00 Three way sync of the service plan could not be resolved. The service plan informa- tion has been lost. 22-371-00 Set by the fax service when it gets no response from the service registry when try- ing to register.
  • Page 317 22-701-04 Module Completion Message Received RAP 22-720-00 Service Registry Bad Data/Corrupted RAP 22-701-04 Module completion message received after IOT returned to standby. 22-720-00 Service bad data/corrupted. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 318 22-721-00 No Response From The Service Registry RAP 22-750-04 to 22-755-17 Configuration Mismatch RAP 22-721-00 Triple A gets no response from the service registry service. 22-750-04 Output device configuration mismatch. Procedure 22-750-17 When the system detects that the accessory card configuration mismatch has changed during the power on sequence.
  • Page 319 42-504-00 Enclosure Fan Over Current RAP 42-505-00 Abatement Fan Over Current RAP 42-504-00 The enclosure fan current demand is inconsistent with expected value. 42-505-00 The abatement fan current demand is inconsistent with expected value. Procedure Procedure Go to OF 6 Fans and Air Systems RAP.
  • Page 320 Status Indicator RAPs February 2013 42-504-00, 42-505-00 2-296 ColorQube® 9303 Family...
  • Page 321 62-277-00 Scanner to DADH Communication Fail Entry 62-310-00 Scanner to Single Board Controller Communication Fail RAP 62-277-00 A communication failure between scanner PWB and DADH PWB has been 62-310-00 A communication failure between the scanner PWB and the single board controller detected.
  • Page 322 62-450-00 to 62-472-00 Calibration Failure RAP Initial Actions WARNING 62-450-00 Calibration dark range not clear. Ensure that the electricity to the machine is switched off while performing tasks that do 62-451-00 Calibration dark range not done. not need electricity. Refer to 14.
  • Page 323 62-473-00 UART RX Wrap Error RAP 62-474-00, 62-475-00 Stepper Speed/Reset Error RAP 62-473-00 UART RX wrap error. 62-474-00 Stepper speed error. Initial Actions 62-475-00 Move before reset error. WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 324 62-476-00 Scan Carriage Home Sensor RAP Enter dC330 code 62-018 carriage home sensor, Q62-018. Stack codes 62-023 and 62-024 to move the carriage home, then away from home. The display changes. 62-476-00 Carriage home sensor is not cleared or made in time. Refer to WD 6.2.
  • Page 325 62-477-00 to 62-481-00 Timing Errors RAP 62-484-00 Apps Code Not Present RAP 62-477-00 Stepper busy error. 62-484-00 Apps code not present. 62-478-00 Real time error. Procedure WARNING 62-479-00 Page synchronization error. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 326 62-485-00 +12V Supply Error RAP 62-486-00 +24V Supply Error RAP 62-485-00 +12V supply error. 62-486-00 +24V supply error. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 327 62-487-00 System Phase Lock Loop (PLL) Error RAP 62A Scanning Document Size RAP 62-487-00 System phase lock loop (PLL) error. The scanner has encountered a document that is larger than expected. Procedure The scanner has encountered a document of unknown size. The document size sensors have incorrectly determined the size of the original.
  • Page 328 The wiring is good. 62B LED Exposure Lamp Failure RAP The LED lamp(s) do not illuminate. Re-seat loose connectors, repair the wiring or install new components as necessary: • DADH/IIT power comms harness, PL 62.16 Item Procedure • IIT video SBC PWB harness, PL 62.10 Item WARNING •...
  • Page 329 70-312-00 Tray 1 to Tray 3 Communication Failure RAP 70-305-00, 70-325-00 Lower Left Door Open RAP 70-312-00 IME to tray 1, tray 2 and tray 3 communications failure. 70-305-00 Lower left door open. Procedure 70-325-00 Lower left door open during run. WARNING Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do...
  • Page 330 71-101-00 to 71-161-00 Tray 1 Mis-Feed Jam RAP Install new components as necessary: • Tray 1 feed sensor, PL 81.25 Item 71-101-00 Tray 1 misfeed jam • 3 tray module PWB, PL 73.16 Item 71-106-00 LE late to TAR1 sensor from tray 1. •...
  • Page 331 CAUTION 71-215-00 Tray 1 Elevate Up Failure RAP To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 71- 71-215-00 Tray 1 stack height sensor did not actuate within the correct time after the feed / ele- 002 is run in diagnostics.
  • Page 332 71-320-00 Tray 1 Open In Run RAP 71A Tray 1 Empty RAP 71-320-00 Tray 1 was opened during run when the paper is fed from tray 1. Use this RAP when the copier display instructs the operator to add paper to the tray that is not empty.
  • Page 333 71B Tray 1 Wrong Size Paper RAP Use this RAP when the paper fed from the tray does not match the paper size indicated by the Table 1 Tray 1 paper size table tray paper size switch. Tray 1 and tray 2 feed mechanisms are identical. Size Size Size...
  • Page 334 72-101-00 to 72-161-00 Tray 2 Mis-Feed Jam RAP Refer to 7.3. Check tray 2 feed sensor, Q72-102. Refer to: 72-101-00 Tray 2 misfeed jam. • GP 11 How to Check a Sensor. • PJ952, 3 tray module PWB. 72-106-00 LE late to TAR 2 sensor. •...
  • Page 335 • PJ956 on 3 tray module PWB. 72-215-00 Tray 2 Elevate Up Failure RAP • +24V Distribution RAP. 72-215-00 Tray 2 hoist failure • 0V Distribution RAP. Initial Actions Install new components as necessary: WARNING • 3 tray module transport motor, PL 73.16 Item Ensure that the electricity to the machine is switched off while performing tasks that do •...
  • Page 336 72-320-00 Tray 2 Open in Run RAP 72A Tray 2 Empty RAP 72-320-00 Tray 2 was opened during run. Use this RAP when the copier display instructs the operator to add paper to the tray that is not empty. Initial Actions Procedure WARNING WARNING...
  • Page 337 72B Tray 2 Wrong Size Paper RAP NOTE: Standard sizes will be offered as indicated, as well a custom sizes limited to the range supported. Use this RAP when the paper fed from the tray does not match the paper size indicated by the tray paper size switch.
  • Page 338 73-101-00 to 73-161-00 Tray 3 Mis-Feed Jam RAP Refer to 7.4. Check tray 3 feed sensor, Q73-103. Refer to: 73-101-00 Tray 3 misfeed jam. • GP 11 How to Check a Sensor. • PJ953, 3 tray module PWB. 73-106-00 LE late to TAR 3 sensor. •...
  • Page 339 Enter dC330 code 70-025 3 tray transport motor, MOT70-025, PL 73.16 Item 3. Press Start. 73-212-00 Tray 3 Elevate Encoder Failure RAP The motor runs. 73-212-00 Tray 3 encoder failure on hoist. Refer to 7.5. Check 3 tray transport motor, MOT70-025. Refer to: Initial Actions •...
  • Page 340 73-215-00 Tray 3 Hoist Failure RAP Refer to 7.5. Check that the tray 3 limit switch, PL 81.30 Item 25, is not actuated. 73-215-00 Tray 3 hoist failure. While not actuated, check for +24V at both contacts on the switch. Refer to: •...
  • Page 341 73-320-00 Tray 3 Open in Run RAP 73-325-00 Feeder HT Drawer Open in Run RAP 73-320-00 Tray 3 open during run when the paper is fed from tray 3. 73-325-00 Tray 3 horizontal transport drawer open in run. Initial Actions Initial Actions WARNING WARNING...
  • Page 342 73A Tray 3 Out of Paper RAP 74-101-00, 74-160-00 to 74-161-00 Bypass Tray 4 Mis-Feed RAP Use this RAP when the copier display instructs the operator to add paper to tray 3 when the 74-101-00 Tray 4 misfeed jam. The feed sensor did not actuate in the correct time after paper tray is not empty.
  • Page 343 74-120-00 Bypass Tray 4 Guides Move in Run RAP 74-214-00 Bypass Tray 4 Nudger Failure RAP 74-120-00 Bypass tray 4 paper guides moved during run. 74-214-00 Bypass tray 4 nudger failed to operate. Procedure Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 344 74A Bypass Tray 4 Size Sensing Problems RAP Use this RAP to troubleshoot problems when the bypass tray 4 fails to indicate the correct NOTE: The width sensor is a potentiometer. The arm on the potentiometer is attached to paper size. the bypass tray side guide.
  • Page 345 75-101-00, 75-160-00 to 75-161-00 Tray 5 Mis-Feed RAP The feed shaft rotates. 75-101-00 Tray 5 feed sensor did not actuate in the correct time after paper feed from tray 5. Check the drive gears between the motor and the feed shaft. Install new components as necessary: 75-160-00 Extra pick retry O.K.
  • Page 346 • One way pulley clutch, PL 81.46 Item 75-212-00, 75-215-00 Tray 5 Elevate Up Failure RAP • Take away roller, PL 81.46 Item 75-212-00 A signal was not detected by the encoder when the elevator motor was driving up. Enter dC330 code 82-125 confirm sensor (16), Q82-125, PL 82.10 Item...
  • Page 347 • PJ504, tray 5 control PWB. 75-213-00, 75-216-00 Tray 5 Elevate Down Failure RAP • +24V Distribution RAP. 75-213-00 Tray 5 encoder failure on lower. A signal was not detected by the encoder when the • 0V Distribution RAP. elevator motor was driving down. Install new components as necessary: 75-216-00 Tray 5 lower failure.
  • Page 348 75-312-00 IME to Tray 5 Communication Failure RAP Refer to 7.1. Check tray 5 down limit switch, S75-415. Refer to: 75-312-00 Image marking engine to tray 5 communications failure. NOTE: Tray down limit switch S75-415 is located in the paper tray. Press the plate under the paper tray to actuate the switch.
  • Page 349 75-320-00 Tray 5 Opened In Run RAP 75-325-00 Tray 5 Undocked In Run RAP 75-320-00 Tray 5 was opened during run when the paper is fed from tray 5. 75-325-00 Tray 5 was undocked during run when the paper is fed from tray 5. Initial Actions Initial Actions WARNING...
  • Page 350 75A Tray 5 Door Open During Run RAP 75B Tray 5 Empty RAP Use this RAP when the tray 5 door is open during run when the paper is fed from tray 5. Use this RAP to solve problems associated with the tray 5 empty sensor. Initial Actions Initial Actions WARNING...
  • Page 351 82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82-159-00, • 0V Distribution RAP. Install new components as necessary: 82-164-00 to 82-166-00 Media Path Sensor (5) RAP • Vertical transport sensor (5), PL 82.10 Item 82-110-00 The sheet has arrived at the media path sensor (5) too early. •...
  • Page 352 82-125-00 to 82-133-00, 82-153-00, 82-160-00, 82-162-00, Install new components as necessary: • Confirm sensor (16), PL 82.10 Item 82-163-00 Confirm Sensor (16) RAP • Media path driver PWB, PL 1.15 Item 82-125-00 The sheet has arrived at the confirm sensor (16) too early. Enter dC330 code 82-001 vertical transport motor (M2), MOT82-001.
  • Page 353 82-132-00, 82-155-00 Media Path Sensor 16 Duplex Mode If necessary, install new components: • Transport rolls, 82.10. • Drive belts, 82.10. 82-132-00 Lead edge timed out, sheet late at the media path sensor 16 in duplex mode. • Drive gears, 82.10.
  • Page 354 82-133-00 Media Path Sensor 16 Time out from Tray 5 RAP Go to 8.5. Check horizontal transport motor (M6), MOT82-003 and the encoder wire 82-133-00 Lead edge late to the media path sensor 16 when feeding from tray 5. harness. Refer to: •...
  • Page 355 If necessary, install new components: 82-140-00, 82-142-00 Media Path Sheet Too Wide or Narrow • Transport rolls, 82.10. • Drive belts, 82.10. 82-140-00 Media path sheet too wide. • Drive gears, 82.10. 82-142-00 Media path sheet too narrow. Enter dC140 Analog Monitor.
  • Page 356 82-141-00, 82-147-00, 82-148-00, 82-154-00 Media Path If necessary, install new components: • Transport rolls, 82.10. Sensor 14 RAP • Drive belts, 82.10. 82-141-00 or 82-154-00 The sheet has arrived too early at media path sensor 14. • Drive gears, 82.10. 82-147-00 Lead edge time out, sheet late at the media path sensor 14 at pre-registration.
  • Page 357 Go to 8.5. Check horizontal transport motor (M6), MOT82-003 and the encoder wire Go to 8.1. Check SOL82-007. Refer to: harness. Refer to: • GP 12 How to Check a Solenoid or Clutch. • GP 10 How to Check a Motor. •...
  • Page 358 82-145-00, 82-146-00, 82-150-00, 82-151-00, 82-156-00 The vertical transport rolls rotate. Media Path Sensor 14 Time Out in Duplex Mode RAP Check the drive belt and drive gears on the vertical transport, 82.10. 82-145-00 The sheet was too long to clear sensor 14 in duplex mode. If necessary, install new components: •...
  • Page 359 Enter dC330 code 83-004 HPP diverter solenoid, SOL83-004. Press Start. Check that the • Media path driver PWB, PL 1.15 Item diverter gate moves correctly when activating the solenoid The solenoid energizes. Enter dC330 code 89-007 registration motor A1 (M3), MOT89-007. Press Start. The motor Go to 8.1.
  • Page 360 82-161-00 Early Confirm Timeout RAP Enter dC330 code 70-025 3 tray transport motor, MOT70-025. Press Start. The motor runs. 82-161-00 Early confirm timeout. Go to 7.5. Check 3 tray transport motor, MOT70-025. Refer to: • GP 10 How to Check a Motor. Initial Actions •...
  • Page 361 82-500-00, 82-501-00 Vertical Transport Motor M2 Failure • The bearing, shaft and rolls on the transport roll assembly, • Check the drive belt and drive gears on the vertical transport, 82.10. If necessary, install new components: 82-500-00 Transport motor M2 over current fault. •...
  • Page 362 82-502-00, 82-503-00 Horizontal Transport Motor M6 Enter dC140 Analog Monitor. Select 82-102 horizontal transport motor encoder (M6). Press Start. The number of ticks (i.e. 36 ticks) will flash on the display and then return to show 0 ticks. Failure RAP Repeat by selecting stop and then start on the popup menu, the number only remains for a few 82-502-00 Transport motor M6 over current fault.
  • Page 363 82-507-00, 82-508-00 Nip C and Nip D Release Solenoid 82-510-00 Trailer Slowdown Calculation Fail RAP Over Current RAP 82-510-00 System timing error. 82-507-00 An over current condition was detected with nip C release solenoid. Procedure 82-508-00 An over current condition was detected with nip D release solenoid. WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Procedure...
  • Page 364 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 Media The diverter gate moves freely. Path Sensor 13 Duplex Mode RAP Check the operation and condition of the diverter gate. If necessary install a new exit 83-110-00 The sheet too long over media path sensor 13 at duplex start. paper path assembly, PL 10.15 Item 83-111-00 The sheet too short over media path sensor 13 at duplex start.
  • Page 365 Enter dC140 Analog Monitor. Select 82-102 horizontal transport motor encoder (M6). Press • +50V Distribution RAP. Start. The number of ticks (i.e. 36 ticks) will flash on the display and then return to show 0 ticks. • 0V DIstribution RAP. Repeat by selecting stop and then start on the popup menu, the number only remains for a few Install new components as necessary: seconds.
  • Page 366 83-112-00, 83-115-00, 83-116-00, 83-117-00, 83-119-00 Media Install new components as necessary: • Exit / duplex diverter solenoid, PL 10.15 Item Path Sensor 13 Invert Mode RAP • Media path driver PWB, PL 1.15 Item 83-112-00 The sheet too long over media path sensor 13 at invert. The diverter gate moves freely.
  • Page 367 • Drive gears, 82.15. Go to 8.1, check SOL 83004. Refer to: Enter dC140 Analog Monitor. Select 82-102 horizontal transport motor encoder (M6). Press • GP 12 How to Check a Solenoid or Clutch Start. The number of ticks (i.e. 36 ticks) will flash on the display and then return to show 0 ticks. •...
  • Page 368 83-120-00 to 83-125-00 Media Path Sensor 17 RAP • 0V Distribution RAP. Install new components as necessary: 83-120-00 Detected a sheet length too long over media path sensor 17. • Horizontal transport motor (M6), PL 82.15 Item 83-121-00 Detected a sheet length too short over media path sensor 17. •...
  • Page 369 • PJ405 Media Path Driver PWB. 83-500-00 Output Transport Motor M5 Failure RAP • +50V Distribution RAP. 83-500-00 Transport motor M5 over current fault. • 0V Distribution RAP. Initial Actions Install new components as necessary: • Nip D release solenoid, PL 70.30 Item WARNING •...
  • Page 370 83-504-00 HPP Diverter Solenoid Failure RAP 83-506-00 Nip D Release Solenoid Failure RAP 83-504-00 HPP diverter solenoid over current fault. 83-506-00 Nip D release solenoid over current fault. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 371 88-500-00 to 88-502-00, 88-512-00 Preheat Thermal Error • Check that pin 9 to the chassis is open circuit. The resistance of both pre-heaters is within specification. 88-500-00 The registration / preheat assembly is too hot. Check the wiring between PJ5AC, WD 1.2 on the power supply unit...
  • Page 372 88-508-00 Registration / Preheat Air Pump Incorrect Current RAP 88-508-00 The registration / preheat air pumps are drawing incorrect current. Procedure WARNING Registration / preheat Ensure that the electricity to the machine is switched off while performing tasks that do air pumps not need electricity.
  • Page 373 89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Go to 8.1. Check registration motor A2 (M3), MOT89-008. Refer to: Failure RAP • GP 10 How to Check a Motor. 89-110-00 The sheet is too long at registration. • PJ202, Media path driver PWB.
  • Page 374 Enter dC330 code 82-003 Horizontal transport motor (M6) (forward), MOT82-003. Press Start. 89-125-00 to 89-128-00, 89-130-00, 89-131-00 Media Path The motor runs. Sensor 20 Failure RAP Go to 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: 89-125-00 The sheet is too long over media path sensor 20 at pre-transfix. •...
  • Page 375 NOTE: W/TAG 018 machines do not have air pumps install as standard. However, the preheat 89-500-00, 89-502-00 Registration Motor Over Current RAP air pumps in a replacement registration/preheat assembly will function when the unit is 89-500-00 Motor M3_A1 current demand is inconsistent with expected value. installed, refer to service bulletin T8009-12-06 Enter dC330...
  • Page 376 89-504-00 Registration Sensor Over Current RAP 89-504-00 The registration sensor 10 current demand is inconsistent with expected value. Procedure WARNING Registration motor A1 Ensure that the electricity to the machine is switched off while performing tasks that do (M3), MOT89-007 not need electricity.
  • Page 377 89-520-00 Home Sensor Timeout RAP 89-520-00 Stance sensor timeout. The home sensor, mounted on the registration / preheat interface PWB, reports a value incon- sistent with expected value. Registration scan bar, Procedure Q89-005 WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 378 • Registration / preheat assembly, PL 88.10 Item • Media path driver PWB, PL 1.15 Item Perform the following actions: • Check for wiring damage or obstructions preventing jam clearance hatch movement. Refer to 89.1. • If the error persists, install a new registration / preheat assembly PL 88.10 Item Sensor flag on the drive gear...
  • Page 379 89-531-00 to 89-545-00 Registration Process Error RAP 89-550-00, 89-551-00 Media Registration Error RAP 89-531-00 The registration sensor (10) failed to detect the leading edge. 89-550-00 The registration sensor detected excessive skew on the incoming media. 89-551-00 The registration sensor detected excessive offset on the incoming media. 89-532-00 The registration sensor (10) timed out or failed to complete normally.
  • Page 380 89-555-00 Media Registration Out of Range RAP 89-561-00 Media Registration Parameters Reset RAP 89-555-00 The stored registration correction values are out of range. 89-561-00 Registration / preheat assembly calibration failed. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 381 89-562-00 Incorrect Media RAP 89-564-00 Calibration Image Error RAP 89-562-00 No media of the specified size is available. 89-564-00 The machine failed to create a calibration image or sheet. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 382 89-565-00, 89-566-00 Scan Measurement Was Out Of 89-567-00 Calibration Scan Detected Floating Point Range RAP Exception RAP 89-565-00 The intermediate registration value is not valid. 89-567-00 Calibration scan detected floating point exception. This occurs because the scan did not detect the registration calibration image correctly. 89-566-00 The computed calibration parameter is out of range.
  • Page 383 91-500-00, 91-600-00 Initial Position Error RAP 91-501-00 to 91-502-00 Image Timing Error RAP 91-500-00 The staggered full width array (SFWA) was not left at the correct position to start the 91-501-00 Printhead image timing error. imaging process. 91-502-00 Marking sequence timing error. 91-600-00 The staggered full width array (SFWA) stitch or roll motor un-initialized failure.
  • Page 384 91-503-00 Print Image Data Did Not Arrive From the 91-504-00, 91-505-00 Printhead Stitch Motor Over Current Controller in Time RAP 91-503-00 The image did not reach the IME controller PWB. 91-504-00 The printhead stitch adjust motor 1 current demand exceeds expected value. Procedure 91-505-00 The printhead stitch adjust motor 2 current demand exceeds expected value.
  • Page 385 Perform dC971 Head to Head Alignment Adjustment, then check the image quality, refer 91-506-00 to 91-509-00 Roll Motor Over Current RAP 91-506-00 The printhead roll adjust motor 1 current demand exceeds expected value. Check for obstructions or debris blocking motor or printhead movement. The printhead area 91-507-00 The printhead roll adjust motor 2 current demand exceeds expected value.
  • Page 386 • Marking unit driver PWB, PL 92.10 Item 91-510-00, 91-511-00 X Axis Motor Over Current RAP Perform dC971 Head to Head Alignment Adjustment, then check the image quality, refer 91-510-00 The upper X axis motor current demands exceed expected value. 91-511-00 The lower X axis motor current demands exceed expected value.
  • Page 387 • Lower axis drive motor, PL 91.25 Item 91-512-00, 91-605-00 Marking Unit Motor Short RAP • Marking unit driver PWB, PL 92.10 Item 91-512-00 The carriage docking motor current demand exceeds expected value. 91-605-00 One of several marking unit motors, driven by the marking unit driver PWB, is draw- ing more current than expected.
  • Page 388 91-513-00, 91-514-00, 91-581-00, 91-583-00 IOD Drive Error Go to the relevant wiring diagram. Check the relevant motor. Refer to: • GP 10 How to Check a Motor. 91-513-00 The IOD shuttle motor current is inconsistent with the expected value. • PJ102, PJ303, PJ304, PJ401, PJ605, PJ607, Marking Unit Driver PWB.
  • Page 389 • 0V Distribution RAP 91-515-00 Vertical Wiper Motor Over Current RAP If necessary, install a new IOD assembly, PL 94.15 Item 91-515-00 The HM vertical motion motor current demand exceeds expected value. Enter diagnostics select Diagnostic Routines and select dC914 Head to Head Alignment Test.
  • Page 390 91-516-00 Low Pressure Assist Over Current RAP 91-517-00 Marking Unit Air Pump Over Current RAP 91-516-00 The low pressure assist solenoid valve current demand exceeds expected value. 91-517-00 The marking unit ink load air pump current demand exceeds expected value. Initial Actions Initial Actions WARNING...
  • Page 391 91-519-00 to 91-522-00, 91-655-00 to 91-658-00, 91-683-00 Install new ribbon cables as necessary, 92.10. to 91-690-00, 91-807 to 91-811-00 Printhead NVM Read or Go to GP 7 to check the system grounding. The system grounding is good. Write Error RAP 91-519-00 Printhead 1 NVM error detected.
  • Page 392 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 91-555-00 Printhead 1 Reservoir Thermistor value inconsistent with expected value. to 91-803-00, 91-856-00 to 91-859-00 Printhead Thermal 91-556-00 Printhead 2 Reservoir Thermistor value inconsistent with expected value. Error RAP 91-557-00 Printhead 3 Reservoir Thermistor value inconsistent with expected value. 91-523-00 Printhead 1 Left Jet Heater is Too Hot 91-558-00 Printhead 4 Reservoir Thermistor value inconsistent with expected value.
  • Page 393 Perform the printhead thermal tests, dC335. The tests complete successfully. 91-559-00 Marking Unit Components Out of Position RAP The home position sensors are monitored as wiper or carriage motion is performed. This fault Check the PEST fault history, dC123 for marking unit heater faults (umbilicals, printheads occurs when carriage or wiper motion is requested and the sensors are not in the expected and ink melt reservoir).
  • Page 394 • +24V Power Distribution RAP. • 0V Distribution RAP. Install new components as necessary: • HM vertical motion motor, PL 91.15 Item Upper carriage • X axis drive motor upper, PL 91.20 Item home sensor, • X axis drive motor lower, PL 91.25 Item Q91-012 •...
  • Page 395 91-560-00 Carriage Selection Time Out RAP 91-560-00 The carriage drive select motor timed out moving to stop. Upper carriage home sensor, Q91-012 Initial Actions WARNING Selector Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 396 91-562-00, 91-563-00 Upper Carriage Error RAP • GP 10 How to Check a Motor. • PJ607, Marking Unit Driver PWB. 91-562-00 Print Head Carriage no edge found. • +24V Power Distribution RAP 91-563-00 Upper Print Head Carriage unexpected event. • 0V Distribution RAP Install new components as necessary: Initial Actions...
  • Page 397 91-565-00, 91-566-00 Upper Printhead Restraint Error RAP Upper carriage docking 91-565-00 Upper printhead carriage time-out moving restraint motor, MOT91-031 91-566-00 Upper printhead carriage restraint stalled. Upper carriage Procedure home sensor, Q91-012 These fault codes are shown for information only. The machine does not have carriage restraint motors.
  • Page 398 91-567-00 to 91-568-00 Lower Carriage Error RAP Refer to: • GP 10 How to Check a Motor. 91-567-00 Lower Print Head Carriage no edge found. • PJ607, Marking Unit Driver PWB. • +24V Power Distribution RAP 91-568-00 Lower Print Head Carriage unexpected event. •...
  • Page 399 91-570-00, 91-571-00 Lower Printhead Restraint Error RAP 91-570-00 Lower printhead carriage timeout moving restraint. Carriage drive select motor, MOT91-021 91-571-00 Lower printhead carriage restraint stalled. Procedure These fault codes are shown for information only. The machine does not have carriage Lower carriage home restraint motors.
  • Page 400 91-572-00, 91-573-00, 91-575-00 Wiper Vertical Error RAP Enter dC330 code 91-014 to test the HM position sensor, Q91-014. Actuate Q91-014. The display changes. 91-572-00 Printhead wiper vertical motion edge not found. Go to 9.11. Check S91-014. 91-573-00 The wiper encountered an unexpected event while in vertical motion. Refer to: 91-575-00 The vertical wiper could not complete the requested motion.
  • Page 401 91-574-00, 91-576-00, 91-598-00 Wiper Horizontal Error Check the alignment of the HM wiper PL 91.15 Item 13. Refer to 91.3. HM wiper align- ment is good 91-574-00 The head maintenance (HM) wiper did not reach position on time. Install a new HM wiper, PL 91.15 Item 91-576-00 The head maintenance (HM) wiper was not in the expected vertical position.
  • Page 402 91-586-00 Quad Wave Amplifier Short RAP 91-586-00 the quad wave amplifier current demand is inconsistent with the expected value. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 403 91-587-00, 91-588-00 Quad Wave Amplifier Thermal Error 91-607-00, 91-608-00 Printhead to Drum Error RAP 91-607-00 Head to drum contact. Following printhead replacement, thermal data indicates the printhead is in contact with the drum. System should reboot into diagnostics mode when this 91-587-00 The quad wave amp PWB is too hot.
  • Page 404 91-610-00 to 91-613-00 Printhead Wave Amp Calibration Perform the following check: Disconnect the video cable and the wave amp cable from the suspect printhead. Error RAP Refer to Figure 91-610-00 Printhead 1 wave amp calibration error. • The resistance between GND and VPP should be 5K ohms or greater •...
  • Page 405 91-614-00 to 91-617-00 Printhead Data Error RAP 91-630-00 IOD Scan Process Failure RAP 91-614-00 Printhead 1 field data corrupt. 91-630-00 The IOD scan process has failed. 91-615-00 Printhead 2 field data corrupt. The IOD scans a target on the drum to optimize print quality and to check for missing jets. Dur- 91-616-00 Printhead 3 field data corrupt.
  • Page 406 91-631-00 IOD Dark Adjust Failure RAP 91-631-00 The IOD dark adjust failed. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14. Disconnect the power cord. Electricity can cause death or injury.
  • Page 407 91-636-00 IOD in Degraded Mode RAP If the routine is found to be in degraded mode. Refer to Table 2 and perform the actions as required. 91-636-00 The machines print quality maintenance software periodically runs corrective proce- Check and clear all related faults listed in dC122 by using the appropriate RAP to return dures to maintain output quality.
  • Page 408 Table 2 Routine Status Value and Description Status Do not manually write Adjustment Routines Value NVM Description Degraded Actions status value to NVM dC972 Printhead Unifor- Optimal Do not write mity dC972 Printhead Unifor- Non-Optimal Do not write mity dC972 Printhead Unifor- Auto Disabled Run the...
  • Page 409 Only Manually Enabled and Manually Disabled NVM Status values (3 and 4) are to be 91-637-00 Drum Runout Calibration Needed RAP written to NVM. DO NOT write any other Status value (0, 1 or 2) to NVM. 91-637-00 The drum runout table in NVM dC301 was reset.
  • Page 410 CAUTION 91-638-00 IOD Detects Chronic Jet Error RAP Do not disconnect and reconnect the flex cables at the IOD PWB. The flex cables are easily 91-638-00 The IOD has detected chronic jets. damaged. The cable must only be handled in the area of the blue backer. Also use this RAP to recover weak, sputtering or missing jets not detected by the IOD.
  • Page 411 91-660-00 to 91-663-00, 91-820-00 to 91-823-00 Printhead An empty waste tray can indicate a problem with the purge system. Refer to 93-549- Link Error RAP 00 to 93-552-00 and 93-557-00 to 93-560-00 Printheads 1 and 3 Printhead Reser- voir Fill Error RAP or 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Print- 91-660-00 Printhead 1 link broken.
  • Page 412 91-669-00 Excessive Skew RAP 91-670-00 Scanned Image Out of Sequence RAP 91-669-00 The scanned image has too much skew to process. 91-670-00 The expected image did not match the scanned image. Initial Actions Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 413 91-671-00 Fiducials Not Found RAP 91-672-00 Missing Jets RAP 91-671-00 The test pattern fiducials (on/off line pattern) for jet alignment could not be found. 91-672-00 Too many missing jets were detected to perform the operation. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 414 91-673-00 Floating Point Error RAP 91-674-00 to 91-677-00, 91-812-00 to 91-815-00 Printhead Adjustment Error RAP 91-673-00 The machine has detected a floating point calculation error. 91-674-00 The required voltage or normal adjustment exceeds the maximum on printhead 1. Procedure WARNING 91-675-00 The required voltage or normal adjustment exceeds the maximum on printhead 2.
  • Page 415 The fault remains. 91-678-00 to 91-681-00, 91-816-00 to 91-819-00, 91-961-00 to 91-964-00, Printhead Convergence Adjustment Error Perform the following dC972 routines: Option 4 TRC Generation - manual. Option 5 Y Dot Position Correction, select all heads. 91-678-00 Voltage and/or norm adjustment can not bring printhead 1 into tolerance. Install a new printhead, PL 91.20 Item 2 PL 91.25 Item...
  • Page 416 NOTE: Automatic uniformity has no specific media requirements. 91-682-00 Ambient Thermistor Error RAP The correct media is used. 91-682-00 The ambient thermistor reading is invalid. Load the correct media, then perform the following dC972 routines: This fault is raised if the ADC reading for the ambient thermistor is not within the range of a valid temperature reading.
  • Page 417 91-698-00, 91-699-00, 91-706-00, 91-712-00, 91-718-00, 91- Procedure 720-00, 91-729-00, 91-730-00, 91-732-00 IOD Excessive NOTE: The LED on upper (master) printhead PWB indicates the presence of +3.3V. Head Misalignment RAP Perform dC971 Head to Head Alignment Adjustment. The adjustment completed success- 91-698-00 IOD excessive stitch or roll misalignment.
  • Page 418 Refer to: Perform the following: • GP 10 How to Check a Motor. Refer to 9.10, check MOT91-024. • +24V Power Distribution RAP. Check the wiring between PJ303 on the marking unit driver PWB • +50V Power Distribution RAP. MOT91-024. •...
  • Page 419 MOT91-034 runs and the lower carriage moves left or right. 91-721-00, 91-722-00, 91-735-00, 91-736-00 IOD Contamination Error RAP Refer to WD 9.11, check MOT91-034. Check the wiring between PJ303 on the marking unit driver PWB and MOT91- 91-721-00 IOD calibration. 034.
  • Page 420 91-725-00 to 91-728-00, 91-945-00 to 91-948-00, IOD Bad If the head purge does not correct the missing jets, go to 91-638-00 IOD Detects Chronic Jet Error RAP. Target Scan RAP 91-725-00 IOD target. Perform dC969 Clean Ink Smears. Check the prints. The prints are clean. 91-726-00 IOD target missing.
  • Page 421 91-824-00 PQM Insufficient Ink RAP 91-825-00 PQM Insufficient Paper RAP 91-824-00 The machine has insufficient ink to perform the print quality maintenance routine. 91-825-00 The machine has insufficient paper to perform the print quality maintenance routine. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 422 91-826-00 PQM Insufficient Jets RAP 91-827-00 PQM Align Needed RAP 91-826-00 Insufficient jets are available to perform the print quality maintenance routine. 91-827-00 A head to head alignment is required before the print quality maintenance routine can be performed. Procedure Procedure WARNING WARNING...
  • Page 423 91-828-00 PQM Y-Dot Position Needed RAP 91-829-00 PQM Drum Runout Needed RAP 91-828-00 A Y dot position correction is required before the print quality maintenance routine 91-829-00 A drum runout calibration is required before the print quality maintenance routine can be performed. can be performed.
  • Page 424 91-830-00 PQM Uniformity Needed RAP 91-831-00 PQM Uniformity Reset Needed RAP 91-830-00 Printhead uniformity is required before the print quality maintenance routine can be 91-831-00 A printhead uniformity reset is required before the print quality maintenance routine performed. can be performed. Procedure Procedure WARNING...
  • Page 425 91-832-00 PQM Empty Waste Tray RAP 91-833-00 PQM Cleaning Pages Needed RAP 91-832-00 The waste tray must be emptied before the print quality maintenance routine can be 91-833-00 The cleaning pages requested by the print quality maintenance routine can not be performed.
  • Page 426 91-834-00 PQM Tool Not Usable RAP 91-835-00 PQM Tool Manually Disabled RAP 91-834-00 The requested print quality maintenance routine is not usable. 91-835-00 A print quality maintenance routine has been manually disabled. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 427 91-836-00 PQM System Busy RAP 91-837-00 PQM Align Calibration Needed RAP 91-836-00 The print quality maintenance system is busy. 91-837-00 PQM align stitch offset out of calibration. A head to head alignment is required before the print quality maintenance routine can be performed. Procedure Procedure WARNING...
  • Page 428 91-838-00 PQM: CLD Baseline Needed RAP 91-842-00 to 91-845-00 Printhead Nvram Read or Decode Error RAP 91-838-00 PQM: CLD Baseline Needed. The Closed Loop Drift (CLD) baseline has not been run after installation of new printheads. 91-842-00 Printhead 1 Nvram jet mask section read or decode error. Procedure 91-843-00 Printhead 2 Nvram jet mask section read or decode error.
  • Page 429 91-848-00 to 91-851-00 IOD Align Calibration Error RAP 91-852-00 to 91-854-00 Y Dot Position SVD Calculation 91-848-00 IOD align calibration: X stitch measurement limit excessive X stitch was measured and the align calibration process cannot complete. 91-852-00 PQM: TRC Wait for Ypos SVD Complete. 91-849-00 IOD align calibration: Y stitch measurement limit excessive Y stitch was measured 91-853-00 PQM: Unif Wait for Ypos SVD Complete.
  • Page 430 91-855-00 Thermal Safety Circuit Failure Undetected RAP 91-929-00 to 91-940-00 IOD Jet Position Noise RAP 91-855-00 Thermal Safety Circuit Fail. 91-929-00 IOD excessive Head 1 X position noise. 91-930-00 IOD excessive Head 2 X position noise. Procedure 91-931-00 IOD excessive Head 3 X position noise. WARNING 91-932-00 IOD excessive Head 4 X position noise.
  • Page 431 Procedure 91-941-00 to 91-944-00 PQM Too Many Purges RAP Enter dC971 Head to Head Alignment Adjustment. 91-941-00 PQM too many purges head1. Enter dC122 Fault History and observe the last fault shown. The fault is cleared. 91-942-00 PQM too many purges head2. Perform dC968 Head Purge on all 4 Heads.
  • Page 432 Remove the IOD assembly, 91.22. Inspect the IOD for contamination or malfunction. 91-949-00 to 91-952-00 Closed Loop Drift Baseline RAP If necessary install a new IOD assembly PL 94.15 Item 91-949-00 IOD CLD Baseline measurement out of range on head 1. Each power cycle can result in a cold purge, which will cause the waste tray to fill up at a faster 91-950-00 IOD CLD Baseline measurement out of range on head 2.
  • Page 433 91-953-00 to 91-960-00, 91-965-00 to 91-968-00 Closed Print new test patterns from dC972, option 3. The print quality is good. Loop Drift Measurement RAP Install a new printhead, PL 91.20 Item PL 91.25 Item 91-953-00 IOD CLD Adjust measurement out of range on head 1. Go to SCP 5 Final Actions...
  • Page 434 91-970-00 to 91-981-00 Printhead Reservoir and Jet Stack • +3.3V ESTAR Distribution RAP. • 0V Distribution RAP. Heater Unstable RAP Install new components as necessary: 91-970-00 Head 1 right jet stack heater went unstable while printing. • Lower carriage harness, PL 91.25 Item 12 or upper carriage harness, PL 91.20...
  • Page 435 91A Printhead Communications RAP Repair any grounding issues found, This RAP gives additional information on printhead communication problems. Perform the RAP for all current fault codes before this RAP is performed. Install new components as necessary: • Printhead, PL 91.20 Item 2 PL 91.25 Item Initial Actions •...
  • Page 436 Heater harnesses connections Figure 2 Heater harness connections to printheads Status Indicator RAPs February 2013 2-412 ColorQube® 9303 Family...
  • Page 437 92-501-00 to 92-504-00, 92-519-00 Serial Link Safety 92-505-00, 92-506-00 Marking Unit Communications Error Transient RAP 92-501-00 MpSerialLinkSafetyTransient. 92-505-00 Marker unit communications failure 92-502-00 MuSerialLinkSafetyTransient. 92-506-00 Marker unit communications failure 92-503-00 MuidSerialLinkSafetyTransient. Initial Actions WARNING 92-504-00 DDSerialLinkSafetyTransient. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 438 92-510-00, 92-511-00 Marking Unit Ink Delivery 92-515-00, 92-516-00 Drum Driver Communications Error Communications Error RAP 92-510-00 Ink delivery communications failure on marking unit driver PWB. 92-515-00 Drum driver communications failure 92-511-00 Ink delivery communications failure on marking unit driver PWB. 92-516-00 Drum driver communications error Initial Actions Procedure...
  • Page 439 92-520-00 Power Supply Communications Error RAP 92-525-00, 92-526-00 Media Path Communications Error 92-520-00 Power supply communications error 92-525-00 Media path communications failure Procedure WARNING 92-526-00 Media path communications error Ensure that the electricity to the machine is switched off while performing tasks that do Initial Actions not need electricity.
  • Page 440 92-530-00 3TM Serial Link Error RAP 92-531-00 Paper Tray Module Communications Error RAP 92-530-00 Three trays module serial link error. 92-531-00 Paper tray module (3TM) communication error. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 441 92-535-00, 92-536-00 Tray 5 Communications Error RAP 92-541-00 ADC Interrupt Storm Fault RAP 92-535-00 Tray 5 control PWB serial communications error. 92-541-00 ADC interrupt storm. 92-536-00 Tray 5 communications error. Initial Actions WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 442 92-542-00 PS Interrupt Storm Fault RAP 92-543-00, 92-544-00 MU Interrupt Storm Faults RAP 92-542-00 PS interrupt storm. 92-543-00 MU interrupt storm. Initial Actions 92-544-00 MUID interrupt storm. WARNING Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 443 92-545-00 DD Interrupt Storm Fault RAP 92-546-00, 92-547-00 MP Interrupt Storm Faults RAP 92-545-00 DD interrupt storm. 92-546-00 MP interrupt storm. Initial Actions 92-547-00 IMD interrupt storm. WARNING Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 444 92-548-00 TTM Interrupt Storm Fault RAP 92-549-00 PFP Interrupt Storm Fault RAP 92-548-00 TTM interrupt storm. 92-549-00 PFP (Tray 5) interrupt storm. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 445 92-551-00 CIS Interrupt Storm Fault RAP 92-550-00, 92-555-00 System Timer Error RAP 92-551-00 CIS interrupt storm. 92-550-00 Safety timer time out. Initial Actions 92-555-00 System timer skipped. WARNING Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 446 92-552-00 SBC Interrupt Storm Fault RAP 92-554-00 AC Line Failed RAP 92-552-00 SBC interrupt storm. 92-554-00 The AC power cord has been disconnected or the AC supply has failed. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 447 92-556-00, 92-557-00, 92-558-00, 92-559-00 ECM Failure 92-560-00, 92-561-00 Marking Unit Firmware Version Mismatch RAP 92-556-00 ECM PCI access failure. 92-560-00 Marking unit firmware version mismatch. 92-557-00 ECM ADC failed. 92-561-00 Marking unit firmware version mismatch. 92-558-00 ECM PS line cross failed. Procedure WARNING 92-559-00 ECM FPGA access error.
  • Page 448 92-562-00 Drum Driver Firmware Version Mismatch RAP 92-563-00 Power Supply Firmware Version Mismatch RAP 92-562-00 Drum driver firmware version mismatch. 92-563-00 IME power supply firmware version mismatch. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 449 92-564-00 Media Path Firmware Version Mismatch RAP 92-565-00 3TM Firmware Version Mismatch RAP 92-564-00 Media path firmware version mismatch. 92-565-00 3 trays module firmware version mismatch. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 450 92-566-00 Tray 5 Firmware Version Mismatch RAP 92-567-00 ECM FPGA Version Mismatch RAP 92-566-00 Paper feeder platform firmware version mismatch. 92-567-00 ECM FPGA Version Mismatch. The IME and CCS software is incompatible. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 451 92-568-00 ECM Initialization Error RAP 92-569-00 Image FPGA Version Mismatch RAP 92-568-00 IME controls did not initialize correctly. 92-569-00 Image FPGA version mismatch. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 452 92-570-00 Interrupt Storm Fault RAP 92-571-00 Software Error RAP 92-570-00 Interrupt storm fault. 92-571-00 Software error. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 453 92-575-00 ADC Out of Range RAP 92-579-00 CDI Submit Sheet Error RAP 92-575-00 Analog to digital conversion of thermistor readings inconsistent with expected value. 92-579-00 A CDI submit sheet error has been detected. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 454 92-581-00 Image Transfer Error RAP 92-583-00 Cold Temperature Boot Time-out RAP 92-581-00 Image transfer failure from Single board controller PWB to IME controller PWB. 92-583-00 Cold temperature boot time-out. Procedure Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 455 92-585-00 LVDS Contone Terminal Error During Image 92-586-00 Print Engine Speed Fault RAP Transfer RAP 92-586-00 The print engine is running at default speed. 92-585-00 LVDS contone terminal error during image transfer. Procedure Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 456 92-598-00, 92-599-00, 92-600-00, 92-610-000 to 92-614-00, 92-803-00, 92-804-00 DSP2 Overlay Error RAP IME NVRAM Error RAP 92-803-00 DSP2 overlay setup time-out. Critical system settings have been reset to their default values. The system can continue oper- 92-804-00 DSP2 overlay cleanup time-out. ating, but requires manual configuration to custom settings.
  • Page 457 92-805-00 Fuse A Blown RAP Repair the wiring as necessary, 1.1. Install a new drum driver PWB, PL 1.15 Item 92-805-00 Fuse A on the drum driver PWB has blown. Install a new drum driver PWB, PL 1.15 Item 4. The fault remains. Procedure WARNING Perform...
  • Page 458 92-806-00 Fuse B Blown RAP 92-807-00 Diagnostic Routine Not Implemented RAP 92-806-00 Fuse B on the drum driver PWB has blown. 92-807-00 In dC972 automatic TRC generation is not implemented. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 459 Check that the marking unit cooling fan is running, Figure 1. The fan is running. • Check for non Xerox ink sticks and report as appropriate. • Check for wrong colour ink sticks loaded. Go to 9.4. Check the marking unit cooling fan.
  • Page 460 • PJ101, PJ801, Marking Unit Driver PWB. 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00, • PJ760, PJ910, PJ630 Solenoid patch PWB. 93-533-00, 93-957-00 Ink Melt Error RAP The wiring and thermistor is good. 93-523-00 Cyan ink melter is too hot Install a new ink reservoir, PL 93.10 Item 93-524-00 Cyan ink melter is heating too slowly...
  • Page 461 Go to 1.2, WD 8.4 9.17. Check the wiring between: 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt • The power supply unit and the ink melt heaters. Ensure that the ink melt heaters are cor- Thermistor Error RAP rectly connected to PJ5AC on the Power supply unit.
  • Page 462 93-535-00 to 93-537-00, 93-958-00 Upper Umbilical Thermal • Marking unit driver PWB, PL 92.10 Item 4 • Marking unit heater PWB, PL 92.10 Item 5 Error RAP Refer to WD 1.1 9.8, check the wiring between PJ4AC on the Power Supply Unit 93-535-00 Upper umbilical heater is too hot and PJ101 on the Marking Unit Heater...
  • Page 463 93-538-00 to 93-540-00, 93-959-00 Lower Umbilical Thermal Check that the marking unit fan is running, Figure 1. The fan is running. Error RAP Go to 9.4. Check the marking unit fan. 93-538-00 Lower umbilical heater is too hot Refer to: •...
  • Page 464 Check for ink stick jams. 93-557-00 Head 3 black reservoir did not fill within the correct time. • Check for non Xerox ink sticks and report as appropriate. 93-558-00 Head 3 magenta reservoir did not fill within the correct time. •...
  • Page 465 • Install a new purge line, PL 91.25 Item • Cyan ink solenoid valve 15, SOL93-073. • If the ink contamination has reached the ink reservoir through the purge line, install a • Cyan ink solenoid valve 16, SOL93-074. new ink reservoir, PL 93.10 Item •...
  • Page 466 Black ink reservoir Solenoid patch Lower purge hose pair for the lower umbilical Disconnect the air hose Upper purge hose pair from the ink reservoir for the upper umbilical Ink reservoir solenoids and the relevant channels Figure 2 Reservoir pump air hose Figure 1 Component location Status Indicator RAPs February 2013...
  • Page 467 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 • If the ink contamination has reached the melt reservoir through the purge line, install a new ink reservoir, PL 93.10 Item Printheads 2 and 4 Printhead Reservoir Fill Error RAP 93-553-00 Head 2 black reservoir did not fill within the correct time. Move the marking unit to the service position, 6.
  • Page 468 • Cyan ink solenoid valve 14, SOL93-072. • Magenta ink solenoid valve 18, SOL93-076. • Magenta ink solenoid valve 20, SOL93-078. Black ink reservoir All solenoids energise Go to 9.12, WD 9.14 9.15. Check the ink reservoir solenoids. Solenoid patch Refer to: •...
  • Page 469 93-565-00 to 93-599-00 and 93-800-00 to 93-812-00 Printheads 1, 2, 3 & 4 Ink Level Sense Error RAP 93-565-00 Head 1 black reservoir level sense failure 93-566-00 Head 1 magenta reservoir level sense failure 93-567-00 Head 1 cyan reservoir level sense failure 93-568-00 Head 1 yellow reservoir level sense failure 93-569-00 Head 2 black reservoir level sense failure 93-570-00 Head 2 magenta reservoir level sense failure...
  • Page 470 93-592-00 Head 3 yellow reservoir level sense open circuit 93-813-00 to 93-820-00 Ink Melt Reservoir Level Sense Failure RAP 93-593-00 Head 4 black reservoir level sense open circuit 93-813-00 Black melt reservoir level sense open circuit 93-594-00 Head 4 magenta reservoir level sense open circuit 93-814-00 Magenta melt reservoir level sense open circuit 93-595-00 Head 4 cyan reservoir level sense open circuit 93-815-00 Cyan melt reservoir level sense open circuit...
  • Page 471 93-825-00, 93-892-00 Ink Key Plate Motor Over Current 93-871-00 to 93-874-00 Ink Level Sense Error RAP 93-871-00 Black melt reservoir level sense failure. 93-825-00 The ink key plate motor is over current. 93-872-00 Magenta melt reservoir level sense failure 93-892-00 Indicates an over current interrupt from the motor driver chip. 93-873-00 Cyan melt reservoir level sense failure Initial Actions 93-874-00 Yellow melt reservoir level sense failure...
  • Page 472 93-890-00 Marking Unit Air Solenoid Over Current RAP 93-891-00 Ink Transport Over Current RAP 93-890-00 The marking unit air solenoid is taking too much current. 93-891-00 The ink transport motor is taking too much current. Procedure Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 473 93-901-00 to 93-904-00 Ink Melt Reservoir Fill Failure RAP 93-909-00 to 93-924-00 Printhead Reservoir Level Failure 93-901-00 Black melt reservoir over fill failure 93-909-00 Head 1 black reservoir level sense failure 93-902-00 Magenta melt reservoir over fill failure 93-910-00 Head 1 magenta reservoir level sense failure 93-903-00 Cyan melt reservoir over fill failure 93-911-00 Head 1 cyan reservoir level sense failure 93-904-00 Yellow melt reservoir over fill failure...
  • Page 474 93-933-00 to 93-936-00 Head Purge Failure RAP 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP 93-933-00 Head 1 purge failure 93-937-00 A leak has been detected in the black melt reservoir 93-934-00 Head 2 purge failure 93-938-00 A leak has been detected in the magenta melt reservoir 93-935-00 Head 3 purge failure 93-939-00 A leak has been detected in the cyan melt reservoir 93-936-00 Head 4 purge failure...
  • Page 475 93A Ink Melt Reservoir Check RAP Reconnect the air hose from the pump to the ink reservoir, Figure Enter the correct dC330 code to check the ink reservoir solenoids: Procedure • Purge solenoid valve 1, SOL93-059. WARNING • Purge solenoid valve 2, SOL93-060. Ensure that the electricity to the machine is switched off while performing tasks that do •...
  • Page 476 • For 99-564-00, 99-565-00 or 99-568-00 to 99-580-00, go to the 99-564-00 to 99-565-00 93B Ink Leak Checkout RAP PEST Error 23 RAP. This RAP is to be used when an ink leak is present in the machine. • For 99-682-00, 99-684-00, 99-685-00, go to the 99-671-00 to 99-685-00 PEST Error 30 RAP.
  • Page 477 94-504-00 Cleaning Unit Reservoir Pressure Low RAP 94-505-00 Cleaning Unit Reservoir Pressure High RAP 94-504-00 Cleaning unit reservoir pressure is too low. 94-505-00 Cleaning unit reservoir pressure is too high. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 478 94-510-00, 94-512-00 Drum Image Initial Position Error RAP Install a new 12 pin connector, PL 94.10 Item 94-510-00 The imaging software detected the drum at the wrong position. Go to 9.2, WD 9.4 9.19. Check the wiring between the cleaning unit and the drum 94-512-00 The drum has stalled during imaging.
  • Page 479 94-514-00, 94-518-00 Drum Imaging Error RAP 94-519-00 Drum Imaging Error RAP 94-514-00 Image data not ready when needed during drum revolution 94-519-00 Drum Imaging Failure 94-518-00 Software timing error during imaging Procedure WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 480 94-520-00 Cleaning Unit Drive Error RAP 94-522-00 Cleaning Unit Motor Stall RAP 94-520-00 Cleaning unit motor is taking too much current. 94-522-00 Cleaning unit motor stall. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 481 Go to 9.3. Check the cleaning unit motor and encoder. Refer to: • 11, How to Check a Sensor • P/J802 Drum driver PWB. • +5V Distribution RAP. • 0V Distribution RAP Reinstall the original cleaning unit. Install new components as necessary: •...
  • Page 482 94-524-00 Drum Drive Motor Over Current RAP 94-526-00 Drum Drive Stall RAP 94-524-00 Drum drive motor is taking too much current. 94-526-00 Drum has stalled. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 483 Switch off the machine, then switch on the machine, 14. Check for, power supply, drum motor thermal protection circuit and drum motor current feedback PEST faults then perform the relevant RAP. Rear transfix motor and Check the fault history, dC122 for 94-550 or 94-551 faults.
  • Page 484 94-527-00, 94-531-00 Cleaning Unit Early Life Over Current 94-528-00, 94-532-00, 94-533-00 Cleaning Unit Over Current RAP 94-527-00 Oil delivery pump (early life) is taking too much current. 94-528-00 Drum driver oil pump 1 is taking too much current. 94-531-00 Oil delivery pump (early life) is taking too much current. 94-532-00 Drum driver oil pump 2 is taking too much current.
  • Page 485 94-534-00 Drum Drive Belt Slip RAP Remove the drum and abatement fan assembly, refer to 91.24. Manually rotate the drum and observe the drum motor. Abrupt rotations of the drum motor about its tensioning 94-534-00 Excessive slipping of the drum belt. pivot indicates problems with the drum belt, such as voids or contamination in the grooves.
  • Page 486 94-535-00 Drum Driver Command Current Error RAP 94-535-00 The drum driver PWB fails to monitor the drum drive current. Rear transfix motor and encoder Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Rear transfix flexure not need electricity.
  • Page 487 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94- NOTE: If the drum heater test fails to work correctly. Switch the machine off and then on, 14. Enter dC335 and rerun the drum heater test. 546-00, 94-632-00, 94-633-00 Drum Heat Error RAP The tests were good. 94-536-00 Drum front heater is too hot Go to 1.2,...
  • Page 488 94-545-00 Drum Runout Calibration Error RAP 94-547-00, 94-555-00 Y-Axis Belt Ratio Error RAP 94-545-00 Drum runout calibration error - drum motor encoder. 94-547-00 Y-axis belt ratio error. Procedure 94-555-00 Y-axis belt ratio hard error. WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 489 94-548-00 Y-Axis Position Error RAP 94-549-00 Drum Runout Calibration Error RAP 94-548-00 The drum position was incorrect after repositioning. 94-549-00 Drum runout calibration - drum encoder. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 490 94-551-00, 94-552-00, 94-553-00 Drum Y-Axis Error RAP 94-558-00, 94-560-00, 94-562-00, 94-564-00, 94-566-00 Cleaning Unit Position Error RAP 94-551-00 Drum Y-axis home calculation error. 94-558-00 Cleaning unit timing error 94-552-00 Drum Y-axis Initialization error. 94-560-00 Cleaning unit position error 94-553-00 Drum Y-axis home data error. 94-562-00 Cleaning unit fast forward home time-out Procedure WARNING...
  • Page 491 94-568-00, 94-570-00, 94-572-00, 94-573-00 Cleaning Unit 94-574-00 Cleaning Unit Sync Error RAP Data Error RAP 94-574-00 Cleaning unit NVM sync access error 94-568-00 Cleaning unit usage data read error Procedure 94-570-00 Cleaning unit usage data write error WARNING Ensure that the electricity to the machine is switched off while performing tasks that do 94-572-00 Cleaning unit usage data detect error not need electricity.
  • Page 492 94-610-00, 94-612-00 Cleaning Unit Error RAP 94-611-00 Cleaning Unit Removal Pump Test Fail RAP 94-610-00 Cleaning unit delivery pump test fail 94-611-00 Cleaning unit removal pump test fail 94-612-00 Cleaning unit valve test fail Procedure WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 493 21. Switch off, then switch on the machine Verify that the cleaning unit is a Xerox item. Remove, then reinstall the cleaning unit. Cheat the front door interlock. Listen at the front of the cleaning unit. The cleaning unit can If the fault remains, install a new cleaning unit, PL 94.10 Item...
  • Page 494 94-617-00, 94-618-00 Oil Pump Error RAP 94-619 Cleaning Unit Delivery Line Blocked RAP 94-617-00 Oil delivery pump stalled 94-619-00 Oil delivery line blocked. 94-618-00 Oil removal pump stalled Procedure WARNING Procedure Ensure that the electricity to the machine is switched off while performing tasks that do WARNING not need electricity.
  • Page 495 94-620-00 Drum Fan Stall RAP 94-621-00 Abatement Fan Stall RAP 94-620-00 The drum fan has stalled. 94-621-00 The abatement fan has stalled. Initial Actions Initial Actions WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 496 94-622-00 Cleaning Unit Unusable RAP 94-622-00 Cleaning unit previously marked unusable. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14. Disconnect the power cord. Electricity can cause death or injury.
  • Page 497 94-629-00 Extreme Customer Usage RAP 94-631-00 Cleaning Unit Connectivity Failure RAP 94-629-00 DM Gel countdown enabled. 94-631-00 Persistent cleaning unit connectivity failure. Procedure Procedure WARNING WARNING Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 498 94-634-00, 94-635-00 DMU Thermistor Failure RAP 94A Enclosure Fan Error RAP 94-634-00 DMU Thermistor Fail. The IME timed out waiting for the cleaning unit to warm-up. Use this RAP to troubleshoot problems with the drum driver enclosure fan, MOT 42-063. The IME has assumed that the cleaning unit thermistor has failed, although the cleaning unit is at operational temperature.
  • Page 499 94B Drum Drive Control Test Actions RAP • Install a new drum driver PWB, PL 1.15 Item 6 Drum calibrate failed on encoder signal Use this RAP to resolve problems identified by dC708 Drum Drive Control Test. • Go to 9.1.
  • Page 500 Status Indicator RAPs February 2013 2-476 ColorQube® 9303 Family...
  • Page 501 99-000-00 to 99-067-00 PEST Error 1 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-000-00 PEST test started. 99-057 Hard Go to the Printhead Communications RAP. Check pins 7 to 11 on 99-052-00 Board link, MUD link broken. the video cable from the IME controller PWB to the printhead 3 PWB.
  • Page 502 99-081-00 to 99-112-00 PEST Error 2 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-081-00 Wave amp cable, VPP or VSS head 1 open. 99-083 Hard Go to 91-610-00 to 91-613-00. Check the video and wave amp 99-082-00 Wave amp cable, VPP or VSS head 2 open.
  • Page 503 99-120-00 to 99-140-00 PEST Error 3 RAP 99-143-00 to 99-150-00 PEST Error 4 RAP 99-120-00 Media path driver PWB safe mode. 99-143-00 Thermistor, MU ambient open. 99-121-00 Motor, H bridge enable MPD open. 99-144-00 Thermistor, MU ambient short. 99-130-00 Solenoid, nip C over current. 99-150-00 Solenoid, ink delivery valves over current.
  • Page 504 99-180-00 to 99-217-00 PEST Error 5 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-180-00 Board link 3TM safe mode. 99-212 Soft Switch off the machine, 14. Check all 24V devices for heat or 99-185-00 Board link PFP safe mode. noise and the harnesses for damage or short circuits (i.e.
  • Page 505 Table 1 PEST Hard and Soft Fault Codes 99-221-00 to 99-244-00 PEST Error 6 RAP Code Hard/Soft Action 99-221-00 Main board 1.225V out of range. 99-216 Soft Switch off the machine, 14. Check all 50V devices for heat or 99-230-00 Power AC voltage below min. noise and the harnesses for damage or short circuits (i.e.
  • Page 506 Table 1 PEST Hard and Soft Fault Codes 99-250-00 to 99-271-00 PEST Error 7 RAP Code Hard/Soft Action 99-250-00 Power IMEC ADC 1.1V out of range. 99-240 Hard The power supply is good and believes the voltage is OK. But check 99-251-00 Power 1.2V out of range.
  • Page 507 99-272-00 to 99-292-00 PEST Error 8 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-272-00 Drum driver PWB, 24V fuse A (F602) open. 99-274 Hard Go to the RAP. Refer to WD 9.1 WD 9.2 Check down stream of 99-273-00 Drum driver PWB, 24V fuse B (F603) open.
  • Page 508 99-293-00 to 99-312-00 PEST Error 9 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-293-00 Fuse MUD 50V open. 99-304 Hard Check that PJ801 on the marking unit driver PWB is securely con- 99-301-00 Connector, marking unit driver PWB. nected.
  • Page 509 99-313-00 to 99-329-00 PEST Error 10 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-313-00 Connector, MU solenoid patch PWB. 99-314 Hard Check that PJ810 on the solenoid patch PWB is securely connected. 99-314-00 Connector, MU solenoid patch PWB. Check the wiring for an open circuit, repair as necessary, 1.1.
  • Page 510 99-330-00 to 99-349-00 PEST Error 11 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-330-00 Connector, IOD pre-amplifier PWB. 99-332 Hard Check that PJ4 on the registration / preheat interface is securely con- 99-331-00 Connector DMU hot plug open. nected.
  • Page 511 99-360-00 to 99-382-00 PEST Error 12 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-360-00 Connectors TTM 1 open. 99-366 Hard LCSS: Go to the 12-199-00-110 Unexpected Sheet at Finisher Entry 99-361-00 Connector TTM 2 open. RAP.
  • Page 512 99-394-00 to 99-413-00 PEST Error 13 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-394-00 Power triacs PS short triac. 99-405 Hard Refer to IME Controller test points TP703-706 (Lower Left corner of 99-395-00 Power, triacs MUH short triac. the board, with labels HD1-HD4 to indicate which head) Check at each test point.
  • Page 513 99-414-00 to 99-428-00 PEST Error 14 RAP Table 1 PEST Hard and Soft Fault Codes Code Hard/Soft Action 99-414-00 Heater, head reservoir 1 short. 99-415 Hard Go to the 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 99-415-00 Heater, head reservoir 2 short. to 91-803-00, 91-856-00 to 91-859-00 Printhead Thermal Error RAP.
  • Page 514 Table 1 PEST Hard and Soft Fault Codes 99-429-00 to 99-443-00 PEST Error 15 RAP Code Hard/Soft Action 99-429-00 Heater, jet stack H2 right open. 99-426 Hard Go to the AC Power Distribution RAP. Check the AC / heater 99-430-00 Heater, jet stack H3 left open. cabling to printhead 1.
  • Page 515 Table 1 PEST Hard and Soft Fault Codes 99-444-00 to 99-457-00 PEST Error 16 RAP Code Hard/Soft Action 99-444-00 Heater, jet stack H2 left below min. 99-430 Hard Go to the AC Power Distribution RAP. Select the Head 3 Reser- 99-445-00 Heater, jet stack H2 right below min.
  • Page 516 Table 1 PEST Hard and Soft Fault Codes 99-460-00 to 99-477-00 PEST Error 17 RAP Code Hard/Soft Action 99-460-00 Heater, umbilical upper open. 99-447 Soft Go to the AC Power Distribution RAP. Select the Head 3 Reser- 99-461-00 Heater, umbilical lower open. voir and Jetstack Heaters Check.
  • Page 517 Procedure Table 1 PEST Hard and Soft Fault Codes Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to Code Hard/Soft Action dC123. 99-466 Soft Go to 93-535-00 to 93-537-00, 93-958-00 Upper Umbilical Thermal Error RAP.
  • Page 518 99-480-00 to 99-497-00 PEST Error 18 RAP Table 1 PEST codes and action Code Hard/Soft Action 99-480-00 Heater, ink melter cyan open. 99-481 Hard Go to the 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532- 99-481-00 Heater, ink melter magenta open. 00, 93-533-00, 93-957-00 Ink Melt Error RAP.
  • Page 519 Table 1 PEST codes and action 99-500-00 to 99-515-00 PEST Error 19 RAP Code Hard/Soft Action 99-500-00 Thermistor, ink melter cyan open. 99-494 Soft Go to the 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532- 99-501-00 Thermistor, ink melter magenta open. 00, 93-533-00, 93-957-00 Ink Melt Error RAP.
  • Page 520 Table 1 PEST codes and action 99-516-00 to 99-533-00 PEST Error 20 RAP Code Hard/Soft Action 99-516-00 Heater, drum front above max. 99-502 Hard Go to the 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt 99-517-00 Heater, drum rear above max. Thermistor Error RAP. Check the AC / heater cabling umbilical. If it is open or short, install a new cable.
  • Page 521 Table 1 PEST codes and action 99-534-00 to 99-548-00 PEST Error 21 RAP Code Hard/Soft Action 99-534-00 Front drum thermistor, open circuit. 99-520 Soft Go to the 88-500-00 to 88-502-00, 88-512-00 Preheat Thermal Error 99-535-00 Front drum thermistor, short circuit. RAP.
  • Page 522 Table 1 PEST codes and action Table 1 PEST codes and action Code Hard/Soft Action Code Hard/Soft Action 99-535 Hard Refer to WD 9.1. Check the DC cabling to the front drum thermistor. If it 99-545 Hard Go to the 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 is open or short, install a new cable.
  • Page 523 99-549-00 to 99-563-00 PEST Error 22 RAP Table 1 PEST codes and action Code Hard/Soft Action 99-549-00 Thermistor, jet stack H1 left short. 99-552 Hard Go to the 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 99-550-00 Thermistor, jet stack H2 right short. to 91-803-00, 91-856-00 to 91-859-00 Printhead Thermal Error RAP.
  • Page 524 99-564-00 to 99-565-00 PEST Error 23 RAP 99-600-00 to 99-605-00 PEST Error 24 RAP 99-564-00 Thermistor, melt reservoir open. 99-600-00 Purge solenoid valve head 1. 99-565-00 Thermistor, melt reservoir short. 99-601-00 Solenoid, ink purge valve H2 open. Initial Actions 99-602-00 Solenoid, ink purge valve H3 open. WARNING 99-603-00 Solenoid, ink purge valve H4 open.
  • Page 525 99-606-00 to 99-610-00 PEST Error 25 RAP 99-611-00 to 99-625-00 PEST Error 26 RAP 99-606-00 Solenoid, ink dose valve H1 magenta open. 99-611-00 Solenoid, ink dose valve H2 black open. 99-607-00 Solenoid, ink dose valve H1 black open. 99-612-00 Solenoid, ink dose valve H3 yellow open. 99-608-00 Solenoid, ink dose valve H2 cyan yellow open.
  • Page 526 Table 1 PEST codes and action 99-626-00 to 99-640-00 PEST Error 27 RAP Code Hard/Soft Action 99-626-00 Solenoid, ink dose valve H1 yellow short. 99-612 Hard Go to the Ink Melt Reservoir Check RAP. Check the DC cabling to 99-627-00 Solenoid, ink dose valve H1 black short. the reservoir.
  • Page 527 Table 1 PEST codes and action 99-641-00 to 99-655-00 PEST Error 28 RAP Code Hard/Soft Action 99-641-00 Solenoid, ink purge valve H2 below min. 99-627 Hard Go to the Ink Melt Reservoir Check RAP. Check the DC cabling to 99-642-00 Solenoid, ink purge valve H3 below min. the reservoir.
  • Page 528 Table 1 PEST codes and action 99-656-00 to 99-670-00 PEST Error 29 RAP Code Hard/Soft Action 99-656-00 Solenoid, ink dose valve H4 cyan below min. 99-642 Soft Go to the Ink Melt Reservoir Check RAP. Check the DC cabling to 99-657-00 Solenoid, ink dose valve H4 magenta below min.
  • Page 529 Table 1 PEST codes and action 99-671-00 to 99-685-00 PEST Error 30 RAP Code Hard/Soft Action 99-671-00 Solenoid, ink dose valve H2 black above max. 99-657 Soft Go to the Ink Melt Reservoir Check RAP. Check the DC cabling to 99-672-00 Solenoid, ink dose valve H3 cyan above max.
  • Page 530 Table 1 PEST codes and action 99-686-00 to 99-700-00 PEST Error 31 RAP Code Hard/Soft Action 99-686-00 Sensor, ADC ink level MeltResRef yellow open. 99-674 Soft Go to the Ink Melt Reservoir Check RAP. Check the DC cabling to 99-687-00 Sensor, ADC ink level MeltResRef black open. the reservoir.
  • Page 531 99-701-00 to 99-721-00 PEST Error 32 RAP 99-730-00 to 99-742-00 PEST Error 33 RAP 99-701-00 Pump, ink delivery air short. 99-730-00 Pump, ralph air pumps open. 99-702-00 Pump, ink delivery air stall. 99-731-00 Pump, ralph air pumps short. 99-710-00 Fan, rear closure open. 99-732-00 Pump, ralph air pumps stall.
  • Page 532 Table 1 PEST codes and action 99-743-00 to 99-766-00 PEST Error 34 RAP Code Hard/Soft Action 99-743-00 Solenoid, CAR diverter above max. 99-740 Hard Go to the 83-504-00 HPP Diverter Solenoid Failure RAP. Check the DC 99-745-00 Solenoid, duplex open. cabling to the solenoid.
  • Page 533 Table 1 PEST codes and action 99-767-00 to 99-782-00 PEST Error 35 RAP Code Hard/Soft Action 99-767-00 Solenoid, stripper below min. 99-745 Hard Go to the 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 99-768-00 Solenoid, stripper above max. Media Path Sensor 13 Duplex Mode RAP. Check the DC cabling to the exit duplex diverter solenoid.
  • Page 534 99-785-00 to 99-802-00 PEST Error 36 RAP 99-805-00 to 99-823-00 PEST Error 37 RAP 99-785-00 Pump, DMU return open. 99-805-00 Motor, drum maint above max. 99-786-00 Pump, DMU return short. 99-810-00 Motor, head roll 1 open. 99-801-00 Motor, drum maint open. 99-811-00 Motor, head roll 1 short.
  • Page 535 Table 1 PEST codes and action Table 1 PEST codes and action Code Hard/Soft Action Code Hard/Soft Action 99-811 Hard Refer to 9.10. Check the DC cabling to the printhead roll adjust 99-818 Soft Go to the 91-506-00 to 91-509-00 Roll Motor Over Current RAP.
  • Page 536 99-824-00 to 99-838-00 PEST Error 38 RAP Table 1 PEST codes and action Code Hard/Soft Action 99-824-00 Motor, head stitch 1-2 power fault. 99-830 Hard Refer to 9.11. Check the DC cabling to the carriage drive select 99-829-00 Motor, carriage restraint upper/lower fault. motor.
  • Page 537 Table 1 PEST codes and action 99-839-00 to 99-871-00 PEST Error 39 RAP Code Hard/Soft Action 99-839-00 Motor, head maint vertical short. 99-834 Soft Go to the 91-567-00 to 91-568-00 Lower Carriage Error RAP. Check the 99-840-00 Motor, X axis upper open. carriage drive select motor.
  • Page 538 Table 1 PEST codes and action Table 1 PEST codes and action Code Hard/Soft Action Code Hard/Soft Action 99-840 Hard Refer to 9.9. Check the DC cabling to the X axis drive motor upper. 99-847 Soft Go to the 91-510-00, 91-511-00 X Axis Motor Over Current RAP.
  • Page 539 99-872-00 to 99-887-00 PEST Error 40 RAP Table 1 PEST codes and action Code Hard/Soft Action 99-872-00 Motor, ink SKU power low. 99-876 Hard Refer to 8.4. Check the DC cabling to the ink transport motor. Mea- 99-873-00 Motor, ink SKU power high. sure the resistance at PJ406 on the media path driver PWB for an open or short circuit and to the chassis for a short circuit.
  • Page 540 99-890-00 to 99-904-00 PEST Error 41 RAP Initial Actions WARNING 99-890-00 Motor, transfix front open. Ensure that the electricity to the machine is switched off while performing tasks that do 99-891-00 Motor, transfix front short. not need electricity. Refer to 14.
  • Page 541 Table 1 PEST codes and action Table 1 PEST codes and action Code Hard/Soft Action Code Hard/Soft Action 99-894 Soft Go to the 10-500-00 to 10-540-00 Transfix Error RAP. Check the front 99-901 Hard Refer to 8.1. Check the DC cabling to the vertical transport motor. transfix motor.
  • Page 542 99-905-00 to 99-921-00 PEST Error 42 RAP Initial Actions WARNING 99-905-00 Motor, MP6 open Ensure that the electricity to the machine is switched off while performing tasks that do 99-906-00 Motor, MP6 short not need electricity. Refer to 14. Disconnect the power cord. Electricity can cause death or injury.
  • Page 543 Table 1 PEST codes and action Table 1 PEST codes and action Code Hard/Soft Action Code Hard/Soft Action 99-911 Hard Refer to 8.1. Check the DC cabling to the registration motor A1. 99-920 Hard Refer to 8.2. Check the DC cabling to the post transfix motor (M4). Measure the resistance at PJ202 on the media path driver PWB for an Measure the resistance at PJ303 on the media path driver PWB for an open or short circuit and to the chassis for a short circuit.
  • Page 544 99-922-00 to 99-938-00 PEST Error 43 RAP Table 1 PEST codes and action Code Hard/Soft Action 99-922-00 Motor, MP4 power low. 99-925 Hard Refer to 8.2. Check the DC cabling to the exit motor (M5). Measure 99-923-00 Motor, MP4 power high. the resistance at PJ303 on the media path driver PWB for an open or short circuit and to the chassis for a short circuit.
  • Page 545 Table 1 PEST codes and action 99-939-00 to 99-954-00 PEST Error 44 RAP Code Hard/Soft Action 99-939-00 Motor, 3TM tray 3 elevator power fault. 99-936 Hard Refer to 7.5. Check the DC cabling to the 3 tray transport motor. 99-940-00 Motor, 3TM tray 1 feed open. Measure the resistance at PJ956 on the 3 tray module PWB for an open or short circuit and to the chassis for a short circuit.
  • Page 546 Table 1 PEST codes and action Table 1 PEST codes and action Code Hard/Soft Action Code Hard/Soft Action 99-941 Hard Refer to 7.3. Check the DC cabling to the tray 1 feed / elevate 99-951 Hard Refer to 7.1. Check the DC cabling to the tray 5 transport motor. motor.
  • Page 547 99-955-00 to 99-962-00 PEST Error 45 RAP Table 1 PEST codes and action Code Hard/Soft Action 99-955-00 Motor, PFP tray 5 elevate power fault. 99-961 Hard Refer to 12.23. Check the DC cabling to the OCT offset motor. 99-956-00 Motor, PFP tray 5 feed open. Measure the resistance at PJ495 on the OCT PWB for an open or short circuit and to the chassis for a short circuit.
  • Page 548 99-992-00 PEST Error 46 RAP 99-996-00 to 99-999-00 PEST Error 47 RAP 99-992-00 Front door interlock open. 99-996-00 PEST failed to complete. Initial Actions 99-997-00 Misc. WARNING 99-999-00 Hard / soft fault separator. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 549 OF 1 Unusual Noise RAP Possible causes and potential solutions are: • Grinding noise. Use this RAP to isolate unusual noises in the machine. Possible causes are: NOTE: Due to the intermittent nature of unusual noises, this RAP can only give guidance on –...
  • Page 550 Tray 1 and 2 Assembly Possible causes and potential solutions are: • No drive or a knocking noise from the bypass feed motor. Remove tray 1 and tray 2 and run the following components: Possible causes are: • Enter code dC330 code 71-002 T1 Feed / Elevate Motor, to run the tray 1 feed motor, 81.25 Item...
  • Page 551 Horizontal Paper Path • If the noise does not repeat, the source is the exit paper path, PL 10.15 Item 19. Adjust or install new components as necessary. Run the following components: Registration / pre-heat Assembly • Enter dC330 code 82-003 Horizontal Trans Motor Fwd (M6), to run the horizontal trans- port motor forward, PL 82.15 Item 9.
  • Page 552 • Enter dC330 code 82-007 Nip C Release Solenoid to open the nip 'C' release solenoid, Fans PL 82.15 Item 4. Used for short-edge feed and fast color mode. NOTE: A door cheat for the main door is not required. •...
  • Page 553 Possible causes are: • Enter dC330 code 12-250 SU1 Motor Cycle, to run the stapler unit cycle routine, 12.110 Item – The LCSS is not aligned correctly. • Enter dC330 code 12-251 BM Compiler Motor, runs the compiler BM entry roll, PL 12.175 Solution: Item...
  • Page 554 Possible causes are: OF 2 UI Touch Screen Failure RAP – The transport drive shaft or bearings. 12.130. Use this RAP to solve user interface touch screen problems when the machine has power but – Check that the paper guides are closed and located correctly. either the display is missing, is too dark or the user interface touch screen responds incorrectly Solution: or does not refresh.
  • Page 555 Use the following procedure if the machine fails to reach an operational state when switched Rocker Switch check. The switch is good on. The UI screen display’s: blank, energy saver, splash only, progress and Xerox, or repeat- edly cycles back to the install wizard screen each time the machine is switched on.
  • Page 556 NOTE: If a new hard drive is installed then the software will need to be reloaded. The green progress screen is displayed. The display stays at the green ‘Xerox’ screen. Observe the LED’s on the IME controller, Figure 2. Perform the relevant action: Green •...
  • Page 557 7-Segment LED display unit Green LED Figure 3 7-Segment LED display unit Red LED blink code. Figure 2 IME Controller LEDs Status Indicator RAPs February 2013 OF 3 ColorQube® 9303 Family 2-533...
  • Page 558 OF 4 Status Codes and Messages RAP OF 4a Status Codes in Numerical Order Use this RAP for faults and messages without fault codes. Status Code Tables • Table 1 Chain 01 Status codes The status code format is HCC-LLL-EE where HCC is the chain, LLL is the link and EE is the •...
  • Page 559 Table 1 Chain 01 Status codes Table 1 Chain 01 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 01-103-00 Paper jam in areas IME jam at zone 4a Clear the paper jam in area 4a and 01-109-00 Paper jam in areas IME jam at zone 3a...
  • Page 560 Table 1 Chain 01 Status codes Table 1 Chain 01 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 01-113-00 Paper jam in areas IME jam at zone 3a Clear the paper jam in area 3a, 3b 01-510-00 Front door is open The front door is open.
  • Page 561 Table 2 Chain 02 Status codes Table 3 Chain 03 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 02-590-00 Machine power on failed. Configurable services are Switch the machine off 03-547-00 A Fax service error Basic Fax not detected...
  • Page 562 Table 3 Chain 03 Status codes Table 3 Chain 03 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 03-558-03 Please insert money Not defined 03-559-06 Provide payment or Walk up coin entered The Job cannot be completed into the external...
  • Page 563 Table 5 Chain 05 Status codes Status Table 4 Chain 04 Status codes Code UI Message Reason for Message Reference / Action Status 05-526-00 Paper jam in the docu- A sheet is left over the DADH The fault is reset when Code UI Message Reason for Message...
  • Page 564 Table 5 Chain 05 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 05-578-00 Re-order document DADH roller feeds reaches Order new DADH feed 12-579-00 Hole punching not avail- Hole punching is not available Check that the hole feeder - feed roller but...
  • Page 565 Table 7 Chain 12 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 12-610-01 Paper jam in the finisher Paper is detected over the Clear the paper jam.
  • Page 566 Table 7 Chain 12 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 12-627-02 Paper jam in the finisher Page over the exit HVF into Clear the paper jam 12-642-00 Booklet maker staples The booklet maker staples...
  • Page 567 Table 7 Chain 12 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 12-665-00 Finisher main tray is out Bin 1 out of service status Perform the 12-151- 12-718-00 Paper jam in finisher...
  • Page 568 Table 7 Chain 12 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 12-728-00 The booklet maker tray in The booklet maker output tray Empty the tray.
  • Page 569 Table 7 Chain 12 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 12-744-00 Tray 6 (Inserter) is The inserter is unavailable The post process 12-750-00 Unexpected paper size or A shorter than expected sheet...
  • Page 570 Table 7 Chain 12 Status codes Table 7 Chain 12 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 12-765-00 Incompatible or unknown The IME interface indicates Switch the machine 12-921-00 Stapling not available.
  • Page 571 Table 9 Chain 16 Status codes Status Table 8 Chain 14 Status codes Code UI Message Reason for Message Reference / Action Status 16-507-00 Some network services SLP process stopped. Switch the machine off then Code UI Message Reason for Message Reference / Action involving SLP are not Some network control-...
  • Page 572 Table 9 Chain 16 Status codes Table 9 Chain 16 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 16-521-00 Some network services The network control- Machine services are tempo- 16-536-00 Network controller error.
  • Page 573 Table 9 Chain 16 Status codes Table 9 Chain 16 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 16-559-00 Network services using Network controller Check the BOOTP Server 16-570-00 Some network services Network controller - an Switch the machine off then...
  • Page 574 Table 9 Chain 16 Status codes Table 9 Chain 16 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 16-577-00 Network controller con- The network controller Automatic network controller 16-584-00 Network controller con- The network controller Automatic network controller...
  • Page 575 Table 9 Chain 16 Status codes Table 9 Chain 16 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 16-593-00 Some network services Network controller - Check DHCP server network 16-598-00 Some network services Network controller - Another IP address needs to...
  • Page 576 Table 10 Chain 17 Status codes Table 10 Chain 17 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 17-551-00 Server Fax service can- Server Fax service cannot Switch the machine off 17-557-00 The internet Fax service Internet Fax service cannot...
  • Page 577 On Error RAP Demand Image Over- 17-562-00 No communications with Registration with edge server User intervention is write immediately. Xerox SMart eSolutions fails required to review Printing can continue; server. Contact system SMart eSolutions set- other machine services administrator tings.
  • Page 578 Table 11 Chain 19 Status codes Status Table 12 Chain 20 Status codes Code UI Message Reason for Message Reference / Action Status 19-510-00 Please wait..the System is attempting to No service action required. Codes UI Message Reason for Message Reference / Action system is attempting to recover.
  • Page 579 Table 12 Chain 20 Status codes Table 12 Chain 20 Status codes Status Status Codes UI Message Reason for Message Reference / Action Codes UI Message Reason for Message Reference / Action 20-556-00 Fax memory error. Power Fax service error. Reset Fax Fax and LAN Fax are 20-562-00 Fax line 1 is unavailable.
  • Page 580 Table 12 Chain 20 Status codes Status Table 13 Chain 22 Status codes Codes UI Message Reason for Message Reference / Action Status 20-571-00 Fax memory error. Power Fax service error Fax line 1 is unavail- Codes UI Message Reason for Message Reference / Action off then on and notify sys- able.
  • Page 581 Table 13 Chain 22 Status codes Table 13 Chain 22 Status codes Status Status Codes UI Message Reason for Message Reference / Action Codes UI Message Reason for Message Reference / Action 22-505-00 Remove documents from Documents sensed in the To scan from the doc- 22-508-04 Scanning will be delayed Scan start up delayed whilst...
  • Page 582 Table 13 Chain 22 Status codes Status Table 14 Chain 70 to 78 Status codes Codes UI Message Reason for Message Reference / Action Status 22-558-00 - An HFSI item has reached or Reset ‘Actual’ count to Code UI Message Reason for Message Reference / Action exceeded its threshold...
  • Page 583 Table 14 Chain 70 to 78 Status codes Table 14 Chain 70 to 78 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 71-102-00 Ready to scan. Copy- Misfeed in tray 1 Clear the media jam.
  • Page 584 Table 14 Chain 70 to 78 Status codes Table 14 Chain 70 to 78 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 72-530-00 Tray 2 is empty. Add Tray 2 is out of media Add media.
  • Page 585 Table 14 Chain 70 to 78 Status codes Table 14 Chain 70 to 78 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 74-103-00 Unexpected paper size Media size mismatch in tray 4 Open tray 4, check 75-102-01 Misfeed in Tray 5.
  • Page 586 Table 14 Chain 70 to 78 Status codes Table 14 Chain 70 to 78 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 75-305-00 Tray 5 is undocked Tray 5 is undocked Re-dock tray 5 to the 75-530-00 Tray 5 is empty.
  • Page 587 Table 15 Chain 82 to 89 Status codes Table 15 Chain 82 to 89 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 82-100-01 Paper jam in area 1A IME jam at zone 1A (middle Slide tray 5 away from 88-510-00 Please wait...
  • Page 588 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 91-609-00 The machine is not Waste tray removal detected, The waste tray is cur- 91-641-00 -...
  • Page 589 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 91-840-00 - IME in jet substitution and sin- No service action 92-572-00 System fault.
  • Page 590 Reason for Message Reference / Action 93-500-00 Black Ink is empty. IME black ink is empty Load more black solid 93-822-00 Re-order Xerox Col- Magenta ink reorder threshold Load more magenta Load Xerox ColorQube ink. Copying and print- orQube Ink has been reached solid ink.
  • Page 591 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 93-877-00 - This status is raised when the Incompatible black ink 93-883-00 Incompatible cyan ink Cyan sold ink stick expected,...
  • Page 592 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 93-887-00 Incompatible black ink Black metered ink stick Check that the 93-905-00 -...
  • Page 593 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 93-925-00 Black ink stick jam. Add Black ink stick jam Black ink stick jam 93-945-00 -...
  • Page 594 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 93-952-00 - This status is raised when the Incompatible cyan ink 94-502-00 Cleaning unit is not Cleaning unit not present or not...
  • Page 595 Table 16 Chain 91 to 94 Status codes Table 16 Chain 91 to 94 Status codes Status Status Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action 94-568-00 Cleaning unit fault. Call Cleaning unit failure.
  • Page 596 OF 4b Status Messages in Alphabetical Order Table 1 Status messages - to F Status Status Message Tables UI Message Code Reason for Message Reference / Action The status message tables contain all the messages to which a status code can be attributed. 16-556-00 There is an authentica- User intervention is required to •...
  • Page 597 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action 89-561-00 NVM entries for RALPH Refer to OF 12 Service Code 91-641-00 A freeze off means that...
  • Page 598 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action 91-841-00 IME in jet substitution and No service action required.
  • Page 599 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action 93-942-00 Cyan sold ink stick Incompatible cyan ink 93-951-00 This status is raised when Incompatible magenta ink expected, DMO was...
  • Page 600 Black Ink is empty. 93-500-00 IME black ink is empty Load more black solid ink. your system adminis- form to support scan to Load Xerox Col- Copying and printing are not trator file orQube Black Ink available. Check the ink low sensor and harness.
  • Page 601 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Booklet maker staple 12-643-01 Booklet maker staples Install a new booklet maker Booklet Stapler not 12-743-00 Booklet making &...
  • Page 602 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Cleaning unit fault. 94-568-00 Cleaning unit failure. Install a new cleaning unit, Cleaning unit is not 94-502-00 Cleaning unit not present...
  • Page 603 93-510-00 IME cyan ink is empty Load more cyan solid ink. Empty chad bin 12-549-00 Hole punch chad bin is Empty chad bin Load Xerox Col- Copying and printing are not full and needs emptying orQube Cyan Ink available. Check the ink low...
  • Page 604 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Fax job limit has been 20-565-00 All jobs IDs allocated can- Switch the machine off then on, Fax line 2 is unavail- 20-550-00 Extended Fax card failure...
  • Page 605 Table 1 Status messages - to F Table 1 Status messages - to F Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Fax memory is low. 20-546-00 Not enough memory to Switch the machine off then on, Finisher Communica- 12-764-00 The IME cannot detect a...
  • Page 606 Table 1 Status messages - to F Table 2 Status messages G to N Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Finisher main tray out 12-902-00 Finisher is in degraded Switch the machine off then on, Hole punching not 12-579-00 Hole punching is not...
  • Page 607 Table 2 Status messages G to N Table 2 Status messages G to N Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Incompatible black ink 93-888-00 Black DMO ink stick Check that the machine is on Incompatible or 12-765-00 The IME interface indi-...
  • Page 608 93-825-00 The black ink low thresh- Load more black solid ink Jam in tray 5 docking 75-110-00 A Jam in tray 5 docking Clear the misfeed. Copying Load Xerox Col- old has been reached sticks. Print and other machine area area and printing are not available.
  • Page 609 14. Printing and scanning Magenta Ink is empty. 93-505-00 IME magenta ink is Load more magenta solid ink. not available. Notify can continue. If the problem Load Xerox Col- empty Copying and printing are not your system adminis- persists, perform the 16-780-00 orQube Magenta Ink.
  • Page 610 Table 2 Status messages G to N Table 2 Status messages G to N Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Network controller not 03-518-00 The network controller is Switch the machine off then on, Network services 16-510-00 The scan to E-mail pro-...
  • Page 611 No communications 17-562-00 Registration with edge User intervention is required to resources being held due to lack until resources become available. with Xerox SMart eSo- server fails review SMart eSolutions set- of resources Other machine services are unaf- lutions server. Con- tings.
  • Page 612 Table 3 Status messages O to R Table 3 Status messages O to R Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Paper feeder com- 92-535-00 IME communications Switch the machine off then on, GP Paper jam in area 01-105-00 IME jam at zone 3b...
  • Page 613 Table 3 Status messages O to R Table 3 Status messages O to R Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Paper jam in areas 01-114-00 IME jam at zone 3a Clear the paper jam in area 3a, 3b Paper jam in areas 01-106-00 IME jam at zone 3b...
  • Page 614 Table 3 Status messages O to R Table 3 Status messages O to R Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Paper jam in the 05-522-00 Sheet left over DADH Remove sheet.
  • Page 615 Table 3 Status messages O to R Table 3 Status messages O to R Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Paper jam in the 12-624-00 A sheet is over the Clear the area.
  • Page 616 Table 3 Status messages O to R Table 3 Status messages O to R Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Please enter 03-558-02 Not defined Please wait... 93-895-00 This status is raised No service action required.
  • Page 617 Table 3 Status messages O to R Table 3 Status messages O to R Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Please wait... The 12-741-00 The machine is Follow the instructions.
  • Page 618 Ready to scan. 72-102-00 Misfeed in tray 2 Clear the media jam. Copying and Copying and print- printing are not available. Re-order Xerox 93-821-00 Black ink reorder Load more black solid ink. Copying ing not available. Refer to 72-101-00 to 72-161-00...
  • Page 619 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Scan to Distribution Ser- 16-525-00 The network controller’s Some network service are Some jobs may have 19-505-00 Compressor DVMA...
  • Page 620 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Some network services 16-504-00 DDNS error. Some net- The DDNS address resolu- Some network services 16-563-00 Network controller - the...
  • Page 621 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Some network services 16-598-00 Network controller - Another IP address needs to Stapling not available.
  • Page 622 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action The current job exceeds 12-411-00 Copy job will exceed the Empty the tray The hole punch waste 12-649-00 The hole punch chad bin...
  • Page 623 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action The machine is not avail- 82-103-00 Sensor 16 LE time out Slide Tray 5 away from the The server Fax service 17-556-00 Server Fax service can-...
  • Page 624 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Tray 1 is open 71-301-00 the dedicated tray 1 is Check the paper and close Tray 2 lifting 72-536-00 Tray 2 lifting...
  • Page 625 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Tray 4 (Bypass) is not 74-313-00 Tray 4 mechanical fail- Switch the machine off then Tray 5 is overloaded.
  • Page 626 Table 4 Status messages S to Y Table 4 Status messages S to Y Status Status UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action Tray 6 (inserter) is 12-744-00 Inserter unavailable The Post Process Inserter is Unexpected paper size 75-103-01 Media size mismatch in...
  • Page 627 ‘Ready to scan your job’ state. Also, use this RAP if the software loading procedure fails. Yellow Ink is empty. 93-515-00 IME yellow ink is empty Load more yellow solid ink. Load Xerox ColorQube Copying and printing are not Initial Actions yellow ink. available. Check the ink low sensor and harness.
  • Page 628 Table 1 Single board controller PWB The output device is a HVF with a booklet maker. LED ID colour Fault State Description Install new components as necessary: Green A code appears A alpha-numeric codes appear in the win- • OCT, PL 12.00 Item dow, refer to 16.
  • Page 629 Table 2 7-Segment LED display Table 2 7-Segment LED display Decimal Decimal Fault point Fault point POST code name code status Code Description Service action POST code name code status Code Description Service action System memory Flashing Failed system memory Install a new System Machine attempt- Flashing OS resuming drivers...
  • Page 630 OF 6 Fans and Air Systems RAP OF 7 Sleep Mode RAP Use this RAP to diagnose faulty machine fans. Faulty fans can cause smells or overheating. Use this RAP when the machine has problems entering or leaving the sleep (energy saving) mode.
  • Page 631 • Analogue Power Gauge 24V. Refer to WD 1.4 9.4. OF 8 Multi-feed RAP – Source - Power Supply Unit, PJDC2, pin 31. To solve several sheet multi-feeds or extra blank sheet output problems. – Destination - Drum Driver PWB, PJ902, pin 31. –...
  • Page 632 Tray 5 OF 9 Ink Stick Count Mismatch Check the following: Use this RAP when the number of ink sticks in the ink loader does not correspond with the per- The tray moves down when the door is opened, and moves up when the door is closed. cent values shown on the UI display.
  • Page 633 OF 10 Intermittent Failure RAP • Check that the customer power does not drop below the specification when the copier is making copies; use a digital meter and select “Peak Hold”. Refer to GP 22 Electrical Use this RAP to locate failures when no specific cause can be found, i.e. if the machine resets Power Requirements.
  • Page 634 Electric Motors Checkout – Ground connection on the power cord, 12.75. – Static eliminator on bin 0 entry, PL 12.60 Item Refer to GP 10 How to Check a Motor and perform the following: – Static eliminator on the tamper assembly, PL 12.45 Item •...
  • Page 635 OF 11 Unable to Load Ink Sticks OF 12 Service Code RAP When the machine powers off the key plate is moved to prevent the customer from loading ink Where a fault occurs on the machine but the machine is still able to run the status is displayed sticks with the power off.
  • Page 636 NOTE: A number other than 0 indicates a fault. Table 1 Service code table Drum IOD Y Run Reg / Transfix Drive PEST Chronic IOD in Preheat Calibration Service Belt Warning Jets NVRAM Degraded Calibrated NVRAM Table 1 Service code table Code Error Exist...
  • Page 637 Table 1 Service code table Table 1 Service code table Drum IOD Y Run Reg / Transfix Drum IOD Y Run Reg / Transfix Drive PEST Chronic IOD in Preheat Calibration Drive PEST Chronic IOD in Preheat Calibration Service Belt Warning Jets NVRAM...
  • Page 638 Table 2 Service Actions OF 13 Convenience Stapler RAP Fault Description Actions Required To identify problems with the convenience stapler. Registration / Pre- The NVRAM has been cor- Perform dC625 Registration / Pre- Procedure heat Calibration is rupted and was reset to default heat Calibration required dC301...
  • Page 639 OF 14 Extensible Interface Platform RAP Use this RAP when experiencing faults with the Xerox Extensible Interface Platform. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to 14.
  • Page 640 Check the connection between the Card Reader and the Secure Access Authentication Overview Device. Xerox Secure Access uses an external device, such as a card reader or biometric device, to • Check which LED’s are on or blinking on the Secure Access Authentication Device. If the authorize access to the machine.
  • Page 641 Disconnect the small power cord from the Secure Access Authentication Device. Check • If the UI on the machine is locked and no secondary PIN is required. Check that the Xerox there is +5V at the connector that plugs into the Secure Access Authentication Device. If Secure Access is installed correctly, and ask customer to check the configuration at the there is no +5V, install a new the power supply.
  • Page 642 OF 16 POST Error RAP Power on Self Test (POST) occurs each time the machine is powered on. POST verifies the functionality of key subsystems before passing control to Print Engine Self Test (PEST). • Use this RAP when the UI has stalled and shows the splash-logo screen, or the system appears to have power but the UI is blank.
  • Page 643 7-Segment LED display unit Red LED, (IME error) blink code. Visible with the rear cover removed. Figure 3 SBC LED display unit Green LED, (IME OK) Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 644 The sequence loops continuously so each set of blinks does not need to be read consec- Table 1 POST Hard Fault Codes utively. Error Code Service action After the flutter count the number of blinks to determine the hundreds digit. At the end of POST_IMAGE_FPGA_MAPPING_FAILURE 224 Switch off, then switch on the machine, the first digit there will be a pause.
  • Page 645 Table 1 POST Hard Fault Codes Table 1 POST Hard Fault Codes Error Code Service action Error Code Service action ENG_ECM_FPGA_ACCESS_ERROR Switch off, then switch on the machine, ENG_MP_INT_STORM Go to the 92-546-00, 92-547-00 14. If the fault remains, install a new Interrupt Storm Faults RAP.
  • Page 646 Table 3 7-Segment LED display Decimal Table 3 7-Segment LED display Fault point Decimal POST code name code status Code Description Service action Fault point NC platform avail- Flashing NC platform available See NOTE: POST code name code status Code Description Service action able Display Test...
  • Page 647 3 Image Quality Image Quality RAPs TP 23 Drum Run Out and Y-Stitch Test Pages............... 3-102 TP 24 Registration Calibration Page ................3-103 IQ 1 Image Quality Entry RAP..................TP 25 IME Test Print ....................... 3-104 IQ 2 Copy or Print Damage RAP..................3-20 TP 26 Print Head Uniformity/Colour Bands Test Page ...........
  • Page 648 Image Quality February 2013 ColorQube® 9303 Family...

  • Page 649: Image Quality Raps

    IQ 1 Image Quality Entry RAP Procedure Use this RAP to determine the source of an image quality problem. NOTE: If possible, use the customer job to recreate the image quality defect. Print TP 1 Initial Test Print Pages. The test pages are good. Symptom descriptions use terminology listed in Table 1.
  • Page 650 Use the DADH to make copies of the initial test pages, 1. The copies are good. Go to IQ 27 Unacceptable Received Fax Image Quality RAP. Go to IQ 29 DADH, Document Glass and Scanner RAP. Refer to Table 1. Go to the relevant image quality RAP. If possible, use the customer document to make a copy from the document glass or DADH, at Make 3 copies of the colour bands test page, TP 26...
  • Page 651 Table 1 Image Quality Symptoms Term Description IQ RAP Test Pages Displaced or Fragmented Distorted images. Displaced images. See digital defects. Image Dropout Areas of missing ink pixels usually in mid-scale density areas. Image may look grainy. IQ 6 TP 11 Duplex Ghosting Faint image which shows as a gloss differential from the previous print or previous area repeated onto a subsequent print.
  • Page 652 Table 1 Image Quality Symptoms Term Description IQ RAP Test Pages Rotated image The image on the printed document has turned 90 degrees to the image printed on the original document. Go to the Scan- ning Document Size RAP. Scratch A very thin gloss band or area of removed ink from the image in the process direction caused by obstructions present in the IQ 16 TP 5...
  • Page 653 Figure 1 IQ defects 1 Image Quality February 2013 IQ 1 ColorQube® 9303 Family...
  • Page 654 Figure 2 IQ defects 2 Image Quality February 2013 IQ 1 ColorQube® 9303 Family...
  • Page 655 Figure 3 IQ defects 3 Image Quality February 2013 IQ 1 ColorQube® 9303 Family...
  • Page 656 Figure 4 IQ defects 4 Image Quality February 2013 IQ 1 3-10 ColorQube® 9303 Family...
  • Page 657 Figure 5 IQ defects 5 Image Quality February 2013 IQ 1 ColorQube® 9303 Family 3-11...
  • Page 658 Figure 6 IQ defects 6 Image Quality February 2013 IQ 1 3-12 ColorQube® 9303 Family...
  • Page 659 Figure 7 IQ defects 7 Figure 8 IQ defects 8 Image Quality February 2013 IQ 1 ColorQube® 9303 Family 3-13...
  • Page 660 Figure 9 IQ defects 9 Image Quality February 2013 IQ 1 3-14 ColorQube® 9303 Family...
  • Page 661 Figure 10 IQ defects 10 Image Quality February 2013 IQ 1 ColorQube® 9303 Family 3-15...
  • Page 662 Figure 11 IQ defects 11 Image Quality February 2013 IQ 1 3-16 ColorQube® 9303 Family...
  • Page 663 Figure 12 IQ defects 12 Image Quality February 2013 IQ 1 ColorQube® 9303 Family 3-17...
  • Page 664 Figure 13 IQ defects 13 Image Quality February 2013 IQ 1 3-18 ColorQube® 9303 Family...
  • Page 665 Test Pages NOTE: These test pages are designed to enhance subtle defects. Defects revealed by these prints may not occur in the course of ordinary printing. In servicing the system, you should min- Test pages aid in the identification of print quality problems. Table 2 lists test pages available imize the defects shown by the prints but not necessarily eliminate them.

  • Page 666: Iq 2 Copy Or Print Damage Rap

    IQ 2 Copy or Print Damage RAP Press the machine status button on the keypad. Select the Faults tab on the UI, then Use this RAP when the output copies or prints have nicks, tears, creases, folds, or curled Current Messages. If the message ‘Cleaning unit life extended, image quality may edges.
  • Page 667 Check the items that follow: Check the alignment of the HVF/HVF BM to the machine, refer to ADJ 12.1-171 Machine • Look for torn paper in the LCSS paper path. Torn fragments can pass through the IOT and to HVF/HVF BM Alignment. The alignment is good. LCSS paper path without causing a problem until they finally wedge themselves at some point.

  • Page 668: Iq 3 Blurred Image On Copies Rap

    IQ 3 Blurred Image on Copies RAP Use this RAP when copied images are blurred. Refer to Figure Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Figure 2 TP 14 test print Figure 1 Blurred copied image Image Quality February 2013 IQ 2, IQ 3...

  • Page 669: Iq 4 Wrong Copied Colours Rap

    Procedure IQ 4 Wrong Copied Colours RAP WARNING Use this RAP when the colour of the copy does not match the colour of the original. Ensure that the electricity to the machine is switched off while performing tasks that do NOTE: Due to the nature of solid ink printing, some difference in colour reproduction is normal.

  • Page 670: Iq 5 Jagged Or Blurry Lines Or Text Rap

    IQ 5 Jagged or Blurry Lines or Text RAP • Weak intensity and poor Y-dot placement in all colours and all jets of a single print- head, Figure 4. A pale band across the whole width of a head with misplacement in Use this RAP to troubleshoot the following defects: the process direction.
  • Page 671 Go to 91-637-00 Drum Runout Calibration Needed RAP. Perform SCP 5 Final Actions. Figure 2 Drum run-out defect Weak Jets with Y-Dot Error Checkout Refer to Figure Figure 1 Y-stitch or printhead roll error Image Quality February 2013 IQ 5 ColorQube®...
  • Page 672 Weak Intensity and Y-Dot Error in All Colours Across a Printhead Checkout Refer to Figure Figure 3 Weak jets with Y-dot error Go to 91-638-00 IOD Detects Chronic Jet Error RAP. Figure 4 Weak intensity and poor Y-dot position Procedure Print TP 1 Initial Test Print Pages.
  • Page 673 Y-Dot Error Checkout Install new printheads as necessary, PL 91.20 Item 2 PL 91.25 Item Refer to Figure Re-define the image quality defect, refer to IQ 1 Image Quality Entry RAP. Perform SCP 5 Final Actions. Perform SCP 5 Final Actions. Figure 5 Abnormal Y-dot position Procedure Perform...
  • Page 674 Blurry / Jagged Text Defect Checkout Perform ADJ 91.1 Printhead Attachment Check. Refer to Figure Perform dC972 option 5, Y-dot position correction. Print TP 1 Initial Test Print Pages. Compare the test pages with 3. The test pages are good. Perform the following dC972 routines:...

  • Page 675: Iq 6 Missing Ink Or Grainy Output Rap

    IQ 6 Missing Ink or Grainy Output RAP Perform ADJ 91.1 Printhead Attachment Check. Use this RAP when the output has white spots or a grainy appearance, Figure Perform SCP 5 Final Actions. A grainy appearance can be caused by: •...
  • Page 676 Initial Actions Perform dC335 Heater Monitor and Exerciser. Check the operating temperature of the drum and registration/preheat assemblies. The temperatures are within the set point WARNING range. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.

  • Page 677: Iq 7 Metering Blade Timing Rap

    IQ 7 Metering Blade Timing RAP Use this RAP to diagnose faults with operation of the cleaning unit metering blade. Blade engage out of tolerance zone Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.

  • Page 678: Iq 8 Cross Process Ink Artifacts (Smudge) Rap

    IQ 8 Cross Process Ink Artifacts (Smudge) RAP Procedure WARNING Use this RAP when the output has extra ink in localized areas in the cross process direction, Figure Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.
  • Page 679 Perform dC969 Clean Ink Smears. Print three copies of TP 4 Yellow Solid Fill Test pages (TP 2 to TP 10). The test pages are good. Install a new stripper blade assembly, PL 10.12 Item Perform SCP 5 Final Actions. Perform SCP 5 Final Actions.

  • Page 680: Iq 9 Deletions In The Process Direction Rap

    IQ 9 Deletions in the Process Direction RAP • Scraped Ink - A line of missing ink in the process direction, Figure 7. Edges of the defect are rough or jagged. Ink may appear in the margin or the trailing edge. Dis- Use this RAP to troubleshoot the following defects: tinct from multiple missing jets by the irregular edges of the deletion.
  • Page 681 X-Stitch Defect Checkout The test pages are good. Refer to Figure Perform dC914 Head to Head Alignment Test. Check the motion of the print- head stitch adjust motors, PL 91.20 Item 4 PL 91.25 Item 4. The stitch adjust motors run. Check the motion of the printhead X-axis drive motors, PL 91.20 Item 5 PL 91.25 Item...
  • Page 682 Missing or Weak Jet Checkout Refer to Figure Table 1 Problem jet identification Jet number colour label Jet problem Purple Detected missing jets that have not been labelled as chronic Chronic jet Green Missing jet for which jet substitution is enabled manually Black Jetting issue not identified by IOD.
  • Page 683 Figure 5 Weak jet 187 Figure 6 Sputtering jet 157 Figure 3 Missing jet on dithers only Figure 4 Missing jet 157 Image Quality February 2013 IQ 9 ColorQube® 9303 Family 3-37...
  • Page 684 Scraping Checkout Multiple Missing Jets Checkout Refer to Figure Refer to Figure 8. Shows multiple missing jets of a single primary colour. Figure 7 Scraping Figure 8 Multiple missing jets Procedure Procedure Check for accumulations of ink or media debris on components that could scrape the drum. Perform the following: Perform the following: Perform...
  • Page 685 Purge Line Obstruction Checkout NOTE: Drooling may occur after a purge is completed and the printhead will continue to ‘ooze’ small amounts of ink out of the printhead. Drooling may also occur at initial warm Refer to Figure up and effects all four printheads and does not continue after the purge cycle. This may eventually lead to clogged jets and may stain the face plate.
  • Page 686 Printhead Maintenance Checkout Perform dC965 Printhead Maintenance Cycle Test. Observe wiper motion during the test. Look for erratic wiper motion that may indicate wiper chatter or motor failure. The wiper moves Refer to Figure smoothly across the printhead jetstack area. Perform the following: Check the wiper mechanism, refer to the 91-572-00, 91-573-00, 91-575-00...

  • Page 687: Iq 10 Incorrect Margin, Misregistration Or Skew Rap

    Internally Leaking Printhead Checkout IQ 10 Incorrect Margin, Misregistration or Skew RAP Procedure Use this RAP to determine the source of margin, misregistration or skew, Figure Evaluate the colour bands test page, 26. Check for the following defect: Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.
  • Page 688 NOTE: W/TAG 018 machines do not have air pumps install as standard. However, Make 3, duplex prints of TP 2, cyan solid fill test page (TP 2 to TP 10). Check the prints for the preheat air pumps in a replacement registration/preheat assembly will function skew, refer to IQS 1 Registration and Skew.

  • Page 689: Iq 11 Smudges, Debris, Smears In The Process Direction, Or Paper Stack Marks Rap

    IQ 11 Smudges, Debris, Smears in the Process Direction, The defect is in the finisher. Dock and connect the finisher. Compare the marks to Figure The marks are similar to Figure 1, approximately 1 mm wide. or Paper Stack Marks RAP Use this RAP to troubleshoot the following defects: The machine has a HVF.
  • Page 690 NOTE: W/TAG 018 machines do not have air pumps install as standard. However, the preheat air pumps in a replacement registration/preheat assembly will function when the unit is installed, refer to service bulletin T8009-12-06. Refer to 88-508-00 Registration/preheat Air Pump Incorrect Current RAP. The Registration/ preheat air pump is good.
  • Page 691 Figure 2 HVF BM ejector marking example Figure 3 Streaking from IOT Image Quality February 2013 IQ 11 ColorQube® 9303 Family 3-45...

  • Page 692: Iq 12 Missing Or Partial Image Rap

    IQ 12 Missing or Partial Image RAP Initial Actions WARNING Use this RAP to troubleshoot wide deletions in the process direction that affect a complete printhead or a when a single colour is missing from a single printhead. Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.

  • Page 693: Iq 13 All Colours Uneven Rap

    Perform SCP 5 Final Actions. IQ 13 All Colours Uneven RAP Use this RAP to troubleshoot uneven colours in all four primary colours (cyan, magenta, yellow Perform SCP 5 Final Actions. and black). Install new ribbon cables on the printhead that now shows the defect, Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.
  • Page 694 X-Axis Checkout Perform dC914 Head to Head Alignment Test to check carriage motion. After cor- recting any obstructions, perform dC971 Head to Head Alignment Adjust. Reprint Refer to Figure the stitch identification test print, The prints are good. Install new components as necessary: •...
  • Page 695 Uniformity Checkout Refer to Figure Figure Figure 4 Figure Figure 3 Printhead non-uniformity on dithers Figure 2 Printhead wide non-uniformity Image Quality February 2013 IQ 13 ColorQube® 9303 Family 3-49...
  • Page 696 Figure 4 Jet to jet non-uniformity Figure 5 Jet to jet non-uniformity on dithers Procedure NOTE: Before printing the test pages, ensure that A4 or 8.5 x 11 inch plain paper is loaded long edge feed into tray 4. Use the best quality media available. Do not use hole punched paper.
  • Page 697 Option 6 Reset head uniformity data NOTE: Certain colours (such as darker shades of blue, red and green) are more prone to show process direction banding. If banding is not seen on the test prints but the issue is Option 2 Head to head alignment adjust with a particular shade of a colour as opposed to all or many shades of a colour, no other Option 3 Head to head uniformity adjustments or repairs actions are possible.
  • Page 698 Ringing Checkout Procedure Refer to Figure 6. This example is LEF in the process direction. Ringing is both pattern and If printing on A4 or 8.5 x 11 inch paper, change the media orientation in the tray. Reprint the image orientation dependent. customer job.

  • Page 699: Iq 14 Some Colours Uneven Rap

    IQ 14 Some Colours Uneven RAP • Light discolouration in wide bands across a whole printhead in the process direction, Fig- 5. Uniform light discolouration across a whole printhead. If observed, go to Ink Mixing Use this RAP to troubleshoot the following defects: in the Printhead or in the Ink Melt Reservoir Checkout.
  • Page 700 Missing Jet Checkout Ink Mixing at the Printhead Faceplate Checkout Missing jets usually occur on a single printhead. Figure 2 shows examples of missing jets on Figure 3 is an example of ink mixing at the surface of the printhead faceplate, showing the multiple printheads to indicate various combinations of colours.
  • Page 701 Ink Mixing in the Printhead or in the Ink Melt Reservoir Checkout Ink mixing may occur in the printhead or in the ink melt reservoir. Ink mixing in the printhead appears as a band across the image, Figure 4. Ink mixing in the ink melt reservoir appears as discolouration in all four printheads, Figure Figure 5 Ink mixing in the ink melt reservoir...
  • Page 702 NOTE: Before printing 26, ensure that A4 or 8.5 x 11 inch plain paper is loaded long edge Banding Checkout feed into tray 4. Use the best quality media available. Do not use hole punched paper. Refer to Figure 6 Figure Print the colour bands test page, 26.
  • Page 703 Print 1. Evaluate the cyan / magenta test page and the red, blue and green bands on the colour bands test page for non-uniform bands in the process direction. The prints are good and are without non-uniform bands. Perform the following dC972 Print Head Uniformity routines: Option 6 Reset head uniformity data...

  • Page 704: Iq 15 Wrong Colour Rap

    NOTE: Certain colours (such as darker shades of blue, red and green) are more prone to IQ 15 Wrong Colour RAP show process direction banding. If banding is not seen on the test prints but the issue is Use this RAP when the colours on the image are wrong. Refer to Figure Figure Figure 3...
  • Page 705 Switch off, then switch on the machine, 14, to clear any corrupt data. Print the colour bands and dithers test pages, 11. The colours are correct compared to the service test pattern. Perform dC968 Head Purge 3 times. Print 3 sets of cleaning pages, 22.
  • Page 706 Figure 3 Incorrectly loaded ink black into cyan Figure 2 Ink mixing (cyan into yellow) Image Quality February 2013 IQ 15 3-60 ColorQube® 9303 Family...
  • Page 707 Figure 4 Corrupt image data Figure 5 Service test pattern Image Quality February 2013 IQ 15 ColorQube® 9303 Family 3-61...

  • Page 708: Iq 16 Scratches Or Gloss Marks In The Process Direction Rap

    IQ 16 Scratches or Gloss Marks in the Process Direction Print TP 15 Media Path Test Pages to isolate where the marking is taking place. Inspect, clean, or install new rollers as necessary. If the problem persists perform the following: Use this RAP when the output displays scratches or gloss marks in the process direction.

  • Page 709: Iq 17 Gloss Marks In The Cross-Process Direction Rap

    IQ 17 Gloss Marks in the Cross-Process Direction RAP Print 5 duplex copies of TP 6 Red Solid Fill Test Pages (TP 2 to TP 10). Inspect the final test page only for metering blade chatter, refer to Figure 1. The test pages are good. Use this RAP when the output has gloss marks in the cross process direction.
  • Page 710 Feed direction Metering blade chatter Jagged streaks Figure 1 Cross-process gloss defects Image Quality February 2013 IQ 17 3-64 ColorQube® 9303 Family...

  • Page 711: Iq 18 Irregular Duplex Gloss Differences Rap

    IQ 18 Irregular Duplex Gloss Differences RAP Perform SCP 5 Final Actions. Use this RAP when the output displays gloss variations visible on large areas of high ink cover- age. Irregular gloss defects can be in any direction, Figure Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.

  • Page 712: Iq 19 Image Ghosting Rap

    IQ 19 Image Ghosting RAP Check that the front drum thermistor, PL 94.20 Item 9 and the rear drum thermistor, 94.20 Item 10 are not bent or misaligned. Check for paper debris between the thermistors Use this RAP to fix image ghosting problems. Two types of ghosting are possible, simplex and and the drum and ensure that the thermistors are making good contact with the drum.
  • Page 713 Figure 1 Example of simplex ghosting Figure 2 Duplex transfix roller ghosting Image Quality February 2013 IQ 19 ColorQube® 9303 Family 3-67...

  • Page 714: Iq 20 Wavy Or Stringy Lines Rap

    IQ 20 Wavy or Stringy Lines RAP Perform dC959 Cleaning Unit Exerciser and run the slow speed exerciser. The slow speed exerciser completes successfully. Use this RAP to fix images that have wavy or stringy lines of ink, or have a blistered appear- ance.

  • Page 715: Iq 21 Oil On Output Rap

    IQ 21 Oil on Output RAP Chronic spots or streaks Use this RAP when prints are contaminated with cleaning unit oil. of oil. May indicate a fault with the cleaning unit. Oil can transfer to prints in the form of spots, streaks, or cross-process lines from the metering blade or drum stripper blade.
  • Page 716 Initial Actions Re-install the original cleaning unit. Go to IQ 7 Metering Blade Timing • Check that the media is free of defects. Media defects can resemble oil spots. RAP. • Press the Machine Status button on the keypad, select the Fault tab on the UI, then Cur- rent Messages.

  • Page 717: Iq 22 Repeating Spot Deletions Rap

    IQ 22 Repeating Spot Deletions RAP Use this RAP when the output displays spot deletions, Figure Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity.

  • Page 718: Iq 23 Residual Ink From Previous Print Rap

    Procedure IQ 23 Residual Ink From Previous Print RAP Check the stripper gate transport rollers J and L, PL 10.10 for dirt or debris. The rollers are Use this RAP when the output has residual ink from a previous image. Refer to Figure 1 clean.
  • Page 719 Figure 2 Residual ink due to excessive skew Figure 1 Residual ink due to incomplete transfix Image Quality February 2013 IQ 23 ColorQube® 9303 Family 3-73...

  • Page 720: Iq 24 Wrinkling Rap

    IQ 24 Wrinkling RAP Use this RAP when the output is wrinkled. Refer to Figure 1 Figure NOTE: Some wrinkling of envelope flaps is normal. Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Figure 2 Wrinkles related to uneven ink coverage Figure 1 Wrinkles, reduced margins or image skew Image Quality February 2013...
  • Page 721 Procedure Go to SCP 5 Final Actions. WARNING Test the customers print job on the newly opened media. Ensure that the electricity to the machine is switched off while performing tasks that do • If the wrinkle defect is on a print job. Enter the Print Setup options / Properties / not need electricity.

  • Page 722: Iq 25 Random Spots Rap

    IQ 25 Random Spots RAP Initial Actions WARNING Use this RAP when the output has random spots. Refer to Figure Ensure that the electricity to the machine is switched off while performing tasks that do Random spots are usually ink debris from the stripper blade, abatement plenum or printheads. not need electricity.
  • Page 723 NOTE: Ink pixel build up on the metering blade is normal and should not be cleaned off Perform the slow speed exerciser routine in dC959 Cleaning Unit Exerciser. The test is suc- cessful. Go to the 94-520-00 Cleaning Unit Drive Error RAP. Open the front door and remove the inner cover.

  • Page 724: Iq 26 Poor Ink Adhesion Rap

    IQ 26 Poor Ink Adhesion RAP Initial Actions WARNING Use this RAP when the ink does not adhere to the media. Refer to Figure Ensure that the electricity to the machine is switched off while performing tasks that do Poor ink adhesion can be caused by overly glossy media coatings, improper oil application, or not need electricity.

  • Page 725: Iq 27 Unacceptable Received Fax Image Quality Rap

    IQ 27 Unacceptable Received Fax Image Quality RAP Install a new cleaning unit, PL 94.10 Item Use this RAP to identify the causes of poor reception. Check the cleaning unit metering blade for pieces of paper. Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. NOTE: Ink pixel build up on the metering blade is normal and should not be cleaned off.

  • Page 726: Iq 28 Show Through On Copies Rap

    IQ 28 Show Through on Copies RAP IQ 29 DADH, Document Glass and Scanner RAP Use this RAP when copies have show through. Use this RAP to identify defects caused by the DADH, document glass or scanner. Show through can be caused by the exposure lamp shining through low weight paper picking Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.

  • Page 727: Iq 30 Blocking Rap

    If the fault persists after the height of the DADH has been adjusted, install a new IQ 30 Blocking RAP lower baffle assembly, PL 5.30 Item 14. Re-adjust the height of the DADH to the Use this RAP when the output has ink transfer between images in the output tray stack. default setting, refer to ADJ 5.2 DADH Height Adjustment.
  • Page 728 Image Quality February 2013 IQ 29, IQ 30 3-82 ColorQube® 9303 Family...

  • Page 729: Tp 1 Initial Test Print Pages

    TP 1 Initial Test Print Pages These A4 (8.5 x 11) pages are a set of diagnostic test prints used to initially diagnose image Cyan/magenta test page quality issues in 1. TP 1 prints the five test pages shown in Figure Text print test page Initial test print pages are printed from dC612.

  • Page 730: Tp 2 To Tp 10 Solid Fill Test Pages

    TP 2 to TP 10 Solid Fill Test Pages TP 2 Cyan solid fill Solid fills are used to purge the jets of contamination or to correct cross-colour contaminated jets. Solid fills are also used to examine media damage, cleaning unit function, skew, and mar- gins.

  • Page 731: Tp 11 Colour Bands And Dithers Test Pages

    TP 11 Colour Bands and Dithers Test Pages These six A4 (8.5 x 11 inch) pages are a set of 6 diagnostic test prints used to diagnose image quality issues related to colour uniformity. Figure 1 shows the test pages printed. Colour bands and dithers test pages are printed from dC612.

  • Page 732: Tp 12 Chase Page

    TP 12 Chase Page Chase pages are picked from the selected tray and fed through the media path. No image is jetted onto the drum. Chase pages are printed from dC612. NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed. Use the best quality media available.

  • Page 733: Tp 13 Text Test Pages

    TP 13 Text Test Pages Figure 1 shows the three text test pages used to represent black, text-only printed documents. Text test pages are printed from dC612. NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed. Use the best quality media available.

  • Page 734: Tp 14 Drum Stripper Blade Test Page

    TP 14 Drum Stripper Blade Test Page This page is a diagnostic test print used to diagnose errors related to the drum stripper blade and stripper drive. The drum stripper blade test page records stripper blade activity during two typical drum stripper activation sequences. In addition to blade timing, anomalies in the blade such as warping, bounce, or edge damage may be visible in the stripped area of the image.

  • Page 735: Tp 15 Media Path Test Pages

    TP 15 Media Path Test Pages Figure 2 shows the media path test page. Print the media path test page using the same size media as the affected print. Reconstruct the media path by aligning the test pages vertically. Jam zone 1a at the top to 4b at the bottom. Compare markings on the affected print to the fea- tures on the test print to determine the jam zone, nip, or ribs affecting the output.
  • Page 736 Figure 2 Media path test pages Image Quality February 2013 TP 15 3-90 ColorQube® 9303 Family...

  • Page 737: Tp 16 Stitch Identification Test Pages

    TP 16 Stitch Identification Test Pages The print heads work together to stitch the image together. The X-stitch and Y-stitch pages print when the stitch identification selection is made from dC612. Stitch identification test pages are printed from dC612. NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed. Use the best quality media available.

  • Page 738: Tp 17 Service Usage Profile

    TP 17 Service Usage Profile This series of A4 (8.5 x 11 inch) prints list the information about the machine usage and printer status, Figure Purpose The service usage profile tracks printer activity, consumable usage and printer history. This data is stored in NVRAM. Service usage profile data includes error logs that retain detail on the type, date, location and frequency of engine and jam errors.

  • Page 739: Tp 18 Trc Generation Test Pages

    TP 18 TRC Generation Test Pages These four A4 (8.5 x 11 inch) pages have red, green, blue, or black step dithers. TRC generation test pages are printed from dC972 option 4. NOTE: Before printing this test page, ensure that A4 or 8.5 x 11 inch plain paper is loaded LEF into tray 4.

  • Page 740: Tp 19 Y-Dot Position Correction Test Page

    TP 19 Y-Dot Position Correction Test Page This A4 (8.5 x 11 inch) print consists of 1 and 5 pixel thick lines in the cross process direction. The colours of the lines are blue, green, red, black, yellow, magenta, and cyan. The Y-dot position correction test page is printed from dC972 option 5.

  • Page 741: Tp 20 Oil Bar Chase And Metering Blade Timing Test Pages

    TP 20 Oil Bar Chase and Metering Blade Timing Test Pages These test pages are used to check the operation of the cleaning unit. The oil bar chase and metering blade timing test pages are printed from dC959 cleaning unit exerciser.
  • Page 742 NOTE: The metering blade may not completely remove all pixels from the drum in the wiped area, this is normal behavior. Tolerance zones are Blade engage marked by dashed lines nominal target line on either side of the nominal target line Tolerance zones are Blade disengage marked by dashed lines...

  • Page 743: Tp 21 Jet Test Pages

    TP 21 Jet Test Pages The service jet test pages, shown in Figure 1, consists of eight test pattern pages. The first 4 pages show the conditions of print heads 1 and 2. The second 4 pages show the condition of These A4 (8.5 x 11 inch) pages are a set of diagnostic test prints used to check print head jet print heads 3 and 4.
  • Page 744 Definitions of Jet Conditions Masked jets may be visible on the jet test pages as white space where the coloured bar for the jet should be. Problem jets identified by the customer but not by the machine, NOTE: Service jet test pages are printed without jet substitution turned on and therefore will which cannot be revived, can be masked manually.
  • Page 745 Figure 6 Customer version of the jet test pages Figure 7 shows the customer version of the jet test page. This version also prints long-edge feed with the default source being tray 3. The image portion of the print is intended to show the customer effective print quality with current jet substitution settings.
  • Page 746 The text at the bottom of the customer version, Figure 7, provides the following: • Max left/right: Indicates shift position in relation to the drum. Shifting involves all the jets in the imaging process. • JSC[On,On]: indicates jet substitution is enabled (On) for both customer and machine set- tings.

  • Page 747: Tp 22 Cleaning Pages

    TP 22 Cleaning Pages NOTE: Do not use the cleaning pages to evaluate image quality. The two-sheet cleaning page, Figure 1, prints following a purge from dC968 to clear the jets of any ink discolouration. The cleaning page must print long-edge feed on A4 or 8.5 x 11 inch media.

  • Page 748: Tp 23 Drum Run Out And Y-Stitch Test Pages

    TP 23 Drum Run Out and Y-Stitch Test Pages Figure 1 shows the drum run out test pages without the defect on the horizontal lines. The two- page drum run out test print provides visual indication on the success or failure of drum run out and Y-stitch calibrations.

  • Page 749: Tp 24 Registration Calibration Page

    TP 24 Registration Calibration Page This print is generated by dC625 to calibrate the registration/preheat assembly. Calibration procedure requires A4 or 8.5 x 11 inch media. NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed. Use the best quality media available.

  • Page 750: Tp 25 Ime Test Print

    TP 25 IME Test Print • The front and rear LED’s give the same information. • There is a 7-segment LED display unit on the rear of the machine attached to the SBC This test print isolates the IME from other system issues. The image is a simple pattern of PWB.

  • Page 751: Tp 26 Print Head Uniformity/Colour Bands Test Page

    • 123 indicates a media resource error. Load the proper media or other needed items (ink, TP 26 Print Head Uniformity/Colour Bands Test Page cleaning unit, etc.). This error can occur during warm-up if the drum is dirty. A resource This A4 (8.5 x 11 inch) page has seven solid fill bars of colours, yellow, magenta, cyan, black, error detected during warm-up may require larger than the A4 or 8.5 x 11 inch media in red, green and blue.
  • Page 752 Figure 1 Print head uniformity/colour bands test page Image Quality February 2013 TP 26 3-106 ColorQube® 9303 Family...

  • Page 753: Iqs 1 Registration And Skew

    IQS 1 Registration and Skew NOTE: The measurement for skew and margin for Side 1 and Side 2 may not match Image Registration Margins Table 1 lists the registration specifications of the DADH, IIT and IOT. Refer to Figure 1. Process direction margin is measured on the leading edge at the center (3). Cross-process margin is measured on the rear edge near the leading edge corner (4).

  • Page 754: Iqs 2 Image Area

    IQS 2 Image Area Image Area Guaranteed image area is the maximum area over which IQ specifications are valid. Refer to Table 1 Figure Table 1 Image Area Specifications Characteristic Specification Maximum image area 448.6 mm (17.6 inches) (process) x 300.3 mm (11.8 inches) (cross-process) Minimum image area 210 mm (8.2 inches) (process) x 104 mm (4 inches) (cross-pro-...

  • Page 755: Iqs 3 Y-Dot Position

    IQS 3 Y-Dot Position IQS 4 Y-Stitch Specification Specification Figure 1, shows a level of position error that provides a basis for determining defect severity. If Figure 1 shows a level of y-stitch error that provides a basis for determining defect severity. If Y-dot position error exceeds Figure 1, corrective action is necessary.

  • Page 756: Iqs 5 X-Stitch

    IQS 5 X-Stitch IQS 6 Blurry Text Specification Specification Figure 1 shows a level of X-stitch error that provides a basis for determining defect severity. If Figure 1 shows a level of blurry text error that provides a basis for determining defect severity. X-stitch error exceeds Figure 1, corrective action is necessary.

  • Page 757: Iqs 7 Curl

    IQS 7 Curl IQS 8 Uniformity in the Process Direction Media Curl Specification All modules shall handle flat curl of ±12 mm in both process and cross process direction in Figure 1 shows the cyan / magenta and the colour bands print that is printed out in 1.
  • Page 758 Image Quality February 2013 IQS 7, IQS 8 3-112 ColorQube® 9303 Family...
  • Page 759 4 Repairs/Adjustments REPs 1 - Standby Power REPs 10 - Transfix and Copy/Print Transportation REP 1.1 Wiring Harness Repairs ..................REP 10.1 Transfix Roller....................4-59 REP 1.2 Molex SL Connectors..................REP 10.2 Front Transfix Linkage and Gear Kit ............... 4-60 REP 1.3 Male Hirose DF1B Connectors .................
  • Page 760 REPs 12-171 - HVF REP 12.52-171 BM Crease Rolls..................4-189 REP 12.53-171 Compiler Paper Pusher ................. 4-192 REP 12.1-171 HVF Covers ..................... 4-123 REP 12.54-171 Pusher Upper and Lower Sensors ............4-193 REP 12.2-171 HVF Stapler Assembly ................4-126 REP 12.55-171 HVF PSU Assembly ................4-193 REP 12.3-171 Top Tray ....................
  • Page 761 REPs 62- Scanner REP 81.12 Tray 5 Feed Motor ..................4-299 REP 81.13 Nip D Release Solenoid................4-299 REP 62.1 Scanner Module....................4-243 REP 82.1 3 Tray Module Transport Motor ..............4-300 REP 62.2 Top Cover ....................... 4-246 REP 82.2 3 Tray Module Transport Drive Belt ..............4-300 REP 62.3 CVT Glass, CVT Ramp and Document Glass Assembly........
  • Page 762 REP 91.32 Cleaning Unit Cam Shaft Assembly.............. 4-377 ADJs 82 - Paper Transport REP 91.33 Cleaning Unit Plug Connector ..............4-379 ADJ 82.1 Media Registration Calibration ................ 4-425 REP 91.34 Drum Pulley ....................4-380 ADJs 91 - Marking Unit REP 91.35 Front and Rear Drum Thermistor..............4-381 ADJ 91.1 Printhead Attachment Check................

  • Page 763: Rep 1.1 Wiring Harness Repairs

    REP 1.1 Wiring Harness Repairs • DADH/IIT power comms harness, PL 62.16 Item • Media path driver PWB to Tray 5 PWB harness, PL 75.68 Item Purpose • Tray 5 elevator harness, PL 75.70 Item WARNING • Tray 5 elevator motor harness, PL 81.40 Item Switch off the electricity to the machine.

  • Page 764: Rep 1.2 Molex Sl Connectors

    REP 1.2 Molex SL Connectors Figure 2. Remove the terminal from the connector housing using the Molex extractor tool. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 765 Figure 5. Check that the crimp is correctly made. Correct Incorrect Loose strands of wire Figure 3 Crimping the terminal. Insert the wire fully into the terminal so that the stripped portion of the wire is within the Crimp loose inner grip of the terminal.

  • Page 766: Rep 1.3 Male Hirose Df1B Connectors

    REP 1.3 Male Hirose DF1B Connectors NOTE: These connectors can be repaired using either crimp terminals or pre-crimped ter- minals with flying lead and butt connector, as required. Removal Figure 2. Insert the terminal into the appropriate position of the crimp tool and close the WARNING tool just enough to hold the terminal.
  • Page 767 Figure 3. Insert the crimped terminal into the appropriate position of the crimp tool and Figure 4. Check that the crimp is correctly made. close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi- nal.

  • Page 768: Rep 1.4 Amp Ei Connectors

    REP 1.4 AMP EI Connectors Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. Remove the terminal from the housing NOTE: The male housings contain socket terminals, and the female housings contain pin ter-...
  • Page 769 Replacement Figure 4. Insert the crimped terminal into the appropriate position of the crimp tool and close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi- Select the correct replacement terminal and identify the appropriate crimp positions for nal.

  • Page 770: Rep 1.5 Hirose Df11 Connectors

    Figure 5. Check that the crimp is correctly made. REP 1.5 Hirose DF11 Connectors Removal WARNING Correct Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 771: Rep 1.6 Amp Ct Connectors

    REP 1.6 AMP CT Connectors Figure 1. Remove the damaged crimp terminal from the connector housing. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 772: Rep 1.7 Molex Mini-Fit Junior Connectors

    REP 1.7 Molex Mini-Fit Junior Connectors Figure 2. Remove the terminal from the housing, using the Molex, Mini-Fit extractor tool. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 773 Figure 3. Insert the terminal into the appropriate position of the crimp tool and close the Figure 5. Check that the crimp is correctly made. tool just enough to hold the terminal. Correct Incorrect: Loose strands of wire Insulation in the crimp Figure 3 Crimping the terminal Insert the wire fully into the terminal so that the stripped portion is within the inner grip of the terminal.

  • Page 774: Rep 1.8 Front Door Interlock Switch

    REP 1.8 Front Door Interlock Switch REP 1.9 Power Supply Unit Parts List on PL 1.15 Parts List on PL 1.15 Removal Removal WARNING WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Switch off the electricity to the machine. Refer to 14.
  • Page 775 Remove the power supply unit, Figure Disconnect the ribbon cable Lift and remove the Disconnect from the drum power supply unit J6AC driver PWB Disconnect Disconnect J5AC Remove 2 Remove 2 JDC3 screws screws J4AC J8AC JDC1 JDC4 Figure 1 Disconnect harnesses Figure 2 Remove the power supply unit Remove the ribbon cable, Figure...
  • Page 776 Replacement Replacement is the reverse of the removal process. If a W/TAG 001 power supply unit is being installed, the blanking cover, PL 70.25 Item 14 (supplied with the new power supply unit) must be installed into the lower rear cover, Fig- Connect the ribbon cable to JDC2...
  • Page 777 Install the power supply unit, Figure Fit the lugs on the rear of the power supply unit over the support brackets Rest the power supply Install the 4 fixing screws to on the supports secure the power supply Figure 6 Install the power supply unit Re-connect the connectors to the power supply unit and the ribbon cable to the drum driver PWB, Figure...
  • Page 778 Repairs/Adjustments February 2013 REP 1.9 4-20 ColorQube® 9303 Family...

  • Page 779: Rep 2.1 User Interface Assembly

    REP 2.1 User Interface Assembly Prepare to detach the UI control panel, Figure Parts List on PL 2.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 780 CAUTION Remove the 4 nuts, PL 62.10 Item 8 and the 4 washers. Ensure no strain is placed upon the UI harness. Remove the UI base, PL 62.10 Item 19 and the 4 grommets, PL 62.10 Item Detach the UI control panel, Figure Replacement The replacement is the reverse of the removal procedure.

  • Page 781: Rep 2.2 User Interface Touch Screen

    REP 2.2 User Interface Touch Screen Remove the user interface touch screen, Figure Parts List on PL 2.10 Removal WARNING Remove the retainer Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 782: Rep 2.3 User Interface Pwb

    REP 2.3 User Interface PWB Remove the user interface PWB, Figure Parts List on PL 2.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 783: Rep 3.1 Ime Controller Pwb

    REP 3.1 IME Controller PWB Remove the IME controller PWB, Figure Parts List on PL 92.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 784: Rep 3.2 Quad Wave Amp Pwb

    REP 3.2 Quad Wave Amp PWB Remove the quad wave amp PWB, Figure Parts List on PL 92.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 785: Rep 3.3 Marking Unit Heater Pwb

    REP 3.3 Marking Unit Heater PWB Remove the marking unit heater PWB, Figure Parts List on PL 92.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 786: Rep 3.4 Marking Unit Driver Pwb

    REP 3.4 Marking Unit Driver PWB Remove the marking unit driver PWB, Figure Parts List on PL 92.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 787: Rep 3.5 Media Path Driver Pwb

    REP 3.5 Media Path Driver PWB Remove the media path driver PWB, Figure Parts List on PL 1.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 788: Rep 3.6 Drum Driver Pwb

    REP 3.6 Drum Driver PWB Disconnect the PJs, Figure Parts List on PL 1.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 789: Rep 3.7 Single Board Controller Pwb

    Remove the drum driver PWB, Figure REP 3.7 Single Board Controller PWB Parts List on PL 3.11 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 790: Rep 3.8 Hard Disk Drive

    Remove the single board controller PWB, Figure REP 3.8 Hard Disk Drive Parts List on PL 3.11 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 791: Rep 3.9 Nvm Module Pwb And Battery

    Remove the hard disk drive, Figure REP 3.9 NVM Module PWB and Battery Parts List on PL 3.11 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 792: Rep 3.10 Power Distribution Pwb

    Replacement REP 3.10 Power Distribution PWB CAUTION Parts List on PL 3.11 Removal Do not use a NVM module PWB that has previously been in another machine as it will transfer WARNING the machine serial number and speed to the new machine. Destroy used NVM modules. Switch off the electricity to the machine.
  • Page 793 Remove the power distribution PWB, Figure Remove the power distribution PWB. Remove 5 screws marked A. Figure 2 Removal Replacement CAUTION When installing the PWB cover, PL 3.11 Item 11, ensure that the PJ222 connector for the hard disk drive/single board controller PWB harness is not unlatched. Replacement is the reverse of the removal procedure.
  • Page 794 Repairs/Adjustments February 2013 REP 3.10 4-36 ColorQube® 9303 Family...

  • Page 795: Rep 5.1 Top Cover Assembly

    REP 5.1 Top Cover Assembly Parts List on PL 5.20 Remove the top Remove the 2 latch pins. Removal cover assembly. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 796: Rep 5.2 Top Access Cover Assembly

    REP 5.2 Top Access Cover Assembly Replacement The replacement is the reverse of the removal procedure. Make sure that the 2 springs on the Parts List on PL 5.20 idler rolls are in the correct position, Figure 2. Then install the top cover. Removal WARNING Switch off the electricity to the machine.

  • Page 797: Rep 5.3 Feed Assembly

    REP 5.3 Feed Assembly Remove the feed assembly, Figure Parts List on PL 5.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 798: Rep 5.4 Input Tray Assembly

    REP 5.4 Input Tray Assembly Remove the input tray assembly, Figure Parts List on PL 5.35 Removal Remove 3 WARNING self tapping Loosen the screws screw. Switch off the electricity to the machine. Refer to 14. Disconnect the power cord marked A.

  • Page 799: Rep 5.5 Baffle Assembly

    REP 5.5 Baffle Assembly CAUTION When the top access cover assembly, feed assembly, input tray assembly and CVT roll are Parts List on PL 5.30 removed the DADH structure is weak. Do not lower the DADH in this configuration. Removal Carefully install the DADH frame on the machine.
  • Page 800 10. Remove the baffle assembly, Figure DADH frame. Disengage the hinge pin. Slide the tab through slot in DADH frame. Disengage the lugs in the lower cover. Remove the baffle assembly. Feed the harness and ground harness through the frame. Solenoid link arm.

  • Page 801: Rep 5.6 Takeaway Roll Assembly

    Replacement REP 5.6 Takeaway Roll Assembly The replacement is the reverse of the removal procedure. Make sure that the torsion springs Parts List on PL 5.35 and harness are in the correct position, Figure Removal WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 802: Rep 5.7 Duplex Solenoid

    Remove the takeaway roll assembly, Figure REP 5.7 Duplex Solenoid NOTE: To release the tension of the drive belt on the feed motor, refer to 5.1. Parts List on PL 5.30 Removal WARNING Remove 2 E-clips. Switch off the electricity to the machine. Refer to 14.
  • Page 803 Remove the drive assembly, Figure Remove the duplex solenoid, Figure Disconnect PJ205. Remove the screw. Disconnect the link arm. Release the tension and Release the duplex sole- disengage the drive Disconnect the ground harness. noid from the clips. belts. Release the harness. Remove the drive assembly.

  • Page 804: Rep 5.8 Takeaway And Cvt Sensor

    REP 5.8 Takeaway and CVT Sensor Replacement The replacement is the reverse of the removal procedure. Make sure the spring plate and idler Parts List on PL 5.20 roll torsion springs are in the correct position. Also make sure that the CVT sensor actuator is Removal in the correct position below the CVT roll and the idler shaft.

  • Page 805: Rep 5.9 Dadh Tray Size Sensors

    REP 5.9 DADH Tray Size Sensors REP 5.10 Registration Sensor Parts List on PL 5.35 Parts List on PL 5.25 Removal Removal WARNING WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Switch off the electricity to the machine. Refer to 14.

  • Page 806: Rep 5.11 Exit Sensor

    Replacement REP 5.11 Exit Sensor The replacement is the reverse of the removal procedure. Make sure that the torsion spring is Parts List on PL 5.30 installed correctly, Figure Removal WARNING Switch off the electricity to the machine. Refer to 14.
  • Page 807 Prepare to remove the exit sensor, Figure Remove the exit sensor, Figure Disconnect PJ196. Remove the exit sensor. Disengage the lugs in the lower cover. Remove 2 Remove the lower cover. screws. Carefully remove the left hand end of the document pad from the baffle assembly.

  • Page 808: Rep 5.12 Dadh Counterbalance

    REP 5.12 DADH Counterbalance REP 5.13 Exit Roll Assembly Parts List on PL 5.10 Parts List on PL 5.35 Removal Removal WARNING WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Switch off the electricity to the machine. Refer to 14.

  • Page 809: Rep 5.14 Feed Roll Assembly

    REP 5.14 Feed Roll Assembly Remove the DADH feed roll assembly, Figure Parts List on PL 5.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 810: Rep 5.15 Duplex Gate, Cvt Roll And Cvt Motor, Drive Belt

    Replacement REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt The replacement is the reverse of the removal procedure. When the feed rolls are Parts List on PL 5.25 installed, make sure the lowest roll, (retard roll), is positioned as shown in Figure Removal If a new feed roll assembly is installed, reset the DADH feed count to zero.
  • Page 811 Disengage the back CVT roll bearing, Figure Release the front CVT roll bearing, PL 5.25 Item 4. Remove the CVT roll and CVT motor, drive belt, Figure Compress the two ends of the bearing together. Remove the CVT roll. Remove the CVT Push the bearing to disengage.

  • Page 812: Rep 5.16 Document Width Sensor

    Replacement REP 5.16 Document Width Sensor The replacement is the reverse of the removal procedure. Make sure the white washer is Parts List on PL 5.35 installed correctly, Figure Removal Perform the DADH CVT motor adjustment, refer to 5.1. WARNING Switch off the electricity to the machine.

  • Page 813: Rep 5.17 Input Tray Static Eliminator

    Remove the document width sensor, Figure REP 5.17 Input Tray Static Eliminator Parts List on PL 5.35 Removal WARNING Release the harness. Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 814: Rep 5.18 Exit Roll Idler

    REP 5.18 Exit Roll Idler Remove the exit roll idlers, Figure Parts List on PL 5.30 Removal Bearing Lift out the exit roll idlers. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity Remove the 2 bearings.

  • Page 815: Rep 5.19 Dadh Removal

    Replacement REP 5.19 DADH Removal The replacement is the reverse of the removal procedure. Make sure that the torsion spring Parts List on PL 5.10 and document finger are installed correctly, refer to Figure Removal WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 816: Rep 5.20 Mylar Guide Strip

    Remove the DADH from the machine, Figure REP 5.20 Mylar Guide Strip Parts List on PL 5.30 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 817: Rep 10.1 Transfix Roller

    REP 10.1 Transfix Roller Prepare to remove transfix roll, Figure Parts List on PL 10.20 NOTE: It may be necessary to use a screwdriver to manually rotate the front and rear transfix motor shafts to move the transfix roller away from the drum. Removal WARNING Switch off the electricity to the machine.

  • Page 818: Rep 10.2 Front Transfix Linkage And Gear Kit

    Remove transfix roller, Figure REP 10.2 Front Transfix Linkage and Gear Kit Parts List on PL 10.20 Removal Take note of the cautions above. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 819 Remove the front plate, Figure Prepare to remove transfix linkage and gear, Figure Remove 4 screws Remove 4 screws Remove 2 screws. Support the weight of the transfix linkage and gear. Refer to note. Disconnect the front transfix flexure Remove the front plate. Push the bearing out.
  • Page 820 Remove the transfix linkage and gear, Figure Figure 5 Transfix linkage Replacement Remove the transfix Remove the retract Replacement is the reverse of the removal procedure. linkage and gear. spring. Before installing the new transfix linkage, use the transfix roller retaining screws to pre - tap the three transfix roller retaining holes in the linkage.

  • Page 821: Rep 10.3 Rear Transfix Linkage And Gear Kit

    REP 10.3 Rear Transfix Linkage and Gear Kit Disconnect harnesses, Figure Parts List on PL 10.20 Removal Disconnect the ground WARNING lead Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 822 Remove 3 gears, Figure Remove 2 screws and 2 bushes, Figure Remove 1 long screw and 1 bush Remove 2 KL-clips and 2 bushes Remove 1 long screw and 1 bush Remove 3 KL-clips and 3 gears Figure 3 Gear removal Figure 4 Screw and bush removal CAUTION CAUTION...
  • Page 823 Remove the rear outer frame, Figure 10. Prepare to remove the rear transfix linkage and gear, Figure Disconnect the harnesses from both sides of the mount Remove the rear outer frame from the machine. Take care not to drop the gear Remove 1 screw to remove the...
  • Page 824 11. Remove the rear transfix linkage and gear, Figure Replacement Replacement is the reverse of the removal procedure. NOTE: Before tightening the screws, Figure 5, it may be necessary to position the bushes removed in Figure Ensure that the arm is in the correct position relative to the gear. Ensure that the spring is re-installed.

  • Page 825: Rep 10.4 Front Transfix Motor

    REP 10.4 Front Transfix Motor REP 10.5 Rear Transfix Motor Parts List on PL 10.20 Parts List on PL 10.20 Removal Removal WARNING WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Switch off the electricity to the machine. Refer to 14.

  • Page 826: Rep 10.6 Transfix Blade

    REP 10.6 Transfix Blade Replacement Insert the transfix blade into the machine, Figure Parts List on PL 10.20 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 827: Rep 10.7 Pre Transfix Sensor

    REP 10.7 Pre Transfix Sensor Parts List on PL 88.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. WARNING Take care during this procedure.
  • Page 828 Remove the lower platelet assembly, Figure Horizontal paper path Raise the cover assembly and heat shield. To release the cover assembly. Turn the dial to align the hole on the dial with the arrow as shown. Remove the screw through the hole in the frame.

  • Page 829: Rep 10.8 Post Transfix Motor (M4) And Gearbox

    Remove the air pump cover, Figure REP 10.8 Post Transfix Motor (M4) and Gearbox Parts List on PL 10.10 Removal Release the clips marked A to remove the cover. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity.

  • Page 830: Rep 10.9 Stripper Solenoid Assembly

    REP 10.9 Stripper Solenoid Assembly Replacement Replacement is the reverse of the removal procedure. Parts List on PL 10.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 831: Rep 10.10 Roller Drive J

    REP 10.10 Roller Drive J Remove the 25T gear and bearing, Figure Parts List on PL 10.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 832 Lower the upper baffle, Figure Remove roller drive J, Figure Remove roller drive J. Remove the e-clip and Remove screw Loosen screw by two bearing. turns then lower the baffle. Figure 2 Lower the upper baffle Figure 3 Roller removal Replacement Replacement is the reverse of the removal procedure.

  • Page 833: Rep 10.11 Roller Drive L

    REP 10.11 Roller Drive L Remove the 25T gear and rear bearing, Figure Parts List on PL 10.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 834 Lower the upper baffle, Figure Remove the roller drive L, Figure Remove screw Loosen the screw by two Remove roller drive L. turns then lower the baffle. Remove e-clip and bearing. Figure 2 Lower the upper baffle Figure 3 Roller removal Replacement Replacement is the reverse of the removal procedure.

  • Page 835: Rep 10.12 Exit / Duplex Solenoid

    REP 10.12 Exit / Duplex Solenoid Open the exit transport jam clearance door, Figure Parts List on PL 10.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 836 Remove the paper guide, Figure Remove the exit/duplex solenoid, Figure With the jam clearance door opened, release the 3 retaining tabs. Then remove the inner paper guide. Disconnect the harness. Remove the screw and ground lead. Figure 3 Solenoid removal Figure 2 Paper guide removal Replacement Replacement is the reverse of the removal procedure.

  • Page 837: Rep 10.13 Diverter Gate

    REP 10.13 Diverter Gate Open the exit transport jam clearance door, Figure Parts List on PL 10.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 838 Remove the ground lead, Figure Remove the diverter gate from the top exit baffle, Figure Remove the screw and ground lead. Carefully release the tab. Slide to release the guide Figure 3 Release the diverter gate Figure 2 Ground screw removal Repairs/Adjustments February 2013 REP 10.13...

  • Page 839: Rep 10.14 Exit Motor (M5)

    Remove the exit / duplex solenoid from the diverter gate assembly, Figure REP 10.14 Exit Motor (M5) Parts List on PL 10.15 Item 11 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity.
  • Page 840 Release the exit motor, Figure Remove the exit motor, Figure Disconnect the harness then remove the motor. Remove 2 screws. Figure 2 Motor release Figure 3 Motor removal Replacement Replacement is the reverse of the removal procedure. Repairs/Adjustments February 2013 REP 10.14 4-82 ColorQube®...

  • Page 841: Rep 10.15 Duplex Start Sensor (13)

    REP 10.15 Duplex Start Sensor (13) Remove the duplex sensor, Figure Parts List on PL 10.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Remove the sensor then from the customer supply while performing tasks that do not need electricity. Electricity disconnect the harness.

  • Page 842: Rep 10.16 Exit Sensor (15)

    Replacement REP 10.16 Exit Sensor (15) Replacement is the reverse of the removal procedure. Parts List on PL 10.15 Ensure that the lugs on the sensor are located correctly in the sensor holder, Figure Removal WARNING Switch off the electricity to the machine. Refer to 14.
  • Page 843 Open the exit transport jam clearance door, Figure Remove the sensor cover, Figure Release 2 cover retainers. Remove the sensor Release 2 cover retainers. cover. Open the jam clearance door by releasing the catch. Figure 2 Cover removal Figure 1 Open jam clearance door Repairs/Adjustments February 2013 REP 10.16...
  • Page 844 Remove the exit sensor, Figure Check the lugs secure the sensor in position Figure 4 Sensor location Remove the exit sensor then disconnect the harness. Figure 3 Sensor removal Replacement Replacement is the reverse of the removal procedure. Ensure that the lugs on the sensor are located correctly in the sensor holder, Figure Repairs/Adjustments February 2013...

  • Page 845: Rep 10.17 Roller Nip P

    REP 10.17 Roller Nip P Remove roller nip P, Figure Parts List on PL 10.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 846: Rep 10.18 Roller Nip N

    REP 10.18 Roller Nip N Prepare to remove the roller nip N, Figure Parts List on PL 10.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 847: Rep 10.19 Exit Illuminator Pwb

    Remove roller nip N, Figure REP 10.19 Exit Illuminator PWB Parts List on PL 10.15 Removal Remove the cover and roller nip N. WARNING Remove the screws marked A. Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity.

  • Page 848: Rep 10.20 Exit Paper Path

    Remove the exit illuminator PWB, Figure REP 10.20 Exit Paper Path Parts List on PL 10.15 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 849 Remove the exit paper path, Figure Replacement Replacement is the reverse of the removal procedure. Ensure that the exit module counter balance spring is located in the keeper, Figure Keeper Remove the exit paper path Remove the screws marked A. Counter balance spring Figure 2 Exit paper path removal Figure 3 Correct location (viewed at the rear)

  • Page 850: Rep 10.21 Stripper Blade, Gate And Baffle

    Install the exit path, Figure REP 10.21 Stripper Blade, Gate and Baffle Parts List on PL 10.12 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 851 Remove the stripper blade with the stripper blade retaining tool attached, Figure Squeeze as indicated to open the stripper blade retaining tool. Position the stripper blade retaining tool over the stripper blade and under the cover. Depress the Stripper blade retaining catch to tool release the...
  • Page 852 Remove the stripper gate and baffle, Figure After the stripper blade has been installed, remove the stripper blade retaining tool and store the tool in the base of the machine, Figure Open and close the stripper baffle several times. Check that the blade guard is correctly engaged and covering the blade when the baffle is open.

  • Page 853: Rep 10.22 Upper Baffle

    REP 10.22 Upper Baffle Prepare to remove the upper baffle, Figure Parts List on PL 10.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 854: Rep 10.23 Stripper Guide Latch Cam Shaft

    Remove the upper baffle, Figure REP 10.23 Stripper Guide Latch Cam Shaft Parts List on PL 10.10 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 855 Remove the centre 25T gear, Figure Unhook the spring and push the latch fork away from the shaft. Remove the e-clip then the shaft. Remove the KL-clip, gear and bearing. Unhook the spring and push the latch fork away from the shaft. Figure 1 Gear removal Remove the stripper guide latch cam shaft, Figure...

  • Page 856: Rep 10.24 Front And Rear Flexure Encoder

    REP 10.24 Front and Rear Flexure Encoder Parts List on PL 10.20 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 857: Rep 12.1-110 Lcss Covers

    REP 12.1-110 LCSS Covers Remove the covers, Figure Parts List on 12.10. NOTE: Removing the top cover first will allow easy removal of the front and rear covers. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Remove the top from the customer supply while performing tasks that do not need electricity.

  • Page 858: Rep 12.2-110 Input Drive Belt And Paper Entry Transport Motor

    REP 12.2-110 Input Drive Belt and Paper Entry Transport Replacement Motor Place the belt around the pulleys. Install the motor screws, but do not tighten. Parts List on 12.40. Install the spring Removal Rotate the shaft by hand to ensure the belt runs smoothly over the pulleys and allow the WARNING spring to tension the belt, 12.4-110.

  • Page 859: Rep 12.3-110 Intermediate Paper Drive Belt

    REP 12.3-110 Intermediate Paper Drive Belt Replacement Lubricate the belt tensioner, refer to 4.1. Parts List on 12.60. Install the belt over the pulleys, ensuring that the belt is on all five pulleys. Removal NOTE: Two of the pulleys are free to slide along the shaft. Ensure the belt is correctly WARNING located on these pulleys.

  • Page 860: Rep 12.4-110 Paper Output Drive Belt And Transport Motor

    REP 12.4-110 Paper Output Drive Belt and Transport Motor Parts List on 12.60. Remove the motor and Removal belt. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 861: Rep 12.5-110 Bin 1 Drive Belts

    REP 12.5-110 Bin 1 Drive Belts Parts List on 12.30. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. WARNING Take care during this procedure.
  • Page 862 Remove the bin 1 drive belt (rear) Figure NOTE: Keep all of the components removed as a set. The set of rear frame components are different from the front frame set. Remove 2 screws Remove 3 screws and release the lower and middle PWB standoffs, leaving the PWB attached by only the top Move motor assembly to...
  • Page 863 Remove the bin 1 drive belt (front) Figure Replacement NOTE: Ensure the correct set of components are used for each side of the LCSS. Reverse the removal procedure to replace the bin 1 drive belts. If not already lowered, NOTE: The bin 1 level can critically affect the overall stack registration. Refer to fully lower bin 1, refer to figure 1.

  • Page 864: Rep 12.6-110 Tamper Assembly

    REP 12.6-110 Tamper Assembly Figure 2, remove the tamper assembly. Parts List on 12.45. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 865: Rep 12.7-110 Hole Punch Unit, Motor And Sensors

    Replacement REP 12.7-110 Hole Punch Unit, Motor and Sensors Parts List on 12.20. NOTE: Ensure that the slots in the tamper assembly locate correctly in the LCSS frame. Removal NOTE: Ensure that the sensors are correctly located in the tamper assembly, they are easily mis-located when being re-connected to the harnesses.
  • Page 866 Remove the hole punch unit, motor assembly and sensors, Figure Remove 2 screws. Remove the thumb screw and slide out the punch unit. Disconnect the motor harness and remove the hole punch motor assembly. Remove 2 screws, remove sensors and disconnect the Remove the screw securing the sensor bracket.

  • Page 867: Rep 12.8-110 Stapler Traverse Assembly

    Replacement REP 12.8-110 Stapler Traverse Assembly Reverse the removal procedure to replace the hole punch unit, motor assembly and sen- Parts List on 12.55. sors. Removal If necessary, perform ADJ 12.3-110 Hole Punch Position. WARNING NOTE: When installing the hole punch motor assembly, ensure that the belt tensioner arm Switch off the electricity to the machine.

  • Page 868: Rep 12.9-110 Staple Head Unit

    CAUTION REP 12.9-110 Staple Head Unit When removing and replacing the stapler traverse assembly, support the weight of the assem- Parts List on 12.55. bly underneath the stapler and take care not to damage wiring. Removal Remove the stapler traverse assembly, Figure WARNING Switch off the electricity to the machine.

  • Page 869: Rep 12.10-110 Ejector Assembly Sensors

    Remove the staple head unit from the stapling unit Figure REP 12.10-110 Ejector Assembly Sensors Parts List on 12.50. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 870 Figure 1, remove the ejector assembly. Remove the appropriate sensor by releasing the sensor tabs and disconnecting the har- ness. Replacement CAUTION When installing the ejector assembly onto the LCSS, ensure that the ejector fingers do not damage the wiring to the staple head unit. Reverse the removal procedure to replace the eject assembly or sensors.

  • Page 871: Rep 12.11-110 Bin 1 Upper Level Sensor

    REP 12.11-110 Bin 1 Upper Level Sensor Remove the bin 1 upper level sensor, Figure Parts List on 12.35. Removal Release the WARNING sensor and Switch off the electricity to the machine. Refer to 14. Disconnect the power cord disconnect from the customer supply while performing tasks that do not need electricity.

  • Page 872: Rep 12.12-110 Paddle Wheel Shaft Assembly

    REP 12.12-110 Paddle Wheel Shaft Assembly Figure 1, remove the paddle motor assembly. Parts List on 12.25. Removal Disconnect 2 harnesses WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 873 Figure 2, prepare the rear components. Figure 3, prepare the front components. Remove the E-clip and bearing Remove the gear and flag assembly Remove 2 screws Remove the E-clip Remove 3 screws Remove E-clip and bearing Figure 2 Rear preparation Figure 3 Front preparation Ensure that the compiler ejector is in the home position (fully to the left).
  • Page 874 Figure 4, remove the paddle wheel shaft assembly. Install the flag and E-clip, refer to Figure Figure 5, ensure the paddles and flag are correctly aligned. Align paddles with the output cover Slide shaft assembly to the rear Remove the shaft assembly Ensure the encoder flag is within the sensor Figure 5 Paddle alignment...

  • Page 875: Rep 12.13-110 Lcss Un-Docking

    REP 12.13-110 LCSS Un-Docking Figure 1, release the LCSS link bracket assembly. Parts List on 12.15. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 876: Rep 12.14-110 Lcss Pwb

    REP 12.14-110 LCSS PWB REP 12.15-110 Entry Guide Cover Parts List on 12.75. Parts List on 12.70. Removal Removal WARNING WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord Switch off the electricity to the machine. Refer to 14.
  • Page 877 Figure 1, remove the entry guide cover. Replacement Bias the entry guide cover away from the paper guide when you tighten the screws. The clearance between the entry guide cover and the paper guide must be a minimum of 1 mm. Refer to Figure NOTE: If the clearance is less than 1 mm, then install a new entry guide cover.

  • Page 878: Rep 12.16-110 Docking Latch Assembly

    REP 12.16-110 Docking Latch Assembly Figure 2, remove the docking latch assembly. Parts List on 12.15. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 879: Rep 12.17-110 Ejector Belt

    REP 12.17-110 Ejector Belt Figure 1, remove the ejector belt. Parts List on 12.50. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 880: Rep 12.18-110 Paddles

    REP 12.18-110 Paddles Parts List on PL 12.25 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. NOTE: This procedure shows the replacement of the paddles with the paddle wheel shaft assembly installed.

  • Page 881: Rep 12.1-171 Hvf Covers

    REP 12.1-171 HVF Covers Parts List on PL 12.100 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. WARNING Take care during this procedure.
  • Page 882 Remove the top cover, Figure Remove the front cover, Figure NOTE: In step 1 remove the Inserter unit if fitted (See 12.82-171), or remove the NOTE: The top cover must be removed before removing the front cover. Inserter removable cover, PL 12.100 Item Remove 2 screws.
  • Page 883 Remove the rear cover, Figure NOTE: The top cover must be removed before removing the rear cover. Remove 3 screws at the rear. Remove 3 screws at the front. Remove the vent cover. Remove 3 screws. Remove 2 screws. Lift the rear cover to disengage the bottom locating tabs from Remove the frame.

  • Page 884: Rep 12.2-171 Hvf Stapler Assembly

    Replacement REP 12.2-171 HVF Stapler Assembly The replacement procedure is the reverse of the removal procedure. Parts List on 12.110. Removal Depending on the installed options and the covers removed, refit covers in the following sequence: WARNING Switch off the electricity to the machine. Refer to 14.
  • Page 885 Figure 2. With the power cord disconnected, reach behind the stapler and move the ejec- Figure 3. Remove the stapler assembly. tor unit to the out position, by turning the encoder of the ejector unit motor, MOT12-236 in the direction indicated. Remove the screw.

  • Page 886: Rep 12.3-171 Top Tray

    REP 12.3-171 Top Tray Remove the top tray, Figure Parts List on 12.100. Removal Remove top Remove the E- WARNING the tray. clip and bearing. Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 887: Rep 12.4-171 Bin 1 Removal

    REP 12.4-171 Bin 1 Removal Remove Bin 1. Figure 1 Parts List on 12.105. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 888: Rep 12.5-171 Right Side-Cover Removal

    REP 12.5-171 Right Side-Cover Removal Remove the right side-cover, Figure Parts List on 12.105. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 889: Rep 12.6-171 Hvf Ejector Assembly

    REP 12.6-171 HVF Ejector Assembly Remove the pressing plate and sensor support bracket. Figure Parts List on 12.110. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.
  • Page 890 Remove the support bracket and ejector assembly, Figure When refitting the pressing plate, the shaft of the front support finger drive gear must fit in the ejector assembly, see Figure 4. Replace the front pressing plate finger. Front pressing plate finger. Move the cover to the front to locate the shaft end.

  • Page 891: Rep 12.7-171 Pressing Plate Fingers

    REP 12.7-171 Pressing Plate Fingers REP 12.8-171 Front and Rear Support Fingers Parts List on 12.110. Parts List on 12.110. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.

  • Page 892: Rep 12.10-171 Stacker Idler Rolls

    NOTE: Set the front and rear support fingers so that their ends are aligned when extended. REP 12.10-171 Stacker Idler Rolls Figure Parts List on 12.115. With the pressing plate installed, set the front and rear support finger alignment, Figure 2.

  • Page 893: Rep 12.11-171 Front Tamper Motor Assembly

    Replacement REP 12.11-171 Front Tamper Motor Assembly Figure 2. Ensure the sprung brackets are parallel and re-install the idler rolls in the sprung Parts List on 12.125. brackets. Removal NOTE: To ease the installation of the idler roll, push the spring bracket downwards from WARNING the top.

  • Page 894: Rep 12.12-171 Bin 1 Elevator Motor Assembly

    Remove the front tamper assembly, Figure REP 12.12-171 Bin 1 Elevator Motor Assembly NOTE: The front tamper home sensor is removed to prevent the sensor from being dam- Parts List on 12.105. age when the front tamper assembly is removed. Removal WARNING Take care during this procedure.

  • Page 895: Rep 12.13-171 Hvf/Hvf Bm Un-Docking

    REP 12.13-171 HVF/HVF BM Un-Docking Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.

  • Page 896: Rep 12.14-171 Hvf Upper Exit Guide (5C)

    REP 12.14-171 HVF Upper Exit Guide (5c) Figure 2. Remove the inboard pivot screw. Parts List on 12.125. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 897: Rep 12.15-171 Hvf Rear Tamper Assembly

    Figure 3. Remove the upper exit guide. REP 12.15-171 HVF Rear Tamper Assembly Parts List on 12.110. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.
  • Page 898 Remove the rear tamper assembly, Figure Replacement Reverse the removal procedures to reinstall the rear tamper assembly. Ensure that the rear tamper assembly is located correctly, Figure Disconnect 3 PJs. Ensure that the fixing brackets Ensure that the rear support are located on the tabs at the pins are located correctly on front.

  • Page 899: Rep 12.16-171 Bm Flapper

    REP 12.16-171 BM Flapper Figure 1, remove the BM flapper bracket assembly. Parts List on 12.150. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 900: Rep 12.17-171 Bm Pwb

    Figure 2, remove the BM flapper assembly. REP 12.17-171 BM PWB Parts List on 12.175. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14. Disconnect the power cord from the cus- tomer supply while performing tasks that do not need electricity.
  • Page 901 Figure 2, remove the BM PWB. Replacement CAUTION Figure 2, ensure the BM harness and bin 2 harness are correctly positioned in the retainers to prevent damaged when the BM is moved to the extremities of its travel. Reverse the removal procedures to replace the BM PWB. The booklet maker PWB is supplied with a label with the customized NVM values for the new BM PWB.

  • Page 902: Rep 12.18-171 Bm Crease Blade Motor

    REP 12.18-171 BM Crease Blade Motor Parts List on 12.170. Purpose This procedure is used to repair the following components: • BM crease blade motor encoder sensor, PL 12.170 Item • BM crease blade motor, PL 12.170 Item • Motor encoder, PL 12.170 Item •...
  • Page 903 Figure 1, remove the BM crease blade motor assembly. Remove the motor assembly from the frame. Remove circlip, front crank and bearing. Remove 4 screws. Remove the E-clip and bearing, release the connecting rod. Remove the circlip, rear crank and bearing. Disconnect the Remove E-clip and motor harness.

  • Page 904: Rep 12.19-171 Bm Crease Roll Motor

    Figure 2, remove the BM crease blade motor. REP 12.19-171 BM Crease Roll Motor Parts List on 12.175. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.
  • Page 905 Remove the crease roll motor assembly, Figure Replacement Reverse the removal procedure to replace the BM crease roll motor. NOTE: As necessary, cut any tie wraps securing the crease roll motor harness. Before installing the motor check that the bearing is located on the drive shaft, Figure Check that the bearing is on the drive shaft.

  • Page 906: Rep 12.20-171 Bm Backstop Motor Assembly

    REP 12.20-171 BM Backstop Motor Assembly Figure 1, remove the BM backstop motor. Parts List on 12.160. Purpose This procedure is used to repair the following components: Remove allen • Ground wire, PL 12.160 Item the key and spring. • Motor damper, PL 12.160 Item •...

  • Page 907: Rep 12.21-171 Bm Backstop Assembly

    REP 12.21-171 BM Backstop Assembly Remove the two harness clamps, Figure Parts List on 12.165. Removal Lay down the BM assembly to access the WARNING backstop assembly. Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity.
  • Page 908 Remove the belt clamp, Figure 11. Remove the shaft from the BM backstop assembly, Figure Remove 2 screws. Remove the belt clamp. Remove the shaft through the BM backstop assembly bottom of the BM assembly. Figure 2 Belt clamp Figure 4 Remove the shaft Use the allen key, PL 12.160 Item 9 to remove the 2 screws and remove shaft support,...

  • Page 909: Rep 12.22-171 Bm Entry Roll

    When installing the shaft ensure that the anti-play shoe has not moved out of position, REP 12.22-171 BM Entry Roll Figure Parts List on 12.150. Purpose This procedure is used to repair the following components: • BM entry roll pulley, PL 12.150 Item Correct position of the anti-play shoe.

  • Page 910: Rep 12.23-171 Bm Entry Sensor

    Figure 1, remove the BM Entry Roll. REP 12.23-171 BM Entry Sensor Parts List on 12.150. Removal WARNING Remove E-clip, bearing, pulley and belt. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.
  • Page 911 Remove the sensor. Disconnect the sensor harness. Remove the baffle. Remove 2 screws. Remove 2 screws. Figure 1 Sensor removal Replacement Reverse the removal procedure to replace the BM entry sensor. Repairs/Adjustments February 2013 REP 12.23-171 ColorQube® 9303 Family 4-153...
  • Page 912 REP 12.24-171 BM Crease Roll Gate Motor REP 12.25-171 BM Compiler Motor and BM Flapper Motor Parts List on 12.175. Parts List on 12.175. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure.
  • Page 913 REP 12.26-171 Back Stop Drive Assembly Parts List on 12.165. Purpose Remove KL-clip This procedure is used to repair the following components: and pulley. • BM backstop link springs, PL 12.160 Item • BM backstop link, PL 12.160 Item • BM backstop drive shaft, PL 12.165 Item •...
  • Page 914 Figure 2, remove the backstop link. Figure 3, remove the BM backstop idler bracket assembly. Remove the link and two springs. Remove the bracket Press down on the link and Press down on the link and Remove 2 screws. assembly and belt. release the rear tensioner release the front tensioner link.

  • Page 915: Rep 12.27-171 Bm Staple Heads

    Figure 4, remove the BM backstop belt. REP 12.27-171 BM Staple Heads Parts List on 12.185. Removal Remove KL-clip, tensioner WARNING link and bearing. Take care during this procedure. Sharp edges may be present that can cause injury. Slide the shaft WARNING to one side.
  • Page 916 Replacement Reverse the removal procedure to replace the BM staple heads. Perform 12.3-171, Stapler Anvil Alignment. Loosen 1 screw using a 5.5 mm socket and ratchet driver. Using a 5.5 mm socket and short extension fully Disconnect the loosen the screw until the Remove 2 screws stapler harness staple head is released.
  • Page 917 REP 12.28-171 BM Stapler Bracket Assembly Figure 1, remove the BM staple head carrier closed sensor actuator. Parts List on 12.185. Purpose This procedure is used to repair the following parts: Remove • Front follower, PL 12.185 Item the KL-clip. •...
  • Page 918 Figure 2, lower the stapler bracket. Pull the stapler bracket Release the rear follower handle to open the staplers from the slot using a fully. screwdriver. Figure 2 Lowering stapler bracket Repairs/Adjustments February 2013 REP 12.28-171 4-160 ColorQube® 9303 Family...
  • Page 919 Figure 3, remove the latch shaft. Remove KL-clip and pull shaft forward 50 mm (2 inches). Pull the shaft completely to the rear to remove. Remove 2 E-clips and the front follower. Push the shaft to the rear to release the latch slide. Compress the spring, remove the rear follower and spring.
  • Page 920 Figure 4, prepare to remove the BM stapler bracket assembly. Remove KL-clip. Disconnect harnesses and ground wire. Release the spring from the side frame. Remove E-clip. Disconnect Remove 2 E-clips. ground wire. Figure 4 Preparation Repairs/Adjustments February 2013 REP 12.28-171 4-162 ColorQube®...

  • Page 921: Rep 12.29-171 Bm Conveyor Belts

    Figure 5, remove the BM stapler bracket assembly. REP 12.29-171 BM Conveyor Belts Parts List on 12.190. Removal WARNING Lever out the bearing Take care during this procedure. Sharp edges may be present that can cause injury. using a WARNING screwdriver.
  • Page 922 Figure 1, remove the idler roller. Figure 2, remove the BM conveyor belt. Release the belt from the drive pulley. Push the other bearing though the frame to remove the idler roller. Push out the shaft and remove one bearing. Remove the E-clip.

  • Page 923: Rep 12.30-171 Bm Tamper Assembly And Tamper 1 Motor

    REP 12.30-171 BM Tamper Assembly and Tamper 1 Motor Figure 1, remove the tamper assembly. Parts List on 12.155. Purpose Remove 2 screws Remove 2 screws and earth connector This procedure is used to repair the following components: • BM tamper 1 motor, PL 12.155 Item •...
  • Page 924 Figure 2, remove the front and rear tamper assemblies. Also remove the tamper gear and Figure 3, remove the tamper guide plate from each of the tamper assemblies. tamper motor. Remove 2 screws, then Remove remove the motor. the gear. Remove Remove the the E-clip.

  • Page 925: Rep 12.31-171 Hvf Buffer Guide Assembly

    REP 12.31-171 HVF Buffer Guide Assembly Figure 2. Remove the pivot screw. Parts List on 12.125. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 926: Rep 12.32-171 Hvf Input Jam Clearance Guide

    REP 12.32-171 HVF Input Jam Clearance Guide Replacement Position the spigot at the guide rear in the hole in the rear frame. The rest of the replacement Parts List on 12.125. procedure is the reverse of the removal procedure. Removal WARNING Take care during this procedure.

  • Page 927: Rep 12.33-171 Buffer Pocket Jam Clearance Guide Assembly

    REP 12.33-171 Buffer Pocket Jam Clearance Guide Figure 2. At the front of the HVF, remove the buffer pocket jam clearance guide. Assembly Parts List on 12.125. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 928: Rep 12.34-171 Inserter Jam Clearance Guide Assembly

    REP 12.34-171 Inserter Jam Clearance Guide Assembly REP 12.35-171 Diverter Exit Gate Parts List on 12.125. Parts List on 12.125. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine...

  • Page 929: Rep 12.36-171 Crease Blade Assembly

    Figure 2. Remove the diverter exit gate. REP 12.36-171 Crease Blade Assembly Parts List on 12.170. Purpose Diverter This procedure is used to repair the following components: • Connecting rod, PL 12.170 Item Remove the • Crease blade assembly, PL 12.170 Item diverter exit gate.
  • Page 930 Figure 1, remove the crease blade assembly. Figure 2, remove the front blade support. Remove 2 screws. Remove front blade support. Remove E-clip. Release the front connecting rod and bearing. Remove E-clip. Figure 2 Front support removal Manoeuvre the blade assembly Remove 4 screws.
  • Page 931 Figure 3, remove the rear blade support. CAUTION Do not loosen the three red screws that surround the lower support guides Figure 4, remove the support guides (4 places). Remove rear blade support. Remove E-clip. Depress the centre of the guide. Release the rear connecting rod and bearing.

  • Page 932: Rep 12.37-171 Stacker Driving Shaft Bearings

    REP 12.37-171 Stacker Driving Shaft Bearings Parts List on 12.115. Removal Remove the cir- WARNING clip, thrust washer and Take care during this procedure. Sharp edges may be present that can cause injury. inner bearing. WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 933: Rep 12.38-171 Hvf Stacker Driving Belts

    REP 12.38-171 HVF Stacker Driving Belts Remove the stacker driving belt, Figure Parts List on 12.105. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Remove the circlip WARNING and upper pulley if required.

  • Page 934: Rep 12.39-171 Hvf Bm Diverter Gate

    REP 12.39-171 HVF BM Diverter Gate Figure 2. Remove the BM diverter gate. Parts List on 12.125. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Open Guide 5b. Switch off the electricity to the machine. Refer to 14.

  • Page 935: Rep 12.40-171 Hvf Input Roll

    REP 12.40-171 HVF Input Roll Figure 2. At the front of the HVF, remove the circlip and bush. Parts List on 12.130. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 936: Rep 12.41-171 Hvf Inserter Guide Roll

    Figure 3. At the rear of the HVF, remove the input roll. REP 12.41-171 HVF Inserter Guide Roll Parts List on 12.130. Removal Lift the shaft and remove WARNING the belt from the pulley. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 937: Rep 12.42-171 Hvf Buffer Pocket Roll

    Figure 2. At the rear of the HVF, remove the Inserter guide roll. REP 12.42-171 HVF Buffer Pocket Roll Parts List on 12.130. Removal WARNING Remove the circlip. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 938: Rep 12.43-171 Hvf Booklet Entrance Roll

    At the rear of the HVF, remove the buffer pocket roll. The bracket can be moved if neces- REP 12.43-171 HVF Booklet Entrance Roll sary, to improve access, (two screws), Figure Parts List on 12.130. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Remove the circlip.

  • Page 939: Rep 12.44-171 Hvf Buffer Lower Roll

    Figure 2. At the rear of the HVF, remove the booklet entrance roll. REP 12.44-171 HVF Buffer Lower Roll Parts List on 12.130. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.

  • Page 940: Rep 12.45-171 Hvf Buffer Upper Roll

    Figure 2. At the rear of the HVF, remove the buffer lower roll. REP 12.45-171 HVF Buffer Upper Roll Parts List on 12.130. Removal WARNING Remove the buffer Take care during this procedure. Sharp edges may be present that can cause injury. lower roll.

  • Page 941: Rep 12.46-171 Hvf Stacker Exit Feed Roll

    Figure 2. Remove the buffer upper roll. REP 12.46-171 HVF Stacker Exit Feed Roll Parts List on 12.130. Removal Remove the circlip. Slide the pulley and the bush along the shaft. WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Slip the belt off the pulley.

  • Page 942: Rep 12.47-171 Hvf Top Exit Feed Roll

    Figure 2. Remove the stacker exit feed roll. REP 12.47-171 HVF Top Exit Feed Roll Parts List on 12.130. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Remove the idler, WARNING (1 screw). Switch off the electricity to the machine 14.
  • Page 943 Figure 2. Remove the circlip and bush. Remove the front magnet bracket screws. Figure 3. At the rear of the HVF, Remove the circlip, bush, pulley and the rear screws from the magnet bracket. Remove the circlip. Slide the pulley and the bush along the shaft.

  • Page 944: Rep 12.48-171 Compiler Paddle Motor Assembly

    Figure 4. Remove the top exit feed roll. REP 12.48-171 Compiler Paddle Motor Assembly Parts List on PL 12.120 Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.

  • Page 945: Rep 12.49-171 Compiler Paddle Unit

    REP 12.49-171 Compiler Paddle Unit Parts List on 12.115. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity.
  • Page 946 REP 12.50-171 BM Exit Sensor Figure 2, remove the BM exit sensor. Parts List on 12.185. Removal WARNING Disconnect the harness Take care during this procedure. Sharp edges may be present that can cause injury. then remove WARNING the sensor. Switch off the electricity to the machine 14.
  • Page 947 REP 12.51-171 Compiler Paper Pusher Motor Assembly REP 12.52-171 BM Crease Rolls Parts List on 12.115. Parts List on 12.180. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.
  • Page 948 Figure 1, Release the crease roll assembly at the rear. Figure 2, Release the crease roll assembly at the front. Remove 3 screws. Remove 3 screws. Remove E-clip and release the Remove the E-clip and release the arm. arm. NOTE: Flat washer between the bearing NOTE: Flat washer between and arm the bearing and arm...
  • Page 949 Figure 3, Flex the front plate to remove the crease roll assembly. Figure 4, remove the crease rolls. Remove the screws marked A. Remove the E-clips and bearings marked B. Remove the external circlips to Remove the external circlips to remove the rolls.
  • Page 950 REP 12.53-171 Compiler Paper Pusher Remove the front and rear screws and push the left edge of the compiler exit guide plate downward away from the pinion shaft, Figure Parts List on 12.115. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine.
  • Page 951 REP 12.54-171 Pusher Upper and Lower Sensors REP 12.55-171 HVF PSU Assembly Parts List on 12.115. Parts List on 12.140. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.
  • Page 952 REP 12.56-171 BM Right Hand Cover Replacement Reverse the removal procedure to replace the BM right hand cover. Parts List on 12.185. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine 14.
  • Page 953 REP 12.57-171 HVF Main PWB Disconnect the PJs, remove 9 screws and remove the PWB assembly, Figure Parts List on 12.140. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Figure 1 ESD Symbol CAUTION Ensure that ESD procedures are observed during the removal and installation of the HVF main PWB.
  • Page 954 REP 12.58-171 Not Used REP 12.59-171 Crease Roll Gate Assembly Parts List on 12.180. Purpose This procedure is used to repair the following components: • Crease roll gate rack gear, PL 12.180 Item • Crease roll gate rack drive gear, PL 12.180 Item •...
  • Page 955 Figure 1, remove the crease roll gate rack drive gear and both crease roll gate rack gears. Figure 2, Remove the front and rear crease roll gate racks. Remove E-clip and rear rack. Remove the E-clip and 2 gears. Remove E-clip and front rack.
  • Page 956 Figure 3, remove the crease roll gate. Figure 4, remove the grease roll gate front guide. Twist the gate to allow the shaft to exit the slot, then lift out the gate. Remove the guide. Remove screw. Figure 3 Gate removal Remove two screws.
  • Page 957 Figure 5, remove the grease roll gate rear guide. REP 12.60-171 BM Paper Guide Assembly Parts List on 12.150. Purpose This procedure is used to repair the following components: • Paper guide, PL 12.150 Item • Nip spring, PL 12.150 Item •...
  • Page 958 Figure 1, remove the front bearing. Figure 2, remove the rear bearing. Remove Remove the the E-clip. E-clip, then the bearing. Remove the bearing. Figure 1 Front bearing removal Figure 2 Rear bearing removal Repairs/Adjustments February 2013 REP 12.60-171 4-200 ColorQube®...
  • Page 959 Figure 3, remove the BM paper guide assembly. Figure 4, remove the components from the BM paper guide assembly. Carefully disengage the spring legs from the guide and remove the shaft assembly. Release the nip springs to remove the nip shaft and nip rolls.
  • Page 960 REP 12.61-171 BM Module Figure 1, disconnect PJ562 and PJ559 from the BM PWB. Parts List on 12.145. Removal WARNING Mandatory safety warning. This procedure must be performed by 2 people. The module is heavy. WARNING Do not undock the HVF BM from the machine. The HVF BM is unstable when undocked from the machine.
  • Page 961 Figure 2, disconnect the harness from bin 2. Figure 3, prepare to remove the BM module. Align approximately two reams of paper against the Make sure that the top of the paper Remove 2 screws. edge of the HVF BM. stack is level with the base of the BM Disconnect the harness.
  • Page 962 Figure 4, prepare to remove the BM module. Figure 5, Release the latches. Fully pull out the BM module. Disconnect the ground harness. Secure the harness to the harness Fully push in the slide. retainers. Figure 4 Preparation Pull up the right side latch to release the slide from the rail.
  • Page 963 WARNING Figure 6, remove the BM module. Use safe handling procedures when removing the module. Refer to 16. The module is heavy. WARNING Mandatory safety warning. This procedure must be performed by 2 people. The module is heavy. CAUTION Do not damage the BM front cover when the BM module is removed. NOTE: The BM module weight is 23 Kg (50.6 lb.).
  • Page 964 Replacement Figure 7, prepare to install the BM module. CAUTION Do not damage the harnesses when the BM module is installed. Ensure that the rails are cor- rectly aligned with the slides. Put the BM module on the paper stack in front of the HVF BM. Route the bin 2 harness and the ground harness to the rear of the HVF BM.
  • Page 965 REP 12.62-171 BM Slide Assembly Figure 1, Remove the slide assembly from the HVF BM frame. Parts List on 12.145. Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury.
  • Page 966 Figure 2. Remove the bracket and the slide rail from the right side of the BM module. Figure 3. Remove the two brackets from the slide rail. Remove screw. Remove screw. Remove the bracket Remove the bracket from from the slide rail. the slide rail.
  • Page 967 Figure 4, Remove the bracket and the slide rail from the left side of the BM module. Figure 5, Remove the two brackets from the slide rail Remove screw. Remove screw. Remove the bracket from the Remove the bracket from slide rail.
  • Page 968 REP 12.63-171 Transport Motor 1 REP 12.64-171 Bypass Feed Motor Parts List on 12.120. Parts List on 12.120. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.
  • Page 969 REP 12.65-171 Buffer Motor REP 12.66-171 Transport Motor 2 Parts List on 12.120. Parts List on 12.120. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.
  • Page 970 REP 12.67-171 Tri Folder Covers Remove the rear cover, the top cover and the right side cover as required, Figure Parts List on 12.200. NOTE: Open the top cover and remove the rear cover to access to the top cover rear fas- teners and the top cover interlock sensor connector.
  • Page 971 REP 12.68-171 Tri-Folder Drive Assembly Replacement Detach the coupler alignment tool from the drive unit, refer to Figure Parts List on 12.205. Install the drive assembly, Figure Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine.
  • Page 972 Centralize the coupler alignment tool onto the crease roll motor encoder disc, PL 12.175 Slacken off the drive unit retaining screws, Figure Item 13 Figure Drive unit Position the coupler alignment tool onto the crease roll motor encoder disc. Loosen the drive unit, 4 screws.
  • Page 973 Centralize the coupler alignment tool with the drive unit coupler, Figure Secure the drive unit in the centralized position, Figure Alignment tool Drive coupler Slide out the BM and remove the coupler alignment tool. Ensure the drive coupler is centralized with the alignment tool.
  • Page 974 REP 12.69-171 Tri Folder Crease Roll Drive Assembly Remove the clutch and bearing from the idler bracket, Figure Parts List on 12.205. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14.
  • Page 975 REP 12.70-171 Tri-Folder Feed Roller and Drive Belt REP 12.71-171 TF Assist Gate Solenoid Parts List on 12.205. Parts List on 12.215. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure.
  • Page 976 REP 12.72-171 Tri Folder Crease Roll Springs REP 12.73-171 Tri Folder Top Cover and Idler Assemblies Parts List on 12.215. Parts List on 12.210. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure.
  • Page 977 Remove the idler assemblies, Figure REP 12.74-171 Tri Folder Roller Assembly and Diverter Solenoid Parts List on 12.215. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Remove the top cover Switch off the electricity to the machine. Refer to 14.
  • Page 978 Remove the roller assembly through the front door, Figure Remove the diverter gate solenoid and crease roll pulleys as required, Figure Diverter gate lever. Remove 2 screws. Remove Diverter gate solenoid. Crease roll pulleys Remove 2 front screws. Assist gate solenoid Remove 2 rear screws.
  • Page 979 REP 12.75-171 Bin 1 Limit Switches Disconnect the PJs and remove the upper or lower limit switch and bracket as required, Figure Parts List on 12.105. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine.
  • Page 980 REP 12.76-171 Bin 1 Upper Level Sensor REP 12.77-171 Tri Folder Door Interlock Switches and Sensor Parts List on 12.110. Removal Parts List on 12.215. WARNING Removal Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Take care during this procedure.
  • Page 981 REP 12.78-171 Tri Folder Entry and Assist Gate Sensors REP 12.79-171 Tri Folder Exit Sensor Parts List on 12.215. Parts List on 12.215. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure.
  • Page 982 REP 12.80-171 Tri Folder PWB Remove the PWB, Figure Parts List on 12.205. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity.
  • Page 983 REP 12.81-171 Tri Folder Main and Bin 2 Tray Harnesses Remove the bin 2 tray harness, Figure Parts List on 12.205. Bookletmaker PWB to tri-folder PWB harness. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine.
  • Page 984 REP 12.82-171 Inserter Undocking Replacement Reverse the undocking procedure to dock the Inserter unit to the HVF. Parts List on 12.300. Lock the Inserter onto the HVF by sliding the latch handle towards the front, Figure Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine.
  • Page 985 REP 12.83-171 Inserter Front and Rear Covers REP 12.84-171 Inserter Motor Parts List on 12.300. Parts List on 12.315. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.
  • Page 986 REP 12.85-171 Inserter PWB Parts List on 12.310. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Figure 1 ESD Symbol CAUTION Ensure that ESD procedures are observed during the removal and installation of the inserter PWB.
  • Page 987 REP 12.86-171 Inserter Clutch Replacement Reverse the removal procedures to replace the Inserter clutch. Parts List on 12.310. When replacing the bracket, check that the clutch torque arm locates in the locating tab. Removal Put the reverse roll drive belt over the drive idler and check that the reverse roll idler gear WARNING shaft locates properly into the frame.
  • Page 988 REP 12.87-171 Inserter Top Cover Interlock Switch REP 12.88-171 Inserter Jam Cover Interlock Switch Parts List on 12.305. Parts List on 12.300. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure.
  • Page 989 Remove the top cover door and the interlock switch, Figure REP 12.89-171 Main Tray and Paper Length Sensors Parts List on 12.300. Removal Remove 2 screws from Remove the Remove 2 latch WARNING the rear. rear pivot screw, pins. then the top Take care during this procedure.
  • Page 990 REP 12.90-171 Bottom Tray and Paper Sensors Remove the bottom tray sensor bracket, Figure NOTE: Observe the position of the two springs when lifting the bottom tray. Parts List on 12.300. Removal WARNING Remove the pivot shaft Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Remove the Switch off the electricity to the machine.
  • Page 991 REP 12.91-171 Inserter Top Cover and Inserter Pickup REP 12.92-171 Lower Jam Cover and Acceleration Sensor Sensor Parts List on 12.300. Parts List on 12.310. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Take care during this procedure.
  • Page 992 REP 12.93-171 Inserter LE and TE Sensors Replacement Reverse the removal procedure to replace the LE and TE paper path sensors. Parts List on 12.310. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine.
  • Page 993 REP 12.94-171 Inserter Bottom Plate Sensor REP 12.95-171 Inserter Pickup Assembly and Reverse Feed Roller Parts List on 12.300. Removal Parts List on PL 12.310 WARNING Removal Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Take care during this procedure.
  • Page 994 Remove the reverse roller and coupling from the reverse roller shaft, Figure REP 12.96-171 HVF Fixed and Adjustable Casters Parts List on 12.100. For clarity the top Removal cover is not shown. Release the tab then remove the WARNING retard cover. Take care during this procedure.
  • Page 995 Remove the 2 screws and remove the fixed caster, Figure Support the HVF frame. Remove the screw and stop plate and rotate the caster adjust- ment wheel to unscrew the caster from the frame, Figure Stop plate Figure 1 HVF Fixed Caster Removal Figure 2 HVF Adjustable Caster Removal Replacement Reverse the removal procedure to replace the HVF fixed and adjustable casters.
  • Page 996 REP 12.97-171 Pause To Unload PWB Assembly REP 12.98-171 Inserter Idle Roller Assembly Parts List on 12.140. Parts List on 12.310. Removal Removal WARNING WARNING Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury. WARNING WARNING Switch off the electricity to the machine.
  • Page 997 Remove the 2 screws at the rear of the idle roller assembly, Figure NOTE: Check that the loading gear remains engaged with the loading shaft gear. Remove the idle roller assembly. Disconnect and then release the harness from the frame. Remove 3 screws.
  • Page 998 REP 12.99-171 Tri-Folder Removal Undock the tri-folder from the HVF. Replacement Parts List on 12.200, PL 12.205 Reverse the removal procedures to replace the tri-folder module. Removal WARNING Take care during this procedure. Sharp edges may be present that can cause injury. WARNING Switch off the electricity to the machine, 14.

  • Page 999: Rep 12.100-171 Ejector Paddle Assembly (W/Tag V-004)

    REP 12.100-171 Ejector Paddle Assembly (W/TAG V-004) Replacement Rotate the paddle shaft to ensure that the locating tab is uppermost, Figure Parts List on PL 12.110 Ensure that the longest paddle is positioned towards the stacker tray. Removal Hold the paddle assembly by the two short tabs and clip onto the shaft. WARNING NOTE: Ensure that the paddle assembly is correctly oriented to fit onto the plastic locat- Switch off the electricity to the machine,...

  • Page 1000: Rep 12.101-171 Paddle Wheel

    REP 12.101-171 Paddle Wheel Parts List on PL 12.115 Removal WARNING Switch off the electricity to the machine. Refer to 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. WARNING Take care during this procedure.

This manual is also suitable for:

Colorqube 9303fColorqube 9301Colorqube 9302Colorqube 9303

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