Page 1 OCUMENT OMPANY XEROX DocuColor 3535/2240/1632 Service Manual 701P39969 CAUTION February, 2003 Certain components in the DocuColor 3535/2240/ 1632 are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.
Page 2 Do not place tools with a reflective surface into the ROS opening. Do not look ity will be accepted by Xerox Corporation arising out of any inaccuracies or in the area of the ROS window if the power is On and the laser is energized.
Page 3: Table Of Contents
Introduction About this Manual ......................Organization........................How to Use this Documentation..................Symbology and Nomenclature ..................Translated Warnings ....................... Initial issue Introduction 02/03 DC 3535/2240/1632...
Page 4 Introduction Initial issue 02/03 DC 3535/2240/1632...
Page 5: About This Manual
About this Manual Adjustments Adjustments include procedures for adjusting the parts that must be within specification for the This Service Manual is part of the multinational documentation system for DocuColor 3535/ correct operation of the system. 2240/1632 copier/printers. The Service Documentation is used in order to diagnose machine malfunctions, adjust components and has information which is used to maintain the product in Use the adjustment procedures for the correct sequence of operation for specifications, warn- superior operating condition.
Page 6 Warnings, Cautions, and Notes CAUTION The use of controls or adjustments other than those specified in the Laser Safety Training Pro- Warnings, Cautions, and Notes will be found throughout the Service Documentation. The gram may result in an exposure to dangerous laser radiation. words WARNING or CAUTION may be listed on an illustration when the specific component associated with the potential hazard is pointed out;...
Page 7 Electrostatic Discharge (ESD) Field Service Kit The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive components are being handled. This includes activities like replacing or reseating of circuit The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of boards or connectors.
Page 8 Signal Nomenclature DC Voltage Measurements in RAPs Refer to Figure 7 for an example of Signal Nomenclature used in Circuit Diagrams and BSDs. The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead.
Page 9: Translated Warnings
Translated Warnings Initial issue Introduction 02/03 DC 3535/2240/1632...
Page 10 Quand ces symboles s'affichent le représentant Xerox est prévenu des risques DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des encourus concernant une exposition au rayon laser.
Page 11 DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des the power switch on or electrical power applied to the machine. activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des d'alimentation branché.
Page 12 REP 4.2 IBT Motor Assembly activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon d'alimentation branché. WARNING REP 5.4 DADF Control PWB To avoid personal injury or shock, do not perform repair or adjustment activities with WARNING the power switch on or electrical power applied to the machine.
Page 13 DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des the power switch on or electrical power applied to the machine. activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des d'alimentation branché.
Page 14 WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. the power switch on or electrical power applied to the machine.
Page 15 REP 7.4 Tray 1 Feed/Lift Motor d'alimentation branché. REP 7.10 Tray 2 Feeder (TTM) WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. To avoid personal injury or shock, do not perform repair or adjustment activities with DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des the power switch on or electrical power applied to the machine.
Page 16 activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon the power switch on or electrical power applied to the machine. d'alimentation branché. DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des REP 7.16 Tray 2 Feeder (3TM) activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon...
Page 17 WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. the power switch on or electrical power applied to the machine.
Page 18 WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. the power switch on or electrical power applied to the machine.
Page 19 WARNING REP 12.4 Finisher Personal injury may result from grasping hot areas of Fuser Module. If a hot Fuser Mod- WARNING ule must be removed, grasp Fuser Module by Grip Rings (Figure 1). To avoid personal injury or shock, do not perform repair or adjustment activities with DANGER: Des blessures peuvent résulter si les zones chaudes du module de four sont the power switch on or electrical power applied to the machine.
Page 20 d'alimentation branché. activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon d'alimentation branché. REP 12.10 Rail REP 12.16 Finisher PWB WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 21 the power switch on or electrical power applied to the machine. To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des d'alimentation branché.
Page 22 WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon d'alimentation branché.
Page 23 1 Service Call Procedures Service Call Procedures....................Initial Actions ........................Call Flow ......................... Detailed Maintenance Activities (HFSI)................Cleaning Procedures....................... Final Actions........................Initial issue Service Call Procedures 02/03 DC 3535/2240/1632...
Page 24 Service Call Procedures Initial issue 02/03 DC 3535/2240/1632...
Page 25: Service Call Procedures
Service Call Procedures Service Strategy The service strategy for the DocuColor 3535/2240/1632 Copier/Printer is to perform any High Frequency Service Item (HFSI) actions before attempting to repair any problems. Some prob- lems will be corrected by this strategy without the need to diagnose them. The Repair Analysis Procedures (RAPs) will be used for any remaining problems.
Page 26: Initial Actions
Initial Actions Purpose The purpose of the Initial Action section of the Service Call Procedures is to determine the rea- son for the service call and to identify and organize the actions which must be performed. Procedure Gather the information about the service call and the condition of the copier/printer. Question the operator(s).
Page 27: Call Flow
Call Flow Check the DADF Document Sensors for debris or damage. Check the mechan- ical drives and Feed Rolls for contamination, wear, damage, or binding. This procedure should be performed at every service call. Go to the RAP for the displayed fault code. Initial Actions Check the image quality in the BASIC COPIER MODE: Ask the operator about the problem.
Page 28 The problem is Image Quality (print mode) Verify that the AC power, Scan, and DDI cables are connected correctly. If the cables are OK, refer to the Network Controller service documentation to verify the correct operation of the DFE. If the Network Controller appears to be working correctly, check the following in the IOT: •...
Page 29: Detailed Maintenance Activities (Hfsi)
Detailed Maintenance Activities (HFSI) Perform the Service Actions in Table 1 for any High Frequency Service Item (HFSI) counters that are over threshold or approaching the threshold. Using the customer's out- Procedure put volume numbers (high, medium, or low volume), evaluate which HFSI actions should Clean the ADC Sensor on every call.
Page 30: Cleaning Procedures
Cleaning Procedures Final Actions Purpose Purpose The purpose is to provide cleaning procedures to be performed at every call. The intent of this procedure is to be used as a guide to follow at the end of every service call. Procedure Procedure CAUTION...
Page 31 2 Status Indicator RAPs Chain 1 3-357 IOT-ESS Communication Failure 17..............2-34 3-358 IOT-ESS Communication Failure 18..............2-35 1-300 RAP........................3-359 IOT-ESS Communication Failure 19..............2-35 1-301 RAP........................2-10 3-360 IOT-ESS Initialization Failure ................2-36 1-302 RAP........................2-11 3-364 DMA Transfer Failure.................... 2-36 1-303 RAP........................
Page 32 4-361 Drum Motor ......................2-63 6-382 ROS SOS C Length ....................2-105 4-362 IOT NVM Read Write .................... 2-65 6-383 ROS SOS K Length ....................2-106 4-363 K Drum Motor......................2-66 6-385 ROS ASIC ......................2-106 4-371 IOT Controller Timing Failure................2-68 6-389 Carriage Over Run Right..................
Page 33 8-184 Registration Sensor Off..................2-165 9-911 Drum (M) Type Mismatch..................2-205 8-620 Regicon Temp Sensor ..................2-166 9-912 Drum (C) Type Mismatch ..................2-206 8-622 Regicon Data Overflow (A1 Patch X)..............2-166 9-913 Drum (K) Type Mismatch ..................2-206 8-623 Regicon Data Overflow (A2 Patch Y)..............2-167 9-920 Toner Cartridge (Y) Empty ..................
Page 34 12-262 Eject Clamp Home Sensor Off................2-267 16-361 IOT/ESS Communication Failure 1 (ExtPrt)............2-323 12-267 Decurler ......................2-269 16-362 IOT/ESS Communication Failure 2 (ExtPrt)............2-324 12-281 Set Clamp ......................2-271 16-363 IOT/ESS Communication Failure 3 (ExtPrt)............2-324 12-301 Top Cover Interlock..................... 2-273 16-364 IOT/ESS Communication Failure 4 (ExtPrt)............
Page 35 16-729 TIFF Data......................2-349 16-958 Tray 5 Size ......................2-375 16-730 ART Command ....................2-350 16-959 Tray 1 Size ......................2-376 16-731 TIFF Data......................2-350 16-960 Tray 2 Size ......................2-376 16-735 Job Template ...................... 2-351 16-961 Tray 3 Size ......................2-377 16-737 Server Read......................
Page 36 102-313 AS Uses Wrong API..................2-401 102-365 Reserve Attribute ....................2-427 102-314 Wait Event Time Out ..................2-402 102-366 Reserve Function Code ..................2-428 102-315 CTS Internal...................... 2-402 102-367 Unsupported Function..................2-428 102-316 Send Request Queue Full SIO ................. 2-403 102-368 Short of UI Memory ...................
Page 37 103-372 IOT Sc Soft Failure ................... 2-453 116-365 Spool Fatal ......................2-478 103-701 Changed Output Bin: Side To Center ............... 2-453 116-366 Report Generator Software ................2-479 103-702 Changed Output Bin: Finisher To Center............2-454 116-367 Parallel I/F Software..................2-479 116-368 Dump Print ......................
Page 38 121-335 Foreign Interface Wake Up Answer Fail ............2-504 121-336 Unknown Foreign Device.................. 2-505 121-337 Foreign Device Self Diag Fail ................2-505 121-338 Foreign Interface Answer Time Out ..............2-506 121-350 Foreign Interface Logic Fail ................2-506 Chain 202 202-399 Internal Timer....................2-507 Other Faults OF 1-1 +3.3 VDC ......................
Page 39: Initial Issue
1-300 RAP The Left Cover is open. Procedure Enter dC330 [001-301] and press the Start button. Open and close the Left Cover 2.7). The Display changes state. +24 VDC is measured between +24 LVPS P/J502-1 and GND(-). Replace the LVPS 9.1).
Page 40 1-301 RAP The Left Lower Cover is open Procedure Enter dC330 [001-302] and press the Start button. Open the Left Lower Cover. Actuate the LH Lower Cover Interlock Switch 2.3) with a screwdriver. The display changes state. Go to the OF 99-2 RAP and repair the LH Lower Cover Interlock Switch.
Page 41 1-302 RAP The Front Cover or the Right Side Cover is open. Initial Actions Check the operation of the Actuator and the switch. Procedure Open the Front Cover. Cheat the Front Interlock Switch. The Fault Code 001-302 is cleared. +24VDC is measured between the I/F PWB P/J531-1 (+) and GND (-). +24VDC is measured between the Front Interlock Switch P/J171-B1 (+) and GND (-).
Page 42 1-303 RAP The Tray Module Left Door is open. Procedure Enter dC330 [001-304] and press the Start button. Actuate the Tray Module LH Cover Interlock Switch 16.13) with a screwdriver. The Display changes state. +24 VDC is measured between the Tray Module PWB P/J554-3 (+) and GND (-). Refer to Figure 1 and check the wires from the Tray Module PWB P/J554-3 to Tray...
Page 43 1-306 RAP The Duplex Cover is open. Procedure Enter dC330 [008-300] and press the Start button. Open the Duplex Transport. Actuate the Duplex Cover Interlock Switch 12.2) with a screwdriver. The Display changes state. Deactuate the Duplex Cover Interlock Switch. Approximately +3.3 VDC is measured between the Drawer Connector P/J626-A6 (+) and GND (-).
Page 44 Status Indicator RAPs Initial issue 02/03 1-306 2-14 DC 3535/2240/1632...
Page 45: Billing Restoration Failure
3-205 Billing Meter Mismatch 3-206 Billing Restoration Failure The billing meters on the three serialized PWBs do not match. One of the billing meters on the three serialized PWBs do not match the others. Procedure Procedure Switch the power off then on. If the fault remains, perform Switch the power off then on.
Page 46: Iit Software Failure
3-317 IIT Software Failure 3-318 IIT Software Failure Configuration mismatch Procedure Switch the power off then on. The problem continues. Procedure Change the position of the document sensor. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures. Reinstall the software.
Page 47: Iit Video Driver Failure
3-319 IIT Video Driver Failure 3-320 IIT-ESS Communication Failure 1 Video Driver declared a DMA or compression error. Controller received check code error (incorrect parameter instruction). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 48: Iit-Ess Communication Failure 2
3-321 IIT-ESS Communication Failure 2 3-322 IIT-ESS Communication Failure 3 Controller received check code error (wrong sequence number in sent message packet). Controller received check code error (wrong packet number in sent message packet). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 49: Iit-Ess Communication Failure 4
3-323 IIT-ESS Communication Failure 4 3-324 IIT-ESS Communication Failure 5 Controller received check code error (wrong message packet length in sent packet). Controller received check code error (sent packet checksum error). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 50: Iit-Ess Communication Failure 6
3-325 IIT-ESS Communication Failure 6 3-326 IIT-ESS Communication Failure 7 Controller received check code error (parity error in IISS). Controller received check code error (framing error in IISS). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 51: Iit-Ess Communication Failure 8
3-327 IIT-ESS Communication Failure 8 3-328 IIT-ESS Communication Failure 9 Controller received check code error (over-run error in IISS). Controller received check code error (transmission aborted after header received). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 52: Iit-Ess Communication Failure 10
3-329 IIT-ESS Communication Failure 10 3-330 IIT-ESS Communication Failure 11 Controller received check code error (wrong sequence number in received message packet). Controller received check code error (wrong packet number in received message packet). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 53: Iit-Ess Communication Failure 12
3-331 IIT-ESS Communication Failure 12 3-332 IIT-ESS Communication Failure 13 Controller received check code error (wrong message packet length in received packet). Controller received check code error (received packet checksum error). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 54: Iit-Ess Communication Failure 14
3-333 IIT-ESS Communication Failure 14 3-334 IIT-ESS Communication Failure 15 Controller received check code error (parity error in UART) Controller received check code error (UART framing error) Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 55: Iit-Ess Communication Failure 16
3-335 IIT-ESS Communication Failure 16 3-336 IIT-ESS Communication Failure 17 Controller received check code error (UART over-run error). Controller received check code error (reception aborted after header received). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 56: Iit-Ess Communication Failure 18
3-337 IIT-ESS Communication Failure 18 3-340 IOT-ESS Communication Failure 1 Controller received check code error (reception aborted after header received). Controller received check code error (incorrect parameter instruction). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 57: Iot-Ess Communication Failure 2
3-341 IOT-ESS Communication Failure 2 3-342 IOT-ESS Communication Failure 3 Controller received check code error (wrong sequence number in sent message packet). Controller received check code error (wrong packet number in sent message packet). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 58: Iot-Ess Communication Failure 4
3-343 IOT-ESS Communication Failure 4 3-345 IOT-ESS Communication Failure 5 Controller received check code error (wrong message packet length in sent packet). Controller received check code error (sent packet checksum error). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 59: Iot-Ess Communication Failure 6
3-346 IOT-ESS Communication Failure 6 3-347 IOT-ESS Communication Failure 7 Controller received check code error (parity error in IOT). Controller received check code error (framing error in IOT). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 60: Iot-Ess Communication Failure 8
3-348 IOT-ESS Communication Failure 8 3-349 IOT-ESS Communication Failure 9 Controller received check code error (IOT over-run error). Controller received check code error (transmission aborted after header received). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 61: Iot-Ess Communication Failure 10
3-350 IOT-ESS Communication Failure 10 3-351 IOT-ESS Communication Failure 11 Controller received check code error (wrong sequence number in received message packet). Controller received check code error (wrong packet number in received message packet). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 62: Iot-Ess Communication Failure 12
3-352 IOT-ESS Communication Failure 12 3-353 IOT-ESS Communication Failure 13 Controller received check code error (wrong message packet length in received packet). Controller received check code error (received packet checksum error). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 63: Iot-Ess Communication Failure 14
3-354 IOT-ESS Communication Failure 14 3-355 IOT-ESS Communication Failure 15 Controller received check code error (UART parity error). Controller received check code error (UART framing error). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 64: Iot-Ess Communication Failure 16
3-356 IOT-ESS Communication Failure 16 3-357 IOT-ESS Communication Failure 17 Controller received check code error (UART over-run error). Controller received check code error (reception aborted after header received). Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 65: Iot-Ess Communication Failure 18
3-358 IOT-ESS Communication Failure 18 3-359 IOT-ESS Communication Failure 19 Controller received check code error. Controller received check code error. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 66: Iot-Ess Initialization Failure
3-360 IOT-ESS Initialization Failure 3-364 DMA Transfer Failure IOT driver initialization failure. Compression/extraction did not complete. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures.
Page 67: Overflow On Write Loop Back
3-365 Overflow on Write Loop Back 3-366 Library Fail The extended data exceeds the reserved buffer size Procedure Switch the power off then on. The problem continues. Procedure Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures.
Page 68: Marker Code Detect Failure
3-370 Marker Code Detect Failure 3-747 Print Instruction Failure The end code cannot be found in the compressed data. The print parameter is incorrect. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 69: Insufficient Number Of Document Pages
3-750 Insufficient Number of Document Pages 3-761 Tray Select Error Insufficient number of pages programed when making a book. The paper sizes are different than the tray that will be selected by the APS. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on.
Page 70: Insufficient Page Memory
3-941 Insufficient Page Memory 3-942 Document Size Error Procedure DADF mode: The DADF Document Sensors cannot determine the size of the original. Switch the power off then on. The problem continues. Platen mode: The APS Sensor cannot determine the size of the original. Return to Service Call Procedures.
Page 71: Tray 1 Not In Position
3-946 Tray 1 Not In Position 3-947 Tray 2 Not In Position Tray 1 not in ready position. Tray 2 not in ready position. Initial Actions Initial Actions • Check that the paper size setting is correct. • Check that the paper size setting is correct. •...
Page 72: Tray 3 Not In Position
3-948 Tray 3 Not In Position 3-949 Tray 4 Not In Position Tray 3 not in ready position. Tray 4 not in ready position. Initial Actions Initial Actions • Check that the paper size setting is correct. • Check that the paper size setting is correct. •...
Page 73: Tray 1 Empty
3-950 Tray 1 Empty 3-951 Tray 2 Empty Paper is not detected in Tray 1 Paper is not detected in Tray 2 Procedure Procedure Remove Tray 1. Enter dC330 [007-120] and press Start. Actuate the Tray 1 No Paper Sensor The machine is equipped with a 3TM.
Page 74: Tray 3 Empty
3-952 Tray 3 Empty Paper is not detected in Tray 3 Procedure The machine is equipped with a 3TM. Remove Tray 3. Enter dC330 [007-122] and press Start. Actuate the Tray 3 No Paper Sensor 16.9). The display changes. Press Stop. Check the circuit of the Tray 3 No Paper Sensor (Figure 1).
Page 75: Tray 4 Empty
3-953 Tray 4 Empty Paper is not detected in Tray 4. Procedure The machine is equipped with a 3TM. Remove Tray 4. Enter dC330 [007-123] and press Start. Actuate the Tray 4 No Paper Sensor 16.11). The display changes. Press Stop. Check the circuit of the Tray 4 No Paper Sensor (Figure 1).
Page 76: Tray 5 Empty
3-954 Tray 5 Empty Paper is not detected in Tray 5. Procedure Enter dC330 [007-125] and press Start. Actuate the Tray 5 No Paper Sensor. The display changes. Press Stop. Check the circuit of the Tray 5 No Paper Sensor (Figure 1).
Page 77: Tray 5 Paper Size Mismatch
3-958 Tray 5 Paper Size Mismatch 3-959 Tray 1 Paper Size Mismatch The paper in the Tray 5 does not match the paper size selected. The paper in Tray 1 does not match the paper size selected. Procedure Procedure The correct size paper is loaded in Tray 5. The correct size paper is loaded in Tray 1.
Page 78: Tray 2 Paper Size Mismatch
3-960 Tray 2 Paper Size Mismatch 3-961 Tray 3 Paper Size Mismatch The paper in Tray 2 does not match the paper size selected. The paper in Tray 3 does not match the paper size selected. Procedure Procedure The correct size paper is loaded in Tray 2. The machine is equipped with a 3TM.
Page 79: Tray 4 Paper Size Mismatch
3-962 Tray 4 Paper Size Mismatch 3-965 No Paper (ATS or APS mode) The paper in Tray 4 does not match the paper size selected. The paper does not match the paper size selected. Procedure Procedure The machine is equipped with a 3TM. The correct size paper is loaded.
Page 80: Magnification
3-971 Magnification 3-972 Over Number of Document Pages Stored Incompatible Magnification selected Procedure Switch the power off then on. The problem continues. Procedure Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures. Show the customer how to set the number of document pages to the maximum count: Change parameters and rerun job.
Page 81: Next Document Specified
3-974 Next Document Specified 3-975 Document replacement request Manual placement of Next Document Specified Document replacement request when 2-sided is selected when the Platen is used for scanning Procedure Procedure Manually change documents on platen glass. The problem continues. Manually change documents on platen glass. The problem continues. Return to Service Call Procedures.
Page 82: Stapler Position Error
3-980 Stapler Position Error 3-985 Tray 5 Pause Check The Stapler is not available at the specified position. The Tray 5 tray jammed. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures.
Page 83: Print Completion Error
3-986 Print Completion Error The number of spooled pages does not match the output. Procedure Switch the power off then on. The problem continues. Return to Service Call Procedures. Count the number of prints to ensure job integrity. Initial issue Status Indicator RAPs 02/03 3-986...
Page 84 Status Indicator RAPs Initial issue 02/03 3-986 2-54 DC 3535/2240/1632...
Page 85 4-340 IOT RAM Failure MCU PWB RAM test failed. Procedure Switch the power off, then on. The problem continues. Return to Service Call Procedures. Check the connection between the MCU PWB and the MCU NVM PWB. If the check is OK, replace the MCU PWB 13.1).
Page 86: Iot Logic Failure
4-341 IOT Logic Failure MCU PWB cannot detect INTLK +5 VDC. Initial Actions • Check that the Waste Toner Bottle and all four Drum Cartridges are seated correctly. • Check fault history for 9-925 faults. If this fault has occurred recently, go to the 9-925 RAP.
Page 87: Flash Rom Limit Failure
4-342 Flash ROM Limit Failure 4-343 IOT Flash ROM Read Write Limit failure of Flash ROM Flash ROM operation failure. Procedure Procedure Switch the power off, then on. The problem continues. Switch the power off, then on. The problem continues. Return to Service Call Procedures.
Page 88: Iot Micro Pitch
4-344 IOT Micro Pitch 4-345 MCU/HVPS Communication The micro pitch did not occur within the specified time. Communication error between MCU PWB and HVPS Control PWB Procedure Procedure Switch the power off, then on. The problem continues. There is +5 VDC from P/J574-5 to P/J574-4 on the HVPS Control PWB. Return to Service Call Procedures.
Page 89: Transfer Belt Home Fault
4-346 Transfer Belt Home Fault Replace the MCU PWB 13.1). If the problem continues, replace the I/F PWB 9.1). The IBT Home Sensor does not detect the Belt Home signal. NOTE: If this fault is declared 3 times in succession, print mode will be disabled. In order to clear this condition, reset NVM location 741-056 to 0.
Page 90: Transfer Belt Out Of Position
4-347 Transfer Belt Out of Position The IBT Edge Sensor does not sense the Transfer Belt edge in the correct position. Initial Actions Check the following: • Check that the IBT Belt Cleaner is not damaged, binding, or incorrectly assembled. •...
Page 91: Transfer Belt Edge Not Detected
4-348 Transfer Belt Edge Not Detected The IBT Edge Sensor cannot sense the Transfer Belt edge. Initial Actions Check the following: • Check that the IBT Belt Cleaner is not damaged, binding, or incorrectly assembled. • Ensure that the Transfer Belt is clean, free from damage, especially the inboard edge. •...
Page 92: Marking Software Logic
4-349 Marking Software Logic 4-358 ESS IOT Communication Control Logic detected a fatal failure in the Marking software. Communication failure between the ESS and IOT. Procedure Procedure Switch the power off, then on. The problem continues. Switch the power off, then on. The problem continues. Return to Service Call Procedures.
Page 93: Drum Motor
4-361 Drum Motor NOTE: If you can measure frequency (Hz) with your meter, then you may check for 1 - 1.3 KHz on P/J535-B2. Drum Motor failure. 2.5V AC and DC is measured (1 - 1.3 KHz is measured). Initial Actions •...
Page 94 • P/J535-B4 (+) and GND (-) • P/J535-B5 (+) and GND (-) Less than +1 VDC is measured ON P/J535-B3,B4 and B5. • Check connection between MCU PWB and I/F PWB (P410). • If no problems are found, replace the MCU PWB 13.1).
Page 95: Iot Nvm Read Write
4-362 IOT NVM Read Write Read Write at the MCU PWB NVM R/W. Procedure Switch the power off, then on. The problem continues. Return to Service Call Procedures. Check the connection between the MCU PWB and the MCU NVM PWB. If the problem continues, replace the MCU PWB 13.1).
Page 96: K Drum Motor
4-363 K Drum Motor Replace Drum Motor 1.1). Drum Motor K failure. • Check connection between MCU PWB and I/F PWB (P410). Initial Actions • If no problems are found, replace the MCU PWB 13.1). • Remove all Drum Cartridges. •...
Page 97 • If no problems are found, replace the MCU PWB 13.1). • If the problem persists, replace the I/F PWB 9.1). Figure 2 4-363 RAP Circuit Diagram - Drum Motor (K) (DC3535) Figure 1 4-363 RAP Circuit Diagram - Drum Motor (K) (DC2240/1632) Initial issue Status Indicator RAPs 02/03...
Page 98: Iot Controller Timing Failure
4-371 IOT Controller Timing Failure 4-414 IBT Belt Cleaner There is a communication failure between the ESS and IOT. IBT Belt Cleaner near end of life. Procedure Procedure Switch the power off, then on. The problem continues. Replace the IBT Belt Cleaner Assembly 5.3).
Page 99: Nd Btr Unit
4-415 2nd BTR Unit 4-417 Transfer Belt Assembly It is time to replace the 2nd BTR Unit. Transfer Belt Assembly near end of life. Procedure Procedure Replace the 2nd BTR Unit 2.8). The problem continues. Replace the Transfer Belt Assembly 5.3).
Page 100: Transfer Belt Assembly
4-420 Transfer Belt Assembly 4-421 IBT Belt Cleaner Life End Transfer Belt Assembly end of life. IBT Belt Cleaner Assembly end of life. Procedure Procedure Replace the Transfer Belt Assembly 5.3). The problem continues. Replace the IBT Belt Cleaner Assembly 5.3).
Page 101: Iot Nvm Corrupt
4-605 IOT NVM Corrupt The system detected that the NVM of the IOT is empty. Procedure Switch the power off, then on. The problem continues. Return to Service Call Procedures. Replace the MCU PWB 13.1). CAUTION Careful replacement of the MCU NVM PWB (REP 1.15) is important to avoid serious machine failure.
Page 102: Belt Walk Failure
4-640 Belt Walk failure This hidden fault is declared if the dynamic (short term) color-to-color registration exceeds specification while image formation is in progress. Initial Actions Adjust the color registration (ADJ 9.6). If the problem remains, continue with the procedure. Procedure Switch on the power.
Page 103: Belt Edge Learn Failure
4-641 Belt Edge Learn Failure This hidden fault is declared if the dynamic (short term) color-to-color registration exceeds specification while edge learning is in progress. Initial Actions Check the edge of the Transfer Belt 5.3) for wear or damage. Adjust the color registration (ADJ 9.6).
Page 104: Belt Edge Check Failure
4-642 Belt Edge Check Failure 4-650 IOT Cycle Down Time Out This hidden fault is declared if the dynamic (short term) color-to-color registration exceeds Incorrect print processing continued for 2 minutes. specification while edge checking is in progress after power on or interlock actuation. Procedure Procedure Check the harness connections between the ESS PWB...
Page 105: Nd Btr Life End
4-908 2nd BTR Life End 2nd BTR end of life. Procedure Replace the 2nd BTR 2.8) (REP 9.24). The problem continues. Return to Service Call Procedures. Was the 2nd BTR Unit HFSI Counter reset in dC135 on the PWS. Reset the 2nd BTR Unit Counter. Replace the MCU PWB 13.1).
Page 106 Status Indicator RAPs Initial issue 02/03 4-908 2-76 DC 3535/2240/1632...
Page 107 5-110 Registration Sensor On Open the Document Feed Assembly and block the Registration Sensor with a sheet of paper. The display changes to L. The Registration Sensor did not detect a document within 800 msec. after the Feed Motor energized. Go to the 5-702 Registration Sensor RAP...
Page 108: Registration Sensor Off
5-111 Registration Sensor Off The document did not deactuate the Registration Sensor within 1000 msec after the DADF Belt Motor energized. Initial Actions This fault can be caused by an operator loading a large quantity of documents with too much curl.
Page 109: Registration Sensor Inversion
5-112 Registration Sensor Inversion • Check the Duplex Lower Chute for warping 20.7). Replace the chute if it is warped more than 0.6 mm end-to-end. The document does not actuate the DADF Registration Sensor within 1000 msec after the Belt •...
Page 110: Registration Sensor Inversion
5-113 Registration Sensor Inversion • Duplex Roll Drive for a mechanical load 20.6). • Duplex Chute for deformation 20.7). The document does not deactuate the DADF Registration Sensor 1500 msec after the Belt • Registration Roll for a transportation failure due to contamination, torn paper, or wear Motor energized for document inversion.
Page 111: Exit Sensor On
5-115 Exit Sensor On • Platen Glass for contamination 20.11). • Document Transport Height (ADJ 5.4). The DADF Exit Sensor does not detect a document 1500 msec after the DADF Exit Motor • DADF Exit Sensor for an improper installation 20.9).
Page 112 Figure 3 DADF Control PWB Status Indicator RAPs Initial issue 02/03 5-115 2-82 DC 3535/2240/1632...
Page 113: Exit Sensor Off
5-116 Exit Sensor Off • Static Eliminator for deformation 20.9). • Exit Roll Drive Belt for disengagement and damage 20.9). The document does not deactuate the DADF Exit Sensor after the DADF Exit Sensor actuated. Initial Actions Check the customer’s documents to ensure they meet the specification for the DADF. Ensure the Exit Roll and Exit Pinch Roll are clean and properly installed 20.9).
Page 114 Figure 3 DADF Control PWB Status Indicator RAPs Initial issue 02/03 5-116 2-84 DC 3535/2240/1632...
Page 115: Document Size Mismatch
5-195 Document Size Mismatch Different sized documents are detected in the NO MIX mode. Initial Actions This fault can be caused by the following: • Mixed size documents are fed without selecting that option on the UI. • There is too much curl in the documents being fed through the DADF. •...
Page 116: Original Size Sensor
5-274 Original Size Sensor At power on, the DADF Registration Sensor turns off, and the DADF Size Sensor 1 or the DADF Size Sensor 2 turns on (Size Sensor detection failure) Procedure Enter dC330 [5-150] and select Start. The display indicates High. Remove the DADF Entrance Tray 20.1).
Page 117: Dadf Ram Failure
5-275 DADF Ram Failure RAM failure of the DADF PWB. Procedure Switch the power off then on. The problem continues. Return to Service Call Procedures. Replace the DADF Control PWB 20.3). Initial issue Status Indicator RAPs 02/03 5-275 DC 3535/2240/1632 2-87...
Page 118: Top Cover Interlock Open
5-301 Top Cover Interlock Open The Top Cover is open. Procedure Manually actuate both DADF Top Cover Interlock Switches (front/rear) at the same time. The 5-301 fault is cleared. Remove the DADF Rear Cover (REP 5.18). Close the DADF Top Cover. Less than +1.0 VDC is measured between the DADF Control PWB P/J599-17 (+) and GND.
Page 119: Set Gate Solenoid Rap
5-700 Set Gate Solenoid RAP Use this RAP when directed to troubleshoot problems with the DADF Set Gate Solenoid. Initial Actions Remove the following: • Front Cover 20.1) • Entrance Tray 20.1) • Lower Chute Assembly (REP 5.8) • Rear Cover (REP 5.18) Check the linkage of the Set Gate Solenoid.
Page 120: Feed Motor Rap
5-701 Feed Motor RAP Use this RAP when directed to troubleshoot problems with the Feed Motor. Initial Actions Remove the following: • Front Cover 20.1) • Entrance Tray 20.1) • Lower Chute Assembly (REP 5.8) • Rear Cover (REP 5.18) Check the Feed Belt 20.4).
Page 121: Registration Sensor Rap
5-702 Registration Sensor RAP Use this RAP when directed to troubleshoot problems with the Registration Sensor. Initial Actions Remove the following: • Front Cover 20.1) • Entrance Tray 20.1) • Lower Chute Assembly (REP 5.8) • Rear Cover (REP 5.18) Ensure the document path is clear.
Page 122: Dadf Belt Motor Rap
5-703 DADF Belt Motor RAP Use this RAP when directed to troubleshoot problems with the DADF Belt Motor. Initial Actions Remove the following: • Front Cover 20.1) • Entrance Tray 20.1) • Lower Chute Assembly (REP 5.8) • Rear Cover (REP 5.18) Procedure...
Page 123: Document Sensor Timing
5-900 Document Sensor Timing 5-901 Power On Document Present One of the following DADF Interlocks was opened during DADF operation: The Document Sensor detects a document at Power On. • DADF Interlock Switch 20.3) Initial Actions • Top Cover Interlock Switch (Front) 20.2) Clean the Document Sensor.
Page 124: Power On Registration Sensor
5-902 Power On Registration Sensor 5-903 Power On Exit Sensor The Registration Sensor detected a document when the Top Cover/platen Interlock was closed The DADF Exit Sensor detected a document when the Top Cover/platen Interlock was closed or power was switched on. or power was switched on.
Page 125: Power On Duplex Sensor
5-904 Power On Duplex Sensor 5-940 Document Removed During Start The DADF Duplex Sensor detected a document when the Top Cover/platen Interlock was The Control Logic detected that the document was removed immediately after the DADF closed or power was switched on started.
Page 126: Document Miscount
5-941 Document Miscount The software detected a document miscount. Procedure Rerun the job. 5-941 continues. Return to Service Call Procedures. Replace the DADF Control PWB 20.3). Status Indicator RAPs Initial issue 02/03 5-941 2-96 DC 3535/2240/1632...
Page 127 6-277 IIT/DADF Communication Communication cannot be established between the IIT/IPS and the DADF Control PWB. Procedure Switch on the power. CR4 on the DADF Control PWB illuminates. +5VDC is measured between the DADF Control PWB P/J550-6 (+) and ground (-). Check the +5VDC circuit to the DADF Control PWB P/J550-6 by referring to Section 7 Wiring Data (DADF+5VDC) Replace the DADF Control PWB...
Page 128: Dadf Open
6-300 DADF Open 6-312 IIT Memory Hot Line The DADF was opened during the DADF Job. The system detected an open circuit in the IIT Memory Hot Line. Procedure Procedure Enter dC330 [006-300] and place a magnet over the Platen Open Switch 18.4).
Page 129: Ess Ram Test Error
6-340 ESS RAM Test Error 6-345 ESS ROM At power on, the system detected a IIT/IPS PWB RAM test error. • The NVM value cannot be written at the IIT/IPS PWB Write. • A communication failure with the ROM was detected. Procedure Procedure Switch the power off then on.
Page 130: Ips Fan
6-355 IPS Fan The control logic detects an IPS Fan failure. Procedure Enter dC330 [006-014] and select Start. The IPS FAN 18.4) energizes. Switch off the power. Remove the Platen Glass (REP 6.2) and the IPS Cover 18.3). Switch on the power. Enter dC330 [006-014] and select Start.
Page 131: Carriage Position
6-360 Carriage Position Replace the IIT/IPS PWB 18.3). A carriage position error was detected. Check the following: Procedure • Carriage Motor Belt for disengagement, damage, or no tension 18.5). Switch the power off. Remove the Platen Glass (REP 6.2). Manually move the Full Rate Car- •...
Page 132: Scan Registration Sensor
6-361 Scan Registration Sensor Replace the IIT/IPS PWB 18.3). Registration Sensor failure at carriage initialization. Check the following: Procedure • Carriage Motor Belt for disengagement, damage, or no tension 18.5). Switch the power off. Remove the Platen Glass (REP 6.2). Manually move the Full Rate Car- •...
Page 133: Exposure Lamp
6-371 Exposure Lamp Open circuit of the Lamp was detected. Procedure Enter dC330 [006-002]. Press Start. The Exposure Lamp illuminates. Switch off the power. Remove the Platen Glass (REP 6.2) and the IPS Cover 18.3). Switch the power on. (Refer to Figure 1.) There is +24VDC from P/J724-3 on the IIT/ IPS PWB to ground (-).
Page 134: Ros Polygon Motor
6-372 ROS Polygon Motor 6-380 ROS SOS Y Length The Control Logic has detected a ROS Motor failure. The interval of the ROS Start-of-Scan (Y) signals exceeds the specified value. Procedure Procedure Enter dC330 [006-031] and select Start. +3.3VDC is measured between the MCU PWB +5VDC is measured between the MCU PWB P/J401-B20 (+) and ground (-) J402 (+) and ground (-)
Page 135: Ros Sos M Length
6-381 ROS SOS M Length 6-382 ROS SOS C Length The interval of the ROS Start-of-Scan (M) signals exceeds the specified value. The interval of the ROS Start-of-Scan (C) signals exceeds the specified value. Procedure Procedure +5VDC is measured between the MCU PWB P/J401-B19 (+) and ground (-). +5VDC is measured between the MCU PWB P/J401-A1 (+) and ground (-).
Page 136: Ros Sos K Length
6-383 ROS SOS K Length 6-385 ROS ASIC The interval of the ROS Start-of-Scan (K) signals exceeds the specified value. The Control Logic detected an operation failure of the ROS ASIC in the MCU PWB. Procedure Procedure +5VDC is measured between the MCU PWB P/J401-A2 (+) and ground (-). Switch power off then on.
Page 137: Carriage Over Run Right
6-389 Carriage Over Run Right Replace the IIT/IPS PWB 18.3). The carriage has overrun at the Scan End. Check the following: Procedure • Carriage Motor Belt for disengagement, damage, or no tension 18.5). Switch the power off. Remove the Platen Glass (REP 6.2).
Page 138: Carriage Over Run Left
6-390 Carriage Over Run Left Replace the IIT/IPS PWB 18.3). The carriage has overrun at the Home End. Check the following: Procedure • Carriage Motor Belt for disengagement, damage, or no tension 18.5). Switch the power off. Remove the Platen Glass (REP 6.2).
Page 139: Scan Initialize Motor Driver
6-391 Scan Initialize Motor Driver A Carriage Motor error was detected after initialization was started. Procedure Manually move the Full Rate Carriage to the left until it stops. Enter dC330 [006-005] (Scan) and select Start. The Carriage Motor energizes. +24 VDC is measured at P/J725-1 and -2 on the IIT/IPS PWB. Replace the IIT/IPS PWB 18.3).
Page 140 Status Indicator RAPs Initial issue 02/03 6-391 2-110 DC 3535/2240/1632...
Page 141 7-104 Tray 1 Feed Out Sensor Replace the Tray Module PWB 16.15). The Tray 1 Feed Out Sensor does not detect paper fed from Tray 2, 3, or 4 within the specified time after the Takeaway Sensor was actuated. Replace the Takeaway Motor 1 16.15).
Page 142 Replace the Tray Module PWB 15.9). Replace the Takeaway Motor 1 15.9). Check the drives of the Takeaway Motor 1 (refer to 15.9) Press Stop. • Ensure that the Chutes 2.3, 15.10) are properly seated and not damaged. • Check the Pinch Rolls 2.3, 15.10) for damage or contamination.
Page 143 Figure 5 7-104 Circuit Diagram - Takeaway Motor 1 3TM Initial issue Status Indicator RAPs 02/03 7-104 DC 3535/2240/1632 2-113...
Page 144: Tray 1 Misfeed
7-105 Tray 1 Misfeed The Tray 1 Feed Out Sensor does not detect paper after feeding from Tray 1. Initial Actions • Check condition and specification of paper in Tray 1. • Check the paper path for obstructions. • Check for wear and clean the Tray 1 Feed Roll, Takeaway Roll and the Pinch Roll. Procedure Open the Left Lower Cover 2.3).
Page 145: Tray 2 Misfeed
7-110 Tray 2 Misfeed With dC330 [008-036] still entered, press Start and check that the voltage at P/J552 pins 1, 2, 5, and 6 each drop to approximately +22 VDC. The voltage The Takeaway Sensor does not detect paper after feeding from Tray 2. P/J552 pins 1, 2, 5, and 6 all drop to approximately +22 VDC when [008- 036] is entered.
Page 146 Takeaway Motor 1 15.9) energizes. Press Stop. +24 VDC is measured between P/J552-3 and GND on the Tray Module PWB. +24 VDC is measured at P/J 555-3 on the Tray Module PWB. Refer to the +24 VDC Wirenets (Figure 5). Check the +24 VDC to the Tray Module PWB.
Page 147 Figure 3 7-110 RAP Circuit Diagram - Takeaway Motor 1 (TTM) Figure 5 7-110 RAP Circuit Diagram - Tray 2 Feed/Lift Motor (3TM) Figure 4 7-110 RAP Circuit Diagram - Takeaway Sensor (3TM) Initial issue Status Indicator RAPs 02/03 7-110 DC 3535/2240/1632 2-117...
Page 148 Figure 6 7-110 RAP Circuit Diagram - Takeaway Motor 1 (3TM) Status Indicator RAPs Initial issue 02/03 7-110 2-118 DC 3535/2240/1632...
Page 149: Tray 3 Misfeed (Ttm)
7-115 Tray 3 Misfeed (TTM) Replace the Takeaway Motor 1 16.15). The Tray 3 Feedout Sensor does not detect paper after feeding from Tray 3. Press Stop. Check the Takeaway Motor 1 and its associated gears 16.15) for dam- age, contamination and misalignment. Initial Actions •...
Page 150 Figure 3 7-115 RAP Circuit Diagram - Takeaway Motor 1 (TTM) Figure 2 7-115 RAP Circuit Diagram - Tray 3 Feed/Lift Motor (TTM) Status Indicator RAPs Initial issue 02/03 7-115 2-120 DC 3535/2240/1632...
Page 151: Tray 3 Misfeed (3Tm)
7-117 Tray 3 Misfeed (3TM) Press Stop. Check the Takeaway Motor 1 and its associated gears 15.9) for damage, contamination and misalignment. The Tray 3 Feed Out Sensor does not detect paper after feeding from Tray 3. Press Stop. Initial Actions •...
Page 152 Figure 3 7-117 RAP Circuit Diagram - Takeaway Motor 1 (3TM) Figure 2 7-117 RAP Circuit Diagram - Tray 3 Feed/Lift Motor (3TM) Status Indicator RAPs Initial issue 02/03 7-117 2-122 DC 3535/2240/1632...
Page 153: Tray 4 Misfeed (Ttm)
7-119 Tray 4 Misfeed (TTM) • Check the Tray 4 Feed / Lift Motor and its associated gears 16.11) for damage, con- tamination and misalignment. The Tray 4 Feed Out Sensor does not detect paper after feeding from Tray 4. •...
Page 154 Figure 3 7-119 RAP Circuit Diagram - Takeaway Motor 2 (TTM) Figure 2 7-119 RAP Circuit Diagram - Tray 4 Feed/Lift Motor (TTM) Status Indicator RAPs Initial issue 02/03 7-119 2-124 DC 3535/2240/1632...
Page 155: Tray 4 Misfeed (3Tm)
7-120 Tray 4 Misfeed (3TM) Replace the Takeaway Motor 1 15.9). The Tray 4 Feed Out Sensor does not detect paper after feeding from Tray 4. Press Stop. Check the Takeaway Motor 1 and its associated gears 15.9) for damage, contamination and misalignment.
Page 156 Figure 3 7-120 RAP Circuit Diagram - Takeaway Motor 1 (3TM) Figure 2 7-120 RAP Circuit Diagram - Tray 4 Feed/Lift Motor (3TM) Status Indicator RAPs Initial issue 02/03 7-120 2-126 DC 3535/2240/1632...
Page 157: Tray 4 Opened (Ttm)
7-122 Tray 4 Opened (TTM) The Tray 4 Feed Out Sensor detected paper when Tray 4 is pulled out and pushed in during a print. Initial Actions • Check condition and specification of paper in Tray 4. • Check the paper path for obstructions and clean the Tray 4 Feed Out Sensor. •...
Page 158: Tray Communication
7-250 Tray Communication Communication fault between Tray Module PWB and MCU PWB. Procedure +5 VDC is measured at P/J541-9 on the Tray Module PWB. 2.5 VDC is measured at P/J541-9 on the Tray Module PWB. Go to Figure 1. Check for a shorted wire between the Tray Module PWB and the MCU PWB.
Page 159: Out Module Logic
7-252 Out Module Logic Incorrect software data was detected. Procedure Switch the power off then on. The problem continues. Return to Service Call Procedures. If the problem continues, replace the MCU PWB 13.1). Reinstall the software. Initial issue Status Indicator RAPs 02/03 7-252 DC 3535/2240/1632...
Page 160: Tray 1 Paper Size Sensor Failure
7-270 Tray 1 Paper Size Sensor Failure An abnormal A/D value was detected by the Tray 1 Paper Size Sensor. Initial Actions • Check that the paper size setting is correct. • Check the Tray 1 Paper Size Sensor 2.1) for damage or incorrect mounting. Repair or replace as required.
Page 161: Tray 2 Paper Size Sensor
7-271 Tray 2 Paper Size Sensor An abnormal AD value was detected by the Tray 2 Paper Size Sensor. Table 1 Tray 2 Size Sensor Values Voltage Initial Actions Paper Size [007-104] [007-105] [007-106] [007-107] (J546-8) • Check that the paper size setting is correct. No Tray 4.78 •...
Page 162 Figure 2 7-271 RAP Circuit Diagram - Tray 2 Paper Size Sensing Status Indicator RAPs Initial issue 02/03 7-271 2-132 DC 3535/2240/1632...
Page 163: Tray 3 Paper Size Sensor (3Tm)
7-272 Tray 3 Paper Size Sensor (3TM) An abnormal AD value was detected by the Tray 3 Paper Size sensor. Initial Actions • Check that the paper size setting is correct. • Check the Tray 3 Paper Size Sensor 15.1) for damage, or incorrect mounting. Repair or replace as required.
Page 164: Tray 4 Paper Size Sensor (3Tm)
7-273 Tray 4 Paper Size Sensor (3TM) An abnormal AD value was detected by the Tray 4 Paper Size Sensor. Initial Actions • Check that the paper size setting is correct. • Check the Tray 4 Paper Size Sensor 15.1) for damage, or incorrect mounting. Repair or replace as required.
Page 165: Tray 5 Paper Size Sensor Failure
7-274 Tray 5 Paper Size Sensor Failure An abnormal A/D value was detected by the Tray 5 Paper Size Sensor. Initial Actions Check the connectors between the Tray 5 Paper Size Sensor and the I/F PWB Procedure Enter dC140 [007-100] and press Start. Move the Tray 5 Paper Size Sensor 2.15).
Page 166: Tray 3 Paper Size Sensor (Ttm)
7-276 Tray 3 Paper Size Sensor (TTM) An abnormal A/D value was detected by the Tray 3 Paper Size Sensor. Initial Actions • Check that the paper size setting is correct. • Check the Tray 3 Paper Size Sensor 16.1) for damage or incorrect mounting. Repair or replace as required.
Page 167: Tray 4 Paper Size Sensor (Ttm)
7-277 Tray 4 Paper Size Sensor (TTM) An abnormal A/D value was detected by the Tray 4 Paper Size Sensor. Initial Actions • Check that the paper size setting is correct. • Check the Tray 4 Paper Size Sensor 16.1) for damage or incorrect mounting. Repair or replace as required.
Page 168: Tray 1 Lift
7-281 Tray 1 Lift The Tray 1 Level Sensor does not detect tray lift. Initial Actions Remove Tray 1 from the machine and empty the paper stock, then: • Manually turn the gear at the rear of Tray 1 to check that the Bottom Plate moves up and down smoothly.
Page 169: Tray 2 Lift
7-282 Tray 2 Lift Press Stop. • Check the Tray 2 Feed / Lift Motor and its associated gears 15.3) for damage, con- The Tray 2 Level Sensor does not detect tray lift. tamination or misalignment. • Ensure that the connectors shown in the circuit diagrams (Figure Figure 4) are securely...
Page 170 Figure 4 7-282 RAP Circuit Diagram - Tray 2 Level Sensor (3TM) Figure 2 7-282 RAP Circuit Diagram - Tray 2 Level Sensor (TTM) Figure 3 7-282 RAP Circuit Diagram - Tray 2 Feed Lift Motor (3TM) Status Indicator RAPs Initial issue 02/03 7-282...
Page 171: Tray 3 Lift (3Tm)
7-283 Tray 3 Lift (3TM) The Tray 3 Level Sensor does not detect tray lift. Initial Actions Remove Tray 3 from the machine and empty the paper stock, then: • Manually turn the gear at the rear of Tray 3 to check that the Bottom Plate moves up and down smoothly.
Page 172: Tray 4 Lift (3Tm)
7-284 Tray 4 Lift (3TM) The Tray 4 Level sensor does not detect tray lift. Initial Actions Remove Tray 4 from the machine and empty the paper stock, then: • Manually turn the gear at the rear of Tray 4 to check that the Bottom Plate moves up and down smoothly.
Page 173: Tray 3 Lift (Ttm)
7-291 Tray 3 Lift (TTM) The Tray 3 Level Sensor does not detect tray lift. Initial Actions Pull out Tray 3 and empty the paper stock, then: • Manually turn the gear on the left side of Tray 3 to check that the Bottom Plate moves up and down smoothly.
Page 174: Tray 4 Lift (Ttm)
7-293 Tray 4 Lift (TTM) The Tray 4 Level Sensor does not detect tray lift. Initial Actions Pull out Tray 4 and empty the paper stock, then: • Manually turn the gear underneath Tray 4 to check that the Bottom Plate moves up and down smoothly.
Page 175: All Trays Lift Sensors
7-397 All Trays Lift Sensors None of the Tray Level Sensors can be energized. Procedure The machine is equipped with a 3TM. Check the dC122 Shutdown History. A 7-281, 7-282, 7-291, or 7-293 fault has occurred. +24 VDC is measured at P/J555-3 on the Tray Module PWB 16.15).
Page 176 Figure 2 7-397 RAP Circuit Diagram +5 VDC to the Tray Module PWB Status Indicator RAPs Initial issue 02/03 7-397 2-146 DC 3535/2240/1632...
Page 177: Tray 1 Paper Size Mismatch
7-930 Tray 1 Paper Size Mismatch The paper in Tray 1 does not match the paper size selected. Procedure The correct size paper is loaded in Tray 1 and the paper guides are set correctly. Load the correct size paper. Go to the 7-270 RAP.
Page 178: Tray 2 Paper Size Mismatch
7-931 Tray 2 Paper Size Mismatch 7-932 Tray 3 Paper Size Mismatch The paper in Tray 2 does not match the paper size selected. The paper in Tray 3 does not match the paper size selected. Procedure Procedure The correct size paper is loaded in Tray 2 and the paper guides are set correctly. The machine is equipped with a 3TM.
Page 179: Tray 4 Paper Size Mismatch
7-933 Tray 4 Paper Size Mismatch 7-935 Job Continue Not Available The paper in Tray 4 does not match the paper size selected. Automatic Tray switching cannot be continued because a tray was not programed. Procedure Procedure The machine is equipped with a 3TM. Program the appropriate tray.
Page 180: Tray 5 Size Mismatch (Slow Scan Direction)
7-954 Tray 5 Size Mismatch (Slow Scan Direction) 7-959 Tray 5 Paper Mismatch 1 The paper in the slow scan direction is shorter than the specified paper size. Incorrect type of transparency detected by the OHP sensor. Procedure Initial Actions The correct size paper is loaded in the Tray 5.
Page 181: Tray 5 Paper Mismatch 2
7-960 Tray 5 Paper Mismatch 2 7-969 Full Paper Stack A different paper type or transparency was detected when plain/heavyweight paper was speci- The Full Paper Stack Sensor detects that Face Down Tray is full. fied. Initial Actions Initial Actions Check the Full Paper Stack Sensor for obstructions and actuator operation.
Page 182 Status Indicator RAPs Initial issue 02/03 7-960, 7-969 2-152 DC 3535/2240/1632...
Page 183: Tray 3 Takeaway Sensor On (3Tm)
8-149 Tray 3 Takeaway Sensor On (3TM) Press Stop. • Ensure that the Chutes 15.10) are properly seated and not damaged. The Takeaway Sensor does not detect paper fed from Tray 3. • Ensure that the connectors shown in the circuit diagrams (Figure Figure 2) are securely...
Page 184: Tray 4 Takeaway Sensor On (3Tm)
8-150 Tray 4 Takeaway Sensor On (3TM) Press Stop. • Ensure that the Chutes 15.10) are properly seated and not damaged. The Takeaway Sensor does not detect paper fed from Tray 4. • Ensure that the connectors shown in the circuit diagrams (Figure Figure 2) are securely...
Page 185: Tray 3 Takeaway Sensor On (Ttm)
8-151 Tray 3 Takeaway Sensor On (TTM) Press Stop. • Ensure that the Chutes 16.6) are properly seated and not damaged. The Takeaway Sensor does not detect paper fed from Tray 3. • Ensure that the connectors shown in the circuit diagrams (Figure Figure 2) are securely...
Page 186: Tray 4 Takeaway Sensor On (Ttm)
8-152 Tray 4 Takeaway Sensor On (TTM) Press Stop. Remove the TTM Rear Cover. Enter dC330 [008-048] and press Start. The Take- away Motor 2 16.15) energizes. The Takeaway Sensor does not detect paper fed from Tray 4. Press Stop. +24 VDC is measured between P/J553-3 and GND on the Tray Module Initial Actions PWB.
Page 187 Figure 2 8-152 RAP Circuit Diagram - Takeaway Motor 1 Figure 3 8-152 RAP Circuit Diagram - Takeaway Motor 2 Initial issue Status Indicator RAPs 02/03 8-152 DC 3535/2240/1632 2-157...
Page 188: Pob Sensor
8-164 POB Sensor The POB Sensor did not detect paper after the Registration Clutch Energized. Initial Actions • Check condition and specification of the paper supply. • Check for paper on the IBT. • Check for obstructions in the paper feed path. •...
Page 189: Registration Sensor On Jam Tray 5
8-175 Registration Sensor On Jam Tray 5 The Registration Sensor does not detect paper fed from the MSI. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the MSI Feed Roll and check for wear. •...
Page 190: Registration Sensor On Jam Tray 1-4
8-176 Registration Sensor On Jam Tray 1-4 The Registration Sensor does not detect paper fed from Tray 1 - 4. Initial Actions • Ensure customer closes Left Lower Cover 2.3) firmly if dog ears also occur. • Check condition and specification of the paper supply. •...
Page 191: Registration Sensor On Duplex
8-180 Registration Sensor On Duplex The Registration Sensor does not detect paper after a duplex feed. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the Registration Roll and check for wear. •...
Page 192 Figure 2 8-180 RAP Circuit Diagram - Duplex Motor Figure 3 8-180 RAP Circuit Diagram - Inverter Reverse Clutch Status Indicator RAPs Initial issue 02/03 8-180 2-162 DC 3535/2240/1632...
Page 193: Registration Sensor On Wait Sensor
8-181 Registration Sensor On Wait Sensor The Registration Sensor does not detect paper after the Duplex Wait Sensor was energized. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. •...
Page 194 Figure 2 8-181 RAP Circuit Diagram - Duplex Wait Sensor Figure 3 8-181 RAP Circuit Diagram - Duplex Motor Status Indicator RAPs Initial issue 02/03 8-181 2-164 DC 3535/2240/1632...
Page 195: Registration Sensor Off
8-184 Registration Sensor Off The Fuser Exit Switch did not detect paper after the Registration Clutch was energized. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Check the Fuser Belt and the Heat Roll for damage or wear. •...
Page 196: Regicon Temp Sensor
8-620 Regicon Temp Sensor 8-622 Regicon Data Overflow (A1 Patch X) Environment Sensor not in range. At A1 patch detection, the XSO correction setting value for either Y, M, C, or K exceeds the setting range (NVM value 0 to 472). Procedure NOTE: Status Code not displayed on UI.
Page 197: Regicon Data Overflow (A2 Patch Y)
8-623 Regicon Data Overflow (A2 Patch Y) 8-624 Regicon Data Overflow (Patch Magnification) At A2 patch detection, the YSO correction setting value of either Y, M, C, or K exceeds the set- MAG Adjusted Set Point of operation results for each of Y,M,C exceeded the set range (NVM ting range (NVM value 0 to 474).
Page 198: Regicon Sample Block (A1 Patch-Rear)
8-625 Regicon Sample Block (A1 Patch-rear) 8-626 Regicon Sample Block (A1 Patch-front) At A1 (IN) patch detection, the number of the sample blocks does not reach the specified num- At A1 (OUT) patch detection, the number of the sample blocks does not reach the specified ber.
Page 199: Regicon Sample Lateral (A1 Patch-Rear)
8-627 Regicon Sample Lateral (A1 Patch-rear) 8-628 Regicon Sample Lateral (A1 Patch-front) At A1 (IN) patch detection, the Fast Scan scan position of CYAN color that is the standard for At A1 (OUT) patch detection, the scan position of CYAN color that is the standard for the rest is the rest is incorrect.
Page 200: Regicon Skew (Patch Y)
8-629 Regicon Skew (Patch Y) 8-630 Regicon Skew (Patch M) During A1 Patch detection, skew deviation for Y exceeded tolerance. During A1 Patch detection, skew deviation for M exceeded tolerance. NOTE: Machine operation continues. Status Code not displayed on UI. Status Code logged in NOTE: Machine operation continues.
Page 201: Regicon Skew (Patch K)
8-631 Regicon Skew (Patch K) 8-900 Static Jam During A1 Patch detection, skew deviation for K exceeded tolerance. When the machine power is turned off then on before a paper path fault is cleared, an 8-900 fault will be displayed. A voltage drop or interruption can also cause this fault. NOTE: Machine operation continues.
Page 202 Status Indicator RAPs Initial issue 02/03 8-631, 8-900 2-172 DC 3535/2240/1632...
Page 203: Nd Btr Contact
9-342 2nd BTR Contact The 2nd BTR did not reach the contact position. Initial Actions • Clean the 2nd BTR Retract Sensor 2.9) and check for damage. • Check the 2nd BTR gears 2.8) for breakage. Procedure Enter dC330 [009-200]. Open the Left Cover and block and unblock the 2nd BTR Retract Sen- sor with a piece of paper.
Page 204 Figure 2 9-342 Rap Circuit Diagram - 2ND BTR Retract Motor Status Indicator RAPs Initial issue 02/03 9-342 2-174 DC 3535/2240/1632...
Page 205: Nd Btr Retract
9-343 2nd BTR Retract The 2nd BTR did not reach the retract position. Initial Actions • Clean the 2nd BTR Retract Sensor 2.9) and check for damage. • Check the 2nd BTR gears 2.8) for breakage. Procedure Enter dC330 [009-200]. Open the Left Cover and block and unblock the 2nd BTR Retract Sen- sor with a piece of paper.
Page 206 Figure 2 9-343 Rap Circuit Diagram - 2ND BTR Retract Motor Status Indicator RAPs Initial issue 02/03 9-343 2-176 DC 3535/2240/1632...
Page 207: St Btr Contact
9-348 1st BTR Contact Check the wires between P/J533 P/J237 (Figure 2) on the 1st BTR Retract Motor for opens, shorts, or loose connections. If the wires are OK, replace the 1st BTR Retract The 1st BTR did not reach the contact position. Motor 5.4).
Page 208 Figure 2 9-348 Rap Circuit Diagram - 1ST BTR Retract Motor Status Indicator RAPs Initial issue 02/03 9-348 2-178 DC 3535/2240/1632...
Page 209: St Btr Retract
9-349 1st BTR Retract Check the wires between P/J533 P/J237 (Figure 2) on the 1st BTR Retract Motor for opens, shorts, or loose connections. If the wires are OK, replace the 1st BTR Retract The 1st BTR did not reach the retract position. Motor 5.4).
Page 210 Figure 2 9-349 Rap Circuit Diagram - 1ST BTR Retract Motor Status Indicator RAPs Initial issue 02/03 9-349 2-180 DC 3535/2240/1632...
Page 211: Ibt Home Sensor
9-350 IBT Home Sensor Go to Figure 2 and check the wires from P/J533 to the IBT Home Sensor for an open wire, loose connection, or a short circuit. If the wires are OK, replace the IBT Home Sensor 5.4). The IBT Home Sensor detected the IBT position strip before the IBT Belt made a complete rev- If the problem continues, replace the MCU PWB 13.1).
Page 212: Drive Logic
9-351 Drive Logic Check the wires (Figure 1) from P/J550 on the I/F PWB to P/J207 on the IBT Steering Motor for shorts, opens, or loose connections. If the wires are OK, replace the MCU PWB The IBT Edge Sensor detected that the IBT Belt is not tracking correctly. 13.1).
Page 213: Full Toner Sensor
9-358 Full Toner Sensor 9-360 Yellow Drum Cartridge Communication The Full Toner Sensor detects a full toner condition. A communication failure with the Yellow Drum Cartridge was detected. Initial Actions Initial Actions • Ensure that the Waste Toner Cartridge is not full. Check that the Yellow Drum Cartridge is seated correctly.
Page 214: Magenta Drum Cartridge Communication
9-361 Magenta Drum Cartridge Communication 9-362 Cyan Drum Cartridge Communication A communication failure with Magenta Drum Cartridge was detected. A communication failure with the Cyan Drum Cartridge was detected. Initial Actions Initial Actions Check that the Magenta Drum Cartridge is seated correctly. Check that the Cyan Drum Cartridge is seated correctly.
Page 215: Black Drum Cartridge Communication
9-363 Black Drum Cartridge Communication 9-380 ATC Sensor (Y) A communication failure with the Black Drum Cartridge was detected. The ATC Sensor (Y) detects a low TC (toner concentration). Initial Actions Initial Actions Check that the Black Drum Cartridge is seated correctly. •...
Page 216: Atc Sensor (M)
9-381 ATC Sensor (M) 9-382 ATC Sensor (C) The ATC Sensor (M) detects a low TC (toner concentration) The ATC Sensor (C) detects a low TC (toner concentration) Initial Actions Initial Actions • Check that Toner/Developer is present. • Check that Toner/Developer is present. •...
Page 217: Atc Sensor (K)
9-383 ATC Sensor (K) 9-390 New Toner Cartridge (K) The ATC Sensor (K) detects an insufficient amount of developer material The New Cartridge Detect Switch (K) was not engaged to reset the Accumulative Dispense time NVM value to 0 when a new cartridge was installed. Initial Actions Initial Actions •...
Page 218: New Toner Cartridge (C)
9-391 New Toner Cartridge (C) 9-392 New Toner Cartridge (M) The New Cartridge Detect Switch (C) was not engaged to reset the Accumulative Dispense When a new Toner Cartridge was installed, the level of the New Cartridge Detect Switch (M) time NVM value to 0 when a new cartridge was installed.
Page 219: New Toner Cartridge (Y)
9-393 New Toner Cartridge (Y) 9-408 Waste Toner Cartridge Near Full When a new Toner Cartridge was installed, the level of the New Cartridge Detect Switch (Y) The Waste Toner Cartridge is nearly full. This fault requires service only if the message remained L when it should be changed to H by the Dispense Motor drive.
Page 220: Toner Cartridge (Y) Near Empty
9-410 Toner Cartridge (Y) Near Empty Go to the 9-380 ATC Sensor Failure RAP. The Yellow Toner Cartridge is nearly empty/empty. This fault requires service only if the mes- sage appears before the Toner Cartridge is depleted. After checking that no failures are detected during normal operation, go to call closeout. NOTE: Continuous running of high density prints can temporarily deplete the toner supply.
Page 221: Toner Cartridge (M) Near Empty
9-411 Toner Cartridge (M) Near Empty The Magenta Toner Cartridge is nearly empty. This fault requires service only if the message appears before the Toner Cartridge is depleted. NOTE: Continuous running of high density prints can temporarily deplete the toner supply. Initial Actions •...
Page 222 Go to the 9-381, ATC Sensor Failure RAP. After checking that no failures are detected during normal operation, go to call closeout. Enter dC330 [009-014] and press Start. The Developer Motor 1.1) energizes. Go to Figure 3. There is +24VDC from P/J535-A11 to A10 on the I/F PWB 9.1).
Page 223: Toner Cartridge (C) Near Empty
9-412 Toner Cartridge (C) Near Empty Go to the 9-382 ATC Sensor Failure (C) RAP. The Cyan Toner Cartridge is nearly empty/empty. This fault requires service only if the mes- sage appears before the Toner Cartridge is depleted. After checking that no failures are detected during normal operation, go to call closeout. NOTE: Continuous running of high density prints can temporarily deplete the toner supply.
Page 224 Figure 2 9-412 Rap Circuit Diagram - DC2240/1632 Developer Motor Figure 3 9-412 Rap Circuit Diagram - DC3535 Developer Motor Status Indicator RAPs Initial issue 02/03 9-412 2-194 DC 3535/2240/1632...
Page 225: Toner Cartridge (K) Near Empty
9-413 Toner Cartridge (K) Near Empty Refer to BSD 4.1 (Figure 1). Check the mechanical drive to the clutch. The Black Toner Cartridge is nearly empty. This fault requires service only if the message Check 9.3. The ATC Sensor (K) fail judgment is OK. appears before the Toner Cartridge is depleted.
Page 226: Change Drum Cartridge (K) Soon
9-428 Change Drum Cartridge (K) Soon 9-429 Change Drum Cartridge (Y) Soon The Drum Cartridge (K) needs to be replaced soon/reached end of life. The Drum Cartridge (Y) needs to be replaced soon. Procedure Procedure Replace the Black Drum Cartridge (refer to Section 6, Machine Consumables).
Page 227: Change Drum Cartridge (M) Soon
9-430 Change Drum Cartridge (M) Soon 9-431 Change Drum Cartridge (C) Soon The Drum Cartridge (M) needs to be replaced soon. The Drum Cartridge (C) needs to be replaced soon. Procedure Procedure Replace the Magenta Drum Cartridge (refer to Section 6, Machine Consumables).
Page 228: Adc Sensor
9-654 ADC Sensor Check the wires and connectors. If the check is OK, replace the I/F PWB 9.1). If The machine logic detected an ADC Sensor operation failure. the problem continues, replace the MCU PWB 13.1). Procedure Enter dC330 [009-079 and press Start. The voltage from P/J536-A4 to GND changed The machine is a DC3535.
Page 229 Figure 1 9-654 Rap Circuit Diagram - DC2240/1632 ADC Sensor Figure 2 9-654 Rap Circuit Diagram - DC3535 ADC Sensor Initial issue Status Indicator RAPs 02/03 9-654 DC 3535/2240/1632 2-199...
Page 230: Environment Sensor Temperature
9-660 Environment Sensor Temperature Replace the Environment Sensor 1.3). An incorrect value was detected by the Environment Sensor (Temperature). Replace the I/F PWB 9.1) and MCU PWB 13.1) in sequence. Procedure Disconnect P/J255. There is 1 Ohm or less measured between P255-3 and P255-4 on the Environment Sensor (Figure Figure 1 9-660 Rap Circuit Diagram - Environment Sensor...
Page 231: New Toner Cartridge (K) Detected
9-670 New Toner Cartridge (K) Detected 9-671 New Toner Cartridge (C) Detected The machine logic detected that the Toner Cartridge has been replaced. This is a message The machine logic detected that the Toner Cartridge has been replaced. This is a message fault only.
Page 232: New Toner Cartridge (M) Detected
9-672 New Toner Cartridge (M) Detected 9-673 New Toner Cartridge (Y) Detected The machine logic detected that the Toner Cartridge has been replaced. This is a message The machine logic detected that the Toner Cartridge has been replaced.This is a message fault fault only.
Page 233: Adc Shutter
9-684 ADC Shutter Go to Figure 2. Check the wires and connectors. If the check is OK, replace the I/F The machine logic detected an ADC Shutter operation failure. 9.1). If the problem continues, replace the MCU PWB 13.1). If the problem continues, replace the ADC Sensor 1.3).
Page 234 Figure 1 9-684 Rap Circuit Diagram - DC2240/1632 ADC Sensor Figure 2 9-684 Rap Circuit Diagram - DC3535 ADC Sensor Status Indicator RAPs Initial issue 02/03 9-684 2-204 DC 3535/2240/1632...
Page 235: Drum (Y) Type Mismatch
9-910 Drum (Y) Type Mismatch 9-911 Drum (M) Type Mismatch Drum Type Mismatch Drum Type Mismatch Initial Actions Initial Actions Ensure that the correct drum type is installed. Ensure that the correct drum type is installed. Procedure Procedure Enter dC330 [009-151], (Drum (Y) Data).
Page 236: Drum (C) Type Mismatch
9-912 Drum (C) Type Mismatch 9-913 Drum (K) Type Mismatch Drum Type Mismatch Drum Type Mismatch Initial Actions Initial Actions Ensure that the correct drum type is installed. Ensure that the correct drum type is installed. Procedure Procedure Enter dC330 [009-153] (Drum (C) Data).
Page 237: Toner Cartridge (Y) Empty
9-920 Toner Cartridge (Y) Empty 9-921 Toner Cartridge (M) Empty The Yellow Toner Cartridge is empty. This fault requires service only if the message appears The Yellow Toner Cartridge is empty. This fault requires service only if the message appears before the Toner Cartridge is depleted.
Page 238: Toner Cartridge (C) Empty
9-922 Toner Cartridge (C) Empty 9-923 Toner Cartridge (K) Empty The Cyan Toner Cartridge is empty. This fault requires service only if the message appears The Black Toner Cartridge is empty. This fault requires service only if the message appears before the Toner Cartridge is depleted.
Page 239: Waste Toner Cartridge Full
9-924 Waste Toner Cartridge Full 9-925 Waste Toner Cartridge Not Set The Waste Toner Cartridge is full. The Waste Toner Cartridge was not installed correctly Initial Actions Initial Actions Replace the Waste Toner Cartridge. Check the Full Toner Sensor for contaminants. Ensure that the Waste Toner Cartridge is installed correctly.
Page 240: Drum Cartridge (K) End Of Life
9-926 Drum Cartridge (K) End Of Life 9-927 Change Drum Cartridge (C) End Of Life The Drum Cartridge (K) needs to be replaced. The Drum Cartridge (C) needs to be replaced. Procedure Procedure Replace the Black Drum Cartridge (refer to Section 6, Machine Consumables).
Page 241: Drum Cartridge (M) End Of Life
9-928 Drum Cartridge (M) End Of Life 9-929 Drum Cartridge (Y) End Of Life The Drum Cartridge (M) needs to be replaced. The Drum Cartridge (Y) needs to be replaced. Procedure Procedure Replace the Magenta Drum Cartridge (refer to Section 6, Machine Consumables).
Page 242: Black Drum Cartridge Not Detected
9-930 Black Drum Cartridge Not Detected 9-931 Cyan Drum Cartridge Not Detected The machine logic detected that Black Drum Cartridge is not installed. The machine logic detected that Cyan Drum Cartridge is not installed. Initial Actions Initial Actions • Ensure Black Drum Cartridge is installed correctly. •...
Page 243: Magenta Drum Cartridge Not Detected
9-932 Magenta Drum Cartridge Not Detected 9-933 Yellow Drum Cartridge Not Detected The machine logic detected that Magenta Drum Cartridge is not installed. The machine logic detected that the Yellow Drum Cartridge is not installed. Initial Actions Initial Actions • Ensure Magenta Drum Cartridge is installed correctly.
Page 244 Status Indicator RAPs Initial issue 02/03 9-932, 9-933 2-214 DC 3535/2240/1632...
Page 245 10-110 Fuser Exit Switch On (Duplex) The Fuser Exit Switch did not energize. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the Fuser Exit Roll and check for wear. •...
Page 246: Fuser Exit Switch Off
10-111 Fuser Exit Switch Off The Fuser Exit Switch did not de-energize. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the Fuser Exit Roll and check for wear. •...
Page 247: Duplex Wait Sensor On
10-125 Duplex Wait Sensor On Press Stop. Check the circuit of the Inverter Reverse Clutch (Figure 5). Refer to the Paper did not arrive at the Duplex Wait Sensor within the specified period of time. OF 99-4 RAP for troubleshooting procedure. Initial Actions Press Stop.
Page 248 Figure 2 10-125 RAP Circuit Diagram - Duplex Wait Sensor Figure 3 10-125 RAP Circuit Diagram - Duplex Motor Status Indicator RAPs Initial issue 02/03 10-125 2-218 DC 3535/2240/1632...
Page 249 Figure 4 10-125 RAP Circuit Diagram - Inverter Forward Clutch Figure 5 10-125 RAP Circuit Diagram - Inverter Reverse Clutch Initial issue Status Indicator RAPs 02/03 10-125 DC 3535/2240/1632 2-219...
Page 250: Main Heater Over Heat
10-348 Main Heater Over Heat NOTE: The voltage measurement mentioned in the next step must be made while the Fuser is warming up. The Front Thermistor detected an overheat condition. +2 - 3.5VDC is measured at P/J404-5 on the MCU PWB (Figure Initial Actions Replace the MCU PWB...
Page 251: Front Thermistor Open
10-349 Front Thermistor Open 10-350 Sub Heater Over Heat The machine logic detected an open circuit in the Front Thermistor. The Rear Thermistor detected an over heat condition. Initial Actions Initial Actions Turn off the power, remove the Fuser Assembly, and allow it to cool down. Turn off the power, remove the Fuser Assembly and allow it to cool down.
Page 252 Figure 2 10-350 RAP Circuit Diagram - Main Heater and Sub Heater Status Indicator RAPs Initial issue 02/03 10-350 2-222 DC 3535/2240/1632...
Page 253: Rear Thermistor Open
10-351 Rear Thermistor Open 10-352 Main Heater Warm Up The machine logic detected an open circuit in the Rear Thermistor. The temperature did not reach the READY temperature within the specified time. Initial Actions Initial Actions Turn off the power, remove the Fuser Assembly and allow it to cool down. Turn off the power, remove the Fuser Assembly and allow it to cool down.
Page 254 Figure 1 10-352 RAP Circuit Diagram - Front Thermistor Figure 2 10-352 RAP Circuit Diagram - Main Heater and Sub Heater Status Indicator RAPs Initial issue 02/03 10-352 2-224 DC 3535/2240/1632...
Page 255: Main Heater On Time
10-353 Main Heater On Time The Main Heater remained on for more than the specified time. Initial Actions Turn off the power, remove the Fuser Assembly, and allow it to cool down. Procedure Measure the resistance between P600-4 and P600-6 on the Fuser Assembly (Figure 1).
Page 256 Figure 2 10-353 RAP Circuit Diagram - Main Heater and Sub Heater Status Indicator RAPs Initial issue 02/03 10-353 2-226 DC 3535/2240/1632...
Page 257: Sub Heater Warm Up
10-354 Sub Heater Warm Up The temperature did not reach the READY temperature. Initial Actions Turn off the power, remove the Fuser Assembly, and allow it to cool down. Procedure NOTE: If this fault is declared 3 times in succession, print and copy mode will be disabled. In order to clear this condition, reset NVM location 744-003 to 0.
Page 258 Figure 2 10-354 RAP Circuit Diagram - Main Heater and Sub Heater Status Indicator RAPs Initial issue 02/03 10-354 2-228 DC 3535/2240/1632...
Page 259: Sub Heater On Time
10-356 Sub Heater On Time The Sub Heater remained on for more than the specified time. Initial Actions Turn off the power, remove the Fuser Assembly, and allow it to cool down. Procedure Measure the resistance between P600-7 and P600-9 on the Fuser Assembly (Figure 1).
Page 260 Figure 2 10-356 RAP Circuit Diagram - Main Heater and Sub Heater Status Indicator RAPs Initial issue 02/03 10-356 2-230 DC 3535/2240/1632...
Page 261: Fan Lock
10-398 Fan Lock The machine is a DC 3535. The machine logic detected a failure of the Fuser Fan, LVPS Fan or the Rear Fan. There is +24 VDC from P/J214 pin 1 to pin 4. Procedure Enter dC330 [004-050]. Press Start. The Fuser Fan 8.1) revolves at high speed.
Page 262 Figure 1 10-398 RAP Circuit Diagram - Fuser Fan Figure 3 10-398 RAP Circuit Diagram - DC 3535 Rear Fan Figure 4 10-398 RAP Circuit Diagram - DC 2240/1632 LVPS Fan Figure 2 10-398 RAP Circuit Diagram - DC 2240/1632 Rear Fan Status Indicator RAPs Initial issue 02/03...
Page 263: Fuser Near End Of Life
10-420 Fuser Near End Of Life Replace the Fuser Assembly in X copies. Procedure The Fuser Assembly was replaced. Replace the Fuser Assembly 7.2) Run the dC135 [954-804]. The initial value is 0. Replace the MCU PWB 13.1). Ensure that the LIFE setting value is 100K, switch power off then on. If the problem continues, replace the MCU PWB 13.1).
Page 264: Fuser End Of Life
10-421 Fuser End Of Life Fuser at end of life. Procedure The Fuser Assembly was replaced. Replace the Fuser Assembly 7.2). Run the dC135 [954-804]. The initial value is 0. Replace the MCU PWB 13.1). Ensure that the LIFE setting value is 100K, switch power off then on. If the problem continues, replace the MCU PWB 13.1).
Page 265 12-100 H Transport Entrance Sensor On • If the problem persists, replace the Finisher PWB 17.13) (Figure The H Transport Entrance Sensor does not detect paper after the Registration Clutch (in IOT) Entrance energized. Gate In Sensor Solenoid Initial Actions •...
Page 266 Figure 4 12-100 RAP Circuit Diagram - Finisher Drive Motor Figure 5 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-100 2-236 DC 3535/2240/1632...
Page 267: H Transport Entrance Sensor Off
12-102 H Transport Entrance Sensor Off • If the problem persists, replace the Finisher PWB 17.13). Paper did not deactuate the H Transport Entrance Sensor. Entrance Sensor Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. •...
Page 268 Figure 3 12-102 RAP Circuit Diagram - Finisher Drive Motor Status Indicator RAPs Initial issue 02/03 12-102 2-238 DC 3535/2240/1632...
Page 269: H Transport Exit Sensor On
12-104 H Transport Exit Sensor On Entrance Interlock The H Transport Exit Sensor did not detect paper within the specific time after the H Transport Sensor Sensor Entrance Sensor has detected the paper. (The specified time differs depending on the paper size.) Initial Actions •...
Page 270 Figure 3 12-104 RAP Circuit Diagram - Finisher Drive Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-104 2-240 DC 3535/2240/1632...
Page 271: H Transport Exit Sensor Off
12-106 H Transport Exit Sensor Off Press Stop. • Ensure that the connectors shown in the circuit diagrams (Figure Figure Figure Paper did not deactuate the H Transport Exit Sensor. Figure 5) are securely connected and that the wires are not damaged. •...
Page 272 Figure 6 Finisher PWB Figure 3 12-106 RAP Circuit Diagram - Finisher Drive Motor Figure 4 12-106 RAP Circuit Diagram - Decurler Cam Home Sensor Figure 5 12-106 RAP Circuit Diagram - Decurler Cam Clutch Status Indicator RAPs Initial issue 02/03 12-106 2-242...
Page 273: Compiler Entrance Sensor On
12-120 Compiler Entrance Sensor On The Compiler Entrance Sensor did not detect paper. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the H Transport Belt and check for wear. •...
Page 274: Compiler Entrance Sensor Off
12-122 Compiler Entrance Sensor Off Paper does not deactuate the Compiler Entrance Sensor. Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the H Transport Belt and check for wear. Procedure Make a copy and observe paper in the Compiler Tray.
Page 275: Set Eject
12-170 Set Eject Compiler The Compiler Paper Sensor did not deactuate after the Eject Motor energized. Paper Sensor Initial Actions • Check condition and specification of the paper supply. • Check for obstructions in the paper feed path. • Clean the Eject Roll and Eject Pinch Roll and check for wear. Procedure Enter dC330...
Page 276 Figure 3 12-170 RAP Circuit Diagram - Eject Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-170 2-246 DC 3535/2240/1632...
Page 277: Staple Move Sensor On
12-241 Staple Move Sensor On Staple Front • The Staple Sensor did not turn on after the Stapler moved to the Staple Position. Corner Sensor • The Staple Sensor did not actuate after the Stapler is in position. Initial Actions •...
Page 278 Figure 3 12-241 RAP Circuit Diagram - Staple Move Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-241 2-248 DC 3535/2240/1632...
Page 279: Staple Move Sensor Off
12-242 Staple Move Sensor Off Staple Front • The Staple Move Sensor did not turn off after the move to the Staple Position started. Corner Sensor • The Staple Move Sensor turned off after Staple Position has been fixed. • The Staple Move Sensor did not turn off after it turned on when paper passed through the 1st position of the Dual Staple when moving to the Rear Staple Position.
Page 280 Figure 3 12-242 RAP Circuit Diagram - Staple Move Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-242 2-250 DC 3535/2240/1632...
Page 281: Staple Home Sensor
12-244 Staple Home Sensor Stapler The Staple Head Home Sensor did not actuate after the Stapler Motor energized to open the Assembly Stapler. Procedure Enter dC330 [012-207] and press Start. Turn the Staple Motor Gear manually to actuate the Staple Head Home Sensor. The display changes. +5 VDC is measured at Stapler Assembly between P/J886-5 and P/J886-1.
Page 282 Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-244 2-252 DC 3535/2240/1632...
Page 283: Front Tamper
12-252 Front Tamper Front Tamper Motor Compiler Front • With the Front Tamper Home Sensor off the Front Tamper Home Sensor did not turn on Connection Tamper Paper after move to the Front Tamper Home position began. Sensor Home • With the Front Tamper Home Sensor on, the Front Tamper Sensor did not turn off when Sensor the Front Tamper Home Sensor deactuates.
Page 284 Figure 3 12-252 RAP Circuit Diagram - Front Tamper Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-252 2-254 DC 3535/2240/1632...
Page 285: Rear Tamper
12-253 Rear Tamper Front Tamper Motor Compiler Front • With the Rear Tamper Home Sensor off The Rear Tamper Home Sensor did not turn on Connection Tamper Paper within 800ms after move to the Rear Tamper Home position has begun. Sensor Home •...
Page 286 Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-253 2-256 DC 3535/2240/1632...
Page 287: Stacker Tray
12-254 Stacker Tray Stack • The Stack Height Sensor did not detect that the tray went down after the Stacker Tray Height lowered at initialization. Sensor • The Stack Height Sensor did not detect that the tray went up after the Stacker Motor was energized.
Page 288 Figure 3 12-254 RAP Circuit Diagram - Stacker Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-254 2-258 DC 3535/2240/1632...
Page 289: Stacker Tray Upper Limit
12-255 Stacker Tray Upper Limit Stack Upper • The system detected that the Stacker Tray Upper Limit Sensor was turned on after the Height Limit Stacker Tray had begun lifting up. Sensor Sensor • The system detected that the Stacker Tray Upper Limit Sensor remained on when lower- ing down of the Stacker Tray has completed.
Page 290 Figure 5 Finisher PWB Figure 3 12-255 RAP Circuit Diagram - Stack Height Sensor Figure 4 12-255 RAP Circuit Diagram - Stacker Motor Status Indicator RAPs Initial issue 02/03 12-255 2-260 DC 3535/2240/1632...
Page 291: Staple Front Corner Sensor On
12-256 Staple Front Corner Sensor On Staple Front • The Stapler Front Corner Sensor does not turn on within 2 sec. after starting to move to Corner Sensor Front Corner. • The Stapler Front Corner Sensor remained on when starting to move to Front Corner. Initial Actions •...
Page 292 Figure 3 12-256 RAP Circuit Diagram - Stapler Move Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-256 2-262 DC 3535/2240/1632...
Page 293: Staple Front Corner Sensor Off
12-257 Staple Front Corner Sensor Off Staple Front • The Staple Front Corner Sensor does not turn off after the move from Front Corner has Corner Sensor completed. • The Staple Front Corner Sensor does not turn off after starting to move from Front Corner. Initial Actions •...
Page 294 Figure 3 12-257 RAP Circuit Diagram - Staple Move Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-257 2-264 DC 3535/2240/1632...
Page 295: Eject Clamp Home Sensor On
12-260 Eject Clamp Home Sensor On Eject Clamp Home Sensor The Eject Clamp Home Sensor does not turn on after the Eject Clamp up started. Initial Actions • Check for obstructions in the Clamp area. Procedure Remove the Rear Cover 17.5) and the Eject Clamp Home Sensor bracket 17.8) (leave sensor connected).
Page 296 Figure 3 12-260 RAP Circuit Diagram - Eject Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-260 2-266 DC 3535/2240/1632...
Page 297: Eject Clamp Home Sensor Off
12-262 Eject Clamp Home Sensor Off The Eject Clamp Home Sensor does not turn off within 200ms after the Eject Clamp DOWN Eject Clamp Home Sensor has started. Procedure Remove the Rear Cover 17.5) and the Eject Clamp Home Sensor bracket 17.8) (leave sensor connected).
Page 298 Figure 3 12-262 RAP Circuit Diagram - Eject Motor Figure 4 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-262 2-268 DC 3535/2240/1632...
Page 299: Decurler
12-267 Decurler Decurler Cam Clutch The Decurler Cam Home Sensor did not actuate after the Decurler Cam Clutch energized. Procedure Compiler Entrance Remove the Rear Cover 17.5). Enter dC330 [012-217] and press Start. Actuate the Sensor Decurler Decurler Cam Home Sensor 17.8) (Figure 1).
Page 300 Figure 4 12-267 RAP Circuit Diagram - Finisher Drive Motor Figure 5 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-267 2-270 DC 3535/2240/1632...
Page 301: Set Clamp
12-281 Set Clamp • Replace the Set Clamp Home Sensor 17.8). • If the problem persists, replace the Finisher PWB 17.13) (Figure The Set Clamp Home Sensor does not actuate after the Set Clamp started operation. Eject Clamp Home Sensor Procedure Clamp Remove the Rear Cover...
Page 302 Figure 4 12-281 RAP Circuit Diagram - Eject Motor Figure 5 Finisher PWB Status Indicator RAPs Initial issue 02/03 12-281 2-272 DC 3535/2240/1632...
Page 303: Top Cover Interlock
12-301 Top Cover Interlock The Finisher Top Cover Interlock is open. Procedure Cheat the Top Cover Interlock Switch (Figure 1). 12-301 is cleared. Disconnect P/J851 on the Finisher PWB. +5 VDC is measured between the Finisher PWB P/J851-1 and GND (Figure Replace the Finisher PWB 17.13)
Page 304: Front Door Interlock Open
12-302 Front Door Interlock Open The Finisher Front Door Interlock is open. Procedure Cheat the Front Door Interlock Switch (Figure 1). 012-302 is cleared. Disconnect P/J851 on the Finisher PWB. +5 VDC is measured between the Finisher PWB P/J851-3 and ground (Figure Replace the Finisher PWB 17.13)
Page 305: H Transport Interlock Open
12-303 H Transport Interlock Open The H Transport Interlock Sensor detected open. Procedure Block the H Transport Interlock Sensor with a sheet of paper (Figure 1). 012-303 is cleared. +5 VDC is measured between the H Transport Interlock Sensor P/J853-1 and -3 (Figure Disconnect Finisher PWB P/J845.
Page 306: Docking Interlock Open
12-305 Docking Interlock Open Top Cover The Docking Interlock is open. Interlock Switch Procedure Block the Docking Interlock Sensor with a sheet of paper (Figure 1). 012-305 is cleared. +5 VDC is measured between the Docking Interlock Sensor P/J866-1 and -3 (Figure Front Door Interlock...
Page 307 Figure 3 Finisher PWB Initial issue Status Indicator RAPs 02/03 12-305 DC 3535/2240/1632 2-277...
Page 308: Finisher Communication
12-350 Finisher Communication Communication cannot be established between the MCU PWB and the Finisher PWB. Procedure Switch the power off then on. CR7 on the Finisher PWB is lit. +24 VDC is measured between the Finisher PWB P/J844-2 and ground. Check the +24VDC circuit to the Finisher PWB P/J844 by referring to Chapter 7 Wir-...
Page 309: Staple Mode Logic
12-399 Staple Mode Logic Stapling cannot be selected for the size of paper in the tray. Procedure Job can be reprogrammed with different staple setting or paper size. Redesign Job. Reprogram job. Initial issue Status Indicator RAPs 02/03 12-399 DC 3535/2240/1632 2-279...
Page 310: Power On H Transport Entrance Sensor
12-901 Power On H Transport Entrance Sensor The H Transport Entrance Sensor detected a paper at power on, when all the interlock were closed, or at initialization. Procedure Enter dC330 [012-103] and press Start. Actuate the H Transport Entrance Sensor (Figure The display changes.
Page 311: Power On H Transport Exit Sensor
12-902 Power On H Transport Exit Sensor The H Transport Exit Sensor detected a paper at power on, when all the Interlock were closed, or at initialization. Procedure Enter dC330 [012-104] and press Start. Actuate the H Transport Exit Sensor (Figure 1).
Page 312: Power On Compiler Entrance Sensor
12-903 Power On Compiler Entrance Sensor The Compiler Entrance Sensor detected a paper at power on, when all the Interlocks are closed, or at initialization. Procedure Enter dC330 [012-101] and press Start. Actuate the Compiler Entrance Sensor (Figure The display changes. Disconnect P/J850 from Finisher Control PWB.
Page 313: Power On Compiler Paper Sensor
12-904 Power On Compiler Paper Sensor • The Compiler Paper Sensor continues to detect paper when the paper was output auto- matically due to the power on initialization. • The Compiler Paper Sensor detected paper with no history of paper output to the Com- piler Tray when all the interlocks were closed.
Page 314: Staple Feed Ready
12-910 Staple Feed Ready Switch the power off. Remove the Stapler Assembly (REP 12.11). Rotate the Staple Motor Gear manually. The staple needles fed. • At the staple preparation operation at initialization, the Staple Ready Sensor does not go to ready (L) status after 13 ready attempts. Replace the Stapler Assembly 17.9).
Page 315 Figure 3 Finisher PWB Initial issue Status Indicator RAPs 02/03 12-910 DC 3535/2240/1632 2-285...
Page 316: Stacker Lower Safety Warning
12-911 Stacker Lower Safety Warning The Height Alignment was not successful during Stacker Tray lowering while stacking. Initial Actions Check the Stack Height Sensor Actuator for disengagement, bending, obstruction and break- (Figure Procedure Remove paper from Stacker Tray. The problem continues. Return to Service Call Procedures.
Page 317: Stacker Tray Staple Set
12-914 Stacker Tray Staple Set The Staple Set count of the Stacker Tray exceeded 50 sets at the Staple Set Eject operation. Initial Actions Check the actuator of the Stacker Paper Sensor for smooth operation (Figure Procedure Remove the Stapled Sets. The problem continues. Return to Service Call Procedures.
Page 318: Stapling
12-916 Stapling The Staple Head Home Sensor turned on by the open operation while the Sensor failed to turn on (stapling was not available due to an error) after the Staple Head began to close. Procedure Position paper in stapler. Enter dC330 [012-020] and press Start.
Page 319 Figure 3 Finisher PWB Initial issue Status Indicator RAPs 02/03 12-916 DC 3535/2240/1632 2-289...
Page 320: Stacker Tray Full Stack
12-960 Stacker Tray Full Stack NOTE: The large white Stacker Drive Pulley can be pulled out to release the Stacker Drives to free the Stacker Tray (REP 12.20). • The system detected small size paper full during the Stacker Tray Height Adjustment operation during lowering.
Page 321 Figure 3 12-960 RAP Circuit Diagram - Stack B Sensor Figure 6 Finisher PWB Figure 4 12-960 RAP Circuit Diagram - Stacker Paper Sensor Figure 5 12-960 RAP Circuit Diagram - Stacker Motor Initial issue Status Indicator RAPs 02/03 12-960 DC 3535/2240/1632 2-291...
Page 322: Mix Full Stack
12-961 Mix Full Stack NOTE: The large white Stacker Drive Pulley can be pulled out to release the Stacker Drives to free the Stacker Tray (REP 12.20). • Compared to the maximum paper size that was loaded at the previous job, the paper size (either feed direction or width direction) of the next job is bigger.
Page 323 Figure 3 12-961 RAP Circuit Diagram - Stack B Sensor Figure 6 Finisher PWB Figure 4 12-961 RAP Circuit Diagram - Stacker Paper Sensor Figure 5 12-961 RAP Circuit Diagram - Stacker Motor Initial issue Status Indicator RAPs 02/03 12-961 DC 3535/2240/1632 2-293...
Page 324: Staple Near Empty
12-965 Staple Near Empty • The Low Staple Switch detected Low Staple at Power On and Interlock Close. • The Low Staple Switch detected Low Staple at Staple Head Close. Procedure Install a new Staple Cartridge loaded with staples. +5VDC measured between the Finisher PWB P/J852-4 and ground (Figure Replace the Finisher PWB...
Page 325: Scratch Sheet Compile
12-966 Scratch Sheet Compile Paper is output to the compiler that is not part of a print or copy job. Procedure Clear the sheets in the Stacker Tray. The problem continues. Return to service call procedures. Rerun the job. If the problem continues, replace the Finisher PWB 17.13).
Page 326: Iot Top Tray Full
12-969 IOT Top Tray Full The Top Tray Full Sensor has detected full status for 10 sec. Procedure Enter dC330 [012-215] and press Start. Position some paper near the Top Tray Full Sensor (Figure 1), then move the paper away. The display changes. Press Stop.
Page 327: X Hard Failure
15-362 X Hard Failure 15-367 X PIO Failure Communication Failure. Communication Failure. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures. Check the connectors on the IIT/IPS PWB 18.3).
Page 328: X Pio Initialization Failure 1
15-370 X PIO Initialization Failure 1 15-371 X PIO Initialization Failure 2 Communication Failure. Communication Failure. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures.
Page 329: X Pio Initialization Failure 3
15-372 X PIO Initialization Failure 3 15-375 X PIO Before Scan Failure Communication Failure. Communication Failure. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures.
Page 330: X Pio Non-Match Failure 1
15-376 X PIO Non-match Failure 1 15-377 X PIO Non-match Failure 2 Communication Failure. Communication Failure. Procedure Procedure Switch the power off then on. The problem continues. Switch the power off then on. The problem continues. Return to Service Call Procedures. Return to Service Call Procedures.
Page 331: Ccd Agc
15-380 CCD AGC Automatic Gain Control (AGC) for CCD Channel 1 red failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Switch the power off, then on. The fault code is still present. Intermittent faults can be caused by condensation on the optics components.
Page 332 Figure 3 15-380 RAP Circuit Diagram - CCD Status Indicator RAPs Initial issue 02/03 15-380 2-302 DC 3535/2240/1632...
Page 333: Ccd Agc
15-381 CCD AGC Automatic Gain Control (AGC) for CCD Channel 2 red failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371.
Page 334 Figure 3 15-381 RAP Circuit Diagram - CCD Status Indicator RAPs Initial issue 02/03 15-381 2-304 DC 3535/2240/1632...
Page 335: Ccd Agc
15-382 CCD AGC Automatic Gain Control (AGC) for CCD Channel 3 green failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 336 Figure 3 15-382 RAP Circuit Diagram - CCD Status Indicator RAPs Initial issue 02/03 15-382 2-306 DC 3535/2240/1632...
Page 337: Ccd Agc
15-383 CCD AGC Automatic Gain Control (AGC) for CCD Channel 4 green failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 338 Figure 3 15-383 RAP Circuit Diagram - CCD Status Indicator RAPs Initial issue 02/03 15-383 2-308 DC 3535/2240/1632...
Page 339: Ccd Agc
15-384 CCD AGC Automatic Gain Control (AGC) for CCD Channel 5 blue failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 340 Figure 3 15-384 RAP Circuit Diagram - CCD Status Indicator RAPs Initial issue 02/03 15-384 2-310 DC 3535/2240/1632...
Page 341: Ccd Agc
15-385 CCD AGC Automatic Gain Control (AGC) for CCD Channel 6 blue failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 342 Figure 3 15-385 RAP Circuit Diagram - CCD Status Indicator RAPs Initial issue 02/03 15-385 2-312 DC 3535/2240/1632...
Page 343: Ccd Aoc1
15-386 CCD AOC1 Automatic Offset Control (AOC) for CCD Channel 1 failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 344: Ccd Aoc2
15-387 CCD AOC2 Automatic Offset Control (AOC) for CCD Channel 21 failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 345: Ccd Aoc3
15-388 CCD AOC3 Automatic Offset Control (AOC) for CCD Channel 3 failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 346: Ccd Aoc4
15-389 CCD AOC4 Automatic Offset Control (AOC) for CCD Channel 4 failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 347: Ccd Aoc5
15-390 CCD AOC5 Automatic Offset Control (AOC) for CCD Channel 5 failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 348: Ccd Aoc6
15-391 CCD AOC6 Automatic Offset Control (AOC) for CCD Channel 6 failed. Initial Actions • Verify that the Platen Glass is installed correctly (REP 6.2). • Verify that NVM location 715-400 = 1 Procedure Enter dC330 [6-002] and press Start. The Exposure Lamp illuminates. Go to the 6-371 RAP.
Page 349: X Detail Failure
15-790 X Detail Failure Communication Failure. Procedure Switch the power off then on. The problem continues. Return to Service Call Procedures. Check the connectors on the IIT/IPS PWB 18.3). If the check is OK, replace the IIT/IPS 18.3) Initial issue Status Indicator RAPs 02/03 15-790...
Page 350 Status Indicator RAPs Initial issue 02/03 15-790 2-320 DC 3535/2240/1632...
Page 351: Scanner
16-311 Scanner 16-315 IIT Interface Scanner not detected during power up. IIT interface error. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Check connections between Scanner and IOT.
Page 352: Page Memory
16-316 Page Memory 16-317 Page Memory Page memory not detected. Page Memory error. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Check installation of Page Memory of the Scanner.
Page 353: Optional Page Memory
16-318 Optional Page Memory 16-361 IOT/ESS Communication Failure 1 (ExtPrt) Optional page memory error. Incorrect parameter set Procedure Procedure Switch power off then on. The problem continues. Switch the power off, then on. If the problem continues, check the connections at the MCU PWB and the I/F PWB.
Page 354: Iot/Ess Communication Failure 2 (Extprt)
16-362 IOT/ESS Communication Failure 2 (ExtPrt) 16-363 IOT/ESS Communication Failure 3 (ExtPrt) ACK not received after 2 resends because the sequence number of the message packet is ACK not received after 2 resends because the packet number of the message packet is incor- incorrect.
Page 355: Iot/Ess Communication Failure 4 (Extprt)
16-364 IOT/ESS Communication Failure 4 (ExtPrt) 16-365 IOT/ESS Communication Failure 5 (ExtPrt) ACK not received after 2 resends because the message length of the message packet is incor- ACK not received after 2 resends because the checksum of the message packet is incorrect. rect.
Page 356: Iot/Ess Communication Failure 6 (Extprt)
16-366 IOT/ESS Communication Failure 6 (ExtPrt) 16-367 IOT/ESS Communication Failure 7 (ExtPrt) ACK not received after 2 resends because a parity error was declared by the IOT hardware. ACK not received after 2 resends because a parity error was declared by the IOT hardware. Procedure Procedure Switch the power off, then on.
Page 357: Iot/Ess Communication Failure 8 (Extprt)
16-368 IOT/ESS Communication Failure 8 (ExtPrt) 16-369 IOT/ESS Communication Failure 9 (ExtPrt) ACK not received after 2 resends because an overrun error was declared by the IOT hard- ACK not received after 2 resends because a receive abort signal is detected after header rec- ware.
Page 358: Dfe/Ess Communication Failure 1
16-371 DFE/ESS Communication Failure 1 16-372 DFE/ESS Communication Failure 2 Incorrect parameter set ACK not received after 2 resends because the sequence number of the message packet is incorrect. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU PWB and the I/F PWB.
Page 359: Dfe/Ess Communication Failure 3
16-373 DFE/ESS Communication Failure 3 16-374 DFE/ESS Communication Failure 4 ACK not received after 2 resends because the packet number of the message packet is incor- ACK not received after 2 resends because the message length of the message packet is incor- rect.
Page 360: Dfe/Ess Communication Failure 5
16-375 DFE/ESS Communication Failure 5 16-376 DFE/ESS Communication Failure 6 ACK not received after 2 resends because the checksum of the message packet is incorrect. ACK not received after 2 resends because a parity error was declared by the IOT hardware. Procedure Procedure Switch the power off, then on.
Page 361: Dfe/Ess Communication Failure 7
16-377 DFE/ESS Communication Failure 7 16-378 DFE/ESS Communication Failure 8 ACK not received after 2 resends because a framing error was declared by the IOT hardware. ACK not received after 2 resends because an overrun error was declared by the IOT hard- ware.
Page 362: Dfe/Ess Communication Failure 9
16-379 DFE/ESS Communication Failure 9 16-380 DFE/ESS Communication Failure 10 ACK not received after 2 resends because an overrun error was declared by the IOT hard- NAK-generated sequence number error. ware. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch the power off, then on.
Page 363: Dfe/Ess Communication Failure 10
16-380 DFE/ESS Communication Failure 10 16-381 DFE/ESS Communication Failure 11 NAK-generated sequence number error. NAK-generated packet number error. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch the power off, then on. If the problem continues, check the connections at the MCU PWB and the I/F PWB.
Page 364: Dfe/Ess Communication Failure 12
16-382 DFE/ESS Communication Failure 12 16-383 DFE/ESS Communication Failure 13 NAK-generated message length error. NAK-generated checksum error. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch the power off, then on. If the problem continues, check the connections at the MCU PWB and the I/F PWB.
Page 365: Dfe/Ess Communication Failure 14
16-384 DFE/ESS Communication Failure 14 16-385 DFE/ESS Communication Failure 15 NAK-generated parity error. NAK-generated framing error. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch the power off, then on. If the problem continues, check the connections at the MCU PWB and the I/F PWB.
Page 366: Dfe/Ess Communication Failure 16
16-386 DFE/ESS Communication Failure 16 16-387 DFE/ESS Communication Failure 17 NAK-generated framing error. NAK-generated receive abort error. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch the power off, then on. If the problem continues, check the connections at the MCU PWB and the I/F PWB.
Page 367: Dfe/Ess Communication Failure 19
16-389 DFE/ESS Communication Failure 19 16-390 DFE/ESS Communication Failure 20 NAK-generated packet number error. Initialization request from DFE not received within the allotted time. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch the power off, then on.
Page 368: Dfe Not Detected
16-399 DFE Not Detected 16-450 SMB Host Name External controller is not connected or is not functioning. PC of the same host name is duplicated on a network. Procedure Procedure Switch the power off, then on. If the problem continues, check the connections at the MCU Switch power off then on.
Page 369: Ip Address Duplicated
16-452 IP Address Duplicated 16-453 IP Address Acquisition PC of the same IP address exists on a network. The IP address failed to be granted from the DHCP server. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 370: Dynamic Dns Update
16-454 Dynamic DNS Update 16-460 Full Status Detected Dynamic DNS update failed. Full Status Detected at HDD Access. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 371: Read Error (Partition A)
16-590 Read Error (Partition A) 16-591 Read Error (Partition B) A verify error occurred in the HDD partition A at PC-Diag operation from PWS. A verify error occurred in the HDD partition B at PC-Diag operation from PWS. Procedure Procedure Switch power off then on.
Page 372: Read Error (Partition C)
16-592 Read Error (Partition C) 16-593 Read Error (Partition D) A verify error occurred in the HDD partition C at PC-Diag operation from PWS. A verify error occurred in the HDD partition D at PC-Diag operation from PWS. Procedure Procedure Switch power off then on.
Page 373: Read Error (Partition E)
16-594 Read Error (Partition E) 16-595 Read Error (Partition H) A verify error occurred in the HDD partition E at PC-Diag operation from PWS. A verify error occurred in the HDD partition H at PC-Diag operation from PWS. Procedure Procedure Switch power off then on.
Page 374: Plw Memory
16-701 PLW Memory 16-702 PLW Memory An insufficient memory is detected while using the ART EX. System detected insufficient buffer for the print page that cannot be compressed. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 375: E-Mail To Invalid Box
16-703 E-mail To Invalid Box 16-704 Security Box System detected an unopened or invalid Mailbox and aborted a job when receiving an Email. The system detected that a Mailbox was full (it exceeded the maximum number of documents per Box) and aborted a job. Full status was detected at access and a job was aborted. Procedure Procedure Switch power off then on.
Page 376: Security Storage Without Hd
16-705 Security Storage without HD 16-706 Maximum User Number Registry for Secure Print has failed because Security Storage cannot be done due to no HDD The system detected that a job exceeded the maximum number of users for Secure and Proof available.
Page 377: Plw Command
16-709 PLW Command 16-716 Spool TIFF Data An ART EX Command error has occurred during PLW processing. Unable to spool TIFF files because disk capacity is exceeded. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 378: Other Errors
16-721 Other Errors 16-726 Decomposer Auto Judgement An error occurred during printing that is not defined. Cannot switch decomposer; a print Language auto judgement error occurred. Procedure Auto Judgement Error Switch power off then on. The problem continues. Procedure Return to service call procedures. Switch power off then on.
Page 379: Tiff Data
16-728 TIFF Data 16-729 TIFF Data The data contains a Tag that is not set in the Image File Expansion Library. The specified settings exceed the upper limit of the valid number of colors and pixels. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 380: Art Command
16-730 ART Command 16-731 TIFF Data ART IV Command Invalid. Invalid TIFF Data. The TIFF data is broken or cut halfway. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 381: Job Template
16-735 Job Template 16-737 Server Read The system tried to output the Job Template List while the Job Template was being updated. Read error from the Job Template Pool Server Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 382: Job Template Path
16-739 Job Template Path 16-740 Job Template Login The specified path of the Job Template Pool Server cannot be found. Job Template Server Login Error. Cannot log in to the Job Template Pool Server. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 383: Job Template Connection
16-741 Job Template Connection 16-742 HDD File Cannot connect to the Job Template Pool Server. File system was full when the Job Template was stored into the local HDD. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 384: Job Template Installation
16-743 Job Template Installation 16-744 Job Template Address Job template pool server installation error or job template pool server setting failure The Job Template Pool Server address cannot be solved (Response to the DNS library error) Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 385: Job Template Definition
16-745 Job Template Definition 16-748 HDD Full The Job Template Pool Server address cannot be solved (The DNS address is not set) Full status was detected at HDD access and a job was aborted. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 386: Xjcl Syntax
16-749 XJCL Syntax 16-757 Auditron User Syntax error of the JCL command was detected. Invalid Auditron User Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 387: Auditron Function
16-758 Auditron Function 16-759 Auditron Limit An auditron function is disabled. Auditron reached limit. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Consult the account administrator to add a right.
Page 388: Decomposer
16-760 Decomposer 16-761 FIFO Error during decompose processing. Image Enlargement Error, FIFO EMPTY Error. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Print in fast print mode.
Page 389: Decomposer
16-762 Decomposer 16-763 Patch The print language is not installed or an unsupported function (print language, print utility.) was Original patch does not exist. required. The Decomposer specified with PJL or Auto SW is not installed. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 390: Server Transmission
16-764 Server Transmission 16-765 Server Storage SMTP Server Connection Error, result code: 421/451 SMTP Server HD Full, Result code: 452 Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 391: Server Storage
16-766 Server Storage 16-767 Mailbox SMTP Server File System has a problem, result code: 552. Mailbox not found, or no access. E-mail destination address Incorrect, result code: 550/551. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 392: Mail From Command
16-768 Mail From Command 16-769 DSN Unsupported Mail From Command, Sending Address Incorrect, Login Error. SMTP Server Not Applicable to DSN Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 393: Template Processing
16-770 Template Processing 16-771 Scan Data Repository The system aborted a job due to insufficient HDD capacity at Job Template processing. The Scanned Data Repository Address cannot be solved. DNS Address is not set. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 394: Scan Data Repository
16-772 Scan Data Repository 16-773 IP Address The Scan Data Repository address cannot be solved (Response to the DNS library error) Self-machine IP address invalid, DHCP Lease Expired. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 395: Hdd Compression
16-774 HDD Compression 16-775 HDD Capacity HDD Full has occurred when the S-Formatter did the compression type conversion of the JBIG Image Conversion Error. Insufficient HDD capacity is detected during image conversion pro- compressed images into the MH system (partition #1). cess by S-Formatter.
Page 396: Image Conversion
16-776 Image Conversion 16-777 HDD Access An error has occurred due to other causes than HDD Access during image conversion process The HDD Access Error has occurred during image conversion process by S-Formatter. by S-Formatter. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 397: Hdd Capacity
16-778 HDD Capacity 16-779 Scan Image Conversion The insufficient HDD capacity was detected during scanned image conversion process by I- An error has occurred due to other causes than HDD Access during scanned image conver- Formatter. sion process by I-Formatter. Procedure Procedure Switch power off then on.
Page 398: Hdd Access
16-780 HDD Access 16-781 Scan Server The HDD Access Error has occurred during scanned image conversion process by I-Format- Net Connection Error during Scanning. Connection to the Server cannot be established during ter. Scan to Server file transfer operation. Procedure Procedure Switch power off then on.
Page 399: Scan Server Login
16-782 Scan Server Login 16-783 Server Path Server Login Error during Scanning. Cannot log in to the Server during Scan to Server file Server Path Error at Scanning. The specified path cannot be found at Scan to Server file trans- transfer operation.
Page 400: Server Write
16-784 Server Write 16-785 Server HDD Full Write Error at Scanning. The Server cannot be written to at the Scan to Server file transfer. Server File Full at Scanning. The Server File System became full during the Scan to Server file transfer.
Page 401: Hdd Scan Write
16-786 HDD Scan Write 16-787 Job Template Syntax Internal HDD Write Error at Scanning. A temporary file cannot be written to the internal HDD at This is a syntax error in the Job Template during Scan to Server operation and limited to the the Scan to Server file transfer.
Page 402: Mailbox To Pc
16-788 Mailbox to PC 16-793 I/O HD Full Retrieval Failed at Scan to PC (via Web Browser. Procedure Switch power off then on. The problem continues. Procedure Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 403: Tray 1 Empty
16-950 Tray 1 Empty 16-951 Tray 2 Empty Tray 1 Empty Tray 2 Empty Procedure Procedure Switch power off then on. Add paper. The problem continues. Switch power off then on. Add paper. The problem continues. Return to service call procedures. Return to service call procedures.
Page 404: Tray 3 Empty
16-952 Tray 3 Empty 16-953 Tray 4 Empty Tray 3 Empty Tray 4 Empty Procedure Procedure Switch power off then on. Add paper. The problem continues. Switch power off then on. Add paper. The problem continues. Return to service call procedures. Return to service call procedures.
Page 405: Tray 5 Empty
16-954 Tray 5 Empty 16-958 Tray 5 Size Tray 5 Empty Tray 5 Size Mismatch Procedure Procedure Switch power off then on. Add paper. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 406: Tray 1 Size
16-959 Tray 1 Size 16-960 Tray 2 Size Tray 1 Size Mismatch Size Mismatch Tray 2 Size Mismatch Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 407: Tray 3 Size
16-961 Tray 3 Size 16-962 Tray 4 Size Tray 3 Size Mismatch Tray 4 Size Mismatch Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Load proper paper in the tray.
Page 408: Ats/Aps No Paper
16-965 ATS/APS No Paper 16-966 ATS/APS No Destination APS/ATS NG No Paper. ATS/APS No Destination, other than No Paper. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 409: Full Hdd
16-981 Full HDD 16-982 Full HDD Full status was detected at HDD access. Full status was not cleared even during waiting for Full status was detected at HDD access. Full status was not cleared even during waiting for timing. One or more pages are already stored. timing.
Page 410 Status Indicator RAPs Initial issue 02/03 16-981, 16-982 2-380 DC 3535/2240/1632...
Page 411: Network Controller Software Fail
17-310 Network Controller Software Fail 17-941 Tray 1 not in position Fatal error in NC software. The Network Controller reports that Tray 1 is not in a ready condition. Procedure Procedure Refer to the Network Controller service documentation. Check that Tray 1 is closed, and that the paper guides are set correctly. If this does not resolve the problem, go to the 3-946 RAP.
Page 412: Tray 2 Not In Position
17-942 Tray 2 not in position 17-943 Tray 3 not in position The Network Controller reports that Tray 2 is not in a ready condition. The Network Controller reports that Tray 3 is not in a ready condition. Procedure Procedure Check that Tray 2 is closed, and that the paper guides are set correctly.
Page 413: Tray 4 Not In Position
17-944 Tray 4 not in position 17-946 Tray 1 Empty The Network Controller reports that Tray 1 is not in a ready condition. The Network Controller reports Tray 1 empty. Procedure Procedure Check that Tray 4 is closed, and that the paper guides are set correctly. If this does not resolve Load Tray 1.
Page 414: Tray 2 Empty
17-947 Tray 2 Empty 17-948 Tray 3 Empty The Network Controller reports Tray 2 empty. The Network Controller reports Tray 3 empty. Procedure Procedure Load Tray 2. If this does not resolve the problem, go to the 3-951 Load Tray 3. If this does not resolve the problem, go to the 3-952 Status Indicator RAPs Initial issue...
Page 415: Tray 4 Empty
17-949 Tray 4 Empty 17-950 Tray 5 Empty The Network Controller reports Tray 4 empty. The Network Controller reports Tray 5 empty. Procedure Procedure Load Tray 4. If this does not resolve the problem, go to the 3-953 Load Tray 5. If this does not resolve the problem, go to the 3-954 Initial issue Status Indicator RAPs...
Page 416: Tray 1 Size Mismatch
17-951 Tray 1 Size Mismatch 17-952 Tray 2 Size Mismatch The Network Controller reports that the paper detected in Tray 1 does not match the size des- The Network Controller reports that the paper detected in Tray 2 does not match the size des- ignated for the print job.
Page 417: Tray 3 Size Mismatch
17-953 Tray 3 Size Mismatch 17-954 Tray 4 Size Mismatch The Network Controller reports that the paper detected in Tray 3 does not match the size des- The Network Controller reports that the paper detected in Tray 3 does not match the size des- ignated for the print job.
Page 418: Ats/Aps Mismatch
17-955 ATS/APS Mismatch 17-960 Tray 5 Size Mismatch The Network Controller reports that, in Auto Tray Select or Auto Paper Select, no paper of the The Network Controller reports that the paper in Tray 5 is different than the specified paper designated size could be located.
Page 419: Incorrect Transparency Type
17-961 Incorrect Transparency Type 17-963 Full Stack Incorrect type of transparency detected by the OHP sensor. The Network Controller reports that the Top Tray is full. Initial Actions Procedure • Ensure that only approved transparencies (no white strip) are used. Empty the Top Tray.
Page 420: Stacker Tray Full
17-965 Stacker Tray Full 17-966 Mix Full Stack The Network Controller reports that the Stacker Tray in the Finisher is full. The Network Control reports one of the following conditions: • Compared to the maximum paper size that was loaded at the previous job, the paper size Procedure (either feed direction or width direction) of the next job is bigger.
Page 421: Staple Near Empty
17-967Staple Near Empty 17-968 Extra Sheet in Compiler The Network Controller reports one of the following conditions: Procedure • The Low Staple Switch detected Low Staple at Power On and Interlock Close. Go to the 12-966 RAP. • The Low Staple Switch detected Low Staple at Staple Head Close. Procedure Replace the Staple Cartridge.
Page 422: Top Tray Full (Finisher)
17-969Top Tray Full (Finisher) The Network Controller reports that the Top Tray Full Sensor in the H-Transport has detected that the IOT Top Tray is full, for longer than 10 sec. Procedure Empty the Top Tray. If the problem continues, go to the 12-969 RAP.
Page 423 021-360 Foreign Device Failure The Foreign Device (3rd-party device such as vend station or mechanical Auditron) failed its internal self-test, or the self-test result has not been returned from the Foreign Device at power-on. Procedure CAUTION Do not attempt to troubleshoot this circuit by jumpering the Transmit Data or Receive Data lines (P343 pins 4 ~ 6 on the ESS PWB).
Page 424 Status Indicator RAPs Initial issue 02/03 021-360 2-394 DC 3535/2240/1632...
Page 425: Receive Buffer Overflow
102-200 Receive Buffer Overflow 102-201 Send Buffer Overflow The data received from the Controller exceeded the buffer amount of the destination in the The data to be sent from the Panel exceeded the buffer amount of the destination in the Panel. Panel.
Page 426: Request Queue Full
102-202 Request Queue Full 102-203 Send Request Queue Full Debug The event that requires more than the processing capability for the request arising in the Panel Data cannot be sent from the Panel to the Controller. has occurred. Procedure Procedure Switch power off then on.
Page 427: Sio Parameter
102-204 SIO Parameter 102-205 SIO Command Serial communication failure. Incorrect message size at SIO receiving request, or incorrect Serial communication failure. A command error has occurred at SIO receiving request. Mailbox ID when a message is sent. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 428: Sio Status
102-206 SIO Status 102-207 Communication Manager Target Serial communication failure. A header status error of the RX packet or a message status error Serial communication failure. Incorrect Mailbox value on the cm_send_msg statement, or the of the RX packet has occurred. target is not SYS when receiving from SIO.
Page 429: Communication Manager Command
102-208 Communication Manager Command 102-209 EVM Returns Wrong Value Serial communication failure. A command error has occurred when receiving from SIO. Return value error from EVM. Panel-SW failure Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 430: Send Queue Full
102-310 Send Queue Full 102-311 Receive Queue Full Over the upper limit of the processing capability to send data from the Panel to the Controller. The data received from the Controller exceeded the upper limit of the processing capability in the Panel.
Page 431: Evm Uses Wrong Api
102-312 EVM Uses Wrong API 102-313 AS Uses Wrong API Illegal use of API by EVM. Illegal use of API by AS Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 432: Wait Event Time Out
102-314 Wait Event Time Out 102-315 CTS Internal Time-Out of the event waiting timer. The response message from the Controller was not noti- CTS Internal Error fied for a specified time. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 433: Send Request Queue Full Sio
102-316 Send Request Queue Full SIO 102-317 Receive Message Queue Full Over the upper limit of the processing capability to send data from the Panel to the Controller. The data received from the Controller exceeded the upper limit of the processing capability in the Panel.
Page 434: Receive Finish Queue Full
102-318 Receive Finish Queue Full 102-319 Send with No ACK The data received from the Controller exceeded the upper limit of the processing capability in Serial communication failure. Sending failure, ACK was not returned. the Panel. Procedure Procedure Switch power off then on. Status code 116-325 is displayed temporarily, then 102-319 is Switch power off then on.
Page 435: Polling
102-320 Polling 102-321 Send Message Serial communication failure. Communication failure (polling error) Serial communication failure. Sending message error. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 436: Target
102-322 Target 102-323 Address Serial communication failure. Target error. Serial communication failure. Address error. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 437: Size
102-324 Size 102-325 Object Creation Serial communication failure. Size error Object creation error. The specified object failed to be created due to a setting or specifying error on gm_create. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 438: Memory Overflow
102-326 Memory Overflow 102-327 Button Overflow Memory overflow. The memory in the GUAM exceeded the upper limit. Button overflow. The memory for the (synchronous display) button in the GUAM exceeded the upper limit. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 439: Ui Internal With Out Of Area
102-328 UI Internal with Out of Area 102-329 UI Internal with Invalid Coordinates I/F failure in the UI. The coordination value out of the area of the displayed screen was I/F failure in the UI. The coordination value that cannot be displayed was detected (X = 4 times detected (W x H = 640 x 240) number position) Procedure...
Page 440: Interface With Invalid Parameter Lcd
102-330 Interface with Invalid Parameter LCD 102-331 UI Internal with Invalid LED Request Interface failure. Incorrect parameter was detected at the Drv. I/F between the DM and LCD. I/F failure in the UI. The request for lighting up an incorrect LED was received. Procedure Procedure Switch power off then on.
Page 441: Interface With Invalid Parameter Cp
102-332 Interface with Invalid Parameter CP 102-333 Interface with Impossible Communication Interface failure. Incorrect parameter was detected at the Drv. I/F between the DM and CP. Interface failure. Impossible communication with the Control Panel was detected. H/W connec- tion failure in the Panel, or the internal connection was unable to be detected correctly. Procedure Procedure Switch power off then on.
Page 442: Interface With Receiving Error Key Code
102-334 Interface with Receiving Error Key Code 102-335 Interface with Receiving Invalid Coordinates Interface failure. Invalid Key Code was received from the Control Panel. Interface failure. Invalid coordination value was received from the Control Panel with a param- eter. Procedure Procedure Switch power off then on.
Page 443: Interface Dm - Acd Drv. I/F
102-336 Interface DM - ACD Drv. I/F 102-337 Frame Data Error with Invalid Data Type Interface failure. Incorrect parameter was detected at the Drv. I/F between the DM and ACD. Invalid frame data was detected. The incorrect value of the Data Type detected by Frame ID was detected.
Page 444: Frame Data Error Offset Address Out Of Scope
102-338 Frame Data Error Offset Address Out of Scope 102-339 Display Request Code Invalid Invalid frame data was detected. The Offset Address out of range was extracted from the Text Code failure. The system detected that the Code requested to be displayed was incorrect. Frame ID.
Page 445: Interface Guam - Dm I/F
102-340 Interface GUAM - DM I/F 102-341 Event Queue Full Interface failure. Incorrect parameter was detected at the I/F between the GUAM and DM. Event queue full Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 446: Event Queue Empty
102-342 Event Queue Empty 102-343 Invalid Class Event queue empty Invalid class Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 447: Invalid Type
102-344 Invalid Type 102-345 Timer Queue Full Invalid type Timer queue full Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 448: Invalid Timer Number
102-346 Invalid Timer Number 102-347 Undefined Trap Invalid timer number Undefined trap Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 449: Command Access Exception
102-348 Command Access Exception 102-349 Invalid Command Exceptional command access Illegal command Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 450: Privilege Command
102-350 Privilege Command 102-351 No FPU Exception Privilege command Exceptional FPU non-existence Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 451: Address Alignment
102-352 Address Alignment 102-353 Data Access Exception Address mis-alignment Exceptional data access Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 452: Tag Overflow
102-354 Tag Overflow 102-355 No Co Processor Exception Tag overflow Exceptional Co Processor non-existence Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 453: Short Of Area
102-356 Short of Area 102-357 Cancel Wait Status Insufficient area Forced cancellation of the wait status Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 454: Time Out
102-358 Time Out 102-359 Queue Overflow Time-Out Queue overflow Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Switch power off then on.
Page 455: Context
102-360 Context 102-361 Object Context error Object error Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Perform re-installation of the software.
Page 456: No Object
102-362 No Object 102-363 Invalid ID Object non-existence Incorrect ID Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Perform re-installation of the software.
Page 457: Parameter
102-364 Parameter 102-365 Reserve Attribute Parameter error Reserve attribute Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Perform re-installation of the software.
Page 458: Reserve Function Code
102-366 Reserve Function Code 102-367 Unsupported Function Code number for reserve function Unsupported function Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 459: Short Of Ui Memory
102-368 Short of UI Memory 102-369 Invalid Interface Value Insufficient memory, or connection failure Invalid interface value. Panel-SW failure Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 460: Interface Length
102-370 Interface Length 102-371 Interface Parameter Interface length failure. The parameter notified from the Controller was incorrect. Interface parameter failure. The parameter notified from the Controller was incorrect. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 461: Interface Sequence
102-372 Interface Sequence 102-373 Channel Interface sequence failure. The initial command from the Controller was not notified within a Channel failure. The channel notified from the Controller was incorrect. specified time. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 462: Invalid User Job Id
102-374 Invalid User Job ID 102-375 Internal Resource Incorrect User Job ID. The Job ID parameter notified from the Controller was incorrect. Internal resource failure. Panel-SW failure. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 463: Internal Memory
102-376 Internal Memory 102-377 UI Timer Internal memory failure. Panel-SW failure. Timer failure. Panel-SW failure Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 464: Interface Format
102-378 Interface Format 102-379 Dispatch Interface format failure. The data format notified from the Controller was incorrect. Dispatch failure Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 465: Copy Interface
102-380 Copy Interface 102-382 Scanner Interface Copy interface failure Scanner interface failure Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 466: Report Interface
102-383 Report Interface 102-384 Server Access Report interface failure Server access failure Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 467: Service Object Overflow
102-385 Service Object Overflow 102-386 Invalid Service Object Service object overflow Invalid service object Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 468: Invalid Service Object Attribute
102-387 Invalid Service Object Attribute 102-388 Attribute Invalid service object attribute Attribute Error Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 469: Argument
102-389 Argument 102-390 Job Parameter Argument Error Job parameter argument error Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Perform re-installation of the software.
Page 470: Job Actual Parameter
102-391 Job Actual Parameter 102-392 Auditron Job execution argument error Invalid Auditron Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Again, switch power off then on.
Page 471: File Access
102-393 EP 102-394 File Access Software failure Invalid file access Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Perform re-installation of the software.
Page 472 102-395 NVM 102-396 FF NVM failure FF error Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software. Perform re-installation of the software.
Page 473: Delay Release Queue Full
102-397 MGR 102-398 Delay Release Queue Full MGR error. Delay release queue full. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures. Perform re-installation of the software.
Page 474: Internal
102-399 Internal Internal error. Procedure Switch power off then on. The problem continues. Return to service call procedures. Perform re-installation of the software. If the problem continues, replace the Control Panel 18.2) Status Indicator RAPs Initial issue 02/03 102-399 2-444 DC 3535/2240/1632...
Page 475: Serial Number Failure
103-203 Machine Code Failure 103-204 Serial Number Failure Product Number Failure (Not initialized). Serial Number Failure (Not initialized). Procedure Procedure CAUTION CAUTION During this procedure, do not make any prints or any copies until clear the fault. If the configu- During this procedure, do not make any prints or any copies until clear the fault.
Page 476: All Machine Codes Mismatch
103-207 All Machine Codes Mismatch 103-208 All Serial Numbers Mismatch At least one of the three Product codes are mismatched. At least one of the three Serial Numbers are mismatched. Procedure Procedure CAUTION Switch the power off then on. The fault is cleared. During this procedure, do not make any prints or any copies until clear the fault.
Page 477: Rom Failure
103-320 ROM Failure 103-321 Backup SRAM Failure A write error has occurred in the ROM on the ESS PWB. A write error has occurred in the NVM on the ESS PWB. Procedure Procedure Switch the power off then on. The fault is cleared. Switch the power off then on.
Page 478: Ess Rom Dimm #3 Check Failure
103-330 ESS ROM DIMM #3 Check Failure 103-331 ESS ROM DIMM #1 Not Found An ESS ROM DIMM #3 check failure was detected. The system detected that the ESS ROM DIMM #1 was not installed. Procedure Procedure Switch the power off then on. The fault is cleared. Switch the power off then on.
Page 479: Ess Standard Rom Error
103-332 ESS Standard ROM Error 103-333 ASIC Failure (Panther-t) An error was detected in the ESS built-in standard ROM. An error was detected in the Panther. Procedure Procedure Switch the power off then on. The fault is cleared. Switch the power off then on. The fault is cleared. Remove and replace the ESS built-in standard ROM.
Page 480: Standard Post Script Font Rom Error
103-334 Standard Post Script Font ROM Error 103-335 Post Script Font ROM Not Found An error was detected in the standard built-in Post Script Font ROM. Post Script Font ROM installation was detected. Procedure Procedure Switch the power off then on. The fault is cleared. Switch the power off then on.
Page 481: Ess Ram Dimm #3 W/R Check Failure
103-336 ESS RAM DIMM #3 W/r Check Failure 103-337 ESS Standard RAM Error A failure was detected during Read/Write Check of the ESS RAM DIMM #3. An error was detected in the ESS built-in standard RAM. Procedure Procedure Switch the power off then on. The fault is cleared. Switch the power off then on.
Page 482: Same Post Script Font Roms Found
103-338 Same Post Script Font ROMs Found 103-339 ROM DIMM Of Another Product Found The system detected that the same Post Script Font ROM was installed. The system detected that the ROM DIMM for another machine was installed. Procedure Procedure Switch the power off then on.
Page 483: Iot Sc Soft Failure
103-372 IOT Sc Soft Failure 103-701 Changed Output Bin: Side To Center IOT Controller software failure was detected. The output tray was changed (Side Tray to Center Output Tray). Initial Actions Procedure Check Fault History (dC122) for faults (especially Tray Module faults) that occurred at the Switch the power off then on.
Page 484: Changed Output Bin: Finisher To Center
103-702 Changed Output Bin: Finisher To Center The output tray was changed (Finisher Tray to Center Output Tray). Procedure Switch the power off then on. The problem continues. Return to service call procedures. Again, switch the power off then on. Status Indicator RAPs Initial issue 02/03...
Page 485 116-200 Main PWBA IC 116-201 HDD An error was detected in the IC in the ESS PWB. The HDD was not booted due to a HDD error detected on booting Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 486: Timer
116-206 Timer 116-207 Ethernet Board A timer error was detected. A timer error was detected in the Ethernet board. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 487: Ess Ps-1 Rom Check
116-209 ESS PS-1 ROM Check 116-310 ESS PS-2 ROM Check A failure was detected when the ESS PS-1 ROM was checked. A failure was detected when the ESS PS-2 ROM was checked. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 488: Ess Font Rom Dimm #3 Check
116-311 ESS Font ROM DIMM #3 Check 116-314 Ethernet Address A failure was detected when the ESS FONT ROM DIMM #3 was checked. A Ethernet error was detected. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 489: Ess Ram Dimm #1 W/R Check
116-315 ESS RAM DIMM #1 W/R Check 116-316 ESS RAM DIMM #2 W/R Check A failure was detected during W/R of the ESS RAM DIMM #1. A failure was detected during W/R of the ESS RAM DIMM #2. Procedure Procedure Switch power off then on.
Page 490: Standard Rom Dimm Check
116-317 Standard ROM DIMM Check 116-318 Option ROM DIMM Check An error was detected when the standard ROM DIMM was checked. An error was detected when the optional ROM DIMM was checked. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 491: Serial
116-319 Serial 116-320 STREAMZ Software There is no serial board at the serial board initialization failure. Fatal error of the STREAMZ. Due to an error during the software processing, the subsequent processes cannot be performed. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 492: System Software
116-321 System Software 116-323 ESS NVRAM W/R Check Due to an error during the software processing, the subsequent processes cannot be per- An error was detected at the W/R check of the NVM in the ESS PWB. formed. Procedure Procedure Switch power off then on.
Page 493: Exception Error
116-324 Exception Error 116-325 ESS Fan CPU exceptional error. ESS Fan failure is detected or +24 VDC is failed. Procedure Procedure Switch power off then on. The problem continues. • Remove Rear Cover (REP 14.2). • Remove cover from +24V LVPS 9.1).
Page 494: Ess Rom Dimm #1 Flash
116-326 ESS ROM DIMM #1 Flash 116-327 ESS ROM DIMM #2 Flash A failure was detected in the ESS ROM DIMM #1 Flash. A failure was detected in the ESS ROM DIMM #2 Flash. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 495: L2 Cache
116-328 L2 Cache 116-329 Serial I/F Software A L2 Cache failure was detected. The system call error related to the serial I/F was detected. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 496: Hdd File System
116-330 HDD File System 116-332 Invalid Log Info The system detected that the an error has occurred or the HDD was not formatted during HDD A failure related to log was detected. check at power on. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 497: Localtalk Software
116-333 LocalTalk Software 116-335 MFIO HD Due to an error during the software processing, the subsequent processes cannot be per- HD failure to be detected by MFIO formed. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 498: Redirector Hd
116-336 Redirector HD 116-337 Template HDD Write Error HD failure to be detected by Redirector <Write error in obtaining JT> Procedure An error has occurred when the Job Template was stored in the local HD. Switch power off then on. The problem continues. Procedure Return to service call procedures.
Page 499: Short Of Memory
116-340 Short of Memory 116-341 ROM DIMMs Mismatch When the system detected that the memory was insufficient. several invalid ROM DIMM versions that are installed The combination of the installed ROM DIMMs is invalid for use at the same time. When installing multiple ROM DIMMs, it is neces- Procedure sary to match the major version with the minor version.
Page 500: Jt Monitor
116-342 JT Monitor 116-344 MF IO Fatal errors to be detected by the JT monitor Fatal errors to be detected by MFIO Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 501: Token Ring Board
116-345 Token Ring Board 116-346 Formatter Token Ring Control IC Access error Fatal errors to be detected by the Formatter were detected. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 502: Redirector
116-348 Redirector 116-349 SIF on Calling Pflite Function Fatal errors detected by Redirector An error has occurred when calling the Pflite function with SIF. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 503: Appletalk Software
116-350 AppleTalk Software 116-351 EtherTalk Software Overall fatal errors of the AppleTalk Fatal error related to the EtherTalk Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 504: Netware Software
116-352 NetWare Software 116-353 lpd Software Fatal error related to the NetWare Fatal error related to the lpd Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 505: Snmp Agent Software
116-355 SNMP Agent Software 116-356 EWS Software Fatal error related to the SNMP Agent Fatal error related to the EWS Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 506: Ps Software
116-357 PS Software 116-358 Salutation Software PS Fatal System Error Fatal error related to the Salutation Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 507: Plw Software
116-359 PLW Software 116-360 SMB Software Fatal error in PLW Fatal error related to the SMB Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 508: Spool Fatal Hd
116-361 Spool Fatal HD 116-365 Spool Fatal Fatal error of the SPL HD Fatal error of the SPL The spool Cont detected an error at HDD access. Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 509: Report Generator Software
116-366 Report Generator Software 116-367 Parallel I/F Software An operation failure of the Report Generator Overall fatal errors of the Parallel Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 510: Dump Print
116-368 Dump Print 116-370 XJCL Fatal error of Dump Print Fatal error of XJCL Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 511: P-Formatter
116-372 P-Formatter 116-373 Dynamic DNS Software Fatal error of P-Formatter Fatal error related to DDNS Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 512: Auto Switch
116-374 Auto Switch 116-375 I-Formatter Fatal error of Auto SW Formatter problem. Due to an error during the software processing, the subsequent processes cannot be per- Procedure formed. Switch power off then on. The problem continues. Procedure Return to service call procedures. Switch power off then on.
Page 513: Port 9100 Software
116-376 Port 9100 Software 116-377 Video DMA [Detection Conditions] Port 9100 Software Fail [Detection Conditions] Video DMA failure was detected. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 514: Mcr Software
116-378 MCR Software 116-379 MCC Software Fatal error of MCR (Mail Contents Requester) Fatal error of MCC (Mail Contents Creator) Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 515: Mf Ui Cont Software
116-380 MF UI Cont Software 116-381 Data Link Layer Error between Cont and UI Panel Fatal error of MF UI cont Controller - MF UI panel: Communication error on the Data Link layer Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 516: Panel Application Layer Command Error On Ui
116-382 Panel Application Layer Command Error on UI 116-388 HDD Not Connected Controller - MF UI panel: Command error at the application level The necessary HDD was not installed. A necessary parameter was not sent from the Panel, an length error was detected in a variable Though the system has the configuration requiring the installation of the HDD (with Fax), it parameter, or the confirmation message was not returned for a specified time after the request detected that the HDD was not installed.
Page 517: No Add-On Ram
116-389 No Add-On RAM 116-390 Standard ROM and NVM Version Mismatch The necessary expansion RAM was not installed. A mismatch of the versions between the standard ROM and NVM was detected. Though the system has the configuration requiring the installation of the expansion RAM (with Procedure the HD), it detected that the expansion RAM was not installed.
Page 518: Usb Software
116-395 USB Software 116-396 Mail IO Software Fatal error related to USB Fatal error related to Mail IO Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 519: Ipp Software
116-398 IPP Software 116-399 JME Software Fatal error related to IPP Fatal error related to JME Due to an error during the software processing, the subsequent processes cannot be per- Due to an error during the software processing, the subsequent processes cannot be per- formed.
Page 520: Execute Forced Separation Of Two Sides
116-701 Execute forced separation of two sides 116-702 Perform printing by using a substitution font Due to insufficient memory, 2-Sided print is impossible. [Detection Conditions] Printed with a substitution font. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 521: Ps Interpret Error
116-703 PS Interpret error 116-710 HP-GL spool file overflow An error has occurred in language analysis [Detection Conditions] HP-GL/2 memory overflow Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 522: Plw Form Synthesis Error
116-711 PLW form synthesis error 116-712 Insufficient PLW form capacity Synthesis is impossible because the size/orientation of the PLW form's drawing is different The PLW form/logo data cannot be registered because of the insufficient RAM or Hard Disk from that of the paper. space.
Page 523: A Hp-Gl Command Error Was Detected
116-714 A HP-GL command error was detected 116-715 PLW form registry error [Detection Conditions] HP-GL/2 command error The PLW form data cannot be registered because of the restriction of the number of forms. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 524: Plw Form Synthesis Error
116-718 PLW form synthesis error 116-737 Insufficient ART user defined area The specified form is not registered. The user defined data (external characters, patterns, etc.) cannot be registered because of insufficient RAM capacity. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 525: Form Synthesis Error
116-738 Form synthesis error 116-739 Insufficient form/logo capacity Synthesis is impossible because the size/orientation of the form's drawing is different from that The form/logo data cannot be registered because of the insufficient RAM or Hard Disk space. of the paper. Procedure Procedure Switch power off then on.
Page 526: Value Calculation Error
116-740 Value Calculation Error 116-741 Form registry error The number calculated in the interpreter exceeded the limit value. The form data cannot be registered because of the restriction of the number of forms. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 527: Logo Registry Error
116-742 Logo registry error 116-743 Form/logo size overflow The logo data cannot be registered because of the restriction of the number of logos. The received data (forms/logos) indicating that forms/logos cannot be registered (due to insuf- ficient area) exceeded the registered buffer size. Procedure Procedure Switch power off then on.
Page 528: Art Command Error
116-745 Art Command Error 116-746 Form synthesis error The decomposer checks the syntax error and excess of each limit value at decomposing. The specified form is not registered. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures.
Page 529: White Page Detected
116-747 White page detected 116-748 White page detected After subtracting the paper margin from the valid coordinate area, the result of the calculation [Detection Conditions] There is no drawing data in the page data. will be negative. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on.
Page 530: Attached Document Failure Of E-Mail To Xxx
116-780 Attached document failure of E-mail to XXX 116-790 Printed without the stapler Attached document email failure. Printed without stapler. Procedure Procedure Switch power off then on. The problem continues. Switch power off then on. The problem continues. Return to service call procedures. Return to service call procedures.
Page 531: Token Ring Rap
116-900 Token Ring RAP Initial Actions • Ensure that the Token Ring PWBA is connected to a good wall drop using a good network cable. • Print a System Settings List. With the assistance of the Systems Administrator verify that the network settings are correct.
Page 532 Status Indicator RAPs Initial issue 02/03 116-900 2-502 DC 3535/2240/1632...
Page 533: Foreign Interface/Ess Communication Fail
121-310 Foreign Interface/Foreign Device Communication 121-333 Foreign Interface/ESS Communication Fail Fail Communication cannot be established between the Foreign Interface and the ESS PWB. Communication cannot be established between the Foreign Interface and the Foreign Device Procedure (3rd-party device such as vend station or mechanical Auditron). CAUTION Procedure Do not attempt to troubleshoot this circuit by jumpering the Transmit Data or Receive Data...
Page 534: Foreign Interface Login Fail
121-334 Foreign Interface Login Fail 121-335 Foreign Interface Wake Up Answer Fail The enquiry result of the login information was an error at WAKE UP ANSWER. The WAKE UP ANSWER cannot be received. Procedure Procedure CAUTION CAUTION Do not attempt to troubleshoot this circuit by jumpering the Transmit Data or Receive Data Do not attempt to troubleshoot this circuit by jumpering the Transmit Data or Receive Data lines (P343 pins 4 ~ 6 on the ESS PWB).
Page 535: Unknown Foreign Device
121-336 Unknown Foreign Device 121-337 Foreign Device Self Diag Fail The connected Foreign Device type was unknown at WAKE UP ANSWER. The self diagnostics result of the connected Foreign Device was an error at WAKE UP ANSWER. Procedure Procedure Switch the power off, then on. The problem continues. Switch the power off, then on.
Page 536: Foreign Interface Answer Time Out
121-338 Foreign Interface Answer Time Out 121-350 Foreign Interface Logic Fail The answer from the Foreign Interface excluding WAKE UP ANSWER cannot be received. Due to an error during the software processing, the subsequent processes cannot be per- formed. Procedure Procedure CAUTION CAUTION...
Page 537 202-399 Internal Timer Procedure Switch the power off then on. The fault is cleared. Reload system software. Return to Service Call Procedures. Initial issue Status Indicator RAPs 02/03 202-399 DC 3535/2240/1632 2-507...
Page 538 Status Indicator RAPs Initial issue 02/03 202-399 2-508 DC 3535/2240/1632...
Page 539 OF 1-1 +3.3 VDC OF 1-2 +5 VDC Use this RAP to troubleshoot a failure with the +3.3 VDC. Use this RAP to troubleshoot a failure with the +5 VDC. Procedure Procedure Perform the following: Perform the following: • Remove the Rear Cover (REP 14.2).
Page 540: Of 1-3 +24 Vdc Enable
OF 1-3 +24 VDC Enable Use this RAP to determine why the +24V LVPS is not enabled. Procedure The machine is a DC 3535. Refer to Figure 1. +3.3 VDC is measured between P/J505-3 (+) on the 24V LVPS and GND (-).
Page 541 OF 1-4 AC Power Check the AC voltage distribution by referring to Chapter 7 Wiring Data. AC Power Failure Initial Actions Check Circuit Breaker. Procedure Refer to Figure 1. AC Line Voltage is measured between the Noise Filter PWB FS75 and FS74 9.2).
Page 542 OF 1-5 AC POWER OFF RAP NOTE: Normal operation for the printer when the power is switched off is for AC power to remain applied to all power supplies for approximately 6 seconds for DC 2240/1632 and 25 seconds for the DC 3535 Use this RAP to troubleshoot problems with the machine when one of the following occurs: •...
Page 543: Of 2-1 Dark / Blank Display
OF 2-1 Dark / Blank Display Replace the IIT/IPS PWB 18.3). UI Display is dark with minimal legibility, or no text or graphics are visible. +5 VDC is measured between J726-A10 and -A9. Initial Actions Ensure all external cables and power cords are connected. Replace the IIT/IPS PWB 18.3).
Page 544 Figure 1 OF 2-1 RAP Circuit Diagram Status Indicator RAPs Initial issue 02/03 OF 2-1 2-514 DC 3535/2240/1632...
Page 545: Of 99-1 Reflective Sensor Rap
OF 99-1 Reflective Sensor RAP There is either an open circuit or a failed PWB. Use the Circuit Diagram to Sensors consist of a light-emitting diode and a photo transistor. When energized, the light from trace the output wire to the PWB. If the wire is OK, replace the PWB. the LED causes the photo transistor to conduct, drawing current through a pull-up resistor.
Page 546: Of 99-2 Transmissive Sensor
OF 99-2 Transmissive Sensor Disconnect the sensor. Use a jumper wire to connect the output wire from the sensor (typically pin 2 on a 3 pin connector) to DC COM or GND. The display Sensors consist of a light-emitting diode and a photo transistor. When energized, the light from changes from H to L.
Page 547: Of 99-3 Switch
OF 99-3 Switch Procedure Enter dC330 [XXX-XXX]. Actuate the switch. The display changed. Refer to Figure 1. There is +3.5 / 5VDC measured between Pin 2(+) of the Switch and GND(-). Check the wire between the switch Pin 2 and the PWB Pin 3 for an open circuit and poor contact.
Page 548: Of 99-4 Generic Solenoid/Clutch Rap
OF 99-4 Generic Solenoid/Clutch RAP One of the two wires between the control PWB and the clutch or solenoid is open. Repair or replace the wiring as required. Solenoids and electric clutches are essentially electromagnets. Typically, a positive voltage is applied to one end of a coil, and a current driver is connected to the other end.
Page 549: Of 99-6 2 Wire Motor Open
OF 99-6 2 Wire Motor Open OF 99-7 2 Wire Motor On Procedure Procedure Turn off the power. Remove the PWB connector. Refer to Figure 1. There is 10 Ohm’s or NOTE: Before performing this RAP, ensure that the motor is free to rotate. less measured between the connector Pin 3 and the frame.
Page 550: Of 99-8 Set Gate Solenoid Open
OF 99-8 Set Gate Solenoid Open Procedure Refer to Figure 1. There is +24VDC measured between the Nip/Release Solenoid Pin 1 (+) and GND (-). There is +24VDC measured between the PWB Pin 5 (+) and GND(-). Check +24VDC inputs on the PWB. If the check is OK, replace the PWB. Check the wire between the PWB Pin 5 and the Nip/Release Solenoid Pin 1 for an open circuit or poor contact.
Page 551 3 Image Quality Image Quality RAPs IQ1 IOT Image Quality Entry RAP .................. IQ2 IIT Image Quality Entry RAP ..................IQ3 Low Image Density RAP ..................IQ4 Wrinkled Image/Paper RAP ..................IQ5 Residual Image (Ghosting) RAP ................IQ6 IOT Background RAP....................IQ7 Deletions RAP ......................
Page 552 Image Quality Initial issue 02/03 DC 3535/2240/1632...
Page 553: Iq1 Iot Image Quality Entry Rap
IQ1 IOT Image Quality Entry RAP Refer the customer to user documentation to review the following image quality settings: • Original Type The purpose of this RAP is to serve as the entrance vehicle into the Image Quality RAPs sec- •...
Page 554 Table 1 Image Quality Defects Defect - green indicates hotlink to Description Corrective Action image samples High Frequency Bands Repeating interval bands that are most noticeable in low density (20-30%) halftone areas of the copy. These bands run Go to the IQ14 perpendicular to process direction.
Page 555: Iq2 Iit Image Quality Entry Rap
IQ2 IIT Image Quality Entry RAP Initial Actions Clean the Lens, the top and bottom surface of the Platen Glass, and all Mirrors with Lens and This RAP is for troubleshooting IIT (Scanner/ADF) problems only. Before proceeding, verify Mirror Cleaner and a soft, lint-free cloth. that the defect is present in Copy mode only.
Page 556: Iq3 Low Image Density Rap
IQ3 Low Image Density RAP IQ4 Wrinkled Image/Paper RAP This RAP troubleshoots the causes of output images showing image density lower than speci- Areas of prints (usually 11x17 in./A3) have distinctive “worm track” patterns or light “cloudy” fication. areas in the image. Actual wrinkles in the paper itself can also occur. Initial Actions Initial Actions •...
Page 557: Iq5 Residual Image (Ghosting) Rap
IQ5 Residual Image (Ghosting) RAP Initial Actions • Check the end-of-life counter for the Drum Cartridge. If the unit is at or near end-of-life, replace the Drum Cartridge (see Machine Consumables in Section 6). NOTE: Some ghosting on transparencies is unavoidable. •...
Page 558 Figure 1 IQ5 RAP Circuit Diagram Image Quality Initial issue 02/03 DC 3535/2240/1632...
Page 559: Iq6 Iot Background Rap
IQ6 IOT Background RAP IQ7 Deletions RAP Initial Actions Initial Actions • Perform IOT Image Quality Entry RAP first. Reload with fresh, dry paper of the correct specifications. Paper contaminants (such as fibers or other particles) may cause spot deletions by interfering with the second transfer. If the prob- •...
Page 560 Figure 1 IQ7 RAP Circuit Diagram Image Quality Initial issue 02/03 3-10 DC 3535/2240/1632...
Page 561: Iq8 Color-To-Color Misregistration Rap
IQ8 Color-to-Color Misregistration RAP Initial Actions Adjust the color registration (ADJ 9.6). If the problem remains, continue with this procedure. Check the fault history for 4-640, 4-641, or 4-642 faults. Procedure The problem is an incorrect horizontal and/or vertical positioning of one or more of the four colors.
Page 562: Iq9 Skew/Misregistration Rap
Check the components in the Registration Transport Assembly 2.6) for wear, Load some new, dry 24 lb. 11X17/A3 Xerox COLOR Xpressions (NASG), or 90 GSM Colortech slipping, damage, or contamination. Clean/replace as required + (ESG) into each paper tray (use 8.5X11/A4 in Tray 1). Make 3 full color copies from each paper tray.
Page 563: Iq12 Process Direction Bands, Streaks, And Smears Rap
IQ12 Process Direction Bands, Streaks, and Smears RAP Check the IBT Cleaner Assembly; check for toner buildup on the top side of the Cleaner Blade that contacts the IBT Belt. Replace the IBT Cleaner Assy if required 5.3). Ensure that the Initial Actions blade and the Mylar backing are free from damage.
Page 564: Iq13 Unfused Copy/Toner Offset Rap
IQ13 Unfused Copy/Toner Offset RAP IQ14 Repeating Bands, Streaks, Spots, and Smears RAP Initial Actions Procedure • Replace the paper in use with fresh, dry paper of the correct specification. Measure the distance between the repeating defects. Locate the distance on the table below. Perform the indicated repair actions •...
Page 565: Iq15 Mottle Rap
IQ15 Mottle RAP NOTE: If a paper type has a User IQ Default listed for it in Tables 2 or 3, ensure that the customer has not changed the IQ setting before attempting this process; reset to the This RAP troubleshoots the causes of output images showing image density that varies from default if necessary.
Page 566 NOTE: Performing the adjustments in the following table may not eliminate mottle completely, and/or may introduce other IQ problems; the intent is to reach the best compromise. Table 1 Heavyweight Mottle Options (DC 2240/1632 only) Weight Customer Paper Type Adjustment Coated only Set NVM location 746-980 (BTR2 Transfer Bias for HW1) to 1 (default).
Page 567 Table 2 2nd BTR Transfer Remote locations - DC 2240/1632 Table 3 2nd BTR Transfer Remote locations DC 3535 Default Paper Name User IQ default (Side 1) (Side 2) Default Paper Name User IQ default (Side 1) (Side 2) Plain Paper A (Bond) 746-059 746-076 Plain Paper A (Bond)
Page 568: Iq16 Spots Rap
IQ16 Spots RAP IQ17 Missing Colors RAP Initial Actions One or more of the primary (YMCK) colors is missing from the image. Ensure that the paper in use is fresh, dry, and within specification for weight and quality. Initial Actions Check print driver and copier control panel settings to ensure the media is being run in the Determine if the problem is in copy or print mode.
Page 569: Iq20 1St Btr Checkout Rap
IQ20 1st BTR Checkout RAP Procedure Make a copy of the Color Test Pattern. If the high density gradation patches (100%, 85%, and 70%) for one or more of C, Y, M, or K appear to be light, perform the following: •...
Page 570 Figure 1 IQ20 RAP Circuit Diagram Image Quality Initial issue 02/03 IQ20 3-20 DC 3535/2240/1632...
Page 571: Iq21 Developer Bias Rap
IQ21 Developer Bias RAP Procedure WARNING HIGH VOLTAGE! Exercise caution when performing the voltage checks in this procedure. Enter dC140 [09-026]. Check the voltage at P/J580 for the affected color(s). There should be approximately 370 VAC and -540 VDC (+/- 10%) present. The voltages are within range. There is +24 VDC from P/J501 pin 13 to...
Page 572 Figure 1 IQ21 RAP Circuit Diagram Image Quality Initial issue 02/03 IQ21 3-22 DC 3535/2240/1632...
Page 573: Iq22 2Nd Btr Checkout Rap
IQ22 2nd BTR Checkout RAP Procedure TBD - refer to Figure Initial issue Image Quality 02/03 IQ22 DC 3535/2240/1632 3-23...
Page 574 Figure 1 IQ22 RAP Circuit Diagram Image Quality Initial issue 02/03 IQ22 3-24 DC 3535/2240/1632...
Page 575: Iq23 Bcr Checkout Rap
IQ23 BCR Checkout RAP Procedure The problem is very high single-color background Swap the Drum Cartridge that creates the high single-color background with any of the other Drum Cartridges and make a test print. The background color remains the same. Replace the Drum Cartridge causing the single-color background (see Machine Consum- ables...
Page 576 Figure 1 IQ23 RAP Circuit Diagram Image Quality Initial issue 02/03 IQ23 3-26 DC 3535/2240/1632...
Page 577: Image Quality Specifications
Image Quality Specifications Registration and border deletions are checked using the Step Scales on the Geometric Test Pattern, an example of which is shown in Figure 1. All of the scales are 20mm in height, and The following steps are used to set up the machine for the purpose of making test pattern cop- are made up of four 5mm steps.
Page 578 The machine should reproduce all of the text in the 0.2 G Text Blocks on the output copy. Place Test Pattern 82E8220 on the platen and 24# Xerox Color Xpressions 11x 17” or 90 GSM Colotech A3 paper in Tray 1. Make a copy of the test pattern.
Page 579 Figure 2 Color and Geometric Test Patterns Initial issue Image Quality 02/03 DC 3535/2240/1632 3-29...
Page 580 Image Quality Initial issue 02/03 3-30 DC 3535/2240/1632...
Page 581: Image Defect Samples
Image Defect Samples Background The following figures contain examples of defects and their possible causes. • Background • Color Misregistration • Debris-Centered Deletions • Deletions • High Frequency Bands • Irregular Process Direction Streak • Low Image Density • Moire •...
Page 582: Color Misregistration
Color Misregistration Debris-Centered Deletions Figure 1 Color Misregistration Defect Sample Figure 1 DCD Defect Sample Cause Cause Failure of the ROS or IBT “walking” from rear to front or front to rear. Toner agglomerates cause deletions in the areas surrounding them during transfer. Mechanical problem in the IBT Assembly.
Page 583: Deletions
Deletions High Frequency Bands Figure 1 Deletions Defect Sample Figure 1 High Freq. Bands Defect Sample Cause Cause Defective IBT Belt, damp paper, uneven charge. Faulty ROS Assembly or Photoreceptor/Developer Housing gear or bearing problem. Corrective Action Corrective Action Go to the RAP.
Page 584: Irregular Process Direction Streak
Irregular Process Direction Streak Low Image Density Figure 1 Streak Defect Sample Figure 1 Low Density Defect Sample Cause Cause Clog in Developer Housing Trim Bar, malfunction of IBT Cleaner Assembly, contaminated ROS Incorrect electrostatics, defective ADC Sensor, low toner concentration or out-of-specification window.
Page 585: Moire
Moire Mottle Figure 1 Moire Defect Sample Figure 1 Mottle Defect Sample Cause Cause The halftone screen used on the original interferes with the halftone screen used by the copier. Damp or low quality paper, aged developer, low toner concentration Corrective Action Corrective Action Go to the...
Page 586: Newton Rings
Newton Rings Regular (Repeating) Bands, Streaks, Spots, or Smears Figure 1 Newton Rings Defect Sample Figure 1 Repeating Defects Sample Image Cause Cause Highly reflective surfaces on a glossy photograph. Damage, density variation, or deletions caused by rotating component. Spacing equal to effec- tive circumference of part.
Page 587: Residual Image
Residual Image Streak Deletion in Process Direction Figure 1 Residual Image Defect Sample Figure 1 Streak Deletion Defect Sample Cause Cause Improper IBT cleaning and/or defective IBT Belt. Contamination of ROS window, damage to or contact with Transfer Belt or Drum Cartridge Corrective Action Corrective Action Go to the...
Page 588: Wrinkled Image
Wrinkled Image Cloud Defect Figure 1 Wrinkled Image Defect Sample Figure 1 Cloud Defect Sample Cause Cause Non-uniform paper buckle between IBT and Fuser; Fuser “tenting” of paper. Actual wrinkling of Non-uniform paper buckle between IBT and Fuser; Fuser “tenting” of paper the paper itself can also occur.
Page 589: Ibt Cleaner Streak
IBT Cleaner Streak INBOARD EDGE LEAD EDGE Figure 1 IBT Cleaner Streak Defect Sample Cause Damage or wear to IBT Cleaner Assembly Corrective Action Go to the IQ12 RAP. Initial issue Image Quality 02/03 IBT Cleaner Streak DC 3535/2240/1632 3-39...
Page 590 Image Quality Initial issue 02/03 IBT Cleaner Streak 3-40 DC 3535/2240/1632...
Page 591 4 Repairs & Adjustments REPAIRS REP 6.2 Platen Glass...................... 4-40 REP 6.3 IIT Top Cover ....................4-41 Electrical REP 6.4 Lens Kit ......................4-41 REP 1.1 LVPS Bracket ....................REP 6.5 IIT/IPS PWB...................... 4-42 REP 1.2 MCU PWB ......................REP 6.6 UI PWB ......................4-43 REP 1.4 3.3 V LVPS or 5 V LVPS ..................
Page 592 REP 9.10 Developer ....................... 4-80 REP 14.7 Front Cover Assembly ..................4-145 REP 9.11 Toner Dispenser Base Assembly ..............4-81 REP 14.8 Fuser Cover ....................4-146 REP 9.12 IBT Steering Motor Assembly ................. 4-82 REP 14.9 Rear Cover (Tray Module) ................4-146 REP 9.13 Agitator Motor Assembly.................
Page 593: Rep 1.1 Lvps Bracket
REP 1.1 LVPS Bracket Parts List on PL 9.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION PWBs can be damaged by an electrostatic discharge. Observe all ESD procedures to avoid component damage.
Page 594: Rep 1.2 Mcu Pwb
REP 1.2 MCU PWB 10. Remove the screws (5) securing the MCU PWB and remove the MCU PWB. Replacement Parts List on PL 13.1 Install the existing MCU NVM PWB onto the new MCU PWB. Install the new MCU PWB Removal and reassemble the machine.
Page 595: Rep 1.4 3.3 V Lvps Or 5 V Lvps
REP 1.4 3.3 V LVPS or 5 V LVPS REP 1.5 24 V LVPS Parts List on PL 9.1 Parts List on PL 9.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the ma1chine.
Page 596: Rep 1.6 High Voltage Power Supply Chassis
REP 1.6 High Voltage Power Supply Chassis REP 1.7 DEV/BTR2/DTS HVPS; BCR HVPS Parts List on PL 9.1 Parts List on PL 9.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 597: Rep 1.8 I/F (Interface) Pwb
REP 1.8 I/F (Interface) PWB Screws (2) Parts List on PL 9.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the Right Cover (REP 14.3).
Page 598: Rep 1.9 24 V Lvps Chassis
REP 1.9 24 V LVPS Chassis REP 1.10 BTR1 HVPS Parts List on PL 9.1 Parts List on PL 9.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 599: Rep 1.11 Ac Drive Pwb
REP 1.11 AC Drive PWB Replacement CAUTION Parts List on PL 9.2 Ensure that White connector is P43 and the Blue connector is P42. Other connectors are dif- Removal ferent sizes to ensure correct connection. WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 600: Rep 1.12 Ess Pwb
REP 1.12 ESS PWB Parts List on PL 13.1 Remove PS-1 ROM (ALL) and Remove RAM Disconnect Connec- PS-2 ROM (DC2240/1632) Removal Gather all available settings information. This includes the NVM log, the Machine Settings floppy, Configuration Report, etc. If possible save the current Machine Settings to disk. WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 601 If a good Machine Settings floppy is available, exit, then reenter the PWS Tool. Select Read from Floppy when starting the tool. If no floppy is available, or if the data on the existing floppy is questionable, go to step 5. Go to dC351 and select Restore Machine Settings.
Page 602: Rep 1.13 Ess Nvm Pwb
REP 1.13 ESS NVM PWB Replacement Install the new ESS NVM PWB and reassemble the machine. Connect the PWS and Parts List on PL 13.1 switch on the power. Removal CAUTION Gather all available settings information. This includes the machine NVM log, the GP10 is used to maintain the integrity of the serial number and billing data, when one or more Machine Settings floppy disk, copies of the Configuration Report, etc.
Page 603: Rep 1.14 Ps-1 Rom, Ps-2 Rom
REP 1.14 PS-1 ROM, PS-2 ROM If the machine declares a software-related (Chains 102, 103 or 116) fault, there may be an incompatible version of ESS software in the new ROM PWBs. Reload the correct ESS Parts List on PL 13.1 software in accordance with the instructions on the s/w upgrade CD.
Page 604: Rep 1.15 Mcu Nvm Pwb
REP 1.15 MCU NVM PWB Replacement Install the new MCU NVM PWB and reassemble the machine. Connect the PWS and Parts List on PL 13.1 switch on the power. Removal CAUTION Gather all available settings information. This includes the machine NVM log, the GP10 is used to maintain the integrity of the serial number and billing data, when one or more Machine Settings floppy disk, copies of the Configuration Report, etc.
Page 605: Rep 1.17 Vsel Pwb
REP 1.17 VSEL PWB Remove the ESS PWB (Figure Parts List on PL 13.1 Removal Disconnect WARNING P/J310 To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine CAUTION Remove PWBs can be damaged by electrostatic discharge.
Page 606 Remove screws (8) Disconnect P/J390 Figure 4 Removing the VSEL PWB Repairs and Adjustments Initial issue 02/03 REP 1.17 4-16 DC 3535/2240/1632...
Page 607: Rep 4.1 Main Drive Motor Assembly
REP 4.1 Main Drive Motor Assembly Parts List on PL 1.1 Disconnect Removal Connectors (5) WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Fuser Module (REP 10.1).
Page 608: Rep 4.2 Ibt Motor Assembly
REP 4.2 IBT Motor Assembly REP 4.3 Developer Drive Motor Assembly Parts List on PL 1.1 Parts List on PL 1.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 609: Rep 4.4 Drum Motor Assembly
REP 4.4 Drum Motor Assembly NOTE: In next step, do not disconnect connectors. Parts List on PL 1.1 Loosen the I/F PWB chassis mounting screws (2) and move chassis up (REP 1.8). 10. Remove the IBT Motor Assembly (REP 4.2). Removal 11.
Page 610 Repairs and Adjustments Initial issue 02/03 REP 4.4 4-20 DC 3535/2240/1632...
Page 611: Rep 5.1 Dadf
REP 5.1 DADF Remove Screws (2) and remove DADF (Figure Parts List on PL 20.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Disconnect connector (Figure Connector...
Page 612: Rep 5.2 Registration Gate Solenoid
REP 5.2 Registration Gate Solenoid Parts List on PL 20.2 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Front Cover 20.1).
Page 613: Rep 5.3 Left/Right Counterbalance
REP 5.3 Left/Right Counterbalance NOTE: If counterbalance is to be reinstalled, mark as “Right” before removing. Parts List on PL 20.3 Remove Right Counterbalance (Figure Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 614: Rep 5.4 Dadf Control Pwb
REP 5.4 DADF Control PWB REP 5.5 Feed Motor Assembly Parts List on PL PL 20.3 Parts List on PL 20.4 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 615: Rep 5.6 Nudger Roll
REP 5.6 Nudger Roll Remove Nudger Rolls (Figure Parts List on PL 20.4 Removal Remove Clips (2) WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove DADF Inner Cover (Figure Remove Inner Cover...
Page 616: Rep 5.7 Feed Roll Assembly
REP 5.7 Feed Roll Assembly Remove Feed Roll Assembly (Figure Parts List on PL 20.4 Removal WARNING Remove Feed Roll To avoid personal injury or shock, do not perform repair or adjustment activities with Assembly the power switch on or electrical power applied to the machine. Remove Inner Cover (Figure Remove Inner Cover...
Page 617: Rep 5.8 Lower Chute Assembly
REP 5.8 Lower Chute Assembly REP 5.9 Retard Roll Parts List on PL 20.5 Parts List on PL 20.5 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 618: Rep 5.10 Set Gate Solenoid Assembly
REP 5.10 Set Gate Solenoid Assembly Replacement Engage pin with slot (Figure Parts List on PL 20.5 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Open DADF Top Cover.
Page 619 Install Set Gate Solenoid Assembly (Figure Move Solenoid as Position Solenoid shown and tighten on Screws Screws (2) Connect and secure harness in clip Figure 3 Installing Set Gate Solenoid Assembly Initial issue Repairs and Adjustments 02/03 REP 5.10 DC 3535/2240/1632 4-29...
Page 620: Rep 5.11 Registration Sensor
REP 5.11 Registration Sensor Replacement When installing Registration Sensor align holes with alignment pins and tighten screw Parts List on PL 20.5 (Figure Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Open Top Cover.
Page 621: Rep 5.12 Size Sensors 1/2 (Rear/Front)
REP 5.12 Size Sensors 1/2 (Rear/Front) REP 5.13 DADF Belt Motor Assembly Parts List on PL 20.5 Parts List on PL 20.6 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 622: Rep 5.14 Duplex Sensor
REP 5.14 Duplex Sensor Parts List on PL 20.7 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove following: Front Cover 20.1).
Page 623: Rep 5.15 Registration Pinch Roll
REP 5.15 Registration Pinch Roll Prepare to remove the Gate (Figure Parts List on PL 20.8 Removal Remove Screws (2) WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION Do not damage or scratch surface of Registration Pinch Roll.
Page 624 Remove Gate (Figure Remove Registration Pinch Roll (Figure Remove C Clip, shorter Spring, and Bearing CAUTION Plastic edge on Gate is fragile Remove Gate while containing Springs Remove Regis- tration Pinch Roll Remove Screws (2) Remove C Clip longer Observe position Spring of Springs Figure 2 Removing Gate...
Page 625: Rep 5.16 Exit Motor Assembly
REP 5.16 Exit Motor Assembly REP 5.17 Document Transport Parts List on PL 20.9 Parts List on PL 20.10 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 626: Rep 5.18 Rear Cover
REP 5.18 Rear Cover Parts List on PL 20.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION LED harness breakage occurs if Rear Cover is removed without disconnecting LED plug Loosen Screws (3) and remove Rear Cover enough to disconnect LED harness from DADF Control PWB.
Page 627: Rep 5.19 Platen Belt
REP 5.19 Platen Belt Replacement Lock shaft support by matching hole with frame's detent (Figure Parts List on PL 20.10 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Front Cover 20.1).
Page 628 CORRECT INCORRECT Figure 3 Install Platen Belt Connect power cord and switch on power. Enter dC330 [005-055]. Press Start. Rotate Platen Belt for 15 seconds. Press Stop. Check the Belt position. If the belt moved to either side, check the installation of the Shaft Supports.
Page 629: Rep 6.1 Ros
REP 6.1 ROS Parts List on PL 3.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Right Cover (REP 14.3). Remove Rear Cover (REP 14.2).
Page 630: Rep 6.2 Platen Glass
REP 6.2 Platen Glass Replacement Press Platen Glass in direction of arrow A; Press Right Side Plate in direction of arrow B (Fig- Parts List on PL 18.3 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 631: Rep 6.3 Iit Top Cover
REP 6.3 IIT Top Cover REP 6.4 Lens Kit Removal Parts List on PL 18.4 WARNING Removal To avoid personal injury or shock, do not perform repair or adjustment activities with WARNING the power switch on or electrical power applied to the machine. To avoid personal injury or shock, do not perform repair or adjustment activities with Remove DADF (REP...
Page 632: Rep 6.5 Iit/Ips Pwb
REP 6.5 IIT/IPS PWB Remove IIT/IPS PWB (Figure Parts List on PL 18.3 Removal Remove screws (10) Gather all available settings information. This includes the machine NVM log, the Disconnect Machine Settings floppy disk, copies of the Configuration Report, etc. If possible save the connectors (6) current Machine Settings to the floppy.
Page 633: Rep 6.6 Ui Pwb
REP 6.6 UI PWB Parts List on PL 18.2 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION PWBs can be damaged by electrostatic discharge. Observe all ESD procedures. Remove the five screws securing the Control Panel Assembly to the IIT.
Page 634: Rep 6.11 Carriage Cables
REP 6.11 Carriage Cables Position the Carriage Cable Ball so that it is directly at the top of the Capstan (Figure Verify that there are 2.5 Carriage Cable windings on both sides of the Ball. Parts List on PL 18.5 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with...
Page 635 Remove the Carriage Cable (Figure Replacement Install the Carriage Cable. Orient the cable as shown and insert the middle Carriage Cable Ball into the detente in the Capstan (Figure Cable Ball Detach the Spring from the cable hook Remove the ball from its retainer and remove cable Figure 3 Removing Carriage Cable...
Page 636 Prepare the spring/hook end for installation (Figure Prepare the ball end for installation (Figure Cable (Ball End) Hold the Capstan Ball in place and wind the cable so that it feeds from the bottom of the Capstan (2.5 turns) Temporarily tape the cable to the top of the Capstan Temporarily tape the...
Page 637 Check orientation of the ends and number of carriage cable windings (Figure Install Carriage Cable (ball end) (Figure Reconfigure as required. Route the cable to the small pulley and feed it bottom-to-top Spring/Hook end: Ball end: - 2.5 windings - 2.5 windings - Fed from Capstan Bottom - Fed from Capstan top - Oriented toward outside of IIT...
Page 638 Install Carriage Cable (spring/hook end) (Figure If still present, remove any previously installed tape. Install Full Rate Carriage in IIT Frame. NOTE: Cable orientation for all pulleys used at the spring/hook end are fed across the Adjust positions of Full Rate/Half Rate Carriages (ADJ 6.1).
Page 639: Rep 6.12 Carriage Motor
REP 6.12 Carriage Motor Parts List on PL 18.5 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove DADF (REP 5.1). Remove Platen Glass (REP 6.2).
Page 640: Rep 6.13 Exposure Lamp
REP 6.13 Exposure Lamp Parts List on PL 18.6 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION Avoid touching exposure lamp with your bare hands during removal or installation. Oil from your hands will contaminate surface of lamp.
Page 641: Rep 6.14 Lamp Wire Harness
REP 6.14 Lamp Wire Harness Remove Full Rate Carriage (Figure Parts List on PL 18.6 Removal Remove screws (2) WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove DADF (REP 5.1).
Page 642 Remove Lamp Wire Harness from Full Rate Carriage (Figure Turn the Full Rate Carriage upside down. Remove screw Disconnect connector Remove guide and Lamp Wire Harness Figure 3 Removing Lamp Wire Harness Replacement After reinstalling parts, adjust positions of Full Rate/Half Rate Carriages (ADJ 6.1).
Page 643: Rep 7.1 Tray 5
REP 7.1 Tray 5 Install Tray 5. Parts List on PL 2.12 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the Rear Cover (REP 14.2). Remove the Rear Left Upper Cover (REP 14.5).
Page 644: Rep 7.2 Tray 5 Feed Roll
REP 7.2 Tray 5 Feed Roll Parts List on PL 2.14 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Rear Cover (REP 14.2). Remove the Rear Left Upper Cover (REP 14.5).
Page 645: Rep 7.3 Tray 1 Feeder
REP 7.3 Tray 1 Feeder REP 7.4 Tray 1 Feed/Lift Motor Parts List on PL 2.3 Parts List on PL 2.4 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 646: Rep 7.5 Tray 1 Paper Size Sensor
REP 7.5 Tray 1 Paper Size Sensor REP 7.6 Tray 3 (TTM) Parts List on PL 2.1 Parts List on PL 16.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 647: Rep 7.7 Tray 4 (Ttm)
REP 7.7 Tray 4 (TTM) REP 7.8 Tray 1 Parts List on PL 16.1 Parts List on PL 2.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 648: Rep 7.9 Tray 2 (Ttm)
REP 7.9 Tray 2 (TTM) Parts List on PL 16.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Pull out Tray 2. Lift end of tray to disengage lock on rail (not visible) and remove tray.
Page 649: Rep 7.10 Tray 2 Feeder (Ttm)
REP 7.10 Tray 2 Feeder (TTM) Parts List on PL 16.6 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Pull out Tray 2. Remove the Left Cover Assembly (REP 14.11) Remove the Tray 2 Feeder (Figure 1).
Page 650: Rep 7.11 Tray 3 Feeder (Ttm)
REP 7.11 Tray 3 Feeder (TTM) Remove the Tray 3 Feeder from mounting bracket (Figure 2). Parts List on PL 16.6 Removal Remove the Screws (2) WARNING and Bracket To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 651: Rep 7.12 Tray 4 Feeder (Ttm)
REP 7.12 Tray 4 Feeder (TTM) Remove the Tray 4 Feeder Assembly (Figure 2). Parts List on PL 16.5 Removal Loosen WARNING Disconnect Screw To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the Tray 2.
Page 652 Remove the Tray 4 Feeder Guides (Figure 3). Remove Brackets from Tray 4 Feeder Assembly (Figure 4). Remove Remove Screw Remove Screws (2) Screws (2) and Bracket and Upper Guide and Bracket Remove Screws (2) and Lower Guide Remove Screw and Bracket Figure 4 Removing the Brackets Figure 3 Removing the Guides...
Page 653: Rep 7.13 Tray 2 (3Tm)
REP 7.13 Tray 2 (3TM) REP 7.14 Tray 3 (3TM) Parts List on PL 15.1 Parts List on PL 15.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 654: Rep 7.15 Tray 4 (3Tm)
REP 7.15 Tray 4 (3TM) REP 7.16 Tray 2 Feeder (3TM) Parts List on PL 15.1 Parts List on PL 15.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 655: Rep 7.17 Tray 3 Feeder (3Tm)
REP 7.17 Tray 3 Feeder (3TM) REP 7.18 Tray 4 Feeder (3TM) Parts List on PL 15.1 Parts List on PL 15.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 656 Repairs and Adjustments Initial issue 02/03 REP 7.17, REP 7.18 4-66 DC 3535/2240/1632...
Page 657: Rep 8.1 Left Cover Assembly
REP 8.1 Left Cover Assembly Parts List on PL 2.9 Disconnect (3) Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Rear Cover (REP 14.2).
Page 658 Remove Left Cover Assembly (Figure CAUTION Before closing Left Cover Assembly to connect harness, hold up black plastic Duplex Baffle while closing transport. Remove Clip and Marks on Remove disconnect Stop Stop Pin Screw and Motion Damper lift up Stop Hinge Support Left Cover Assembly while per-...
Page 659: Rep 8.2 Duplex Chute
REP 8.2 Duplex Chute CAUTION Before closing Left Cover Assembly to connect harness, hold up black plastic Duplex Baffle Parts List on PL 2.8 while closing transport. Removal Marks on WARNING Stop Pin Motion To avoid personal injury or shock, do not perform repair or adjustment activities with Damper the power switch on or electrical power applied to the machine.
Page 660: Rep 8.3 Duplex Transport Assembly
REP 8.3 Duplex Transport Assembly REP 8.5 Inverter Transport Parts List on PL 12.1 Parts List on PL 11.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 661: Rep 8.6 Registration Transport Assembly
REP 8.6 Registration Transport Assembly Replacement Parts List on PL 2.6 NOTE: bearing is equipped with two Anti-rotation Tabs. If one breaks during removal, install bearing so other tab is employed. Removal WARNING NOTE: Check that ground spring is pressing against bronze bushing after installing it. To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 662: Rep 8.7 Exit Transport Assembly
REP 8.7 Exit Transport Assembly Parts List on PL 2.11 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Open Front Cover. Remove Fuser Cover (REP 14.8).
Page 663: Rep 9.1 Drum Cartridge
REP 9.1 Drum Cartridge REP 9.2 ROS Shutter Motor Parts List on PL 4.1 Parts List on PL 8.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 664: Rep 9.3 Waste Toner Cartridge Cover
REP 9.3 Waste Toner Cartridge Cover REP 9.4 Waste Toner Cartridge Parts List on PL 4.1 Parts List on PL 4.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 665: Rep 9.5 Full Toner Sensor
REP 9.5 Full Toner Sensor REP 9.6 Dispenser Cover Parts List on PL 4.1 Parts List on PL 10.2 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 666: Rep 9.7 Toner Dispenser
REP 9.7 Toner Dispenser CAUTION Connection tube may separate from upper or lower housing. Parts List on PL 6.1 Agitator may disconnect if flex coupling is compressed enough so agitator hits inside bot- Removal tom of lower housing WARNING Pull out Upper and Lower Housings together while ensuring flexible connection tube remains connected.
Page 667: Rep 9.8 Plate Assembly
REP 9.8 Plate Assembly Disconnect Developer housing connectors, 4 large and 4 small (small not shown). Position wires straight out from machine. Wires remain stationary while removing Plate Parts List on PL 4.2 Assembly (Figure Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 668 10. Disconnect Developer Housing Harnesses (Figure 11. Remove Plate Assembly (Figure Open harness clip and remove harness from clip. Remove Screws (6). Disconnect Harness P/J’s (3). Pull Plate Assembly toward front to remove it. Ensure that harnesses are not dam- aged.
Page 669: Rep 9.9 Developer Housing
REP 9.9 Developer Housing Replacement Parts List on PL 6.2 NOTE: If installing a new Developer Housing, go to step 1. If reinstalling existing developer housing, go to step 5. Removal WARNING Install new Developer (REP 9.10) as required. Remove ATC Sensor Setup Data Tag from new Developer Housing. On tag, highlight K, To avoid personal injury or shock, do not perform repair or adjustment activities with C, M, or Y as required for color of developer housing.
Page 670: Rep 9.10 Developer
REP 9.10 Developer Parts List on PL 6.2 Release tabs and Removal remove Cover WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Front Cover (REP 14.7).
Page 671: Rep 9.11 Toner Dispenser Base Assembly
REP 9.11 Toner Dispenser Base Assembly Parts List on PL 6.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Open Front Cover. Remove Drum Cartridges (REP 9.1).
Page 672: Rep 9.12 Ibt Steering Motor Assembly
REP 9.12 IBT Steering Motor Assembly REP 9.13 Agitator Motor Assembly Parts List on PL 1.3 Parts List on PL 4.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 673: Rep 9.14 Mob Sensor Assembly
REP 9.14 MOB Sensor Assembly REP 9.15 IBT Belt Assembly Parts List on PL 1.3 Parts List on PL 5.2 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 674: Rep 9.16 Ibt Cleaner Assembly
REP 9.16 IBT Cleaner Assembly REP 9.17 Auger Assembly Parts List on PL 5.3 Parts List on PL 5.2 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 675: Rep 9.18 Lever Assembly
REP 9.18 Lever Assembly REP 9.19 Left Hinge/Right Hinge Parts List on PL 5.1 Parts List on PL 5.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 676: Rep 9.20 Right Lift Assembly
REP 9.20 Right Lift Assembly 11. Remove Right Lift Assembly (Figure Remove Auger mounting screws (2). Parts List on PL 5.1 Remove lift position screw. Removal Remove secondary position screw. WARNING Remove lower screws (2). To avoid personal injury or shock, do not perform repair or adjustment activities with Remove Right Lift Assembly.
Page 677: Rep 9.21 Left Lift Assembly
REP 9.21 Left Lift Assembly Bearing Washer Parts List on PL 5.1 Screws (2) E-Ring Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Front Cover (REP 14.7).
Page 678: Rep 9.22 Transfer Belt
REP 9.22 Transfer Belt Remove Handle (Figure Parts List on PL 5.3 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION Cover Transfer Belt in a black bag.
Page 679 Position Support (Figure Install Stand Plate (Figure Remove Screw and Support Install Sup- port and Screw Figure 5 Installing Stand Plate Figure 4 Positioning Latch Initial issue Repairs and Adjustments 02/03 REP 9.22 DC 3535/2240/1632 4-89...
Page 680 Place Stand Plate below and stand IBT Belt Assembly. 10. Remove Brackets (Figure Relax tension of Belt on both sides (Figure Remove Screws (5) and Brackets (2) Lock Forcefully push roll and do step 2 Push Tab so Lock engages plate Figure 6 Relaxing Belt Tension Figure 7 Removing Bracket Repairs and Adjustments...
Page 681 11. Pull out Backup Roll Housing from hole below and rotate (Figure 12. Remove Transfer Belt (Figure Lift Backup Rotate Roll Hous- Housing 1/4 ing to disen- turn gage bottom Figure 8 Pulling Out Backup Roll Housing Figure 9 Removing Transfer Belt Initial issue Repairs and Adjustments 02/03...
Page 682 Replacement After installing Transfer Belt, move it to center of IBT Frame so that exposed parts of IBT Drive Roll should be equal (Figure 11). Install Transfer Belt with Reflector at rear (Figure 10). Drive Roll Equal amount of Exposed part of IBT Drive Roll on each side Reflector Figure 11 Positioning Transfer Belt...
Page 683 If Transfer Belt is skewed or wrinkled, perform following steps: (Figure 12). Relax tension of Belt. Rotate Gear in arrow direction and move Transfer Belt. Reposition Belt while Rotating Gear Gear Relax Belt Tension Figure 12 Re-positioning Transfer Belt Initial issue Repairs and Adjustments 02/03 REP 9.22...
Page 684: Rep 9.23 1St Btr Roll
REP 9.23 1st BTR Roll REP 9.24 2nd BTR Roll Parts List on PL 5.4 Parts List on PL 2.8 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 685: Rep 9.26 Atc Sensor
REP 9.26 ATC Sensor 12. Remove ATC Sensor (Figure Parts List on PL 6.2 Removal Lift Lock WARNING and move end away To avoid personal injury or shock, do not perform repair or adjustment activities with from Tab the power switch on or electrical power applied to the machine. Remove Front Cover (REP 14.7).
Page 686 Replacement Remove ATC Sensor Setup Data Tag from new sensor. On tag, highlight K, C, M, or Y as required for color of developer housing. Raise Xerographic Release Lever and install Tag in position shown (Figure Tag with K highlighted Tag with C Tag with M highlighted...
Page 687: Rep 9.27 Retract Shaft
REP 9.27 Retract Shaft Parts List on PL 5.4 Replacement Align Cam and Flag as shown (both on the same side) (Figure Incorrect Alignment Correct Alignment Figure 1 Cam and Flag Alignment Initial issue Repairs and Adjustments 02/03 REP 9.27 DC 3535/2240/1632 4-97...
Page 688 Repairs and Adjustments Initial issue 02/03 REP 9.27 4-98 DC 3535/2240/1632...
Page 689: Rep 10.1 Fuser
REP 10.1 Fuser REP 10.2 Fuser Fan Parts List on PL 7.1 Parts List on PL 8.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 690: Rep 10.3 Main/Sub Heater Rod
REP 10.3 Main/Sub Heater Rod Remove Heater Rods (Figure Parts List on PL 7.2 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. CAUTION Wait until the Fuser cools down before performing this procedure.
Page 691: Rep 12.1 H Transport Assembly
REP 12.1 H Transport Assembly Disengage Hook (2) from the Stud on both sides and remove H Transport Assembly (Fig- Parts List on PL 17.1 Removal WARNING Hook To avoid personal injury or shock, do not perform repair or adjustment activities with Hook the power switch on or electrical power applied to the machine.
Page 692: Rep 12.2 H Transport Belt
REP 12.2 H Transport Belt Remove the output H Transport Roll (Figure Parts List on PL 17.4 Removal Remove the WARNING H Transport Belts To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove H Remove the H Transport Assembly (REP...
Page 693: Rep 12.3 Entrance Sensor And Top Tray Full Sensor
REP 12.3 Entrance Sensor and Top Tray Full Sensor Remove the H Transport Entrance Sensor or Top Tray Full Sensor (Figure Parts List on PL 17.4 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 694: Rep 12.4 Finisher
REP 12.4 Finisher Parts List on PL 17.5 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Separate IIT and IOT. Remove the following parts: H Transport Assembly (REP 12.1)
Page 695: Rep 12.5 Stack Height Sensor Assembly
REP 12.5 Stack Height Sensor Assembly NOTE: It may be necessary to prop the Top Cover open during the next step. Parts List on PL 17.6 Open the Top Cover and remove the Stack Height Sensor Assembly (Figure Removal WARNING Remove the Screw To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 696: Rep 12.6 Eject Roll Assembly
REP 12.6 Eject Roll Assembly Disconnect the connector (Figure Parts List on PL 17.6 Removal Remove WARNING Screws (2) To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the following parts: Rear Cover 17.5)
Page 697 Remove the Thumbscrews (2) (Figure Remove the Tray Guide (Figure Remove Screws (4) Remove Cable from Tray Guide and remove Tray Guide Remove Fastener Figure 3 Removing Thumbscrews and Cable Clamp Figure 4 Removing Tray Guide Initial issue Repairs and Adjustments 02/03 REP 12.6 DC 3535/2240/1632...
Page 698 Remove the Home Sensor (Figure Remove Eject Roll (Figure Disconnect harness and remove Home Sensor Remove Remove Collar Clip, and Gear Actuator, Clutch Remove Clip and Bearing from both ends Figure 5 Remove Home Sensor Disconnect Hook (2) from Eject Shaft and remove Eject Roll Figure 6 Removing Eject Roll Repairs and Adjustments...
Page 699 Remove Eject Shaft (Figure Replacement When replacing Feed Roll or Eject Shaft, replace them simultaneously. When installing the Clutch, be sure to insert the Pawl into Clutch grooves (Figure Remove Clip and Gear Remove Clip Bearing on both sides Remove Eject Shaft Figure 7 Removing Eject Shaft Figure 8 Inserting Pawl into Clutch Grooves...
Page 700 Make sure when installing the Plate, that the Cable Tie (Strain Relief) is inside the Bracket and the cable is routed through the notch (Figure Bracket Notch Cable Tie (Strain Relief) Figure 9 Routing the Cable Repairs and Adjustments Initial issue 02/03 REP 12.6 4-110...
Page 701: Rep 12.7 Decurler Roll
REP 12.7 Decurler Roll Remove the Decurler Roll (Figure Parts List on PL 17.7 Removal WARNING Insert a sheet of paper to keep rollers separated To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the following parts: Front Cover 17.5)
Page 702: Rep 12.8 Finisher Drive Motor
REP 12.8 Finisher Drive Motor Parts List on PL 17.7 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the Rear Cover 17.5).
Page 703: Rep 12.9 Belt
REP 12.9 Belt REP 12.10 Rail Parts List on PL 17.7 Parts List on PL 17.9 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 704 Remove Stapler Assembly (Figure Remove the PWB Cover (Figure Remove Screws (10) and Cover Remove Screws (2), Ground Wire (1) and Stapler Figure 3 Removing the PWB Cover Figure 2 Removing Stapler Assembly Repairs and Adjustments Initial issue 02/03 REP 12.10 4-114 DC 3535/2240/1632...
Page 705 Move the PWB Chassis down (Figure Remove Rear Rail Mounting Screws (2) (Figure Disconnect P849 and P846 and Disconnect remove from P848 and Remove Guide remove from Screws (2) Guide Loosen Screw Remove Screws (2) and allow PWB Chas- sis to hang down Figure 5 Removing Rear Rail Mounting Screws Figure 4 Moving PWB Chassis Down...
Page 706 Remove Front Rail Mounting Screws (2) (Figure Remove the Rail Assembly (Figure Disconnect Connector Remove Screws (2) Figure 7 Removing Rail Assembly Figure 6 Removing Front Rail Mounting Screws Repairs and Adjustments Initial issue 02/03 REP 12.10 4-116 DC 3535/2240/1632...
Page 707 Remove the Carriage Assembly (Figure 10. Remove Screws (5) and remove Rail (Figure Screws (5) Figure 8 Removing the Carriage Assembly Figure 9 Removing Rail Initial issue Repairs and Adjustments 02/03 REP 12.10 DC 3535/2240/1632 4-117...
Page 708: Rep 12.11 Stapler Assembly
REP 12.11 Stapler Assembly Remove the Stapler Assembly (Figure Parts List on PL 17.9 Removal Remove Screws (2), WARNING Ground Wire (1) and Stapler To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Open the Front Cover.
Page 709 Replacement Insert Stapler Assembly Tab into Slot (Figure Slot Figure 3 Inserting Tab into Slot Initial issue Repairs and Adjustments 02/03 REP 12.11 DC 3535/2240/1632 4-119...
Page 710: Rep 12.12 Compiler Tray Assembly
REP 12.12 Compiler Tray Assembly Disconnect Connector (Figure Parts List on PL 17.10 Removal Remove WARNING Remove Screw (2) Plate To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the following parts: Rear Cover 17.5)
Page 711 Remove Thumbscrews (2) (Figure Remove the Tray Guide (Figure Remove Screws (4) Remove Cable from Tray Guide and remove Tray Remove Fastener Guide Figure 3 Removing Thumbscrews (2) and Cable Clamp Figure 4 Removing Tray Guide Initial issue Repairs and Adjustments 02/03 REP 12.12 DC 3535/2240/1632...
Page 712 Release Compiler Tray Harness (Figure Remove the Screw on the Inboard side (Figure Screw Disconnect and remove from Guide Disconnect from Finisher PWB and remove from Guide Move harnesses back through frame Figure 5 Releasing Compiler Tray Harness Figure 6 Removing Screw on Inboard Side Repairs and Adjustments Initial issue 02/03...
Page 713 Remove the Compiler Tray Assembly (Figure Replacement Make sure when installing the Plate, that the Cable Tie (Strain Relief) is inside the Bracket and the cable is routed through the notch (Figure Bracket Notch Cable Tie Figure 7 Removing Compiler Tray Assembly (Strain Relief) Figure 8 Routing the Cable Initial issue...
Page 714: Rep 12.13 Stacker Motor Assembly
REP 12.13 Stacker Motor Assembly Remove the Stacker Motor Assembly (Figure Parts List on PL 17.11 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with Lift PWB Chassis the power switch on or electrical power applied to the machine. and Remove Screws (2) Remove the Rear Cover...
Page 715: Rep 12.14 Front Elevator Bracket
REP 12.14 Front Elevator Bracket Disconnect Connector (Figure Parts List on PL 17.11 Removal Remove WARNING Remove Screw (2) Plate To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the following parts: Rear Cover 17.5)
Page 716 Remove the Thumbscrews (2) (Figure Remove the Tray Guide (Figure Remove Screws (4) Remove Cable from Tray Guide and remove Tray Remove Fastener Figure 3 Removing Thumbscrews Guide and Cable Clamp Figure 4 Removing Tray Guide Repairs and Adjustments Initial issue 02/03 REP 12.14 4-126...
Page 717 Move PWB Chassis (Figure Remove Front Elevator Bracket (Figure Remove Screws (3) and Elevator Bracket Assembly Release Wires from Clamp Move PWB Chassis Remove Figure 6 Removing Elevator Bracket Assembly Loosen Screws Screw Figure 5 Moving PWB Chassis Initial issue Repairs and Adjustments 02/03 REP 12.14...
Page 718 Replacement Make sure when installing the Plate, that the Cable Tie (Strain Relief) is inside the Bracket and the cable is routed through the notch (Figure Bracket Notch Cable Tie (Strain Relief) Figure 7 Routing the Cable Repairs and Adjustments Initial issue 02/03 REP 12.14...
Page 719: Rep 12.15 Paddle Gear Shaft
REP 12.15 Paddle Gear Shaft Remove Screw on Paddle Gear Shaft (Figure Parts List on PL 17.12 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the following parts: Stapler Assembly (REP...
Page 720 Remove the Paddle Gear Shaft (Figure Figure 3 Removing Paddle Gear Shaft Repairs and Adjustments Initial issue 02/03 REP 12.15 4-130 DC 3535/2240/1632...
Page 721: Rep 12.16 Finisher Pwb
REP 12.16 Finisher PWB Disconnect Connectors (Figure Parts List on PL 17.13 Removal WARNING Remove Wire Harness from To avoid personal injury or shock, do not perform repair or adjustment activities with Guides (4) the power switch on or electrical power applied to the machine. CAUTION PWBs can be damaged by electrostatic discharge.
Page 722 Remove the Finisher PWB (Figure Remove Screws (6) and PWB Figure 3 Removing Finisher PWB Replacement Before attempting to install the PWB Cover, make sure the ceramic Cores, installed to the wires, are dressed properly inside the PWB Box. Repairs and Adjustments Initial issue 02/03 REP 12.16...
Page 723: Rep 12.17 Entrance Upper Cover
REP 12.17 Entrance Upper Cover Remove the Gate In Solenoid Assembly (Figure Parts List on PL 17.3 Removal Remove Screw (1) Remove the H Transport Assembly (REP 12.1). and Ground Wire Remove the following: H Transport Front Cover 17.3) H Transport Rear Cover 17.3) Remove the H Transport Cover and cover Stop (Figure...
Page 724 Remove the Entrance Upper Cover (Figure Remove Entrance Upper Cover Remove Screws (4) Figure 3 Removing the Entrance Upper Cover Repairs and Adjustments Initial issue 02/03 REP 12.17 4-134 DC 3535/2240/1632...
Page 725: Rep 12.18 Cam Bracket Assembly
REP 12.18 Cam Bracket Assembly Release Harnesses (Figure Parts List on PL 17.8 Removal Remove Clamp Remove wires from Frame WARNING from Clip To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the Rear Cover 17.5) Position the Actuator...
Page 726 Remove the Cam Bracket Assembly (Figure Replacement Reinstall the Cam Bracket Assembly (Figure Remove Screws (4) Raise Top Cover to raise Roller while performing step 2 Remove Cam Bracket Assembly Align Axle with Hole Figure 3 Removing the Cam Bracket Assembly Figure 4 Inserting Axle of Cam Bracket Assembly into Hole Repairs and Adjustments Initial issue...
Page 727 Engage the solenoid pawl (Figure Rotate Cam so Pawl engages Slot Figure 5 Engaging Pawl with Slot Initial issue Repairs and Adjustments 02/03 REP 12.18 DC 3535/2240/1632 4-137...
Page 728: Rep 12.19 Finisher Rack Assembly
REP 12.19 Finisher Rack Assembly Remove Bottom Plate (Figure Parts List on PL 17.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Finisher (REP 12.4).
Page 729 Remove Rear Rack (Figure Remove Front Rack (Figure Lift to Remove Rack Lift to Remove Rack Remove Remove Thumbscrew Thumbscrew Figure 3 Removing Rear Rack Figure 4 Removing Front Rack Initial issue Repairs and Adjustments 02/03 REP 12.19 DC 3535/2240/1632 4-139...
Page 730: Rep 12.20 Lowering Stacker Tray
REP 12.20 Lowering Stacker Tray Parts List on PL 17.11 Removal If the need arises to lower the Stacker Tray quickly or without power applied perform following: WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 731: Rep 14.1 Top Cover
REP 14.1 Top Cover Parts List on PL 10.2 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Without Finisher, go to step 6. With Finisher, go to step 2.
Page 732: Rep 14.2 Rear Cover (Iot)
REP 14.2 Rear Cover (IOT) REP 14.3 Right Cover Parts List on PL 10.3 Parts List on PL 10.1 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 733: Rep 14.4 Rear Left Middle Cover
REP 14.4 Rear Left Middle Cover Hidden Tabs Parts List on PL 10.3 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Rear Cover (REP 14.2).
Page 734: Rep 14.5 Rear Left Upper Cover
REP 14.5 Rear Left Upper Cover REP 14.6 Left Lower Cover Assembly Parts List on PL 10.3 Parts List on PL 2.3 Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 735: Rep 14.7 Front Cover Assembly
REP 14.7 Front Cover Assembly Parts List on PL 10.1 Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove Front Cover (Figure Hinge Pin Open Tray 1 approximately 100 mm for possible cover support.
Page 736: Rep 14.8 Fuser Cover
REP 14.8 Fuser Cover REP 14.9 Rear Cover (Tray Module) Parts List on PL 10.2 Parts List on PL 16.16 (TTM), PL 15.11 (3TM) Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 737: Rep 14.10 Inner Cover
REP 14.10 Inner Cover REP 14.11 Left Cover Assembly Parts List on PL 8.1 Parts List on PL 16.13 (TTM), PL 15.10 (3TM) Removal Removal WARNING WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
Page 738: Rep 14.12 Left Lower Cover
REP 14.12 Left Lower Cover Parts List on PL 16.16 (TTM), PL 15.11 (3TM) Removal WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Remove the Left Lower Cover (Figure 1).
Page 739: Adj 5.1 Dadf Side Registration
ADJ 5.1 DADF Side Registration • 1 to 1-sided • A3 or 11 x 17 Paper Supply Purpose • 100% Reduce/Enlarge Align image scanned from document with left side edge of paper. • 2 Copies Press Start and discard the first copy. Check On side 1 of copy 2 measure and record the distance between the side edge and the Make two copies from the Platen Glass to be used as DADF originals.
Page 740 Adjustment Adjust Side 1 DADF Side Registration. Enter NVM Rear/Write (dC131) [715-015]. NOTE: Increasing value moves side edge metrics SE1 through SE4 toward edge. If B is more than A, increase the NVM value (15 = approx. 1 mm). If B is less than A, decrease the NVM value (15 = approx. 1 mm). Check results of adjustment and adjust if required.
Page 741: Adj 5.2 Dadf Counterbalance
ADJ 5.2 DADF Counterbalance Adjustment WARNING Purpose To avoid personal injury or shock, do not perform repair or adjustment activities with Correct DADF opening and closing action. the power switch on or electrical power applied to the machine. Check CAUTION When removing the Rear Cover, disconnect LED Connector on DADF PWB.
Page 742: Adj 5.3 Dadf Parallelism
ADJ 5.3 DADF Parallelism Adjustment CAUTION Purpose The DADF Parallelism must be made within ±1mm of the specified range. Enable parallel Document placement and image scan. CAUTION Check When removing the Rear Cover, disconnect LED Connector on DADF PWB. Remove Rear Cover (REP 5.18).
Page 743: Adj 5.4 Document Transport Height
ADJ 5.4 Document Transport Height Adjustment CAUTION Purpose When removing the Rear Cover, disconnect LED Connector on DADF PWB. Enable document feed at the correct speed and free of skew. Remove Rear Cover (REP 5.18). Check Raise DADF and loosen the Screws (2) (Figure WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with...
Page 744 Adjust Document Transport Height (Figure Lower DADF Lower Document Raise Docu- Transport Frame ment Trans- port Frame Adjust Screw Raise DADF Tighten Screws Figure 3 Adjusting Document Transport Height Repeat check. Repairs and Adjustments Initial issue 02/03 ADJ 5.4 4-154 DC 3535/2240/1632...
Page 745: Adj 5.5 Dadf Top Registration
ADJ 5.5 DADF Top Registration Check DADF Top Edge Registration for Side 1. Load both DADF Originals in DADF, 1 on top, with top edge metrics LE1 through Purpose LE3 toward right. Align image scanned from document with top edge of paper. Select the following: •...
Page 746 • 1 Copy Adjustment iii. Press the Start button. Adjust Side 1 DADF Side Registration. Check that top edge metrics are same distance from edge of paper for both copies. Enter NVM Rear/Write (dC131) [710-005]. If the difference is greater than 1 mm, go to step 2 of the adjustment. NOTE: Increasing value moves lead edge metrics LE1 through LE3 toward edge.
Page 747: Adj 5.6 Dadf Document Calibration
ADJ 5.6 DADF Document Calibration Purpose This procedure calibrates the document size detection circuitry in the DADF. Perform this adjustment whenever any the following occur: • Replacement of the DADF. • When an error is detected after replacing Registration Roll, Feed Roll, and Retard Roll. •...
Page 748: Adj 5.7 Dadf Non-Standard Document Custom Registration
ADJ 5.7 DADF Non-standard Document Custom Enter the 710-023 data. (Select the paper direction that the customer specifies from the table below, and enter it.) Registration The following are information regarding the NVM entered above. Purpose Table 1 Preliminary-Document sizes other than DADF detectable document size (non-standard size) are registered and transported as standard document size.
Page 749: Adj 6.1 Full/Half Rate Carriage
ADJ 6.1 Full/Half Rate Carriage Align Half Rate Carriage with Rail Hole (Figure Manually move Full Rate Carriage away from home position approximately 105 mm Purpose while observing Rail Tool Hole to align with Carriage Tool Hole in Half Rate Carriage. Establish Full Rate and Half Rate Carriage position.
Page 750 Install Alignment Tool in front end of Half Rate Carriage (Figure If tool does not install, loosen the set screws (2) and turn the pulley to align the tool holes with each other (Figure Loosen set screws (2) Rotate Pulley Figure 3 Installing Alignment Tool in Front End of Half Rate Carriage Figure 4 Loosening the Set Screws Check that tool will install in other end of carriage.
Page 751 Check that Alignment Tool can be installed through frame into alignment hole in Full Rate Adjustment Carriage (Figure NOTE: Front of Full Rate Carriage shown. Adjustment steps are same for rear of Full Rate If Alignment Tool fits through frame hole into Full Rate Carriage Alignment Hole, perform Carriage.
Page 752 Repairs and Adjustments Initial issue 02/03 ADJ 6.1 4-162 DC 3535/2240/1632...
Page 753: Adj 9.1 Max Setup
ADJ 9.1 Max Setup Purpose To conduct a check of the machine and set it up so that excellent copy quality can be consis- tently obtained by stabilizing the development potential and copy density. Adjustment Max Setup consists of 5 separate adjustments that should be performed in the following sequence: 9.7, IIT Calibration (dC945) NOTE: Perform...
Page 754: Adj 9.2 Atc Sensor Setup (Dc921)
ADJ 9.2 ATC Sensor Setup (dC921) • 752-069 through 752-072 (YMCK ATC Correction Coefficient) • 752-073 through 752-076 (YMCK ATC Correction Offset) Purpose • 752-709 through 752-712 (YMCK Initial Value of Sensitivity Gradient) CAUTION • 752-703 through 752-716 (YMCK Initial Output Value at Standard TC) This procedure should only be performed when the ATC Sensor or Developer Housing is being If one or more ATC Sensors have been replaced, or if you are not sure of the replacement replaced, OR when there is reason to believe that the calibration values in NVM are incorrect.
Page 755: Adj 9.3 Trc Control/Toner Density Setup (Dc922)
ADJ 9.3 TRC Control/Toner Density Setup (dC922) ADJ 9.4 ADC Output Check (dC934) Purpose Purpose To check the output of ATC Sensor and to determine if TC Control performed normally. • To check the following functions • ADC (2 gradation) patch for Potential Control on the IBT Allows manual adjustment of TC if control is not functioning.
Page 756: Adj 9.5 Trc Adjust (Dc924)
ADJ 9.5 TRC Adjust (dC924) Purpose CAUTION Perform this adjustment only to correct a strong customer complaint. Altering the setpoints will affect both Print and Copy modes. Also, there is quite a bit of overlap among the low, medium, and high densities. For these reasons, it is recommended that this procedure not be used unless absolutely necessary.
Page 757: Adj 9.6 Color Registration (Dc685)
ADJ 9.6 Color Registration (dC685) Check the Judgement window. If NG is displayed, perform the Rough Skew Setup then repeat the Fine Skew check. Purpose If OK is displayed in the Judgement window, check the Skew Correction row in the To establish correct horizontal and vertical positioning of the four primary color images Skew Values window.
Page 758 Select the Center Setup button. Select Start. CAUTION Make sure not to hook the wiring harness when moving the MOB Sensor. If Center Setup is OK, dC685 is complete. Use the Cleaning Tool to pull the MOB Sensor back to the original position, and fasten the screw. If Center Setup fails, ensure MOB Sensor is positioned to the rear.
Page 759: Adj 9.7 Iit Calibration (Dc945)
ADJ 9.7 IIT Calibration (dC945) ADJ 9.8 Hard Disk Diagnostics/Setup (dC355) Purpose Purpose • To calculate and set up the White Reference Correction Coefficient. To perform diagnostics and setup (initialization) of each partition in the hard disk. • To correct the IIT sensitivity dispersion (CCD Calibration). NOTE: Perform this procedure only after the customer's approval is obtained.
Page 760: Adj 9.9 Iot Registration Series (Dc129)
Table 3 Diagnostic Routines ADJ 9.9 IOT Registration Series (dC129) Diag Type Details Purpose HDD Read Verifica- Perform the Read verify diagnostics of all the sectors in designated The purpose is to adjust the position of the printed image on the page. This is done by chang- tion partitions.
Page 761 Side Edge Registration for Paper Trays 1 - 5 Purpose LEAD EDGE NOTE: Each Paper Tray has a separate setting for side edge registration. To correctly position the side edge of the image in relation to the outboard edge of the paper. Check Check that paper is loaded in all trays, and that the paper guides are adjusted correctly.
Page 762 Duplex (Side 2) Registration Lead Edge Registration for Tray 5 (MSI) Purpose Purpose The purpose of this procedure is to correctly position the lead edge and side edge of the image NOTE: There are three settings for Tray 5 Lead Edge; one for standard weight paper, one for in relation to the edge of the paper.
Page 763: Adj 9.10 Iit Lead Edge Registration
ADJ 9.10 IIT Lead Edge Registration Adjustment Enter dC131 [715-301]. Purpose Change the value: To adjust the IIT scan timing in the Slow Scan direction and to correct the copy position. • Each bit represents 0.036 mm Check • Increase the value to move the image toward the lead edge. •...
Page 764: Adj 9.11 Iit Side Edge Registration
ADJ 9.11 IIT Side Edge Registration If the value is not within the specified range, perform the Adjustment: Adjustment Purpose Enter dC131 [715-014]. To adjust the IIT scan timing in the Fast Scan direction and to correct the copy position. Change the value: Check •...
Page 765: Adj 9.12 Iit Vertical/Horizontal Magnification
ADJ 9.12 IIT Vertical/Horizontal Magnification Lead Edge Purpose To correct the horizontal (fast scan)/vertical (slow scan) magnification ratio for a 100% copy. Check 200mm +/-1mm CAUTION Perform this procedure only if absolutely required; changing IIT magnification may adversely affect resolution due to ASIC shift, and may cause a color shift. NOTE: Before performing this procedure, make sure that the IOT horizontal/vertical magnifica- tion ratios are correct.
Page 766 Check vertical magnification (Figure Measure the 300mm line running from near LE1 to the trail edge of the 1.8lp ladder. If the dimension is not 300mm ±1.5mm, perform the Adjustment. Lead Edge 300mm +/- 1.5mm Figure 2 Checking Vertical Magnification Adjustment Horizontal Magnification Adjustment •...
Page 767: Adj 9.13 Ui Display Calibration
ADJ 9.13 UI Display Calibration Purpose Adjust the display by making the buttons on the display correspond to the Touch Panel, so that users can correctly select the content indicated on the display. Perform this adjustment when UI PWB or the Control Panel are replaced. Adjustment NOTE: Use the stylus installed under the UI Control Panel for the adjustment.
Page 768: Adj 9.14 Inboard/Outboard Density
ADJ 9.14 Inboard/Outboard Density Purpose To perform the ROS In/Out light quantity correction with this adjustment, when IN/Out densities are different but the parameters other than ROS light quantity judges that all is normal. Adjustment Load A4 paper into Tray 1. Enter dC612.
Page 769 Figure 2 Standard Pattern: Pattern 0 Figure 3 Group 1 <Group 1: when the patterns become darker along the rear> (Fig. 3) <Group 2: when the patterns become darker along the front> (Fig. 4) Initial issue Repairs and Adjustments 02/03 ADJ 9.14 DC 3535/2240/1632 4-179...
Page 770 Figure 4 Group 2 Group 3: when the patterns are dark/light for only both edges. (Fig. 5) Repairs and Adjustments Initial issue 02/03 ADJ 9.14 4-180 DC 3535/2240/1632...
Page 771 Figure 5 Group 3 Initial issue Repairs and Adjustments 02/03 ADJ 9.14 DC 3535/2240/1632 4-181...
Page 772 <Group 4: when the patterns are dark only in the center areas> (Fig. 6) Figure 7 Group 5 Figure 6 Group 4 Select a pattern and change the following NVM corresponding to the pattern. <Group 5: when the patterns are light only in the center areas> (Fig. 7) NOTE: Do NOT use the value other than the recommended values below as the NVM value.
Page 773 Table 2 Pattern No. 0~9 Pattern # [753-801] 1024 1024 1024 1024 1024 [753-802] 1024 1024 1024 1024 1024 [753-803] 1024 1024 1024 1024 1024 1024 [753-804] 1024 1024 1024 1024 1024 1024 [753-805] [753-806] [753-807] [753-808] Table 3 Pattern No. 10~9 Pattern # [753-801] 1024...
Page 774 Repairs and Adjustments Initial issue 02/03 ADJ 9.14 4-184 DC 3535/2240/1632...
Page 775: Adj 12.1 Finisher Alignment
ADJ 12.1 Finisher Alignment Purpose Align IOT copy output with entrance to Finisher H Transport. Adjustment WARNING To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine. Ensure H Transport is set correctly (Figure 1) and...
Page 776 Repairs and Adjustments Initial issue 02/03 ADJ 12.1 4-186 DC 3535/2240/1632...
Page 777 5 Parts List Overview Air System Introduction ........................PL 8.1 Air System......................5-37 Subsystem Information ....................Electrical Components Symbology ........................PL 9.1 Electrical Components: 1 of 3 ................5-38 Parts Lists PL 9.2 Electrical Components: 2 of 3 ................5-39 PL 9.3 Electrical Components: 3 of 3 ................
Page 778 PL 16.12 Tray 4 Feeder: 2 of 2 ..................5-71 PL 16.13 Left Cover Assembly..................5-72 PL 16.14 Tray 3/4 Lift Gear Assembly ................5-73 PL 16.15 Electrical Components and Casters ..............5-74 PL 16.16 Covers ......................5-75 Finisher PL 17.1 Finisher ......................5-76 PL 17.2 Gate Assembly ....................
Page 779: Introduction
NASG - North American Solutions Group - Canada Canada Xerox Europe Symbology Symbology used in the Parts List section is identified in the Symbology section. Service Procedure Referencing If a part or assembly has an associated repair or adjustment procedure, the procedure number will be listed at the end of the part description in the parts lists e.g.
Page 780: Subsystem Information
Subsystem Information Use of the Term “Assembly” The term “assembly” will be used for items in the part number listing that include other itemized parts in the part number listing. When the word “assembly” is found in the part number listing, there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly.
Page 781: Symbology
Symbology A Tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the Tag A Tag number within a circle pointing to an item number shows that the part has been changed number within the circle (Figure 2).
Page 782 A tag number within a circle with no apex shows that the entire drawing has been changed by A tag number within a circle with no apex and having a shaded bar shows that the entire the tag number within the circle (Figure 3). Information on the modification is in the Change Tag drawing was the configuration before being changed by the tag number within the circle Index.
Page 783: Pl 1.1 Drive Unit
PL 1.1 Drive Unit Item Part Description 007K87370 Drum Motor Assembly (DC3535) (REP 4.4) – 007K85750 Drum Motor Assembly (DC2240/1632) (REP 4.4) – Drum Motor (P/O PL 1.1 Item 1) – Gear Bracket (P/O PL 1.1 Item 1) 007K87600 IBT Motor Assembly (REP 4.2) –...
Page 784: Pl 1.2 Main Drive Motor Assembly
PL 1.2 Main Drive Motor Assembly Item Part Description – Friction Clutch (Not Spared) – Shaft (Not Spared) – Gear (32T) (Not Spared) – Gear (28T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) – Gear (20T) (Not Spared) 121K22470 Takeaway Clutch –...
Page 785: Pl 1.3 Ibt Steering Motor And Mob Sensor
PL 1.3 IBT Steering Motor and MOB Sensor Item Part Description 007K85580 IBT Steering Drive Assembly (REP 9.12) – IBT Steering Motor (P/O PL 1.3 Item 1) – Plate (P/O PL 1.3 Item 1) 130K60865 MOB Sensor Assembly (REP 9.14,ADJ 9.6) –...
Page 786: Pl 2.1 Tray 1: 1 Of 2
PL 2.1 Tray 1: 1 of 2 Item Part Description 003E23672 Stop 014E42850 Spacer 110K08541 Tray 1 Paper Size Sensor (REP 7.5) 050K48980 Tray 1 (DC3535) (REP 7.8) – 050K48171 Tray 1 (DC2240/1632) (REP 7.8) – Cover (Not Spared) 892E41110 Label (1) (DC2240/1632) –...
Page 787: Pl 2.2 Tray 1: 2 Of 2
PL 2.2 Tray 1: 2 of 2 Item Part Description 892E90350 Instruction Label (DC3535) – 892E13310 Instruction Label (DC2240/1632) – Pad (Not Spared) – Max Label (Not Spared) – Tray (Not Spared) – Side Guide (Not Spared) – End Guide (Not Spared) –...
Page 788: Pl 2.3 Tray 1 Feeder And Left Lower Cover Assembly
PL 2.3 Tray 1 Feeder and Left Lower Cover Assembly Item Part Description 059K15573 Tray 1 Feeder (REP 7.3) 802K13193 Left Lower Cover Assembly (REP 14.6) – Left Lower Cover (P/O PL 2.3 Item 029E31600 Rivet – Bracket (P/O PL 2.3 Item 2) –...
Page 789: Pl 2.4 Tray 1 Feeder: 1 Of 2
PL 2.4 Tray 1 Feeder: 1 of 2 Item Part Description 127K23230 Tray 1 Feed/Lift Motor (REP 7.4) – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) –...
Page 790: Pl 2.5 Tray 1 Feeder: 2 Of 2
PL 2.5 Tray 1 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 791: Pl 2.6 Registration Transport
PL 2.6 Registration Transport Item Part Description 059K24661 Registration Transport Assembly (REP 8.6) – Bearing (P/O PL 2.6 Item 1) – Bearing (P/O PL 2.6 Item 1) – Takeaway Roll (P/O PL 2.6 Item 1) – Gear (22T) (P/O PL 2.6 Item 1) –...
Page 792: Pl 2.7 Left Cover Unit
PL 2.7 Left Cover Unit Item Part Description 007E64740 Damper Gear (11/23T) – Stud (Not Spared) 004E11831 Damper (White) – Left Upper Cover (Not Spared) 802K45492 Left Cover Assembly – Left Cover (P/O PL 2.7 Item 5) – Screw (Not Spared) –...
Page 793: Pl 2.8 Left Cover Assembly: 1 Of 2
PL 2.8 Left Cover Assembly: 1 of 2 Item Part Description 054K22410 Registration Chute – Holder (Not Spared) 604K07070 2nd BTR (REP 9.24) 809E29620 Spring 015K48381 Support – Left Cover (Not Spared) 007E62630 Gear (22T) 059K15612 Exit Roll 007E75201 Gear –...
Page 794: Pl 2.9 Left Cover Assembly: 2 Of 2
PL 2.9 Left Cover Assembly: 2 of 2 Item Part Description – Bearing (Not Spared) 007K87440 Gear 127K29511 2nd BTR Retract Motor 130E82190 2nd BTR Retract Sensor – Bracket (Not Spared) 130E84300 POB Sensor – Bracket (Not Spared) – Spring (Not Spared) –...
Page 795: Pl 2.11 Exit Transport Assembly
PL 2.11 Exit Transport Assembly Item Part Description 059K24691 Exit Transport Assembly (DC2240/1632) (REP 8.7) – 059K24260 Exit Transport Assembly (DC3535) (REP 8.7) – Exit Transport Cover (Part of Item – Bearing (Part of Item 1) – Pin (Part of Item 1) –...
Page 796: Pl 2.12 Tray 5: 1 Of 2
PL 2.12 Tray 5: 1 of 2 Item Part Description 059K24801 Tray 5 (DC2240/1632) (REP 7.1) – 059K25580 Tray 5 (DC3535) (REP 7.1) Parts List Initial issue 02/03 PL 2.12 5-20 DC 3535/2240/1632...
Page 797: Pl 2.13 Tray 5: 2 Of 2
PL 2.13 Tray 5: 2 of 2 Item Part Description – Spring (Not Spared) – Bracket (Not Spared) – Gear (Not Spared) – Spring (Not Spared) 050K48181 Tray 5 Assembly (DC2240/1632) – 050K48860 Tray 5 Assembly (DC3535) – Upper Frame (Not Spared) 120E11971 Actuator 130E82190...
Page 798: Pl 2.14 Tray 5 Feed Assembly
PL 2.14 Tray 5 Feed Assembly Item Part Description 038E23560 Paper Guide – Takeaway Roll (Not Spared) – Bearing (Not Spared) – Gear (Not Spared) – Pick-up Gear (Not Spared) – Cam Gear (Not Spared) – Stop Lever (Not Spared) –...
Page 799: Pl 2.15 Tray 5 Assembly
PL 2.15 Tray 5 Assembly Item Part Description – Lower Tray (Not Spared) – Cover (Not Spared) – Paper Size Sensor (Not Spared) – Side Guide (Not Spared) – Attention Label (Not Spared) – Instruction Label (Not Spared) – Label (Not Spared) –...
Page 800: Pl 3.1 Ros Assembly
PL 3.1 ROS Assembly Item Part Description – Bracket (Not Spared) 062K10881 ROS (DC2240/1632) (REP 6.1,ADJ 9.6) – 062K11421 ROS (DC3535) (REP 6.1,ADJ 9.6) – Seal Glass (Y) (Not Spared) – Seal Glass (M) (Not Spared) – Seal Glass (C) (Not Spared) –...
Page 801: Pl 4.1 Xerographic Module: 1 Of 2
PL 4.1 Xerographic Module: 1 of 2 Item Part Description 802K47090 Waste Toner Cartridge Cover (REP 9.3) – Waste Toner Cartridge (Not Spared) (REP 9.4) 003K86122 Sensor Holder Assembly – Lever (P/O PL 4.1 Item 3) – Waste Toner Cartridge Interlock Switch (P/O PL 4.1 Item 3) –...
Page 802: Pl 4.2 Xerographic Module: 2 Of 2
PL 4.2 Xerographic Module: 2 of 2 Item Part Description 015K52320 Plate Assembly (REP 9.8) – Wire Harness (P/O PL 4.2 Item 1) – Xero PLate (P/O PL 4.2 Item 1) – Block (M, C, K) (P/O PL 4.2 Item 1) –...
Page 803: Pl 5.1 Lift Unit
PL 5.1 Lift Unit Item Part Description 001K70542 Left Lift Assembly (REP 9.21) 001K70551 Right Lift Assembly (REP 9.20) – Bearing (Not Spared) – Washer (Not Spared) – Plate (Not Spared) 003K12881 Latch Assembly 003E52290 Left Hinge (REP 9.19) 003E52300 Right Hinge (REP 9.19) 006E71740 Shaft...
Page 804: Pl 5.2 Ibt Unit
PL 5.2 IBT Unit Item Part Description 604K07052 IBT Belt Assembly (REP 9.15,ADJ 9.6) 003K12650 Removal Support – Bearing (Not Spared) 007E61910 Gear (14T) 007E61890 Gear (18T) – Shaft (Not Spared) 802K12950 Auger Assembly (REP 9.17) – Screw (Not Spared) –...
Page 805: Pl 5.3 Ibt Belt Assembly
PL 5.3 IBT Belt Assembly Item Part Description – IBT Belt Cleaner Assembly (P/O PL 5.2 Item 1) (REP 9.16) – Blade (P/O PL 5.3 Item 1) – Seal (P/O PL 5.3 Item 1) – Screw (P/O PL 5.3 Item 1) –...
Page 806: Pl 5.4 Ibt Frame Assembly: 1 Of 2
PL 5.4 IBT Frame Assembly: 1 of 2 Item Part Description – Frame (Not Spared) 130E84270 IBT Home Sensor (ADJ 9.6) – Spring (Not Spared) – Clamp (Not Spared) 130K60830 IBT Edge Sensor (ADJ 9.6) 162K56020 Connector (C, K) – Connector (Not Spared) 162K61090 Connector (Y, M)
Page 807: Pl 5.5 Ibt Frame Assembly: 2 Of 2
PL 5.5 IBT Frame Assembly: 2 of 2 Item Part Description – Handle (Not Spared) – Spring (Not Spared) – Gear (Not Spared) – Plate (Not Spared) – Gear (Not Spared) – Bracket (Not Spared) – Top Roll (Not Spared) –...
Page 808: Pl 5.6 Ibt Elevator
PL 5.6 IBT Elevator Item Part Description 809E26330 Spring 015K49480 Rear Plunger 015K49310 Front Plunger – Frame (Not Spared) 014E43150 Spacer Parts List Initial issue 02/03 PL 5.6 5-32 DC 3535/2240/1632...
Page 809: Pl 6.1 Developer Unit: 1 Of 2
PL 6.1 Developer Unit: 1 of 2 Item Part Description 802K45910 Toner Dispenser (Y) (REP 9.7) – Toner Cartridge (Not Spared) 802K45920 Toner Dispenser (M) (REP 9.7) – Toner Cartridge (Not Spared) 802K45930 Toner Dispenser (C) (REP 9.7) – Toner Cartridge (Not Spared) 802K45940 Toner Dispenser (K) (REP 9.7) –...
Page 810: Pl 6.2 Developer Unit: 2 Of 2
PL 6.2 Developer Unit: 2 of 2 Item Part Description 802K28891 Developer Housing (Y, M, K, C) (REP 9.9,ADJ 9.1) – Developer Housing (P/O PL 6.2 Item 1) 130K63000 ATC Sensor (Y, M, K, C) (REP 9.26,ADJ 9.1) 035E65010 Seal 604K07520 Developer (K) (REP 9.10,ADJ 9.1) 604K07490...
Page 811: Pl 7.1 Fuser Assembly: 1 Of 2
PL 7.1 Fuser Assembly: 1 of 2 Item Part Description 126K14892 Fuser (220V) (DC2240/1632) (REP 10.1) – 126K13942 Fuser (120V) (DC2240/1632) (REP 10.1) – 008R12904 Fuser (110V) (DC3535) (REP 10.1) – 008R12905 Fuser (220V) (DC3535) (REP 10.1) Initial issue Parts List 02/03 PL 7.1 DC 3535/2240/1632...
Page 812: Pl 7.2 Fuser Assembly: 2 Of 2
PL 7.2 Fuser Assembly: 2 of 2 Item Part Description – Front Cover (Not Spared) – Rear Cover (Not Spared) – Front Lamp Bracket (Not Spared) 126K13950 Main Heater Rod (110V) (REP 10.3) – 126K13980 Main Heater Rod (220V) (REP 10.3) 126K13990 Sub Heater Rod (220V) (REP 10.3)
Page 813: Pl 8.1 Air System
PL 8.1 Air System Item Part Description 127K32730 ROS Shutter Motor (REP 9.2) – Link (Not Spared) – Spring (Not Spared) – Inner Cover (Not Spared) (REP 14.10) – Duct (Not Spared) 127K29340 Fuser Fan (REP 10.2) – Duct (Not Spared) 127K36640 Rear Fan Initial issue...
Page 814: Pl 9.1 Electrical Components: 1 Of 3
PL 9.1 Electrical Components: 1 of 3 Item Part Description 105K18772 DEV/BTR2/DTS HVPS (DC2240/1632) (REP 1.6 REP 1.7) – 105K20061 DEV/BTR2/DTS HVPS (DC3535) (REP 1.6 REP 1.7) 105E09981 BCR HVPS (DC2240/1632) (REP 1.6 REP 1.7) – 105E11341 BCR HVPS (DC3535) (REP 1.6 REP 1.7) –...
Page 815: Pl 9.2 Electrical Components: 2 Of 3
PL 9.2 Electrical Components: 2 of 3 Item Part Description 101K38982 AC Power Chassis Assembly (220V) (DC2240/1632) – 101K38812 AC Power Chassis Assembly (110V) (DC2240/1632) – 101K39401 AC Power Chassis Assembly (220V) (DC3535) – 101K38821 AC Power Chassis Assembly (110V) (DC3535) –...
Page 816: Pl 9.3 Electrical Components: 3 Of 3
PL 9.3 Electrical Components: 3 of 3 Item Part Description 014K81604 Developer Block 162K62110 Wire Harness 162K55941 Wire Harness (Y, M) 162K55971 Wire Harness (C, K) 162K56000 2nd Wire Harness 113K82310 DTS Connector 162K56031 DTS Wire Harness 962K09800 DC Wire Harness (DC2240/1632) –...
Page 817: Pl 10.1 Front Cover
PL 10.1 Front Cover Item Part Description 891E75951 Logo Plate (DC2240/1632) – 892E89060 Logo PLate (DC3535) 892E78280 Name Plate (16/32) (DC1632) – 892E78290 Name Plate (22/40) (DC2240) 802K46050 Front Cover Assembly (DC2240/1632) (REP 14.7) – 802K47590 Front Cover Assembly (DC3535) (REP 14.7) –...
Page 818: Pl 10.2 Top Covers And Inner Covers
PL 10.2 Top Covers and Inner Covers Item Part Description 802K29610 Top Cover Assembly (DC2240/1632) (REP 14.1) – 802K49800 Top Cover Assembly (DC3535) (REP 14.1) – Top Cover (P/O PL 10.2 Item 1) – Stop (P/O PL 10.2 Item 1) 802E12400 Connector Cover –...
Page 819: Pl 10.3 Rear Cover
PL 10.3 Rear Cover Item Part Description – Data Plate (Not Spared) 802E12480 Blind Cover (DC2240/1632) – 802E33910 Blind Cover (DC3535) 802K28110 Rear Cover Assembly – Rear Cover (P/O PL 10.3 Item 3) (REP 14.2) 802E12490 Blind Cover 802E12500 Rear Left Middle Cover (REP 14.4) –...
Page 820: Pl 11.1 Inverter Transport: 1 Of 2
PL 11.1 Inverter Transport: 1 of 2 Item Part Description 059K16742 Inverter Transport (REP 8.5) Parts List Initial issue 02/03 PL 11.1 5-44 DC 3535/2240/1632...
Page 821: Pl 11.2 Inverter Transport: 2 Of 2
PL 11.2 Inverter Transport: 2 of 2 Item Part Description – Cover (Not Spared) 015K45802 Clutch Assembly – Wire Harness (Not Spared) 121K22870 Reverse Clutch 011E10711 Interlock Actuator – Gear (23T) (P/O PL 11.2 Item 2) – Bracket (Not Spared) –...
Page 822: Duplex Transport
PL 12.1 Duplex Transport Assembly: 1 of 2 Item Part Description – Duplex Transport Upper Cover (Not Spared) 059K18714 Duplex Transport Assembly (REP 8.3) – One-way Pulley (P/O PL 12.1 Item – Bearing (P/O PL 12.1 Item 2) – Bearing (P/O PL 12.1 Item 2) 059K23960 Duplex Transport Roll –...
Page 823: Pl 12.2 Duplex Transport Assembly: 2 Of 2
PL 12.2 Duplex Transport Assembly: 2 of 2 Item Part Description – Spring (Not Spared) 059K23470 Pinch Roll – Cover (Not Spared) 160K66860 Duplex Transport PWB – Wire Harness (Not Spared) – Bracket (Not Spared) 130K61250 Duplex Transport Wait Sensor –...
Page 824: Pl 13.1 Ess
PL 13.1 ESS Item Part Description 160K74231 ESS PWB (DC2240/1632) (REP 1.12) – 160K90570 ESS PWB (DC3535) (REP 1.12) 160K91962 MCU PWB (DC3535) (REP 1.2) – – MCU PWB (P/O PL 13.1 Item 35) (DC2240/1632) (REP 1.2) – Rear Panel (Not Spared) –...
Page 825: Pl 15.1 Tray 2/3/4 Feeder
PL 15.1 Tray 2/3/4 Feeder Item Part Description 050K48840 Tray 2/3/4 (REP 7.13 REP 7.14 REP 7.15) 892E89190 Label (Tray 2) – 892E89200 Label (Tray 3) – 892E89210 Label (Tray 4) 110K08541 Paper Size Sensor (Tray 2/3/4) – Spacer (Not Spared) 003E23672 Stop 059K15573...
Page 826: Pl 15.2 Tray Assembly
PL 15.2 Tray Assembly Item Part Description 892E13310 Instruction Label – Pad (Not Spared) – Max Label (Not Spared) – Tray (Not Spared) – Side Guide (Not Spared) – End Guide (Not Spared) – Link (Not Spared) – Stop (Not Spared) –...
Page 827: Pl 15.3 Tray 2 Feeder: 1 Of 2
PL 15.3 Tray 2 Feeder: 1 of 2 Item Part Description 127K23230 Tray 2 Feed/Lift Motor (REP 7.4) – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) –...
Page 828: Pl 15.4 Tray 2 Feeder: 2 Of 2
PL 15.4 Tray 2 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 829: Pl 15.5 Tray 3 Feeder: 1 Of 2
PL 15.5 Tray 3 Feeder: 1 of 2 Item Part Description 127K23230 Tray 3 Feed/Lift Motor (REP 7.4) – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) –...
Page 830: Pl 15.6 Tray 3 Feeder: 2 Of 2
PL 15.6 Tray 3 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 831: Pl 15.7 Tray 4 Feeder: 1 Of 2
PL 15.7 Tray 4 Feeder: 1 of 2 Item Part Description 127K23230 Tray 4 Feed/Lift Motor (REP 7.4) – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) –...
Page 832: Pl 15.8 Tray 4 Feeder: 2 Of 2
PL 15.8 Tray 4 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 833: Pl 15.9 Electrical Components And Casters
PL 15.9 Electrical Components and Casters Item Part Description – Left Connecting Bracket (Not Spared) – Right Connecting Bracket (Not Spared) 017K92350 Caster 017K92360 Caster – Foot (Not Spared) – Bracket (Not Spared) 160K91000 Tray Module PWB 127K36020 Takeaway Motor 1 007E66060 Gear (23/46T) 007E66070...
Page 834: Pl 15.10 Left Cover Assembly
PL 15.10 Left Cover Assembly Item Part Description 802K25721 Left Cover Assembly (REP 14.11) 003E53700 Shaft 003E53710 Hook 011E10800 Handle 802E23930 Left Cover – Support (P/O PL 15.10 Item 1) – Cover (P/O PL 15.10 Item 1) – Actuator (P/O PL 15.10 Item 1) 809E28970 Spring –...
Page 835: Pl 15.11 Covers
PL 15.11 Covers Item Part Description 802E23950 Front Upper Cover 802E23960 Front Lower Cover 802E23940 Right Cover – Left Lower Cover (Not Spared) (REP 14.12) 802K50490 Rear Cover (REP 14.9) Initial issue Parts List 02/03 PL 15.11 DC 3535/2240/1632 5-59...
Page 836: Pl 16.1 Tray 2/3/4 Assembly
PL 16.1 Tray 2/3/4 Assembly Item Part Description 891E49060 Label (Tray 2) (DC2240/1632) – 892E89190 Label (Tray 2) (DC3535) 050K48171 Tray 2 (DC2240/1632) (REP 7.9) – 050K48980 Tray 2 (DC3535) (REP 7.9) 003E23672 Stop (Tray 2) 014E42850 Spacer (Tray 2) –...
Page 837: Pl 16.2 Tray 2
PL 16.2 Tray 2 Item Part Description 892E74500 Instruction Label – Pad (Not Spared) – Max Label (Not Spared) – Tray (Not Spared) – Side Guide (Not Spared) – End Guide (Not Spared) – Link (Not Spared) – Stop (Not Spared) –...
Page 838: Pl 16.3 Tray 3
PL 16.3 Tray 3 Item Part Description 802E23990 Tray 3 Cover – Pulley (Not Spared) – Lift Shaft (Not Spared) – Bearing (Not Spared) – Pulley (Not Spared) – Pulley (Not Spared) – Cable Guide (Not Spared) 020E93120 Pulley Cable –...
Page 839: Pl 16.4 Tray 4
PL 16.4 Tray 4 Item Part Description 802E23980 Tray 4 Cover – Tray Front Frame (Not Spared) – Lift Shaft (Not Spared) – Lift Gear (Not Spared) – Bearing (Not Spared) – Brake (Not Spared) – Pulley (Not Spared) – Cable Guide (Not Spared) 012E10070 Tray Cable...
Page 840: Pl 16.5 Paper Feeder: 1 Of 2
PL 16.5 Paper Feeder: 1 of 2 Item Part Description – Spacer (Not Spared) – Guide (Not Spared) – Stop (Not Spared) 059K21790 Tray 4 Transport Assembly – Upper Chute (P/O PL 16.5 Item 4) – Takeaway Roll (P/O PL 16.5 Item 4) –...
Page 841: Pl 16.6 Paper Feeder: 2 Of 2
PL 16.6 Paper Feeder: 2 of 2 Item Part Description 059K18900 Takeaway Roll – Bearing (Not Spared) – Chute (Not Spared) – Cover (Not Spared) 130K61510 Takeaway Sensor 162K62810 Wire Harness 059K15573 Tray 2 Feeder (REP 7.10) 054K18270 Chute Assembly –...
Page 842: Pl 16.7 Tray 2 Feeder: 1 Of 2
PL 16.7 Tray 2 Feeder: 1 of 2 Item Part Description 127K23230 Tray 2 Feed/Lift Motor – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) – Front Frame (Not Spared) –...
Page 843: Pl 16.8 Tray 2 Feeder: 2 Of 2
PL 16.8 Tray 2 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 844: Pl 16.9 Tray 3 Feeder: 1 Of 2
PL 16.9 Tray 3 Feeder: 1 of 2 Item Part Description 127K23230 Tray 3 Feed/Lift Motor – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) – Front Frame (Not Spared) –...
Page 845: Pl 16.10 Tray 3 Feeder: 2 Of 2
PL 16.10 Tray 3 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 846: Pl 16.11 Tray 4 Feeder: 1 Of 2
PL 16.11 Tray 4 Feeder: 1 of 2 Item Part Description 127K23230 Tray 4 Feed/Lift Motor – Bracket (Not Spared) 005K83081 One-way Clutch 007K85730 One-way Gear – Gear (13T) (Not Spared) – Bearing (Not Spared) – Shaft (Not Spared) – Front Frame (Not Spared) –...
Page 847: Pl 16.12 Tray 4 Feeder: 2 Of 2
PL 16.12 Tray 4 Feeder: 2 of 2 Item Part Description – Spring (Not Spared) 600K78460 Roll Kit (3 Rolls/Kit) 005K05890 One-way Clutch – Gear (Not Spared) – Shaft (Not Spared) – Chute (Not Spared) – Spring (Not Spared) – Friction Clutch (Not Spared) –...
Page 848: Pl 16.13 Left Cover Assembly
PL 16.13 Left Cover Assembly Item Part Description 802K25731 Left Cover Assembly (REP 14.11) 003E53700 Shaft 003E53710 Hook 011E10800 Handle 802E23930 Left Cover – Support (P/O PL 16.13 Item 1) – Cover (P/O PL 16.13 Item 1) – Actuator (P/O PL 16.13 Item 1) –...
Page 849: Pl 16.14 Tray 3/4 Lift Gear Assembly
PL 16.14 Tray 3/4 Lift Gear Assembly Item Part Description – Transport Guide (Not Spared) 015K49460 Gear Assembly (Tray 3) 015K49450 Gear Assembly (Tray 4) 007E66080 Lift Gear 011K96790 Coupling – Bearing (Not Spared) Initial issue Parts List 02/03 PL 16.14 DC 3535/2240/1632 5-73...
Page 850: Pl 16.15 Electrical Components And Casters
PL 16.15 Electrical Components and Casters Item Part Description 007E66060 Gear (23/46T) 007E66070 Gear (46T) 007E66050 Gear (33T) 127K31840 Takeaway Motor 2 127K36020 Takeaway Motor 1 – Left Coupling (Not Spared) – Right Coupling (Not Spared) – Foot (Not Spared) 017K92350 Caster 017K92360...
Page 851: Pl 16.16 Covers
PL 16.16 Covers Item Part Description – Right Cover (Not Spared) 802E23950 Front Upper Cover 802E23960 Front Lower Cover 802K36580 Rear Cover (REP 14.9) – Left Lower Cover (Not Spared) (REP 14.12) Initial issue Parts List 02/03 PL 16.16 DC 3535/2240/1632 5-75...
Page 852: Pl 17.1 Finisher
PL 17.1 Finisher Item Part Description 802K49900 Gate Assembly 801K03600 H-Transport Assembly (REP 12.1) – Stapler Finisher (Not Spared) 003K12090 Thumbscrew – Rack Assembly (Not Spared) (REP 12.19) – Right Cover (Not Spared) 050E19480 Stacker Tray (REP 12.20) 026E93560 Screw –...
Page 853: Pl 17.2 Gate Assembly
PL 17.2 Gate Assembly Item Part Description – Gate Cover (Not Spared) – Bearing (Not Spared) – Chute (Not Spared) – In Gate (Not Spared) – In Gate Lever (Not Spared) – Gate Bracket (Not Spared) – Link Assembly (Not Spared) –...
Page 854: Pl 17.3 H-Transport Assembly: 1 Of 2
PL 17.3 H-Transport Assembly: 1 of 2 Item Part Description 802K28600 H-Transport Cover Assembly – H-Transport Cover (P/O PL 17.3 Item 1) – Screw (P/O PL 17.3 Item 1) 121E91450 Magnet – Guide (P/O PL 17.3 Item 1) – Roll (P/O PL 17.3 Item 1) –...
Page 855: Pl 17.4 H-Transport Assembly: 2 Of 2
PL 17.4 H-Transport Assembly: 2 of 2 Item Part Description – H-Transport Roll (In) (Not Spared) – H-Transport Roll (Out) (Not Spared) 023E20020 H-Transport Belt (REP 12.2) – Roll (Not Spared) – Support (Not Spared) – Bearing (Not Spared) 802E30150 Harness Guide 802E30140 Cover...
Page 856: Pl 17.5 Covers
PL 17.5 Covers Item Part Description 802E28560 Front Cover 802E28520 Rear Cover 802E28530 Top Cover 802E50710 Left Cover 802E28550 Front Cover Door 802E28570 Left Panel – Hinge (Not Spared) 121E88470 Magnet Parts List Initial issue 02/03 PL 17.5 5-80 DC 3535/2240/1632...
Page 857: Pl 17.6 Top Cover And Eject Roll
PL 17.6 Top Cover and Eject Roll Item Part Description 802K28570 Top Cover – Arm (Not Spared) – Bearing (Not Spared) – Bracket (Not Spared) – Spring (Not Spared) 830E81670 Support – Bracket (Not Spared) – Shaft (Not Spared) 022K61480 Eject Pinch Roll –...
Page 858: Pl 17.7 Paper Transportation: 1 Of 2
PL 17.7 Paper Transportation: 1 of 2 Item Part Description 120E20690 Actuator 121K24610 Decurler Cam Clutch 008E94070 – Shaft (Not Spared) – Bearing (Not Spared) 031E94030 059K20210 Decurler Roll (REP 12.7) 007E67740 Gear (40Z/20T) 007E67750 Gear (40Z) 007E72090 Gear (18Z/21T) –...
Page 859: Pl 17.8 Paper Transportation: 2 Of 2
PL 17.8 Paper Transportation: 2 of 2 Item Part Description 604K11150 Finisher DR Repair Kit 020E34970 Pulley 007E67780 Gear (15Z) 423W28054 Belt 007E67810 Gear (30Z) – Collar (P/O PL 17.8 Item 1) – Gear Pulley (P/O PL 17.6 Item 29) (23Z,16T) (DC2240/1632) –...
Page 860: Pl 17.9 Stapler Unit
PL 17.9 Stapler Unit Item Part Description 041K94260 Carriage Assembly – Bracket (P/O PL 17.9 Item 1) 127K32860 Staple Move Motor – Gear (P/O PL 17.9 Item 1) 130E82530 Staple Move Sensor – Roll (P/O PL 17.9 Item 1) – Staple Front Corner Sensor (Not Spared) –...
Page 861: Pl 17.10 Compiler Tray Assembly
PL 17.10 Compiler Tray Assembly Item Part Description 050K43880 Compiler Tray Assembly (REP 12.12) 127K32850 Front/Rear Tamper Motor – Plate (P/O PL 17.10 Item 1) 130E82530 Front/Rear Tamper Home Sensor – Rack (P/O PL 17.10 Item 1) – Actuator (P/O PL 17.10 Item 1) –...
Page 862: Pl 17.11 Elevator
PL 17.11 Elevator Item Part Description 127K33420 Stacker Motor Assembly (REP 12.13) 015K50680 Front Elevator Bracket (REP 12.14) 019E50340 Clamp – Bearing (Not Spared) 007E67830 Rear Gear – Actuator (Not Spared) 007E67840 Front Gear – Bracket (Not Spared) 007E67820 Rack –...
Page 863: Pl 17.12 Exit Assembly
PL 17.12 Exit Assembly Item Part Description 007E72080 Gear (48Z) – Bearing (Not Spared) 006K21720 Exit Shaft – Collar (Not Spared) 007E72070 Gear (32Z/18T) – Bearing (Not Spared) 006K21970 Paddle Gear Shaft (REP 12.15) 013E20250 Paddle Bearing – Lower Exit Chute (Not Spared) 022K65880 Pinch Roll –...
Page 864: Pl 17.13 Electrical Components
PL 17.13 Electrical Components Item Part Description – PWB Cover (Not Spared) 160K76660 Finisher PWB (REP 12.16) 537K65040 ROM (DC2240/1632) – 537K64130 ROM (DC3535) – PWB Bracket (Not Spared) 962K10120 DC Harness 962K10130 Cable 110E97990 Top Cover/Front Door Interlock Switch 130E82530 Docking Interlock Switch –...
Page 865: Pl 17.14 Rack Assembly
PL 17.14 Rack Assembly Item Part Description 802K36660 Front Rack Assembly – Front Cover (P/O PL 17.14 Item 1) 003K12090 Knob Screw – Screw (P/O PL 17.14 Item 1,PL 17.14 Item 11) – Bracket (P/O PL 17.14 Item 1,PL 17.14 Item 11) –...
Page 866: Pl 18.2 Control Panel
PL 18.2 Control Panel Item Part Description 802K46026 Control Panel Assembly (DC2240/1632) – 802K47294 Control Panel Assembly (DC3535) – Bracket (P/O PL 18.2 Item 1) – Panel Housing (P/O PL 18.2 Item 123K94020 Display 110K11100 Touch Panel (ADJ 9.13) 160K75800 VR PWB (DC2240/1632) (ADJ 9.13) –...
Page 867: Pl 18.3 Platen Glass, Iit/Ips Pwb
PL 18.3 Platen Glass, IIT/IPS PWB Item Part Description – Right Side Plate (Not Spared) 090K92820 Platen Glass (DC2240/1632) (REP 6.2) – 090K02290 Platen Glass (DC3535) (REP 6.2) 050K43070 Registration Gate (DC2240/1632) – 050K48890 Registration Gate (DC3535) – IPS Cover (Not Spared) –...
Page 868: Pl 18.4 Ccd Pwb, Sensor
PL 18.4 CCD PWB, Sensor Item Part Description 127K33160 IPS Fan – Bracket (Not Spared) 130K62000 IIT Registration Sensor – Bracket (Not Spared) 110K08471 Platen Open Switch 130K62580 Platen Angle Sensor Assembly 107E08680 Platen Angle Sensor – Bracket (P/O PL 18.4 Item 6) –...
Page 869: Pl 18.5 Carriage Cable/ Motor
PL 18.5 Carriage Cable/ Motor Item Part Description 063E94040 Tape – Frame (Not Spared) 020E99590 Pulley 012K94110 Front Carriage Cable (REP 6.11) 012K94120 Rear Carriage Cable (REP 6.11) 063E94050 Tape 020E32740 Timing Pulley 023E19300 Belt – Capstan Shaft (Not Spared) 020E25090 Capstan Pulley 413W10950...
Page 870: Pl 18.6 Full/Half Rate Carriage
PL 18.6 Full/Half Rate Carriage Item Part Description – Harness Guard (Not Spared) 041K94050 Full-Rate Carriage Assembly (ADJ 6.1) – Full-Rate Carriage (P/O PL 18.6 Item 2) 117E19780 Lamp Wire Harness (REP 6.14) – No 1 Motor (P/O PL 18.6 Item 2) 062E10040 No 1 Mirror 019E50400...
Page 871: Pl 19.1 Rack (Dc2240/1632)
PL 19.1 Rack (DC2240/1632) Item Part Description – Rack (Not Spared) (DC2240/1632) 017E94710 Swivel Caster (DC2240/1632) 017E94730 Stationary Caster (DC2240/1632) 017E94700 Foot (DC2240/1632) Initial issue Parts List 02/03 PL 19.1 DC 3535/2240/1632 5-95...
Page 872: Pl 19.2 Rack (Dc3535)
PL 19.2 Rack (DC3535) Item Part Description – Plate Assembly (Not Spared) (DC3535) 017E10700 Swivel Caster (DC3535) 017E10710 Rear Caster (DC3535) 017E10840 Foot (DC3535) – End Cap (Not Spared) (DC3535) – Base Support Assembly (Not Spared) (DC3535) Parts List Initial issue 02/03 PL 19.2 5-96...
Page 873: Pl 20.1 Front/Rear Cover, Entrance Tray
PL 20.1 Front/Rear Cover, Entrance Tray Item Part Description 048K76181 Rear Cover Assembly (REP 5.18) – Rear Cover (P/O PL 20.1 Item 1) 140K60480 LED PWB – Wire Harness (P/O PL 20.1 Item 1) 891E65180 Label (Display) 050K36410 Entrance Tray Assembly –...
Page 874: Pl 20.2 Top Cover, Registration Gate Solenoid
PL 20.2 Top Cover, Registration Gate Solenoid Item Part Description 054K13622 Top Cover Assembly – Top Cover (P/O PL 20.2 Item 1) 015E48890 Front Magnet Plate 809E11130 Spring 059K11880 Pinch Roll 015E48900 Front Magnet Plate 110K07850 Top Cover Interlock Switch (Rear) –...
Page 875: Pl 20.3 Counterbalance, Dadf Control Pwb
PL 20.3 Counterbalance, DADF Control PWB Item Part Description 003K91881 Thumbscrew 036K91431 Right Counterbalance (REP 5.3) – Counterbalance (P/O PL 20.3 Item 2) (ADJ 5.2 ADJ 5.3 ADJ 5.4) – DADF Interlock Switch (P/O PL 20.3 Item 2) – Screw (P/O PL 20.3 Item 2) –...
Page 876: Pl 20.4 Document Feed Chute (Upper), Feed Motor
PL 20.4 Document Feed Chute (Upper), Feed Motor Item Part Description 054K13600 Document Feed Upper Chute Assembly 059K11840 Feed Roll Assembly – Upper Baffle (P/O PL 20.4 Item 1) – Drive Shaft (P/O PL 20.4 Item 1) – Gear (P/O PL 20.4 Item 1) 013E92760 Bearing –...
Page 877: Pl 20.5 Document Feed Chute (Lower)
PL 20.5 Document Feed Chute (Lower) Item Part Description 054K18780 Lower Chute Assembly (REP 5.8) – Lower Chute (P/O PL 20.5 Item 1) – Spring (P/O PL 20.5 Item 1) 059K19720 Retard Roll (REP 5.9) – Spring Plate (P/O PL 20.5 Item 1) –...
Page 878: Pl 20.6 Dadf Belt Motor, Duplex Roll
PL 20.6 DADF Belt Motor, Duplex Roll Item Part Description 127K32690 DADF Belt Motor Assembly (REP 5.13) – DADF Belt Motor (P/O PL 20.6 Item – Damper (P/O PL 20.6 Item 1) – Bracket (P/O PL 20.6 Item 1) – Pulley (P/O PL 20.6 Item 1) –...
Page 879: Pl 20.7 Duplex Chute
PL 20.7 Duplex Chute Item Part Description – Duplex Chute (Not Spared) – Wire Harness (Not Spared) 130K60600 Duplex Sensor (REP 5.14) 050K46690 Gate – Screw (Not Spared) – Screw (Not Spared) 054K18790 Lower Chute Assembly – Lower Chute (P/O PL 20.7 Item 7) –...
Page 880: Pl 20.8 Registration Roll
PL 20.8 Registration Roll Item Part Description – Spacer (Not Spared) 007K81120 Gear Pulley – Bearing (Not Spared) 059K19750 Registration Roll 012E09760 Link 809E04210 Rear Spring 005E80250 Clip 013E94561 Bearing 008E90941 Rear Cam 012E91960 Link 022K38040 Registration Pinch Roll (REP 5.15) 008E90931 Front Cam 809E04220...
Page 881: Pl 20.9 Exit Motor/Chute
PL 20.9 Exit Motor/Chute Item Part Description 127K32640 Exit Motor Assembly (REP 5.16) – Exit Motor (P/O PL 20.9 Item 1) – Pulley (P/O PL 20.9 Item 1) – Damper (P/O PL 20.9 Item 1) – Bracket (P/O PL 20.9 Item 1) –...
Page 882: Pl 20.10 Document Transport, Platen Belt
PL 20.10 Document Transport, Platen Belt Item Part Description – Damper (Not Spared) – Static Eliminator (Not Spared) 007E66340 Gear – Collar (Not Spared) 013E80970 Bearing 049E91070 Tension Plate 022K39710 Idler Roll 023E15690 Platen Belt (REP 5.19) – Drive Roll (Not Spared) –...
Page 883: Pl 20.11 Platen Glass, Registration Gate, Exit Tray
PL 20.11 Platen Glass, Registration Gate, Exit Tray Item Part Description 090K92820 Platen Glass (DC2240/1632) (REP 6.2) – 090K02290 Platen Glass (DC3535) (REP 6.2) 050K43070 Registration Gate (DC2240/1632) – 050K48890 Registration Gate (DC3535) 015K83700 Plate 673K51382 Exit Tray (DC3535) – 673K51383 Exit Tray (DC2240/1632) 003E43840...
Page 884: Common Hardware
Common Hardware 354W24254 K-Clip (4) 354W26251 E-Clip (5) Item Part Description 354W27251 E-Clip (6) 112W27651 Screw (M3x6) 354W27254 K-Clip (6) 112W27659 Screw (M3x6) 354W29251 E-Clip (8) 112W27851 Screw (M3x8) 113W20657 Screw (M3x6) 112W28451 Screw (M3x14) 113W16051 Screw (M2x10) 113W20457 Screw (M3x4) 158W45055 Screw (M5x10) 113W20651...
Page 885: Part Number Index
Part Number Index Table 1 Part Number Index Part Number Part List Table 1 Part Number Index PL 15.5 Part Number Part List 006K21720 PL 17.12 001E59600 PL 17.9 006K21730 PL 17.6 001E60050 PL 17.14 006K21970 PL 17.12 001K70542 PL 5.1 006E71740 PL 5.1 001K70551...
Page 886 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List PL 15.5 013E20250 PL 17.12 PL 16.7 013E80970 PL 20.10 PL 16.9 013E92760 PL 20.4 PL 2.4 013E94561 PL 20.8 007K85750 PL 1.1 014E42850 PL 16.1 007K86400...
Page 887 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 019K97540 PL 5.4 041K94050 PL 18.6 019K97550 PL 5.4 041K94260 PL 17.9 019K98190 PL 5.4 041K94271 PL 18.6 019K98200 PL 5.4 042K91990 PL 10.1 020E21050 PL 20.6...
Page 888 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 059K11840 PL 20.4 090K02290 PL 20.11 059K11860 PL 20.9 090K92820 PL 18.3 059K11880 PL 20.2 PL 20.11 059K15573 PL 15.1 101K38812 PL 9.2 PL 16.6 101K38821 PL 9.2...
Page 889 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 117E19780 PL 18.6 PL 16.11 117E20840 PL 18.3 PL 15.5 117K30960 PL 18.4 PL 2.4 117K31400 PL 9.2 PL 16.9 117E94370 PL 9.2 PL 16.7 118E12090 PL 18.6...
Page 890 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 130K61920 PL 17.6 160K66860 PL 12.2 130K62000 PL 18.4 160K74231 PL 13.1 130K62360 PL 17.4 160K75800 PL 18.2 130K62580 PL 18.4 160K76650 PL 13.1 130K63000 PL 6.2...
Page 891 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 162K69070 PL 17.4 802K12950 PL 5.2 162K69330 PL 9.2 802K13193 PL 2.3 300K63850 PL 18.2 802E23930 PL 15.10 413W10950 PL 18.5 PL 16.13 413W77359 PL 20.4 802E23940...
Page 892 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 802K46026 PL 18.2 892E89060 PL 10.1 802K46050 PL 10.1 892E89190 PL 15.1 802K46060 PL 10.1 PL 16.1 802K46070 PL 10.2 892E89200 PL 15.1 802K47090 PL 4.1 PL 16.1...
Page 893 6 General Procedures & Information Diagnostics dC612 Color Test Pattern Print ..................6-98 dC685 Color Registration ....................6-101 Entering Diagnostic Mode using the PWS ..............dC921 TC/ATC Sensor Setup ..................6-101 UI Diagnostic Mode......................dC922 TRC Control......................6-102 DC Quick (CODE Number LIST)..................dC924 TRC Adjust ......................
Page 894 General Procedures and Information Initial issue 02/03 DC 3535/2240/1632...
Page 895 After the PWS has disconnected from the machine, select Exit PWS to close the At the PWS, enter the GSNLock Password and select OK. tool. From the Start menu in the lower left corner, select Programs\Xerox Applications. Select the appropriate PWS for the machine. Initial issue...
Page 896 UI Diagnostic Mode Exiting UI Diagnostic mode CAUTION Diagnostic routines are mainly instructed/executed through the PWS. The UI Diagnostic mode Ensure that the machine is not inadvertently left in UI Diagnostic Mode. is provided for simple tasks that do not require connection with the PWS. There are three ways to exit from the UI Diagnostic mode.
Page 897 DC Quick (CODE Number LIST) Table 1 dC Routines dC Number Name Description Once in the Service Mode, dC Routines can be selected by dC Number or by selecting the appropriate tabs starting at the Service Entry Screen. Set Machine Serial Number. If you have replaced the PWB that has a Read Billing Meter Information Machine Serial Number, check the PWB...
Page 898: Dc100 Service Entry
Table 1 dC Routines dC100 Service Entry dC Number Name Description When entering Diagnostics, this routine allows you to view faults in progress, Non-Zero Jams and HFSI items requiring replacement. Service entry allows you to view product information, Configuration Page Allows viewing of current software version such as: and Market Place setting, Machine Con-...
Page 899: Dc118 Jam Counter
dC118 Jam Counter dC120 Fault Counter Purpose Purpose Displays the number of occurrences of Jams from time of previous Complete Closeout on ser- Displays the number of occurrences of each fault since the last Service Exit with the Complete vice exit until present. Closeout option selected.
Page 900: Dc122 Shutdown History
dC122 Shutdown History dC129 System Registration Setup Purpose Purpose To display the Last 40 Faults (History). Performs the Lead Registration and Side Registration adjustments by looking at the output of the built-in Test Pattern. NOTE: NOTE: For details on the dC129 System Registration adjustment, see ADJ 9.9 IOT Registra- faults detected while in Service Mode are not counted.
Page 901: Dc131 Nvm Read/Write
dC131 NVM Read/Write If the input value is valid (within the range), the system writes the new NVM value in the NVM location in the machine. Purpose If the input value is invalid, the system displays the following message in the infor- Reads, sets or changes the NVM data.
Page 902: 700-Xxx Ess Configuration Nvm List
700-xxx ESS Configuration NVM List Table 1 Chain 700 Chain-Link Name Default Range Description 700-006 Configuration [P, SP, CSP, CFSP] Set up at factory production. It allocates bits in the following P(rinter), F(ax), C(opy), S(can). P=1, F=2, C=4, S=8. 700-073 Page Memory Size 64*1024*102 bytes (Auto Setting)
Page 903 Table 1 Chain 700 Chain-Link Name Default Range Description 700-132 Operation Panel OK Beep 0=Off; 1=Low volume; 2=Medium volume; 3=High volume 700-133 Operation Panel NG Beep 0=Off; 1=Low volume; 2=Medium volume; 3=High volume 700-134 Job Complete Beep with Copy 0=Off; 1=Low volume; 2=Medium volume; 3=High volume 700-135 Job Complete Beep without Copy 0=Off;...
Page 904 Table 1 Chain 700 Chain-Link Name Default Range Description 700-312 Battery Backup SRAM Serial # (2nd Alphanumerics (ASCII) digit) 700-313 Battery Backup SRAM Serial # (3rd Alphanumerics (ASCII) digit) 700-314 Battery Backup SRAM Serial # (4th Alphanumerics (ASCII) digit) 700-315 Battery Backup SRAM Serial # (5th Alphanumerics (ASCII) digit)
Page 905 Table 1 Chain 700 Chain-Link Name Default Range Description 700-338 Market Region (SEEPROM) XC=2 1=FX; 2=XC; 3=XE; 4=AP XE=3 700-339 IOT ROM Major version (Auto Setting) 700-340 IOT ROM Minor version (Auto Setting) 700-341 IOT ROM Revision version (Auto Setting) 700-342 Sys Main ROM Major (Auto Setting)
Page 906: 710-Xxx Dadf Nvm List
710-xxx DADF NVM List Table 1 Chain 710 Chain-Link Name Default Range Description 710-001 ADF Fail Bypass 0=Bypass On 1=Bypass Off 710-002 JAM Bypass 0=Bypass On 1=Bypass Off 710-005 Regi Sensor Off to Belt Motor Slow- 217~283 No. of Steps after the Regi Sensor turned Off and until the Belt Motor started to reduce speed in the Non CVT down Step (Non CVT Mode) Mode.
Page 907 Table 1 Chain 710 Chain-Link Name Default Range Description 710-809 ADF Duplex Sensor Static Jam Count 0~65535 cumulative Jam Counter at the previous clearing (Write not permitted) Since Reset 710-810 ADF Regi sensor On NonInvert Dynam- 0~65535 cumulative Jam Counter (Write not permitted) icJam Count Total 710-811 ADF Regi sensor On Dynamic Jam...
Page 908: 715-Xxx Iit Nvm List
Rear NUT Revolution Angle (990~1980=Right revolution angle; 0~990=Left revolution angle) 715-144 IIT Paper Code XC=2; XE=4 0=P paper; 1=J paper; 2=Digital Color Xpression; 3=Xerox 4200; 4=ColorTech+; 5=Xerox Business 715-200 External Area of FS Sampling 0~511 Speed Priority AE/Fast Scan direction undetected area...
Page 909 Table 1 Chain 715 Chain-Link Name Default Range Description 715-214 Undercolor Data for B/W 0~255 Speed Priority AE/Fixed background color data in B/W Register Mode 715-215 Undercolor Data for Color 0~255 Speed Priority AE/Fixed background color data in Color Register Mode 715-216 Undercolor removal level for color copy 0 0=std.
Page 910 Table 1 Chain 715 Chain-Link Name Default Range Description 715-247 B/W-Offset for Text/Image DADF Single 0~255 For AE offset data DADF Single Side Document text/photo in B/W model Side mode (Real Time AE) 715-248 B/W-Offset for Text DADF Single Side 0~255 For AE offset data DADF Single Side Document text in B/W model mode(Real Time AE)
Page 911 Table 1 Chain 715 Chain-Link Name Default Range Description 715-805 EEPROM Failure Count Since Reset 0~65535 cumulative Fail Counter at the previous clearing (Write not permitted) 715-806 Fan Failure Count Overall Total 0~65535 cumulative Fail Counter (Write not permitted) 715-807 Fan Failure Count Since Reset 0~065535 cumulative Fail Counter at the previous clearing (Write not permitted)
Page 912 Table 1 Chain 715 Chain-Link Name Default Range Description 715-829 Platen AGC Channel 4 Fail Count 0~65535 cumulative Fail Counter at the previous clearing (Write not permitted) Since Reset 715-830 Platen AGC Channel 5 Fail Count 0~65535 cumulative Fail Counter (Write not permitted) Overall Total 715-831 Platen AGC Channel 5 Fail Count...
Page 913: 719--Xxx Iit/Dadf Software Nvm List
Table 1 Chain 715 Chain-Link Name Default Range Description 715-859 DADF RAM CHECK Failures Since 0~65535 cumulative Fail Counter at the previous clearing (Write not permitted) Reset 715-900 Scan Life Count (upper digits) 0~65535 Scan Count Replacement Life (Upper Level) (Write not permitted) 715-901 Scan Life Count (lower digits) 40704...
Page 914: 740--Xxx Iot Manager Nvm List
740--xxx IOT Manager NVM List Table 1 Chain 740 Chain-Link Name Default Range Description 740-020 Market Code XC=2; XE=3 XC=2; XE=3 740-024 RegiCon Request Flag 0~255 0=Performed; 1=Not performed 740-025 Edge Check Request Flag 0~255 0=Performed; 1=Not performed 740-026 ProCon Request Flag 0~255 0=Performed;...
Page 915: 742--Xxx Paper Handling Nvm List
742--xxx Paper Handling NVM List Table 1 Chain 742 Chain-Link Name Default Range Description 742-001 Invert Clutch CW Off Timing 0~163 Paper inversion position adjustment (P Speed) (1bit=2.4462 msec.) 742-002 Invert Clutch CW Off Timing (MF-1) 0~259 Paper inversion position adjustment (Double Speed) DC2240/1632: (1bit=1.31136 msec.) DC3535: (1bit=1.5418 msec.) 742-003...
Page 916 Table 1 Chain 742 Chain-Link Name Default Range Description 742-026 Adjust Side Regi (Tray 5) 0~50 Side Regi Adjustment (Tray 5) (1bit=0.211mm) 742-027 Adjust Side Regi (Dup) 0~50 Side Regi Adjustment (Dup) (1bit=0.211mm) *default=18 for DC2240/1632; 22 for DC3535 742-028 Adjust Lead Regi (All) 0~40 Lead Regi Adjustment (ALL, Offset value) (1bit=0.2544mm)
Page 917 Table 1 Chain 742 Chain-Link Name Default Range Description 742-059 Pre-T/A Start Timing TTM-Tray 3 0~115 Adjusts the Time between Pre-T/A Starts and Standard Signal (IOT) (457~957 msec.) (1bit=2.4462 msec.) 742-060 Pre-T/A Start Timing TTM-Tray 4 0~115 Adjusts the Time between Pre-T/A Starts and Standard Signal (IOT) (431~931 msec.) (1bit=2.4462 msec.) 742-062 Adjust Pre-Feed Position 3TM-Tray 2 0~40...
Page 918 Table 1 Chain 742 Chain-Link Name Default Range Description 742-094 Pre-T/A Start Timing 3TM-Tray 3 0~183 Adjusts the Time between Pre-T/A Starts and Standard Signal (IOT) (365~865 msec.) (1bit=1.5418 msec.) DC3535 742-095 Pre-T/A Start Timing 3TM-Tray 4 0~215 Adjusts the Time between Pre-T/A Starts and Standard Signal (IOT) (429~929 msec.) (1bit=1.31136 msec.) DC2240/1632 742-095 Pre-T/A Start Timing 3TM-Tray 4...
Page 919 Table 1 Chain 742 Chain-Link Name Default Range Description 742-110 Pre-T/A Start Timing TTM-Tray 4 (Half) 37 0~58 Adjusts the Time between Pre-T/A Starts and Standard Signal (IOT) (431~931 msec.) (1bit=4.8924 msec.) 742-111 Main Feed Start Timing 3TM-Tray 2 0~22 Sets time between Main Feed Start and Pre-T/A (330~830 msec.).
Page 920: 744--Xxx Fuser Nvm List
744--xxx Fuser NVM List Table 1 Chain 744 Chain-Link Name Default Range Description 744-001 STS-1 Cont Temp- Low Pwr Mode 0~160 Main-Lamp temperature control in Low-Power Mode. Setting the default as 0 degrees Celsius is same as Fuser- (1 bit=1 deg. C) Off.
Page 921 Table 1 Chain 744 Chain-Link Name Default Range Description 744-050 STS-2 Target run temperature#22 100~200 For optimization of temperature distribution - Transparency SEF (1 bit=1 deg.C). DC3535 only 744-051 Environment temperature correction Environment dependent correction coefficient for level of fusing. Temperature AD value shift amount when the environment temperature varies 1 degrees Celsius from 20 degrees Celsius.
Page 922 Table 1 Chain 744 Chain-Link Name Default Range Description 744-196 Plain Paper S Setting Temperature 0=Light Weight paper (55~63gsm) 1=Plain paper (64~80gsm) 2=Bond (81~105gsm) DC2240/1632 only 744-197 104mm/sec. OHP pitch adjustment 0~10 OHP blocking measures; It prevents OHP blocking by lowering the PPM with increase of pitch. A4LEF=PPM=66/ value (1 count=1 (4+NVM value) A4SEF=PPM=66/(5+NMV value)
Page 923 Table 1 Chain 744 Chain-Link Name Default Range Description 744-239 Applied Time for 104mm/sec. OHP Skip 1~100 (1 bit=5 sec.) DC3535 only modeTarget Run Temp.(T[Run#4]) 744-239 Applied Time for 104mm/sec. OHP Skip 1~100 (1 bit=5 sec.) DC3535 only modeTarget Run Temp.(T[Run#5]) 744-248 Condensation Guard Mode 0~10...
Page 924 746--xxx Xero Transfer NVM List Table 1 Chain 746 Chain-Link Name Default Range Description 746-006 2nd Resistance detection calculation 102~921 Measures the resistance of the Secondary Transfer part composed of 2nd BTR and Backup Roll at printable - DC2240/1632 results (1bit=-4.888V) 1000V and display the voltage at Secondary Transfer corresponding that resistance.
Page 925 Table 1 Chain 746 Chain-Link Name Default Range Description 746-028 1ST BTR Output Remote Half-speed 0~200 (1bit=1%) For primary transfer output adjustment of K Color at FC52mmsec. Displays the multiplication value in primary FC K transfer current of 746-020. ex., At 50=Primary Transfer Current=14 µAx0.5=7 µA 746-029 1ST BTR Output Remote High-speed 0~255 (1bit=1%)
Page 926 Table 1 Chain 746 Chain-Link Name Default Range Description 746-072 Remote for Transparency Side1 0~200 (1bit=1%) For Secondary Transfer output adjustment of Transparency side 1. Displays the multiplication value in second- ary transfer resistance calculation result of 746-006. 746-073 Remote for Tack Film Side1 0~200 (1bit=1%) For Secondary Transfer output adjustment of Tack Film side 1.
Page 927 Table 1 Chain 746 Chain-Link Name Default Range Description 746-091 Plain paper S Control NVM1 (BW 0=Control -S-7 (For BW side 1 of Plain paper A~G) Side1) 1=Control -S-8 (For BW side 1 of paper applicable to the above) 746-092 Plain paper S Control NVM1 (FC Side2) DC2240/ 0=Control -S-9 (FCside2 secondary transfer output for P paper) 1632=5...
Page 928 Table 1 Chain 746 Chain-Link Name Default Range Description 746-967 1st BTR Vmonitor Y 4~178 Displays the voltage at primary transfer resistance detection (100~5000V - 1bit=28.01V) 746-968 1st BTR Vmonitor M 4~178 Displays the voltage at primary transfer resistance detection (100~5000V - 1bit=28.01V) 746-969 1st BTR Vmonitor C 4~178...
Page 929 747--xxx Transfer NVM List (DC 3535 Only) Table 1 Chain 747 Chain- Link Name Default Range Description 747-417 DTS Present Output 0~818 Display Environment * Remote (3.666V/bit) 747-418 Remote for resistance -high-speed FC 100~255 Available when 2nd transfer system resistance is 746-955. Ex.2nd transfer resistance detection calculation result x 746-067 x 746-955=2nd Transfer Output Voltage (v) 747-419 1st BTR Remote/high-speed/ FC/ Y...
Page 930 Table 1 Chain 747 Chain- Link Name Default Range Description 747-441 2nd BTR Output Remote/normal speed/ 0~200 For 2nd transfer output adjustment for Heavy paper 1B Side1. (Multiply by 2nd transfer resistance calculation Side1/Heavy paper 1B result in loc. 746-006)/100. Ex.- In case of 100: 2nd transfer current=245 x -6.515 x 1.0=-1200V 747-442 2nd BTR Output Remote/normal speed/ 0~200...
Page 931 Table 1 Chain 747 Chain- Link Name Default Range Description 747-462 High speed 1st Transfer B/W K ECC #4 1000 0~2000 Environment Control Coefficient of 1st transfer output for K Ex.: In case of 1000: µA=((value in 746-020)+(value in 746-303))x(value in 746-029)x 1.0 747-463 High speed 1st Transfer B/W K ECC #5 1000...
Page 932 Table 1 Chain 747 Chain- Link Name Default Range Description 747-483 Low speed 1st Transfer B/W K ECC #7 1000 0~2000 Environment Control Coefficient of 1st transfer output for K Ex.: In case of 1000: µA=((value in 746-020)+(value in 746-303))x(value in 746-031)x 1.0 747-484 Low speed 1st Transfer B/W K ECC #8 1000...
Page 933 Table 1 Chain 751 Chain-Link Name Default Range Description 751-202 #C_BCR DC corrected VH value 0~1023 VH Output Value of #C Engine after Correction (All Speed common) (1 Count=-1.173V) 751-203 #K_BCR DC corrected VH value 0~1023 VH Output Value of #K Engine after Correction (All Speed common) (1 Count=-1.173V) Initial issue General Procedures and Information 02/03...
Page 934: 752-Xxx Procon Nvm List
752-xxx Procon NVM List Table 1 Chain 752 Chain-Link Name Default Range Description 752-027 Vdark Average 0~1023 ADC average detected value at expansion LED Off. 752-028 Vref Average 0~1023 ADC average detected value of reference board reflection at expansion 752-029 Vcln Average 0~1023 ADC average detected value of belt reflection at expansion...
Page 935 Table 1 Chain 752 Chain-Link Name Default Range Description 752-081 ATC Average [Y] 0~1023 ATC Average detected value after sensor sensitivity correction 752-082 ATC Average [M] 0~1023 ATC Average detected value after sensor sensitivity correction 752-083 ATC Average [C] 0~1023 ATC Average detected value after sensor sensitivity correction 752-084 ATC Average [K]...
Page 936 Table 1 Chain 752 Chain-Link Name Default Range Description 752-156 ATC Control Nominal Value [Y] 0~1023 [Set ATC Control Nominal Value]+[ATC Environment Correction Value]+[ATC Deterioration Correction Value]+[ATC Nominal Value offset] 752-157 ATC Control Nominal Value [M] 0~1023 [Set ATC Control Nominal Value]+[ATC Environment Correction Value]+[ATC Deterioration Correction Value]+[ATC Nominal Value offset] 752-158 ATC Control Nominal Value [C]...
Page 937 Table 1 Chain 752 Chain-Link Name Default Range Description 752-441 Warn LD light amount Setting [C] Warning when the Laser Diode light quantity reached Upper or Lower Limit. 752-442 Warn LD light amount Setting [K] Warning when the Laser Diode light quantity reached Upper or Lower Limit. 752-453 VBias [Y] 0~1023...
Page 938 Table 1 Chain 752 Chain-Link Name Default Range Description 752-873 SW Charge Potential Control ON/OFF 0=Control VH (Add "delta-VH" to VH according to "LD illumination"; 1=No control for VH ("delta-VH"=0) DC3535 only 752-934 RADC Nominal Target [Y] 0~1023 RADC target value set as center DC3535 only 752-935 RADC Nominal Target [M]...
Page 939: 753-Xxx Procon 2 Nvm List
753-xxx ProCon 2 NVM List Table 1 Chain 753 Chain-Link Name Default Range Description 753-001 ADC Tone Correction Switch 2 Patch ADC Gradation Correction. On/Off Switch (0=On, 1=Off) 753-002 IOT Manual ADJ LUT Switch IOT Manual Adjustment LUT On/Off Switch (0=On, 1=Off) 753-004 P LUTCin [K] [E] 0~255...
Page 940 Table 1 Chain 753 Chain-Link Name Default Range Description 753-029 TRC Target RADC [K] [B] 0~1023 Target RADC for Gradation Correction *default=310 for DC2240/1632; 460 for DC3535 753-030 TRC Current RADC [Y] [A] 0~1023 Current RADC for Gradation Correction *default=780 for DC2240/1632; 650 for DC3535 753-031 TRC Current RADC [Y] [B] 0~1023...
Page 941 Table 1 Chain 753 Chain-Link Name Default Range Description 753-840 TRC_Target RADC [Y] [FC] 0~1023 Current RADC for tone calibration DC3535 only 753-841 TRC_Target RADC [M] [C] 0~1023 Current RADC for tone calibration DC3535 only 753-842 TRC_Target RADC [M] [F] 0~1023 Current RADC for tone calibration DC3535 only...
Page 942: 755-Xxx Crum Nvm List
755-xxx CRUM NVM List Table 1 Chain 755 Chain-Link Name Default Range Description 755-001 #Y_Drum Life Count - kCy To determine Drum Life * Range=0~3000 for DC 2240/1632; 0~65535 for DC 3535 755-002 #Y_Drum Cycle Count - Total 0~4294967295 Total P/R cumulative No. of Rotations 755-003 DC Drum Cycle Count 0~4294967295...
Page 943 Table 1 Chain 755 Chain-Link Name Default Range Description 755-036 #M_Shutdown Count - Full Color 0~65535 Accumulates the # of shutdowns during FC jobs. 755-037 #M_Shutdown Count - Black 0~65535 Accumulates the # of shutdowns during B/W jobs. 755-038 #M_Setup Count - Full Color 0~65535 Accumulates the # of Setups immediately after FC jobs.
Page 944 Table 1 Chain 755 Chain-Link Name Default Range Description 755-083 #K_Drum Cycle Count - Total 0~ 4294967295 cumulative # of P/R cycles (1bit=0.1cycle) 755-084 #K_DC Drum Cycle Count 0~ 4294967295 cumulative # of DC charge current P/R cycles (1bit=0.1cycle) 755-085 #K_AC Drum Cycle Count 0~ 4294967295 cumulative # of AC charge current P/R cycles (1bit=0.1cycle)
Page 945 Table 1 Chain 755 Chain-Link Name Default Range Description 755-210 #Y_Area Coverage Count, 4C (51- 0~65535 Area Coverage counter for 4C (51-100%) (1 bit=1 page) DC3535 only 100%) 755-211 #Y_CRU Install - Color Y=1; M=2; 3=C; 4=K DC3535 only 755-301 #M_Area Coverage Count, 4C (0-5%) 0~65535 Area Coverage counter for 4C (0 to 5%) (1 bit=1 page)
Page 946 Table 1 Chain 755 Chain-Link Name Default Range Description 755-410 #C_Area Coverage Count, 4C (51- 0~65535 Area Coverage counter for 4C (51-100%) (1 bit=1 page) DC3535 only 100%) 755-411 #C_CRU Install - Color Y=1; M=2; 3=C; 4=K DC3535 only 755-501 #K_Area Coverage Count, 4C (0-5%) 0~65535 Area Coverage counter for 4C (0 to 5%) (1 bit=1 page)
Page 947: 760-Xxx Regicon Nvm List
760-xxx Regicon NVM List Table 1 Chain 760 Chain-Link Name Default Range Description 760-001 Lposi 3004 0~3004 Permissible misregistration between the center of optical axis of MOB sensor and the center of fine setup pat- DC3535 tern (difference between left and right counter values) 760-002 NGcnt 50000...
Page 948 Table 1 Chain 760 Chain-Link Name Default Range Description 760-026 K-YSO 0~474 Adjusts the slow scan direction write start position by the #. of LS signal counts from the ROS/Image/Patch Start signal. (1 pixel/bit) 760-027 Regi Con/Circum. Length Correction For check during servicing etc. 0=Does not perform Regi Control nor Circumference Length Correction 1=Per- implement SW forms Regi Control, does not perform Circumference Length Correction 2=Does not perform Regi Control, per- forms Circumference Length Correction 3=Performs Regi Control and Circumference Length Correction...
Page 949 Table 1 Chain 760 Chain-Link Name Default Range Description 760-050 M-XBI Adjusts fast scan direction write start position by switching the video clock phase from SOS signal. (DC 2240/1632=1 pixel/bit; DC 3535=1/5 pixel/bit) 760-051 C-XBI Adjusts fast scan direction write start position by switching the video clock phase from SOS signal. (DC 2240/1632=1 pixel/bit;...
Page 950 Table 1 Chain 760 Chain-Link Name Default Range Description 760-060 K-OLXBI Adjust writing-start position in FS direction in Open Loop, by switching video lock phase from SOS signal, based on temperature detection results, separately from normal Regi Con cycle (DC 2240/1632=1 pixel/bit; DC 3535=1/5 pixel/bit). This NVM is defined with the correction amount from the current set values XBI-, XSO-;...
Page 951 Table 1 Chain 760 Chain-Link Name Default Range Description 760-069 Skew Alarm threshold 0~255 Threshold of Skew amount; if this value is exceeded, it is registered as a failure. (2µm/bit) DC3535 760-070 Y-LD light volume at last RegiCon 0~1023 Laser Diode light quantity when Regi Control is performed. 760-071 M-LD light volume at last RegiCon 0~1023...
Page 952 Table 1 Chain 760 Chain-Link Name Default Range Description 760-101 M-Y margin speed switch variation 0~200 (Y margin variation amount when the speed is switched from 104 or 52mm/sec. to 165mm/sec.)-100, for DC3535 Magenta (1 µm/bit) 760-102 K-Y margin speed switch variation 0~200 (Y margin variation amount when the speed is switched from 104 or 52mm/sec.
Page 953 Table 1 Chain 760 Chain-Link Name Default Range Description 760-122 Register set value for YSO-ROS at Y 0~474 PS register set value; for debugging DC3535 165mm/s 760-123 Register set value for YSO-ROS at M 0~474 PS register set value; for debugging DC3535 165mm/s 760-124...
Page 954: 762-Xxx Developer Nvm List
762-xxx Developer NVM List Table 1 Chain 762 Chain-Link Name Default Range Description 762-002 #YMC Normal VM1 value 0~1023 Vm1 Developer DC energized voltage at YMC Color/Normal speed (104mm/sec.) (1bit=-0.684V) 762-008 #YM_DB AC Normal Vp-p value 0~1023 AC peak to peak energized voltage at YM Color/Normal speed. (1bit=1.491Vpp) 762-009 #YM_DB AC Normal monitor value...
Page 955 Table 1 Chain 762 Chain-Link Name Default Range Description 762-061 AC Bias normal test value 0~100 AC Voltage test value at normal speed 762-062 AC Bias normal frequency 0~127 AC Voltage frequency at normal speed 762-064 #YM_DB AC Half-speed Frequency 0~127 AC Energized Voltage Frequency at YM Color Half Speed 762-065...
Page 956 Table 1 Chain 762 Chain-Link Name Default Range Description 762-102 #M_DB DC Vm1 Off half speed timing 0~255 Fall timing from Vm1 to Vm0 for M Color half speed. (1bit=4.8924 msec.) 762-103 #C_DB DC Vm1 Off half speed timing 0~255 Fall timing from Vm1 to Vm0 for C Color half speed.
Page 957: 764-Xxx Output (Finisher) Nvm List
Table 1 Chain 762 Chain-Link Name Default Range Description 762-232 #YM_DB AC Hi-speed Output Phase 0~127 AC energized voltage phase value at YM Color High Speed. Value 762-233 #CK_DB AC Hi-speed Frequency 0~127 AC energized voltage frequency at CM Color High Speed. * Default=63 for DC 2240/1632;...
Page 958: 770-Xxx Ess Io Port/Protocol Setting Nvm List
770-xxx ESS IO Port/Protocol Setting NVM List Table 1 Chain 770 Chain-Link Name Default Range Description 770-001 Parallel Port Enable 0=Stop 1=Start Up 770-002 Parallel Print ModeType 1~23 1=Auto; 3=HPGL2; 5=PostScript; 8=ESCP; 10=TIFF; 14=Dump; 15=ART; 16=PLW 770-003 Parallel PJL Switch 0=Off;...
Page 959 Table 1 Chain 770 Chain-Link Name Default Range Description 770-090 IPP Port Enable 0=Stop; 1=Start Up 770-091 IPP Print Mode Type 1=Auto; 3=HPGL2; 5=PostScript; 8=ESCP; 10=TIFF; 16=ART; 17=PLW; 23=Dump 770-092 IPP JCL Enable is IPP PJL Enable for 0=Off; 1=On 770-093 IPP TBCP Valid Flag 0=None;...
Page 960: 780-Xxx Ess Print Frame Setting Nvm List
780-xxx ESS Print Frame Setting NVM List Table 1 Chain 780 Chain-Link Name Default Range Description 780-013 Paper Type for Tray 1 1~27 1=Plain Paper; 2=Transparency; 6=Label; 8=Coated 1; 10=HW1;12=HW2;14=Recycled Paper; 21=Light- DC2240/1632 weight; 22=Bond; 23~27=Custom Paper 1~5; 31=Coated 2; 35=Coated 1(F); 36=HW1A; 37=HW1B; 38=HW1C;...
Page 961 Table 1 Chain 780 Chain-Link Name Default Range Description 780-036 Image Quality Control Category - 4~31 27=Heavy Weight 2A; 28=Gloss 1C; 29=Gloss 1A; 30=Coated 1 Gloss; 31=Heavy Weight 2S Heavy Weight 2 paper 780-037 Image Quality Control Category - 4~200 200=Heavy Weight 2A;...
Page 962: 790-Xxx Ess Panel Display Setting Nvm List
790-xxx ESS Panel Display Setting NVM List Table 1 Chain 790 Chain-Link Name Default Range Description 790-001 Startup Display Setting 0=Features Programming Screen; 1=Job Management Screen; 2=Machine Status Screen 790-002 Function Setup Startup Display 0=Menu; 1=Copy; 3=Scanner 790-004 Toner Near Empty advance notification 1 0=No display;...
Page 963 Table 1 Chain 790 Chain-Link Name Default Range Description 790-014 Tray 5 Paper sizes _9 0~50 1=Postcard; 2=A6SEF; 3=A6LEF; 4=B6SEF; 5=B6LEF; 6=A5SEF; 7=A5LEF; 8=B5SEF; 9=B5LEF; 10=A4SEF; 11=A4LEF; 12=B4SEF; 13=A3SEF; 14=Postcard (4x6); 15=5.5x8.5SEF; 16=5.5x8.5LEF; 17=8.5x11SEF; 18=8.5x11LEF;19=8.5x13"SEF; 20=8.5x14"; 21=11x15"SEF; 22=11x17"SEF; 23=AP Envelope (Cho-3 gou); 24=8-K SEF;...
Page 964 Table 1 Chain 790 Chain-Link Name Default Range Description 790-094 Default B/W Document Type 0=Text; 1=Text/Photo (Print); 2=Text/Photo (Photo Paper); 3=Text/Photo (Copy Document); 4=Photo (Print); 5=Photo (Photo Paper); 6=Photo (Copy Document) 790-096 Default 4 Color/Auto Document Type 0=Text; 1=Text/Photo (Print); 2=Text/Photo (Photo Paper); 3=Text/Photo (Copy Document); 4=Photo (Print); 5=Photo (Photo Paper);...
Page 965 Table 1 Chain 790 Chain-Link Name Default Range Description 790-132 Fixed Size 2 of Copy Document Size 1~50 1=Postcard; 2=A6SEF; 3=A6LEF; 4=B6SEF; 5=B6LEF; 6=A5SEF; 7=A5LEF; 8=B5SEF; 9=B5LEF; 10=A4SEF; Input 11=A4LEF; 12=B4SEF; 13=A3SEF; 14=Postcard (4x6); 15=5.5x8.5SEF; 16=5.5x8.5LEF; 17=8.5x11SEF; 18=8.5x11LEF;19=8.5x13"SEF; 20=8.5x14"; 21=11x15"SEF; 22=11x17"SEF; 23=AP Envelope (Cho-3 gou); 24=8-K SEF;...
Page 966 Table 1 Chain 790 Chain-Link Name Default Range Description 790-141 Fixed Size 11 of Copy Document Size 1~50 1=Postcard; 2=A6SEF; 3=A6LEF; 4=B6SEF; 5=B6LEF; 6=A5SEF; 7=A5LEF; 8=B5SEF; 9=B5LEF; 10=A4SEF; Input 11=A4LEF; 12=B4SEF; 13=A3SEF; 14=Postcard (4x6); 15=5.5x8.5SEF; 16=5.5x8.5LEF; 17=8.5x11SEF; 18=8.5x11LEF;19=8.5x13"SEF; 20=8.5x14"; 21=11x15"SEF; 22=11x17"SEF; 23=AP Envelope (Cho-3 gou); 24=8-K SEF;...
Page 967 Table 1 Chain 790 Chain-Link Name Default Range Description 790-231 Fixed Size 1 of Scan Document Size 1~50 1=Postcard; 2=A6SEF; 3=A6LEF; 4=B6SEF; 5=B6LEF; 6=A5SEF; 7=A5LEF; 8=B5SEF; 9=B5LEF; 10=A4SEF; Input 11=A4LEF; 12=B4SEF; 13=A3SEF; 14=Postcard (4x6); 15=5.5x8.5SEF; 16=5.5x8.5LEF; 17=8.5x11SEF; 18=8.5x11LEF;19=8.5x13"SEF; 20=8.5x14"; 21=11x15"SEF; 22=11x17"SEF; 23=AP Envelope (Cho-3 gou); 24=8-K SEF;...
Page 968 Table 1 Chain 790 Chain-Link Name Default Range Description 790-240 Fixed Size 10 of Scan Document Size 1~50 1=Postcard; 2=A6SEF; 3=A6LEF; 4=B6SEF; 5=B6LEF; 6=A5SEF; 7=A5LEF; 8=B5SEF; 9=B5LEF; 10=A4SEF; Input 11=A4LEF; 12=B4SEF; 13=A3SEF; 14=Postcard (4x6); 15=5.5x8.5SEF; 16=5.5x8.5LEF; 17=8.5x11SEF; 18=8.5x11LEF;19=8.5x13"SEF; 20=8.5x14"; 21=11x15"SEF; 22=11x17"SEF; 23=AP Envelope (Cho-3 gou); 24=8-K SEF;...
Page 969: 800-Xxx Ess Print Service Setting
Table 1 Chain 790 Chain-Link Name Default Range Description 790-277 Default 5 setting of SCAN Fixed magni- 0~18 1=25.0; 2=35.3; 3=50.0; 4=57.7; 5=61.2 6=64.7; 7=70.7; 8=81.6; 9=86.6 10=115.4; 11=122.5; 12=129.4 fication 13=141.4; 14=163.2; 15=173.2 16=200.0; 17=282.8; 18=400.0% 790-278 Default 6 setting of SCAN Fixed magni- 0~18 1=25.0;...
Page 970: 810-Xxx Ess Copy Service Setting
810-xxx ESS Copy Service Setting Table 1 Chain 810 Chain/Link Name Default Range Description 810-002 Fixed preset color1 (Red) Y component 102 0~128 0%~100%; 0.78%/bit (80%) 810-003 Fixed preset color1 (Red)M Component 128 0~128 0%~100%; 0.78%/bit (100%) 810-004 Fixed preset color1 (Red)C component 0 0~128 0%~100%;...
Page 971 Table 1 Chain 810 Chain/Link Name Default Range Description 810-027 User Preset Color 3 - M component 0~128 0%~100%; 0.78%/bit 810-028 User Preset Color 3 - C component 0~128 0%~100%; 0.78%/bit 810-029 User Preset Color 4 - Y component 0~128 0%~100%;...
Page 972 Table 1 Chain 810 Chain/Link Name Default Range Description 810-063 Color balance (M high density) MERI- 0=Lighter 3; 1=Lighter 2; 2=Lighter 1; 3=Normal; 4=Darker 1; 5=Darker 2; 6=Darker 3 HARI Copy 810-064 Color balance (C low density) MERI- 0=Lighter 3; 1=Lighter 2; 2=Lighter 1; 3=Normal; 4=Darker 1; 5=Darker 2; 6=Darker 3 HARI Copy 810-065 Color balance (C med.
Page 973 Table 1 Chain 810 Chain/Link Name Default Range Description 810-088 Color Shift - Ruddiness 0=-20 degrees; 1=-10 degrees; 2=0 degrees; 3=+10 degrees; 4=+20 degrees 810-089 Color Saturation - Ruddiness 0=Higher 2; 1=Higher 1; 2=Normal; 3=Lower 1; 4=Lower 2 810-090 Sharpness - Ruddiness 0=Sharper 2;...
Page 974: 840-Xxx Ess Scan Setting Nvm List
Table 1 Chain 810 Chain/Link Name Default Range Description 810-128 Operation when Memory Overflow 0=Stop; 1=Print occurs 810-129 Max. No. of Copy Sheets accumulated 999 1~999 1-999=[1~999 pages] 810-130 Build Job Setup Menu Display 0=No display; 1=Display 840-xxx ESS Scan Setting NVM List Table 1 Chain 840 Chain/Link Name...
Page 975: 850-Xxx Ess Foreign Interface Nvm List
850-xxx ESS Foreign Interface NVM List Table 1 Chain 840 Chain/Link Name Default Range Description 850-001 Foreign Interface Enable 0=Enable; 1=Disable 850-009 Print Control Feature Enable 0=No Control; 1=Control 850-010 Interrupt Enable when Subtractive 0=Enable; 1=Disable device connected 850-015 Scan Control Feature Enable 0=No Control;...
Page 976: 870-Xxx Ess Diagnosis Setting Nvm List
870-xxx ESS Diagnosis Setting NVM List Table 1 Chain 870 Chain/Link Name Default Range Description 870-001 Normal Normal, Diag (Auto setting) 870-010 CRU #1 PR Wear previous value 0~99999999 870-011 CRU #2 PR Wear previous value 0~99999999 870-012 CRU #3 PR Wear previous value 0~99999999 870-013 CRU #4 PR Wear previous value...
Page 977: Dc132 Serial Number/Billing Meter Synchronization
dC132 Serial Number/Billing Meter Synchronization dC135 HFSI Counters Purpose Purpose Checks the Billing Meters and sets the Machine Serial Number when fault 103-208 occurs. This routine displays the service life (Threshold) and the current value (count) of the periodic This routine also reads the Billing Meters and can be accessed at any time for this purpose. replacement parts.
Page 978: Dc140 Analog Monitor
dC140 Analog Monitor dC188 Exiting from Service Mode Purpose Procedure Monitors the analog values of the A/D converter sensors by driving each component (e.g.;, Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS. C.C). Temporary change of output values is possible. Output component check is also possi- Select the Service Exit Tab on the Screen.
Page 979: Dc301 Nvm Initialization
dC301 NVM Initialization Table 1 NVM Initialization Name Description Purpose SYS-System The following NVM locations will be initialized: This procedure may be needed when the machine cannot recover for some unknown reasons, including problems such as producing blank copies/prints, continuously declaring system •...
Page 980: Dc305 Ui Component Check
dC305 UI Component Check dC330 Component Control Purpose Purpose Checks the operations of the UI Screen and Control Panel buttons. The purpose of the dC330 Component Control is to display the logic state of input signals and to energize output components. Procedure NOTE: Refer to Table 1...
Page 981 NOTE: When exiting dC330, the machine resets and communication between the PWS and Table 1 Input Component Control Codes the machine is momentarily lost. The PWS will reconnect automatically. Code Name Description 007-103 Tray 1 Size Switch 4 ON = AN value 007-104 Tray 2 Size Switch 1 ON = AN value...
Page 982 Table 1 Input Component Control Codes Table 1 Input Component Control Codes Code Name Description Code Name Description 009-101 Toner_Y New CRU Connection of color is open (The CRU in 012-224 Stapler Move Sensor Non-transmissive position. ON = High use is present, or it is not present). Low=new, 012-225 Stapler Front Corner Sensor Front Corner position.
Page 983 Table 2 Output Component Control Codes Table 2 Output Component Control Codes Code Name Description Conflicts Code Name Description Conflicts 004-011 Drum Motor YMC Rotate at low speed. Remove all Drum Car- 004-003 006-031 Polygon Motor (52mm/sec.) tridges before energizing to prevent Belt Start Signal damage.
Page 984 Table 2 Output Component Control Codes Table 2 Output Component Control Codes Code Name Description Conflicts Code Name Description Conflicts 008-011 Dup Motor 8-009, 010, 008-034 TTM TA Motor 8-029, 030, (200.1mm/sec.) 012, 053, 054, (104mm/sec.) Long 031, 032, 033, Long 055, 056 035, 036...
Page 985 Table 2 Output Component Control Codes Table 2 Output Component Control Codes Code Name Description Conflicts Code Name Description Conflicts 009-002 #M_Disp MOT M Color Disp. MOT turns ON, and switches 009-037 Dev DC chg (K) OFF automatically after 5sec. 009-038 BCR ACDC K CHG DEVE_AC_K changes at connector termi- 009-003...
Page 986 Table 2 Output Component Control Codes Table 2 Output Component Control Codes Code Name Description Conflicts Code Name Description Conflicts 012-011 Rear Tamper Motor Switches off automatically after 100pulses. 012-010, 012- 012-041 Set Clamp Paddle Switches off automatically at Mot: 583 012-030, 012- Middle Front On/Off 012, 012-013,...
Page 987: Dc351 Nvm Background Processing
Table 2 Output Component Control Codes dC351 NVM Background Processing Code Name Description Conflicts Purpose 012-095 Front Tamper Switches off automatically at 100pulses. 012-091, 012- Consists of 5 subroutines: Motor Middle Rear 092, 012-093, • Machine Settings - This routine saves the current machine settings or restores the previ- On/Off 012-094, 012- ously-saved machine settings.
Page 988: Dc355 Hard Disk Diagnostic Program
• Chain 746 dC355 Hard Disk Diagnostic Program • Chains 751 -753 Purpose • Chain 760 NOTE: For details on dC355 Hard Disk Diagnostic Program, see Adjustments: 9.8. • Chain 762 • Chain 764 • Chain 769 If IIT is selected Machine Settings in NVM Chains 710 and 715 will be restored. If IOT is selected, Machine Settings in the following NVM chains will be restored: •...
Page 989: Dc371 Configuration Page
dC371 Configuration Page dC527 DADF Document Calibration Purpose Purpose Allows easy viewing and set-up of machine configuration. NOTE: For details on dC527 DADF Document Calibration, see Adjustments Section 4: 5.6. Procedure Enter the Diagnostic Mode. Refer to Entering Diagnostic Mode using the PWS.
Page 990: Dc612 Color Test Pattern Print
dC612 Color Test Pattern Print NOTE: Not all of the following parameters are applicable to all test patterns; patterns 5 through 36-3 require A4 paper and can be output only from Tray 1 Purpose Select the Paper Tray. Prints the test patterns in the machine, to help identify Image Quality problems. Select Simplex/Duplex Procedure Select Paper Type...
Page 991 Table 1 Test Patterns Description Overview Purpose Location 13-0 Binary Highlight PG (Highlight gradation check) Gradation pattern for highlight adjustment In the gradation reproducibility of Primary color/Secondary color/Ter- LUT: Ctrax off; IOT off tiary color, the highlight parts easily varied can be checked in detail. For checking TRC.
Page 992 Table 1 Test Patterns Description Overview Purpose Location 35-0 Multi-level_Process Gradation pattern for density control The Primary color/Secondary color/Tertiary color gradation reproduc- Control PG LUT: Ctrax off; IOT off ibility can be checked by crossing over to entire gradation. For checking TRC 35-1 Multi-level_Process...
Page 993: Dc685 Color Registration
dC685 Color Registration dC921 TC/ATC Sensor Setup Purpose Purpose NOTE: For details on dC685 Color Registration, see Adjustments Section 4: 9.6. NOTE: For details on dC921 TC/ATC Sensor Setup, see Adjustments Section 4: 9.2. Initial issue General Procedures and Information 02/03 dC685, dC921 DC 3535/2240/1632...
Page 994: Dc922 Trc Control
dC922 TRC Control dC924 TRC Adjust Purpose Purpose To manually fine adjust the low/medium/high densities (TRC) for each color. NOTE: For details on dC922 TRC Control, see Adjustments Section 4: ADJ 9.3 dC922 TRC Control Adjustment. NOTE: For details on TRC Adjust, see Adjustments Section 4: 9.5.
Page 995: Dc929 Max Setup
dC929 Max Setup dC934 ADC/AGC Setup Purpose Purpose Automatically adjusts the ADC Sensor Gain. NOTE: For the execution sequence of the Max Setup Functions, see Adjustments Section 4: 9.1. NOTE: For details on dC934 ADC/AGC Setup, see Adjustment Section 4: 9.4.
Page 996: Dc945 Iit Calibration
dC945 IIT Calibration dC956 Belt Edge Learn Mode Purpose Purpose Functional details: NOTE: For details on dC956 Belt Edge Learn Mode, see Adjustments Section 4: 9.6. • Computes and sets the White Reference Correction Coefficient. • Corrects the IIT Sensitivity Dispersion. NOTE: For details on dC945 IIT Calibration, see Adjustments Section 4: 9.7.
Page 997: Gp 1 Network Printing Simulation
Next. Otherwise, click Have Disk. Print Drivers can be found on the customer Driv- the screens described may be different in the final version. ers CD, or the latest driver can also be downloaded from the Xerox website. Navigate to Procedure the CD or downloaded driver for your PWS’...
Page 998: Gp 2 Machine Startup Troubleshooting
GP 2 Machine Startup Troubleshooting GP 3 Special Boot Modes Purpose Purpose This procedure describes methods of recovering from failure of the machine to successfully This procedure describes methods of recovering from certain unclearable faults. complete the self-test/startup procedure. Procedure Description Some boot-up failures, as well as some unclearable fault codes, may be caused by software When power is applied to the machine, a five-step self test/initialization process is started.
Page 999: Gp 4 Intermittent Problem Rap
To execute: simultaneously press and hold the 3, the Stop, and the Power Save buttons on GP 4 Intermittent Problem RAP the Control Panel while switching on the power. Hold the buttons down until the boot up screen The purpose of this RAP is to provide guidance for resolving an intermittent problem. This is (5 circles) appears and the second circle starts to blink.
Page 1000: Gp 10 Replacing Billing Pwbs
• wires chafing against components of the machine, especially against moving com- GP 10 Replacing Billing PWBs ponents Description • misaligned, misadjusted, or incorrectly installed components This procedure is used to maintain serial number and billing data integrity when Billing PWBs •...

This manual is also suitable for:

Docucolor 3535 Docucolor 1632

Xerox DocuColor 2240 Service Manual

Introduction

1 Service Call Procedures

2 Status Indicator Raps

Quick Links

Chapters

Related Manuals for Xerox DocuColor 2240

Summary of Contents for Xerox DocuColor 2240