Colorqube 9203 Family Service

708P90672
October 2014
Xerox® ColorQube® 9203 Family

Multifunctional Printer
Service Manual
Prepared by:
Communication & Marketing Services
Xerox Ltd
Bessemer Road,
Welwyn Garden City
Hertfordshire
AL7 1BU
United Kingdom
© 2014 Xerox Corporation. All Rights Reserved. XEROX® and XEROX, Design® and ColorQube® are trademarks of Xerox Corporation in the United States and/or other countries.
Other company trademarks are also acknowledged.
While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox Europe arising out of any inaccuracies or omissions.
All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service
personnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or
modules, components or parts of such equipment may affect whether Xerox is responsible to fix machine defects under the warranty offered by Xerox with respect to such equipment. You
should consult the applicable warranty for its terms regarding customer or third-party provided service.
Introduction
About This Manual .......................................................................................................... iii
How To Use This Manual ................................................................................................ iv
Change History................................................................................................................ iv
Documentation Symbol ................................................................................................... xiv
Mod / Tag Identification ................................................................................................... xv
Voltages Resistances and Tolerances ............................................................................ xv
Safety Information ........................................................................................................... xvi
Health and Safety Incident Reporting.............................................................................. xvii
Translated Warnings ....................................................................................................... xviii
October 2014 Introduction

Xerox® ColorQube® 9203 Family i
Introduction October 2014
ii Xerox® ColorQube® 9203 Family
About This Manual Section 6 General Procedures / Information
This manual is part of a multinational service documentation system that is structured in the This section contains all other procedures, product specifications and general information. It
also contains Tag / MOD information. The abbreviations used in this Manual are in GP 40 Glos-
standard Xerox service manual format.
sary of Terms, Acronyms and Abbreviations.
Organization Section 7 Wiring Data
The service manual is the document used as the primary information source for repairing and This section contains PWB layout, lists of plug / jack locations and wiring diagrams of the
maintaining this family of products and is available as EDOC on a CDROM, or in printed for-
power distribution and wire networks in the machine.
mat. The information within the manual is divided into an introduction and eight other sections.
Section 8 Principles of Operation
Section 1 Service Call Procedures
This section contains the Principles of Operation.
This section is used to start and complete a service call. The procedures in this section will
either direct you to a Repair Analysis Procedure (RAP), or identify a faulty component or sub-
Publication Comments Sheet
assembly.
A Publication Comment Sheet is provided at the rear of the hardcopy manual.
Section 2 Status Indicator Repair Analysis Procedures
This section contains the Repair Analysis Procedures (RAPs) and checkouts necessary to
diagnose, isolate and repair faults other than image quality faults.
• The fault codes on the machine user interface are preceded with the number 3.
For example a fault in the scanner might display 362-485-00 on the user interface.
• This manual describes the procedure for the fault under the heading 62-485-00 Supply
12 Volts Error RAP.
Section 3 Image Quality
This section contains the Image Quality Repair Analysis Procedures (IQ RAPs), checkouts and
setup procedures necessary to diagnose, isolate and repair image quality faults.
Section 4 Repairs / Adjustments

This section contains all the repair and adjustment procedures.
Repairs
Repairs include procedures for the removal and installing of parts which have the following
special conditions:
• When there is a personnel or machine safety issue.

• When removal or installation cannot be determined from the exploded view of the parts
list.
• When there is a cleaning or a lubricating activity associated with the procedure.
• When the part requires an adjustment after a part is installed.
• When a special tool is required for removal or installing a part.
Adjustments
Adjustments include procedures for the adjusting of the parts that must be within specification
for the correct operation of the system.
Section 5 Parts List

This section contains the detailed and illustrated spare parts list. Any part that is spared or that
must be removed to access a spared part is illustrated.

Xerox® ColorQube® 9203 Family iii About This Manual
How To Use This Manual Change History
Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the This page gives information on major changes to the service manual. Please go to the relevant
problem, then follow the directions given. update.
How to Differentiate Between Machine Variants • Bus Update May 2009

The machine will be identified in this manual by the identifier ColorQube 9201 / 9202 / 9203. • Bus Update June 2009
• Bus Update July 2009
When a procedure, parts list description or other reference is unique amongst different speeds • XE Launch September 2009
of machine, the appropriate speed range will be quoted. For example, 38 ppm, 45 ppm 50 • SBC / DMO Launch January 2010
ppm. Any artwork will also be specific. • Bus Update March 2010
• Bus Update July 2010
NOTE: This manual services all configurations of the machine. Ignore references to options • Bus Update September 2010
not installed on the machine.
• Bus Update November 2010
Warnings, Cautions And Notes • EDOC Update May 2011
• Bus Update September 2011
• Bus Update May 2012
WARNING • Bus Update May 2013
A warning is used whenever an operating or maintenance procedure, practice, condi- • BUS Update July 2014
tion or statement, if not strictly observed, could result in personal injury. • EDOC Update October 2014
A translated version of all warnings is in Translated Warnings. Bus Update May 2009
The following procedures are updated:
CAUTION • RAP 12-113-00-171, 12-114-00-171, 12-190-00-171, 12-192-00-171 HVF BM Entry

A caution is used whenever an operation or maintenance procedure, practice, condition or • RAP 12-125-00-171, 12-126-00-171 HVF Entry Sensor
statement, if not strictly observed, could result in damage to the equipment. • RAP 16-644-11, 16-644-26, 16-644-46, 16-644-47, 16-644-66, 16-644-67, 16-645-11, 16-
NOTE: A note is used where it is essential to highlight a procedure, practice, condition or state- 645-26, 16-645-46, 16-645-47, 16-645-66, 16-645-67 Unable To Read From File
ment. • RAP 16-664-11, 16-664-28, 16-664-93, 16-664-95, 16-665-95 Parser Utility Closing Fail-
ure
• RAP 94-568-00, 94-570-00, 94-572-00, 94-573-00 Cleaning Unit I/O Error
• RAP 12E-110 LCSS Paper Entry RAP
• RAP 12K-171 HVF Initialization Failure
• RAP OF 5 Boot Up Failure RAP
• RAP OF 16 POST Error
• RAP IQ 3 Blurred Image on Copies
• RAP IQ 5 Jagged or Blurry Lines or Text
• RAP IQ 6 Missing Ink or Grainy Output
• RAP IQ 11 Smudges, Debris, Smears in the Process Direction or, Paper Stack Marks
• RAP IQ 12 Missing or Partial Image
• TP 22 Cleaning Pages
• REP 3.7 Copy Controller PWB
• REP 3.9 Software Module
• REP 10.24 Front and Rear Flexure Encoder
• ADJ 91.1Printhead Attachment Check
• ADJ 12.2-171 Tri-Folder Paper Settings
• GP 4 Machine Software

How To Use This Manual, Change History iv Xerox® ColorQube® 9203 Family
Bus Update June 2009 • RAP IQ 23 Residual Ink From Previous Print
The following procedures are updated: • RAP IQ 25 Random Spots
• RAP IQ 26 Poor Ink Adhesion
• RAP OF 4a Status Codes in Numerical Order • RAP IQ 30 Blocking
• RAP OF 4b Status Messages in Alphabetical Order
• IQS 5 X-Stitch
• RAP 16-612-09 to 16-612-68 Unable to Do Shutdown Sync
• IQS 6 Blurry Text
• RAP 16-750-14, 16-750-19, 16-750-26, 16-750-35, 16-750-38, 16-750-46, 16-750-47, 16-
• TP 1 Initial Test Print pages
750-66, 16-750-67, 16-750-90 Invalid Request
• TP 2 to TP 10 Solid Fill Test Pages
• RAP 16-800-09 to 16-809-47 Other Network Faults 5
• TP 11 Colour Bands and Dithers Test Pages
• RAP 16-940-19 to 16-949-19 Other Network Faults 18
• TP 13 Text Test Pages
• dC133 System Time/Date
• TP 15 Media Path Test Pages
• PJ Locations Table 1
• TP 16 Stitch Identification Test Pages
• PJ Locations Table 3
• TP 18 TRC Generation Test Pages
• Wiring Diagram 3.1
• TP 19 Y-Dot Position Correction Test Page
• TP 20 Oil Bar Chase and Metering Blade Timing Test Pages
• TP 21 Jet Test Pages
Bus Update July 2009 • TP 22 Cleaning Pages
The following procedures are updated: • TP 23 Drum Run Out and Y-Stitch Test Pages
• RAP 01A AC Power Distribution RAP • TP 24 Registration Calibration Page
• RAP 05-258-00, 05-307-00 DADH Cover Interlock Open • TP 26 Printhead Uniformity / Colour Bands Test Page
• RAP 10-500-00 to 10-540-00 Transfix Error • REP 10.7 Pre-Transfix Sensor
• RAP 12-063-00-171, 12-411-00-171 HVF BM Staple Unit 1 Failure • REP 12.49-171 Compiler Paddle Unit
• RAP 12-403-00-171, 12-413-00-171, 12-414-00-171 HVF BM Staple Head 2 and Stapler • REP 81.1 Tray 1 and Tray 2 Paper Feed Assembly
Module • REP 81.6 Bypass Tray Feed Rolls
• RAP 12-473-00-171 to 12-478-00-171 Support Finger Position • REP 83.1 Horizontal Paper Path
• RAP 12A-171 HVF Power Distribution RAP • REP 89.1 Registration/Preheat Assembly and Lower Platelet Assembly
• RAP 73-101-00, 73-106-00 Tray 3 Mis-Feed Jam • REP 91.23 Front and Rear Track Guide
• RAP 89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Failure • REP 91.25 Drum and Front Drum Frame Assembly
• RAP 91-610-00 to 91-613-00 Printhead Waveamp Calibration • GP 1 Service Mode
• RAP 91-636-00 IOD in Degraded Mode • GP 5 Customer Administration Tools
• RAP 91-637-00 Drum Runout Calibration Needed • GP 26 Restriction or Hazardous Substances (RoHS)
• RAP 92-505-00, 92-506-00 Marking Unit Communications Error • GP 27 Cleaning Procedure
• RAP 92-510-00, 92-511-00 Marking Unit Ink On Drum Communications Error • dC103 Billing Plan
• RAP 94-547-00, 94-555-00 Y-Axis Belt Ratio Error • dC133 System Time/Date (removed)
• RAP IQ 1 Image Quality Entry • dC335 Heater Monitor and Exerciser
• RAP IQ 2 Copy or Print Damage • dC373 Print Config Sheet (removed)
• RAP IQ 5 Jagged or Blurry Lines or Text • Wiring Diagram 12.7
• RAP IQ 6 Missing Ink or Grainy Output • Wiring Diagram 12.10
• RAP IQ 7 Metering Blade Timing • Wiring Diagram 12.11
• RAP IQ 9 Deletions in the Process Direction • Wiring Diagram 12.12
• RAP IQ 10 Incorrect Margin, Mis-registration or Skew XE Launch September 2009
• RAP IQ 11 Smudges, Debris, Smears in the Process Direction or Paper Stack Marks The following procedures are updated:
• RAP IQ 13 All Colours Uneven
• SCP 3 Faults Analysis
• RAP IQ 14 Some Colours Uneven
• RAP 01B +3.3V Power Distribution RAP
• RAP IQ 15 Wrong Colour
• RAP 01C +3.3V Power Distribution RAP
• RAP IQ 17 Gloss Marks in the Cross-Process Direction
• RAP 01D +5V Power Distribution RAP
• RAP IQ 20 Wavy or Stringy Lines

Xerox® ColorQube® 9203 Family v Change History
• RAP 01E +12V Power Distribution RAP • TP 26 Printhead Uniformity / Colour Bands Test Page
• RAP 01F -12V Power Distribution RAP • REP 12.6-171 HVF Ejector Assembly
• RAP 01H +24V Power Distribution • REP 12.100-171 Ejector Paddle Assembly (W/TAG V-004)(new)
• RAP 01J +50V Power Distribution • REP 62.1 Scanner Module
• RAP 01K -50V Power Distribution • GP 5 Customer Administration Tools
• RAP 5-310-00 Document Too Short • GP 9 User Interface Service Menu Map (new)
• RAP 12-473-00-171 to 12-478-00-171 Support Finger Position • GP 10 How to Check a Motor
• RAP 22-321-00 SM Failed to Remove Scan to File • GP 15 Location and Function of PWB LED’s
• RAP 22-321-04 Proposal Response Time Out Error • GP 21 Installation Space Requirements
• RAP 22-325-01 Cleaning Unit Extended Life Mode Entered • GP 37 Post Part Replacement
• RAP 22-328-00 Incomplete System Information • dC103 Billing Plan
• RAP 22-350-01, 22-350-02 Software Detects Non-valid Xerox SOK • dC301 NVM Initialization
• RAP 22-351-01 to 22-351-03 SOK Write Failure • dC335 Heater Monitor and Exerciser
• RAP 22-371-00, 22-372-00 Fax Application Registration Error • dC959 Cleaning Unit Exerciser
• RAP 91-638-00 IOD Detects Chronic Jet Error • dC968 Head Purge
• RAP 91-523-00 to 91-558-00 to 91-667-00, 91-800-00 to 91-804-00 Printhead Thermal • dC977 Drum Runout Calibration
Error • Wiring Diagram 1.1
• RAP 91-725-00 IOD Bad Target Scan • Wiring Diagram 9.8
• RAP 91-805-00, 91-806-00 Printhead Communications • Wiring Diagram 12.1
• RAP 91-832-00 PQM Empty Waste Tray • Wiring Diagram 12.2
• RAP 91-833-00 PQM Cleaning Pages Needed • Wiring Diagram 12.3
• RAP 93-547 Printheads 1 and 3 Printhead Reservoir Fill Error • Wiring Diagram 12.4
• RAP 94B Drum Drive Control Test Actions • Wiring Diagram 12.5
• RAP 99-071-00 to 99-112-00 Pest Error 2 • TAGs
• OF 4 Status Tables SBC / DMO Launch January 2010
• OF 5 Boot Up Failure
• OF 16 POST Error
• OF 17 Service Code RAP • RAP 03-316-00 CCM Cannot Communicate with IOT
• RAP IQ 5 Jagged or Blurry Lines or Text • RAP 03-325-00 System Detects the Machine Clock Failed to Increment During Power On
• RAP IQ 7 Metering Blade Timing • RAP 03-338-00 The Main Controller on the CCB / SBC has Reset
• RAP IQ 9 Deletions in the Process Direction • RAP 03-347-00 Main Controller PWB Cannot communicate with UI PWB
• RAP IQ 13 All Colours Uneven • RAP 03-360-00 CCS POST System Memory Error
• RAP IQ 14 Some Colours Uneven • RAP 03-361-00 CCS POST Flash Memory Error
• RAP IQ 15 Wrong Colour • RAP 03-362-00 CCS Power Fault
• RAP IQ 18 Irregular Duplex Gloss Differences • RAP 03-397-00 System Configuration Recovery Attempt
• RAP IQ19 Image Ghosting • RAP 03-398-00, 03-399-00 SIM Card Fault
• RAP IQ 20 Way or Stingy Lines • RAP 03-401, 03-403-00 Fax Not Detected
• RAP IQ 21 Oil on Output • RAP 03-788-00 CCS Runtime could not Enter Power Save Mode
• RAP IQ 24 Wrinkling • RAP 03B Foreign Device PWB Fault
• RAP IQ 25 Random Spots • RAP 05-330-00, 05-331-00 DADH Feed Sensor Failure RAP
• RAP IQ 26 Poor Ink Adhesion • RAP 12-463-00-171, 12-464-00-171 HVF BM +24V Failure
• TP 2 to TP 10 Solid Fill Test Pages • RAP 12-473-00-171 to 12-478-00-171 Support Finger Position
• TP 18 TRC Generation Test Pages • RAP 62-277-00 Scanner to DADH communication Fail Entry
• TP 19 Y - Dot Position Correction Test Page • RAP 62-310-00 Scanner to CCB / SBC communication Fail Entry
• TP 20 Oil Bar Chase and Metering Blade Timing Test Pages • RAP 62-450-00 to 62-472-00 Calibration Failure
• TP 21 Jet Test Pages • RAP 62-473-00 UART RX Wrap Error
• TP 23 Drum Run Out and Y-Stitch Test Pages • RAP 62-476-00 Scan Carriage Home Sensor

Change History vi Xerox® ColorQube® 9203 Family
• RAP 62-485-00 +12V Supply Error • REP 62.16 Carriage Motor (W/TAG 007)
• RAP 62-486-00 +24V Supply Error • REP 62.17 Exposure Lamp Inverter (W/TAG 007)
• RAP 62C Scanner Document Size (W/TAG 007) • REP 62.18 Exposure Lamp (W/TAG 007)
• RAP 62D Exposure Lamp Failure (W/TAG 007) • REP 62.19 Exposure Lamp Ribbon Harness (W/TAG 007)
• RAP 88-500-00 Preheat Thermal Error • REP 62.20 Input Module Angle Sensor (W/TAG 007)
• RAP 92-575-00 ADC Out of Range • REP 62.21 Scanner PWB (W/TAG 007)
• RAP 93-545-00 to 93-548-00 Ink Melt Reservoir Level Sense Error • REP 62.22 Document Size Sensor 1 and Document Size Sensor 2 (W/TAG 007)
• RAP 93-549 to 93-552-00 and 93-557-00 Printheads 1 and 3 Printhead Reservoir Fill • REP 62.23 Scan Cables (W/TAG 007)
Error • REP 62.24 Scan Idler Pulley (W/TAG 007)
• RAP 93-553 to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead Res- • REP 62.25 Platen Down Sensor (W/TAG 007)
ervoir Fill Error • REP 62.26 IIT Video / SBC PWB Harness (W/TAG 007)
• RAP 94-524-00, 94-526-00, 94-534-00 Drum Drive Error • REP 62.27 Scan Motor and Scan Carriage Drive Belt (W/TAG 007)
• RAP 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00 Drum Heat • REP 62.28 Power and Communication Harness (W/TAG 007)
Error • REP 91.31 Umbilical Assembly
• RAP 93A Ink Melt Reservoir Check • ADJ 62.5 Optics Cleaning Procedure (W/TAG 007)
• RAP 99-272-00 to 99-292-00 PEST Error 8 • Parts List updated
• RAP 99-461-00 to 99-477-00 PEST Error 17 • GP 2 Fault Codes and History Files
• RAP 99-480-00 to 99-496-00 PEST Error 18 • GP 3 Service Information
• RAP 99-497-00 to 99-515-00 PEST Error 19 • GP 9 User Interface Service Menu Map
• RAP 99-743-00 to 99-766-00 PEST Error 34 • GP 19 Machine SIM Card Matrix (new)
• RAP 99-767-00 to 99-784-00 PEST Error 35 • GP 20 Paper and Media Size Specification
• OF 4 Status Tables • GP 30 How to Mask a Jet Substitution
• OF 5 Boot Up Failure • dC103 Billing Plan
• RAP IQ 3 Blurred Image on Copies • dC335 Heater Monitor and Exerciser
• RAP IQ 5 Jagged or Blurry Lines or Text • dC612 Print Test Pattern
• RAP IQ 6 Missing Ink or Grainy Output • dC976 Ink Delivery Fault Recovery
• RAP IQ 8 Cross Process Ink Artifacts (smudge) • PJ Locations
• RAP IQ 11 Smudges, Debris, Smears in the Process Direction or Paper Stack Marks • Wiring diagram 1.7 Power Distribution PWB (W/TAG 006)
• RAP IQ 13 All Colours Uneven • Wiring diagram 1.8 Power Distribution PWB (W/O TAG 006)
• RAP IQ 14 Some Colours Uneven • Wiring diagram 3.4 Single Board Controller (W/TAG 006)
• RAP IQ 15 Wrong Colour • Wiring diagram 3.5 Single Board Controller (W/TAG 006)
• RAP IQ 18 Irregular Duplex Gloss Differences • Wiring diagram 3.6 Single Board Controller (W/TAG 006)
• RAP IQ 20 Wavy or Stringy Lines • Wiring diagram 6.4 Scanner PWB (W/TAG 007)
• RAP IQ 24 Wrinkling • Wiring diagram 6.5 Scanner PWB (W/TAG 007)
• RAP IQ 25 Random Spots • Wiring diagram 6.6 Scanner PWB (W/TAG 007)
• TP 1 Initial Test Print Pages • Wiring diagram 8.3 Media Path Driver PWB (3 of 5)
• TP 13 Text Test Pages • Wiring Diagram 9.14 Solenoid Patch PWB
• TP 17 Service Usage Profile • Wiring Diagram 12.4 LCSS PWB
• TP 21 Jet Test Pages • Wiring Diagram 12.6 HVF PWB
• IQS 8 Uniformity in the Process Direction • Wiring Diagram 12.8 HVF PWB
• REP 3.1 IME Controller PWB • Wiring Diagram 12.9 HVF PWB
• REP 3.7 Copy Controller PWB • TAGs
• REP 3.9 Software Module
• REP 3.10 Single Board Controller PWB (W/TAG 006)
• REP 3.11 HDD Single Board Controller Assembly (W/TAG 006)
• REP 3.12 NVM PWB
• REP 62.15 Scan Carriage Home Sensor (W/TAG 007)

Xerox® ColorQube® 9203 Family vii Change History
Bus Update March 2010 • RAP 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00 Drum Heat Error
The following procedures are updated: • RAP 94-616-00 Cleaning Unit Low Oil Detection
• RAP 99-480-00 to 99-496-00 PEST Error 18
• Health and Safety Incident Reporting • RAP 99-497-00 to 99-515-00 PEST Error 19
• SCP 2 Call Actions
• RAP 99-686-00 to 99-700-00 PEST Error 31
• SCP 3 Fault Analysis
• RAP OF 3 Unresponsive Machine
• SCP 4 Subsystem Maintenance
• RAP OF 4 Status Codes and Messages
• RAP 01-525-00 +24V, +/- 12V, +5V Short Circuit and Overload
• RAP OF 5 Boot Up Failure
• RAP 03-355-00 CCM POST Failure Detected (new) • RAP OF16 POST Error
• RAP 03-398-00, 03-399-00 SIM Card Fault • RAP IQ 1 Image Quality Entry
• RAP 05-529-00, 05-526-00 DADH Active Line or Standby Error
• RAP IQ 3 Blurred Image on Copies
• RAP 10-110-00 to 10-110-00, 10-125-00 to 10-128-00 10-147-00, 10-148-00 Post
• RAP IQ 9 Deletions in the Process Direction
Transfix Jam
• RAP IQ 29 DADH, Document Glass and Scanner
• RAP 10-500-00 to 10-540-00 Transfix Error
• TP 1 Initial Test Print Pages
• RAP 12-367-00-171, 12-368-00-171 12-380-00-171 HVF Punch Unit Paper Edge Detect
• IQS 1 Registration and Skew
• RAP 12-460-00-171 to 12-462-00-171 HVF Bin 1 Position
• REP 3.7 Copy Controller
• RAP 12-762-00-171 IME To Finisher Communication Failure
• REP 3.8 HDD Copy Controller Assembly W/O TAG 006
• RAP 16-752-07, 16-752-09, 16-752-14, 16-752-19, 16-752-26, 16-752-28, 16-752-35,
• REP 3.10 Single Board Controller (W/TAG 006)
16-752-46, 16-752-47 Invalid File Details
• REP 3.11 HDD Single Board Controller Assembly W/TAG 006
• RAP 20C Unable To Send a Fax To Some Machines
• REP 3.12 NVM PWB
• RAP 22-352-00 Serial Number Missing (New) • REP 5.5 Baffle Assembly
• RAP 62-310-00 Scanner to CCB / SBC communication Fail Entry • REP 12.76-171 Bin 1 Upper Level Sensor
• RAP 62-450-00 to 62-472-00 Calibration Failure
• REP 12.100-171 Ejector Paddle Assembly (W/Tag V-004)
• RAP 62-473-00 UART RX Wrap Error
• REP 16.2 Network Controller (HDD2) W/O TAG 006
• RAP 62-476-00 Scan Carriage Home Sensor
• REP 62.1 Scanner Module
• RAP 62-485-00 +12V Supply Error
• REP 62.10 LED Exposure Lamps (W/O Tag 007)
• RAP 62-486-00 +24V Supply Error • REP 62.11 Exposure Lamp Ribbon Harness (W/O Tag 007)
• RAP 62A Scanner Document Size (W/TAG 007) • REP 82.9 Vertical Transport
• RAP 62B Exposure Lamp Failure (W/TAG 007)
• REP 91.1 Carriage Drive Train
• RAP 62C Scanner Document Size (W/TAG 007)
• REP 91.2 Vertical Gearbox and Motor
• RAP 62D Exposure Lamp Failure (W/TAG 007)
• REP 91.3 Head Maintenance Wiper
• RAP 62-450-00 to 62-472-00A Calibration Failure
• REP 91.4 Front and Rear Tension Base
• RAP 62-450-00 to 62-472-00B Calibration Failure • REP 91.6 Head Maintenance Horizontal Motion Motor
• RAP 75-320-00 Tray 5 Open in Run (New) • REP 91.20 Ink Reservoir Assembly
• RAP 82-140-00, 82-142-00 Media Path Sheet Too Wide or Narrow
• REP 91.21 Reservoir Pump
• RAP 89-540-00 to 89-545-00 Registration Process Error
• REP 91.25 Drum and Front Drum Frame Assembly
• RAP 91-610-00 to 91-613-00 Printhead Waveamp Calibration
• REP 91.28 Marking Unit Assembly
• RAP 91-674-00 to 91-677-00, 91-812-00 to 91-815-00 Printhead Adjustment Error
• REP 91.31 Umbilical Assembly
• RAP 91-837-00 PQM Align Calibration Needed (New) • Parts List updated
• RAP 91-848-00 to 91-851-00 IOD Align Calibration Error (New) • GP1 Service Mode
• RAP 92-541-00, 92-570-00 Interrupt Storm Fault
• GP 4 Software Machine
• RAP 93-535-00, 93-536-00, 93-537-00 Upper Umbilical Thermal Error
• GP14 How to Switch Off the machine or Switch On the Machine
• RAP 93-538-00, 93-539-00, 93-540-00 Lower Umbilical Thermal Error
• GP21 Installation Space Requirements
• RAP 93-545-00 to 93-548-00 Ink Melt Reservoir Level Sense Error
• GP34 Service Plan
• RAP 93-549 to 93-552-00, 93-557-00 Printheads 1 and 3 Printhead Reservoir Fill Error • GP40 Glossary of Terms, Acronyms and Abbreviations.
• RAP 93-553 to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead • DC 131 Read / Write
Reservoir Fill Error
• DC136 Service Plan

Change History viii Xerox® ColorQube® 9203 Family
• DC 301 NVM Initialization • RAP OF 11 Unable to Load Ink Sticks (New)
• DC914 Head to Head Alignment Test • RAP IQ 4 Wrong Copied Colour
• PJ Locations (update figure 2, figure 4 and figure 14) • RAP IQ 29 DADH, Document Glass and Scanner
• PJ Locations (update table 1 and table 2) • Parts List updated
• Wiring diagram 1.8 Power Distribution PWB (W/O TAG 006) • GP 20 Paper and Media Size Specification
• Wiring diagram 1.9 Power Distribution PWB (W/TAG 006) • Wiring diagram 1.6 Power Distribution PWB
• Wiring diagram 3.3 Copy Controller (W/O TAG 006) • Wiring diagram 1.8 Power Distribution PWB (W/O TAG 006)
• Wiring diagram 3.6 Single Board Controller (W/TAG 006) • Wiring diagram 1.9 Power Distribution PWB (W/TAG 006)
• Principles of Operation • Wiring diagram 3.1 Copy Controller (W/O TAG 006)
Bus Update July 2010 • Wiring diagram 6.4 Scanner PWB (W/TAG 007)
The following procedures are updated: Bus Update September 2010
• SCP 3 Fault Analysis
• RAP 01C +3.3V Power Distribution RAP • RAP 01-535-00 Power Interlock Failed: No Heater Requests
• RAP 05-529-00, 05-526-00 DADH Active Line or Standby Error • RAP 01-542-00, 01-546-00 50V Failure RAP
• RAP 05-300-00 DADH Open • RAP 01A AC Power Distribution
• RAP 12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector Movement Failure • RAP 01F -12V Distribution
• RAP 62-277-00 Scanner to DADH communication Fail Entry • RAP 01H +24V Distribution
• RAP 62-277-00C Scanner to DADH communication Fail (New) • RAP 01J +50V Distribution
• RAP 62-310-00 Scanner to CCB / SBC communication Fail Entry • RAP 03-397-00 System Configuration Recovery Attempt
• RAP 62-310-00C Scanner to CCB / SBC communication Fail (New) • RAP 03-398-00, 03-399-00 SIM Card Fault
• RAP 62-450-00 to 62-472-00 Calibration Failure Entry • RAP 05-257-00 Unknown Document Size
• RAP 62-450-00 to 62-472-00C Calibration Failure (New) • RAP 88-500-00 to 88-502-00 Preheat Thermal Error
• RAP 62-473-00 UART RX Wrap Error Entry • RAP 93-549-00 to 93-552-00 and 93-557-00 to 93-560-00 Printheads 1 and 3 Printhead
• RAP 62-473-00C UART RX Wrap Error (New) Reservoir Fill Error
• RAP 62-476-00 Scan Carriage Home Sensor Entry • RAP 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead
• RAP 62-476-00C Scan Carriage Home Sensor (New) Reservoir Fill Error
• RAP 62-485-00 +12V Supply Error Entry • RAP 94-616-00 Cleaning Unit Low Oil Detected
• RAP 62-485-00C +12V Supply Error (New) • OF 4a Status Messages, Table 16
• RAP 62-486-00 +24V Supply Error Entry • OF 4b Status Messages, Table 1
• RAP 62-486-00C +24V Supply Error (New) • RAP IQ 9 Deletions in the Process Direction
• RAP 62A Scanner Document Size (W/TAG 007) • RAP IQ 20 Wavy or Stringy Lines
• RAP 62B Exposure Lamp Failure (W/TAG 007) • RAP IQ 29 DADH Document Glass and Scanner
• RAP 62C Scanner Document Size (W/TAG 007) • REP 75.9 Tray 5 Docking Latch (New)
• RAP 62D Exposure Lamp Failure (W/TAG 007) • Parts List updated
• RAP 62-450-00 to 62-472-00A Calibration Failure • GP 14 How to Switch Off the Machine or Switch On The Machine
• RAP 62-450-00 to 62-472-00B Calibration Failure • GP 35 Copy and Print Speeds
• RAP 88-500-00 to 88-502-00 Preheat Thermal Error • TAG D-007
• RAP 89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Failure Bus Update November 2010
• RAP 89-540-00 to 89-545-00 Registration Process Error The following procedures are updated:
• RAP 94-616-00 Cleaning Unit Low Oil Detection
• SCP 4 Subsystem Maintenance
• RAP 99-293-00 to 99-312-00 PEST Error 9
• 12-762-00-110, 12-764-00-110, 12-765-00-110 IME to Finisher Communication Failure
• RAP 99-313-00 to 99-329-00 PEST Error 10
RAP
• RAP 99-330-00 to 99-349-00 PEST Error 11
• 12-492-00-171 to 12-494-00-171 IME To Finisher Failure RAP
• RAP 99-360-00 to 99-382-00 PEST Error 12 • 12-762-00-171, 12-764-00-171, 12-765-00-171 IME To Finisher Communication Failure RAP
• RAP OF 3 Unresponsive Machine • 12F-171 Mis-Registration in Stapled and Unstapled Sets RAP
• OF 4 Status Tables
• 62-450-00A to 62-472-00A Calibration Failure RAP

Xerox® ColorQube® 9203 Family ix Change History
• 89-530-00 to 89-534-00 Registration Process Error RAP • 05-335-00 DADH TAR Sensor Failure RAP
• 91-638-00 IOD Detects Chronic Jet Error RAP • 05-345-00. 05-346-00 DADH Exit Sensor Failure RAP
• 92-535-00, 92-536-00 Tray 5 Communications Error RAP • 10-545-00 Drum Position Error for Transfix RAP
• 92-560-00, 92-561-00 Marking Unit Firmware Version Mismatch RAP • 12-113-00-171, 12-114-00-171, 12-190-00-171, 12-192-00-171 HVF BM Entry RAP
• 92-562-00 Drum Driver Firmware Version Mismatch RAP • 12-367-00-171, 12-368-00-171, 12-380-00-171 HVF Punch Unit Paper Edge Detect RAP
• 92-563-00 Power Supply Firmware Version Mismatch RAP • 62-450-00A to 62-472-00V Calibration Failure RAP
• 92-571-00 Software Error RAP • 91-630-00 IOD Scan Process Failure RAP
• 92-581-00 Image Transfer Error RAP • 92-510-00, 92-511-00 Marking Unit Ink On Drum Communications Error RAP
• 94-551-00, 94-552-00, 94-553-00 Drum Y-Axis Error RAP • 94-519-00 Drum Imaging Error RAP
• 94-574-00 Cleaning Unit Sync Error RAP • 94-520-00 Cleaning Unit Drive Error RAP
• 99-071-00 to 99-112-00 PEST Error 2 RAP • 94-522-00 Cleaning Unit Motor Stall RAP
• 99-113-00 to 99-141-00 PEST Error 3 RAP • 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-00, 94-633-
• 99-142-00 to 99-168-00 PEST Error 4 RAP 00 Drum Heat Error RAP
• 99-175-00 to 99-218-00 PEST Error 5 RAP • 94-549-00 Drum Runout Calibration Error RAP
• 99-220-00 to 99-244-00 PEST Error 6 RAP • 94B Drum Drive Control Test Actions RAP
• 99-394-00 to 99-413-00 PEST Error 13 RAP • IQ 3 Blurred Image on Copies RAP
• 99-244-00 to 99-271-00 PEST Error 7 RAP • REP 12.15-110 Entry Guide Cover
• 99-461-00 to 99-477-00 PEST Error 17 RAP • REP 12.16-110 Docking Latch Assembly
• 99-785-00 to 99-804-00 PEST Error 36 RAP • REP 12.19-171 Crease Roll Motor
• 99-805-00 to 99-823-00 PEST Error 37 RAP • REP 12.27-171 BM Staple Heads
• 99-824-00 to 99-838-00 PEST Error 38 RAP • REP 82.7 Tray 5 Takeaway Roller
• 99-839-00 to 99-871-00 PEST Error 39 RAP • REP 91.29 Printhead
• 99-872-00 to 99-888-00 PEST Error 40 RAP • dC708 Drum Drive Control Test
• 99-889-00 to 99-904-00 PEST Error 41 RAP • Wiring Diagram 12.10
• 99-905-00 to 99-921-00 PEST Error 42 RAP The following procedures are new:
• 99-922-00 to 99-938-00 PEST Error 43 RAP • 16A Network Error Entry RAP
• 99-939-00 to 99-954-00 PEST Error 44 RAP • 16B FTP or SMB Unable to Connect to Remote Server RAP
• 99-955-00 to 99-962-00 PEST Error 45 RAP • 16C Remote Directory Lock Failed RAP
• OF 4a Status Messages, Table 7 • 94-634-00, 94-635-00 DMU Thermistor Failure RAP
• OF 4b Status Messages, Table 2 and 4 • REP 12.18-110 Paddles
• OF 5 Boot Up Failure RAP • REP 75-10 Tray 5 Elevator Rack Assembly
• REP 1.1 Wiring Harness Repairs • GP 38 How to Set the Date and Time
• REP 12.8-110 Stapler Traverse Assembly • GP 39 How to Enable HTTP
• REP 12.12-110 Paddle Wheel Shaft Assembly • GP 41 How to Configure the PWS to Ping a Device
• REP 12.101-171 Paddle Wheel (new) • GP 42 How to Set the IP Address of the PWS
• Parts List updated • GP 43 How to Change Ethernet Speed
• dC135 CRU/HFSI Status • GP 44 How to Disable the Firewall of the PWS
• WD 8.5 Media Path Driver PWB (5 of 5) • GP 45 How to Identify the Different Printhead Connectors
• WD 12.9 HVF PWB (4 of 11) Bus Update September 2011
EDOC Update May 2011 The following procedures are updated:
The following procedures are updated: • 12-460-00-171 to 12-462-00-171 HVF Bin 1 Position RAP
• SCP 3 Fault Analysis • 12L-171 Tri-Folder Not Detected RAP
• 01C +3.3V Distribution RAP • 99-824-00 to 99-838-00 PEST Error 38 RAP
• 01E +12V Distribution RAP • OF 16 POST Error RAP
• 03-331-00, 03-332-00 Main Controller Board Cannot Communicate with ESS RAP • REP 1.9 Power Supply Unit
• 03A Foreign Device PWB Fault RAP • REP 75.11 Tray 5 Elevator Tray Guides
• 05-257-00 Unknown Document Size RAP

Change History x Xerox® ColorQube® 9203 Family
• REP 83.4 Horizontal Transport Motor • 16-620-07 to 16-620-90 Registration Service Failed RAP
• REP 91.25 Drum and Front Drum Frame Assembly • 16-674-09, 16-675-00, 16-700-00, 16-701-00, 16-701-68, 16-701-99, 16-702-00, 16-702-
• REP 91.29 Printhead 95, 16-707-00, 16-709-00 XSA Database Failure RAP
• Parts List updated • 75-101-00 Tray 5 Mis-Feed RAP
• dC 967 Head to Drum Spacing Check • 82-502-00, 82-503-00 Horizontal Transport Motor M6 Failure RAP
• Wiring Diagram 3.2 Copy Controller PWB (2 of 3) (W/O TAG 006) • 88-500 to 88-502-00 Preheat Thermal Error RAP
• Wiring Diagram 3.5 Single Board Controller PWB (W/O TAG 006) (2 of 3) • 89-540-00 to 89-545-00 Registration Process Error RAP
• Wiring Diagram 8.2 Media Path Driver PWB (2 of 5) • 93-545-00 to 93-548-00 Ink Melt Reservoir Conductivity Error RAP
• Wiring Diagram 9.8 Marking Unit Heater PWB • 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP
Bus Update May 2012 • 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-00, 94-633-
00 Drum Heat Error RAP
• 91-636-00 IOD in Degraded Mode RAP
• 12-024-00-171, 12-025-00-171 HVF Paddle Roller Position RAP • 91-698-00 to 91-732-00 IOD Excessive Head Misalignment RAP
• 12-113-00-171, 12-114-00-171, 12-190-00-171 HVF BM Entry RAP • 91-827-00 PQM Align Needed RAP
• 91-638-00 IOD Detects Chronic Jet Error RAP • 91-837-00 PQM Align Calibration Needed RAP
• 91-698-00 to 91-732-00 IOD Excessive Head Misalignment RAP • 93-545-00 to 93-548-00 Ink Melt Reservoir Conductivity Error RAP
• 91-827-00 PQM Align Needed RAP • 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP
• 91-837-00 PQM Align Calibration Needed RAP • 93A Ink Melt Reservoir Check
• 92-541-00, 92-570-00 Interrupt Storm Fault RAP • 93B Ink Leak Checkout RAP
• 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 Cleaning Unit Over Current • 99-272-00 to 99-292-00 PEST Error 8 RAP
RAP • 99-394-00 to 99-413-00 PEST Error 13 RAP
• 94-535-00 Drum Driver Command Current Error RAP • 99-480-00 to 99-496-00 PEST Error 18 RAP
• 94-617-00, 94-618-00 Oil Pump Error RAP • 99-516-00 to 99-533-00 PEST Error 20 RAP
• 99-000-00 to 99-070-00 PEST Error 1 RAP • 99-534-00 to 99-548-00 PEST Error 21 RAP
• 99-394-00 to 99-413-00 PEST Error 13 RAP • IQ 1 Image Quality Entry RAP
• 99-767-00 to 99-784-00 PEST Error 35 RAP • IQ 9 Deletions in the Process Direction RAP
• 99-785-00 to 99-804-00 PEST Error 36 RAP • IQ 14 Some Colours Uneven RAP
• OF 17 Service Code RAP • TP 1 Initial Test Print Pages
• IQ 9 Deletions in the Process Direction RAP • TP 25 IME Test Print
• IQ 13 All Colours Uneven RAP • REP 12.5-171 Right Side-Cover Removal
• IQ 16 Scratches or Gloss Marks in the Process Direction RAP • REP 12.6-171 HVF Ejector Assembly
• IQ 20 Wavy or Stringy Lines RAP • REP 12.16-171 BM Flapper
• REP 91.13 Stitch / Roll Motor • REP 12.96-171 HVF Fixed and Adjustable Casters
• REP 91.29 Printhead • REP 89.3 Registration / Preheat Assembly Nip A Kit
• ADJ 12.2-171 Tri-Folder Paper Settings • REP 91.31 Umbilical Assembly
• Parts List updated • PL 2.10
• GP 37 Post Part Replacement Routines • PL 3.10
• Principles of Operation • PL 3.11
The following procedures are new: • PL 5.10
• REP 91.38 Stitch / Roll Motor Lead Screws • PL 5.15
Bus Update May 2013 • PL 5.35
The following procedures are updated: • PL 12.70
• PL 12.75
• SCP 2 Call Actions
• PL 12.110
• 12-473-00-171 to 12-478-00-171 Support Finger Position RAP
• PL 12.115
• 12A-171 HVF Power Distribution RAP
• PL 12.150
• 12D-171 Booklet Quality RAP
• PL 31.10
• 12L-171 Tri-Folder Not Detected RAP

Xerox® ColorQube® 9203 Family xi Change History
• PL 31.11 • 12-492-00-171 to 12-494-00-171 IME To Finisher Failure RAP
• PL 31.12 • 12-762-00-171, 12-764-00-171, 12-765-00-171 IME To Finisher Communication Failure
• PL 62.10 RAP
• PL 62.15 • 12D-110 LCSS Power Distribution RAP
• PL 62.16 • 12F-110 LCSS PWB DIP Switch Settings RAP
• PL 62.18 • 12K-171 HVF Initialization Failure RAP
• PL 73.16 • 16-710-00, 16-710-35, 16-716-00, 16-726-00, 16-728-00, 16-730-00, 16-730-28, 16-730-
• PL 81.10 35, 16-730-66, 16-740-19, 16-750-07, 16-750-09, 16-750-11 Unable To Create Client
• PL 81.40 Handle RAP
• PL 88.11 • 19-410-00 to 19-410-13 Image Structure Failure RAP
• PL 91.20 • 62-310-00 Scanner to Copy Controller/Single Board Controller Communication Fail Entry
RAP
• PL 91.25
• 62-450-00A to 62-472-00A Calibration Failure RAP
• PL 93.10
• 62-450-00A to 62-472-00B Calibration Failure RAP
• dC330 - Table 20 Output codes 12-228 & 12-227
• dC971 Head to Head Alignment Adjustment • 62-450-00A to 62-472-00C Calibration Failure RAP
• TAG 011 • 62-486-00A +24V Supply Error RAP
• 73-101-00, 73-106-00, 73-110-00 Tray 3 Mis-Feed Jam RAP
• TAG 012
• 73-212-00 Tray 3 Elevate Encoder Failure RAP
• TAG 014
• 74-101-00 Bypass Tray Mis-Feed RAP
• TAG 016
• 75-101-00 Tray 5 Mis-Feed RAP
• TAG 017
• TAG 022 • 82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82-159-00, 82-164-00 to 82-166-00
Media Path Sensor (5) RAP
• PJ Locations - Figure 16 IME controller PWB
• 82-125-00 to 82-133-00, 82-153-00, 82-155-00, 82-160-00, 82-162-00, 82-163-00 Con-
firm Sensor (16) RAP
• 82-132-00, 82-155-00 Media Path Sensor 16 Duplex Mode RAP
• Principles of Operation - System overview - options
• 82-133-00 Media Path Sensor 16 Time out from Tray 5 RAP
BUS Update July 2014 • 82-134-00 Media Path Sensor 16 Time-out from Tray 4 RAP
The following procedures are updated • 82-140-00, 82-142-00 Media Path Sheet Too Wide or Narrow RAP
• Translated Warnings • 82-141-00, 82-147-00, 82-148-00, 82-154-00 Media Path Sensor 14 RAP
• SCP 3 Fault Analysis • 82-500-00, 82-501-00 Vertical Transport Motor M2 Failure RAP
• 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload RAP • 82-502-00, 82-503-00 Horizontal Transport Motor M6 Failure RAP
• 01-540-00, 01-544-00 +24V, +/-12V, +5V Failure RAP • 89-125-00 to 89-128-00, 89-130-00 Media Path Sensor 20 Failure RAP
• 01-542-00, 01-546-00 50V Failure RAP • 89-500-00, 89-502-00 Registration Motor Over Current RAP
• 03-316-00 CCM Cannot Communicate with IOT RAP • 89-531-00 to 89-534-00 Registration Process Error RAP
• 03-331-00, 03-332-00 Main Controller Board Cannot Communicate with ESS RAP • 89-550-00, 89-551-00 Media Registration Error RAP
• 03-397-00 System Configuration Recovery Attempt RAP • 89-561-00 Media Registration Parameters Reset RAP
• 05-257-00 Unknown Document Size RAP • 91-504-00, 91-505-00 Printhead Stitch Motor Over Current RAP
• 05-258-00, 05-307-00 DADH Cover Interlock Open RAP • 91-506-00 to 91-509-00 Roll Motor Over Current RAP
• 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00, 10-148-00 Post Transfix • 91-513-00, 91-514-00, 91-581-00, 91-583-00 IOD Drive Error RAP
Jam RAP • 91-562-00, 91-563-00 Upper Carriage Error RAP
• 10-140-00 to 10-146-00, 10-149-00 to 10-151-00 Exit Jam RAP • 91-567-00 to 91-568-00 Lower Carriage Error RAP
• 10-500-00 to 10-540-00 Transfix Error RAP • 91-567-00 to 91-568-00 Lower Carriage Error RAP
• 10-571-00, 10-572-00 Stripper Latch Sensor Error RAP • 91-574-00, 91-576-00, 91-598-00 Wiper Horizontal Error RAP
• 12-043-00-110, 12-046-00-110 Hole Punch Operation Failure RAP • 91-586-00 Quad Wave Amplifier Short RAP
• 12-151-00-110, 12-152-00-110 Sheet Late to Bin 1 RAP • 91-610-00 to 91-613-00 Printhead Waveamp Calibration Error RAP
• 12-171-00-110, 12-172-00-110 Paper Exiting to Bin 0 RAP • 91-636-00 IOD in Degraded Mode RAP
• 12-288-00-171, 12-289-00-171 HVF Nip Split RAP • 91-637-00 Drum Runout Calibration Needed RAP
• 12-460-00-171 to 12-462-00-171 HVF Bin 1 Position RAP

Change History xii Xerox® ColorQube® 9203 Family
• 91-638-00 IOD Detects Chronic Jet Error RAP • TP 21 Jet Test Pages
• 91-698-00 to 91-732-00 IOD Excessive Head Misalignment RAP • REP 3.1 IME Controller PWB
• 91-805-00, 91-806-00 Printhead Communications RAP • REP 10.2 Front Transfix Linkage and Gear Kit
• 91-827-00 PQM Align Needed RAP • REP 10.16 Exit Sensor (15)
• 91-837-00 PQM Align Calibration Needed RAP • REP 12.6-171 HVF Ejector Assembly
• 92-510-00, 92-511-00 Marking Unit Ink On Drum Communications Error RAP • REP 12.16-171 BM Flapper
• 92-571-00 Software Error RAP • REP 12.17-171 BM PWB
• 92-575-00 ADC Out of Range RAP • REP 12.61-171 BM Module
• 92-581-00 Image Transfer Error RAP • REP 12.96-171 HVF Fixed and Adjustable Casters
• 93-501-00 to 93-516-00 Ink Loader Is Jammed RAP • REP 81.4 Tray 1 and Tray 2 Feed Rolls
• 93-545-00 to 93-548-00 Ink Melt Reservoir Conductivity Error RAP • REP 81.5 Tray 3 Feed Rolls
• 93-549-00 to 93-552-00 and 93-557-00 to 93-560-00 Printheads 1 and 3 Printhead Res- • REP 81.6 Bypass Tray Feed Rolls
ervoir Fill Error RAP • REP 81.7 Tray 5 Feed Rollers
• 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead Res- • REP 82.1 3 Tray Module Transport Motor
ervoir Fill Error RAP • REP 82.9 Vertical Transport
• 94-504-00, 94-505-00 Cleaning Unit Reservoir Pressure Error RAP • REP 91.24 Drum Drive Motor and Belt
• 94-520-00 Cleaning Unit Drive Error RAP • REP 91.29 Printhead
• 94-522-00 Cleaning Unit Motor Stall RAP • REP 91.30 Drum Position Encoder Assembly
• 94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP • REP 91.31 Umbilical Assembly
• 94A Enclosure Fan Error RAP • REP 91.38 Stitch / Roll Motor Lead Screws
• 94B Drum Drive Control Test Actions RAP • ADJ 5.2 DADH Height Adjustment
• 99-000-00 to 99-070-00 PEST Error 1 RAP • ADJ 5.5 DADH Regitration Adjustment
• 99-071-00 to 99-112-00 PEST Error 2 RAP • dC608 Document Feeder Registration
• 99-175-00 to 99-218-00 PEST Error 5 RAP • dC625 Registration / Preheat Calibration
• 99-293-00 to 99-312-00 PEST Error 9 RAP • dC914 Head to Head Alignment Test
• 99-394-00 to 99-413-00 PEST Error 13 RAP • dC971 Head to Head Alignment Adjustment
• 99-444-00 to 99-460-00 PEST Error 16 RAP • GP 1 Service Mode
• 99-480-00 to 99-496-00 PEST Error 18 RAP • GP 4 Machine Software
• 99-497-00 to 99-515-00 PEST Error 19 RAP • GP 5 Customer Administration Tools
• 99-626-00 to 99-640-00 PEST Error 27 RAP • GP 15 Location and Function of PWB LEDs
• 99-641-00 to 99-655-00 PEST Error 28 RAP • GP 20 Paper and Media Size Specifications
• OF 1 Unusual Noise RAP • GP 21 Installation Space Requirements
• OF 2 UI Touch Screen Failure RAP (W/O TAG 006) • GP 37 Post Part Replacement Routines
• OF 3 Unresponsive Machine RAP • GP40 Glossary of Terms, Acronyms and Abbreviations
• OF 4a Status Codes and Messages RAP • GP 45 How to Identify the Type A and Type B Printheads
• OF 4b Status Messages in Alphabetical Order • PJ Locations Drum Driver PWB
• OF 5 Boot Up Failure RAP • Location Figures for PWB Connectors and In-line Connectors
• OF 10 Intermittent Failure RAP • System Overview
• OF 16 POST Error RAP The following procedures are new
• OF 17 Service Code RAP • 12-198-00-110 Finisher Stray Sheet Detected RAP
• IQ 1 Image Quality Entry RAP • 16-718-00 to 16-16-724-00 Hard Disk Partition Full RAP
• IQ 4 Wrong Copied Colours RAP • 62-310-00D Scanner to Single Board Controller Communication Fail RAP
• IQ 5 Jagged or Blurry Lines or Text RAP • REP 3.13 8 Pin NVRAM
• IQ 9 Deletions in the Process Direction RAP • REP 12.102-171 Docking Latch Assembly
• IQ 13 All Colours Uneven RAP • GP 46 ColorQube 9201 Low Cost Printhead
• IQ 23 Residual Ink From Previous Print RAP • GP 47 Spare part notices
• IQ 29 DADH, Document Glass and Scanner RAP • TAG 019 Reservoir splash guard

Xerox® ColorQube® 9203 Family xiii Change History
EDOC Update October 2014 Documentation Symbol
The following procedures are updated This symbol is displayed in the service documentation:
• Health and Safety Incident Reporting
• 03-331-00, 03-332-00 Main Controller Board Cannot Communicate with ESS RAP ESD Caution Symbol
• 05A DADH Other Faults RAP
• 12-151-00-110, 12-152-00-110 Sheet Late to Bin 1 RAP
• 12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector Movement Failure RAP
• 12D-110 LCSS Power Distribution RAP
• 12-762-00-171, 12-764-00-171, 12-765-00-171 IME To Finisher Communication Failure
RAP
• 12K-171 HVF Initialization Failure RAP
• 16B FTP or SMB Unable to Connect to Remote Server RAP
• OF 4a Status Codes in Numerical Order
• OF 4b Status Messages in Alphabetical Order CAUTION
• OF 9 Ink Stick Count Mismatch Certain components in this product are susceptible to damage from electrostatic discharge.
• 94-535-00 Drum Driver Command Current Error RAP Observe all ESD procedures to avoid component damage.
• 99-175-00 to 99-218-00 PEST Error 5 RAP
• 99-245-00 to 99-271-00 PEST Error 7 RAP
• 99-824-00 to 99-838-00 PEST Error 38 RAP
• OF1 Unusual Noise RAP
• OF 9 Ink Stick Count Mismatch
• IQ 26 Poor Ink Adhesion RAP
• ADJ 4.1 Machine Lubrication
• GP 7 System Grounding Verification
• GP 27 Cleaning Procedure
• dC132 Serial Number
• All wiring diagrams have been revised for improved viewing on the PWS.
The following procedures are new
• 05G DADH Exit RAP

Change History, Documentation Symbol xiv Xerox® ColorQube® 9203 Family
Mod / Tag Identification Voltages Resistances and Tolerances
Figure 1, shows the Mod/Tag identification symbols. For AC power specifications, refer to GP 22 Electrical Power Requirements.
DC Voltage Levels and Tolerances

DC Voltages should be measured between an available test point and a machine ground.
Table 1 shows the range of the common voltages.
These with tag symbols are used to identify the components Table 1 DC Voltage Levels
or configurations that are part of a machine change covered
Nominal voltage Voltage tolerance range RAP reference
by this tag number.
0 volts 0.00 to 0.10V 01L 0V Distribution RAP
+3.3V ESTAR +/− 2.5% 01B +3.3V ESTAR Distribution RAP
+3.3V +/− 2.5% 01C +3.3V Distribution RAP
+5.V 5.1V +/- 5% 01D +5V Distribution RAP
+12V +/− 5% 01E +12V Distribution RAP
These without tag symbols are used to identify the -12V +/− 5% 01F -12V Distribution RAP
components or configurations that are used when this +17V See Note 01G +17V Distribution RAP
tag is not fitted.
+24V +/- 5% 01H +24V Distribution RAP
+50V 47V to 49V 01J +50V Distribution RAP
-50V -47V to -49V 01K -50V Distribution RAP
Non-standard voltage levels will be quoted on the relevant circuit diagram. All other voltage lev-
els are plus or minus 10%.
Figure 1 Mod / Tag identification symbols
NOTE: During power self test and when in the sleep mode, this supply is 17V unregulated and
is approximately +17V. When the machine is in the active mode, this supply raises to +24V +/-
5%
Resistance Tolerances
All resistance measurement tolerances are plus or minus 10%, unless otherwise stated in the
procedure.
DC Signal Nomenclature
Figure 1 shows the signal nomenclature used in this manual.

Xerox® ColorQube® 9203 Family xv Mod / Tag Identification, Voltages Resistances and
Safety Information
Signal description (event that
causes the signal level change) The WARNING that follows is for general guidance when live working.
WARNING
Do not work in a confined space. 1m (39 inches) space is needed for safe working.
Safety Icons
The safety icons that follow are displayed on the machine:
Hot Surface Symbol

This symbol indicates hot surfaces. Take care when servicing the machine.
Voltage supplied to
the signal circuit
Logic level when the
signal is available
Wire colour
Figure 1 Signal Nomenclature Lethal Voltage Symbol
This symbol indicates potentially lethal voltages. Take care when servicing the machine when
Table 2 shows the signal tolerances.
the power cord is connected.
Table 2 Signal tolerances
Signal voltage (H) logic level (L) logic level
+5V +3.85V or greater At or near 0.8V
+3.3V +2V or greater At or near 0.8V
Non standard signal tolerances will be quoted on the relevant circuit diagram. Fuses
NOTE: The logic level shown with the signal name will be the actual signal as measured with a
service meter. This will not necessarily be the same as the logic state shown on the diagnostic WARNING
screen.
Do not install a fuse of a different type or rating. Installing the wrong type or rating of
Samples of RAP Reference Text fuse can cause overheating and a risk of fire.
Throughout the manual there are linked references that extend the diagnostic procedure or Part Replacement
add more information: Only use genuine Xerox approved spare parts or components to maintain compliance with leg-
islation and safety certification.
• GP 11 How to Check a Sensor.
NOTE: This links to General Procedures information. Disassembly Precautions

Do not leave the machine with any covers removed at a customer location.
• WD 1.5
NOTE: This links to a relevant wiring diagram. Reassembly Precautions

Use extreme care during assembly. Check all harnesses to ensure they do not contact moving
Install new components as necessary:
parts and do not get trapped between components.
• Tray 1 feed sensor, PL 81.25 Item 19.
NOTE: This links to the parts list. If installation of the new component is simple, the parts General Procedures
list artwork is sufficient to show how the component is assembled in the machine. If instal- Observe all warnings displayed on the machine and written in the service procedures.
lation of the new component is not simple, the parts listing will contain cross references to
repair procedures and adjustments, as necessary. Do not attempt to perform any task that is not specified in the service procedures.

Voltages Resistances and Tolerances, Safety Infor- xvi Xerox® ColorQube® 9203 Family
Health and Safety Incident Reporting VI. Appendices
I. Summary The Health and Safety Incident Report involving a Xerox Product (Form # EH&S-700) is avail-
able in the locations that follow:
This section defines requirements for notification of health and safety incidents involving Xerox
products (equipment and materials) at customer locations. • On electronic documentation (EDOC), located in the folder \safety.
• In the hardcopy, located at the end of the manual.
II. Scope
Xerox Corporation and subsidiaries worldwide.
III. Objective
To enable prompt resolution of health and safety incidents involving Xerox products and to
ensure Xerox regulatory compliance.
IV. Definitions
Incident:
An event or condition occurring in a customer account that has resulted in injury, illness or
property damage. Examples of incidents include machine fires, smoke generation, physical
injury to an operator or service representative. Alleged events and product conditions are
included in this definition.
V. Requirements
Initial Report:
1. Xerox organizations shall establish a process for individuals to report product incidents to
Xerox Environment Health & Safety within 24 hours of becoming aware of the event.
2. The information to be provided at the time of reporting is contained in Appendix A (Health
and Safety Incident Report involving a Xerox product).
3. The initial notification may be made by either of the methods that follow:
• Email Xerox EH&S at: usa.product.incident@xerox.com.
• Fax Xerox EH&S at: +1-585-422-8217 [intelnet 8-222-8217].
NOTE: If sending a fax, please also send the original via internal mail.
Responsibilities for resolution:

1. Business Groups / Product Design Teams responsible for the product involved in the inci-
dent shall:
a. Manage field bulletins, customer correspondence, product recalls, safety retrofits.
b. Fund all field retrofits.
2. Field Service Operations shall:
a. Preserve the Xerox product involved and the scene of the incident inclusive of any
associated equipment located in the vicinity of the incident.
b. Return any affected equipment/part(s) to the location designated by Xerox EH&S
and/or the Business Division.
c. Implement all safety retrofits.
3. Xerox EH&S shall:
a. Manage and report all incident investigation activities.
b. Review and approve proposed product corrective actions and retrofits, if necessary.
c. Manage all communications and correspondence with government agencies.
d. Define actions to correct confirmed incidents.

Xerox® ColorQube® 9203 Family xvii Health and Safety Incident Reporting
Translated Warnings
WARNING WARNING
Take care during this procedure. Sharp edges may be present that can cause injury.
Ensure that the electricity to the machine is switched off while performing tasks that do
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause DANGER: Exécuter cette procédure avec précaution. La présence de bords tranchants
death or injury. Moving parts can cause injury. peut entraîner des blessures.
DANGER: Assurez-vous que la machine est hors tension lorsque vous effectuez des AVVERTENZA: procedere con cautela durante questa procedura. Possono essere pre-
tâches ne nécessitant pas d'alimentation électrique. Reportez-vous à GP 14. senti oggetti con bordi taglienti pericolosi.
Débranchez le câble d'alimentation pour prévenir tout risque d'électrocution. Les chocs VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, damit keine Verletzungen durch
électriques peuvent présenter un danger de mort ou entraîner des blessures graves. De die scharfen Kanten entstehen.
plus, certaines pièces, lorsqu'elles sont en mouvement, peuvent être source de AVISO: Tenga cuidado al efectuar este procedimiento. Puede haber bordes afilados que
blessures graves. podrían producir lesiones.
AVVERTENZA: Accertarsi di isolare la macchina dall'alimentazione elettrica quando si
eseguono attività che non richiedono elettricità. Vedere GP 14. Scollegare il cavo di ali-
mentazione. L'elettricità può causare morte o lesioni personali. Le parti in movimento WARNING
possono causare lesioni personali. Take care during this procedure. The stripper blade is very sharp and can cause injury.
VORSICHT: Sicherstellen, dass die Stromversorgung des Geräts bei Arbeiten, die DANGER: Effectuez cette procédure avec précaution. La lame du doigt décolleur est
keinen Strom erfordern, ausgeschaltet ist. Siehe auch GP 14. Den Netzstecker ziehen. très tranchante et peut être source de blessures.
Andernfalls besteht Stromschlaggefahr und Verletzungsgefahr durch bewegliche Teile.
AVVERTENZA: Fare attenzione durante questa procedura. La lama del separatore è
AVISO: Asegúrese de mantener la máquina aislada de la energía eléctrica mientras real- molto tagliente e può causare lesioni personali.
iza tareas que no necesitan electricidad. Consulte GP 14. Desconecte el cable de ali-
VORSICHT: Bei diesem Vorgang vorsichtig vorgehen. Die Abstreifklinge ist sehr scharf
mentación. La energía eléctrica puede producir lesiones o incluso la muerte. Las piezas
und es besteht Verletzungsgefahr.
sueltas pueden producir lesiones.
AVISO: Tenga cuidado durante este procedimiento. El conjunto de dedos de despegue
es muy filudo y puede producir lesiones.
WARNING
Do not work in a confined space. 1 m (39 inches) space is needed for safe working
WARNING
DANGER: Ne pas travailler dans un espace restreint. 1 mètre d'espace est nécessaire
Take care not to topple the LCSS. The LCSS is unstable when undocked from the
pour un dépannage en toute sécurité.
machine. Do not show the customer how to undock the LCSS.
AVVERTENZA: Non lavorare in uno spazio limitato; è necessario uno spazio di almeno
DANGER: Attention à ne pas faire tomber la trieuse/agrafeuse petite capacité. Elle n'est
un metro attorno alla macchina per la sicurezza dell'operatore.
pas stable lorsqu'elle est détachée de la machine. Ne pas montrer au client comment
VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten. détacher la trieuse/agrafeuse.
AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar AVVERTENZA: fare attenzione a non destabilizzare il modulo della pinzatrice/impilatore
con seguridad. da 2000 fogli. Quando è sganciato dalla macchina, il modulo è instabile: non mostrare al
cliente come sganciarlo
VORSICHT: Stapler nicht umstoßen. Nach Trennung des Staplers vom Document Centre
WARNING ist dieser sehr instabil
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If AVISO: Tenga cuidado de que no se caiga el apilador/grapadora de baja capacidad.
the stripper blade is dirty a new blade must be installed.
Cuando no está acoplada a la máquina es inestable. No le muestre al cliente como desa-
DANGER: Effectuez cette procédure avec précaution. La lame du doigt décolleur est coplar el apilador/grapadora de baja capacidad.
très tranchante et peut être source de blessures.
AVVERTENZA: Fare attenzione durante questa procedura. La lama del separatore è
molto tagliente e può causare lesioni personali. WARNING
VORSICHT: Bei diesem Vorgang vorsichtig vorgehen. Die Abstreifklinge ist sehr scharf Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
und es besteht Verletzungsgefahr. DANGER: Prendre des précautions lors du relevé de la tension de la prise de courant
AVISO: Tenga cuidado durante este procedimiento. El conjunto de dedos de despegue alternatif. L'électricité peut entraîner des blessures graves voire mortelles.
es muy filudo y puede producir lesiones.

Translated Warnings xviii Xerox® ColorQube® 9203 Family
AVVERTENZA: Procedere con cautela durante la misurazione della tensione CA della AVVERTENZA: Spegnere la macchina. Vedere GP 14. Scollegare il cavo di alimentazione
rete. L'elettricità può causare infortuni o morte. dall'alimentatore quando si eseguono attività che non richiedono elettricità. L'elettricità
VORSICHT: Bei der Netzspannungsprüfung stets vorsichtig vorgehen può causare morte o lesioni personali. Le parti in movimento possono causare lesioni
AVISO: Tenga cuidado al medir la tensión de la línea de alimentación de corriente personali.
alterna. La electricidad puede causar lesiones e incluso la muerte. VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Siehe auch GP 14. Zie-
hen Sie das Stromkabel ab, wenn Sie Aufgaben ausführen, für die keine Stromversor-
gung benötigt wird. Stromschläge können Todesfällen oder Verletzungen verursachen.
WARNING Bewegliche Teile können zu Verletzungen führen.
Do not install a fuse of a different type or rating. Installing the wrong type or rating of AVISO: Apague la electricidad de la máquina. Consulte el GP 14. Desconecte el cable de
fuse can cause overheating and a risk of fire. alimentación eléctrica de la toma de pared mientras esté realizando tareas que no
necesiten corriente. La electricidad puede causar daños o la muerte. Las partes móviles
DANGER: Ne pas installer de fusible de type ou de calibre différent. Il existe un risque
pueden causar daños.
de surchauffe voire d'incendie.
AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non installare un fus-
ibile di tipo o carica diversi da quelli esistenti. WARNING
VORSICHT: Keine Sicherungen anderer Art oder anderer Leistung auf dem IOT-PWB Do not touch the test pads on the embedded fax PWB while the fax cable is connected
installieren - Überhitzungs- und Brandgefahr.
to the machine. Dangerous voltages may be present that could cause death or injury.
AVISO: No instale un fusible de potencia o tipo distinto. Un fusible de potencia o tipo
DANGER : Ne pas toucher les contacts de test de la carte de circuits imprimés du fax
distinto puede producir sobrecalentamiento y el riesgo de incendio.
intégré tant que le câble du fax est connecté à la machine. Ils représentent un risque de
chocs élec-triques qui sont un danger de mort ou peuvent entraîner des blessures
graves.
WARNING
AVVERTENZA: non toccare le aree di contatto del PWB del fax incorporato mentre il
Keep away from the crease blade mechanism when working in close proximity to the cavo del fax è collegato alla macchina. La presenza di voltaggi pericolosi comporta il
booklet maker while the machine is powered on. The crease blade mechanism activates rischio di morte o lesioni personali.
quickly and with great force.
VORSICHT: Die Testpads (Prüfkontakte) der Platine für das integrierte Fax nicht
DANGER: Ne pas s'approcher du méchanisme de la lame de pliage lors d'une activité à berühren, solange das Faxkabel an das Gerät angeschlossen ist. An den Pads liegt eine
proximité de la plieuse/brocheuse pendant que la machine est sous tension. Ce mécan- Spannung an; es besteht Stromschlag- bzw. Lebensgefahr!
isme s'active rapidement et avec force.
AVISO: No toque la zona terminal de prueba que presenta el circuito impreso del fax
AVVERTENZA: Quando la macchina è accesa, tenersi a debita distanza dalla lama di pie- interno mientras el cable de fax está conectado a la máquina, ya que podrían producirse
gatura mentre si opera in prossimità della stazione libretto. Il meccanismo della lama di descargas peligrosas que podrían provocar lesiones o incluso la muerte.
piegatura si attiva con velocità e forza notevoli.
VORSICHT: Wenn bei eingeschaltetem Gerät nahe am Booklet Maker gearbeitet wird,
von der Schneidevorrichtung fernhalten. Die Schneidevorrichtung wird schnell und mit WARNING
viel Druck ausgelöst.
Take care during this procedure. The drum will become hot during normal operation.
AVISO: Manténgase apartado del mecanismo de la cuchilla hendedora cuando trabaje
DANGER: Faites attention pendant cette procédure. Dans des conditions normales de
junto al realizador de folletos si la máquina está encendida. Dicho mecanismo se activa
fonctionnement, le tambour devient chaud.
de forma rápida y con mucha fuerza.
AVVERTENZA: Prestare attenzione durante questa procedura. Il tamburo diventa caldo
durante il normale funzionamento.
WARNING VORSICHT: Die Trommel wird im Normalbe¬trieb heiß.
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord AVISO: Tome precauciones durante el procedimiento. El cilindro tendá una temperatura
from the customer supply while performing tasks that do not need electricity. Electricity elevada durante el funcionamiento normal.
can cause death or injury. Moving parts can cause injury.
DANGER: Mettez la machine hors tension. Reportez-vous à GP 14. Déconnectez le cor-
don d'alimentation de l'alimentation du client lorsque vous réalisez des tâches qui ne
WARNING
nécessitent pas d'électricité. L'électricité peut être à l'origine de blessures, voire d'un Do not touch the ink loader melt plates while the machine is switched on. Dangerous
accident mortel. Les pièces amovibles peuvent être à l'origine de blessures. voltages may be present that could cause death or injury.

Xerox® ColorQube® 9203 Family xix Translated Warnings
DANGER: Ne pas toucher les plaques de fusion du chargeur d'encre tant que la machine AVISO: No quite el alimentador de documentos automático de doble pasada si está
est sous tension. Elles représentent un risque de chocs électriques qui sont un danger bajado. Cuando está bajado, los resortes de contrapeso están comprimidos y pueden
de mort ou peuvent entraîner des blessures graves. causar lesiones al soltarse.
AVVERTENZA: non toccare le piastre di fusione del caricatore di inchiostro mentre la
macchina è accesa. La presenza di voltaggi pericolosi comporta il rischio di morte o
lesioni personali. WARNING
VORSICHT: Die Schmelzplatten des Tintenfüllbereichs nicht berühren, solange das Use safe handling procedures when removing the module, GP 16. The module is heavy.
Gerät eingeschaltet ist. An den Platten liegt eine Spannung an; es besteht Stromschlag- DANGER: Conformez-vous aux procédures de manipulation de sécurité pour le retrait
bzw. Lebensgefahr! du module. Reportez-vous à GP 16. Le module est lourd.
AVISO: No toque las planchas fundidas del cargador de tinta mientras la máquina esté AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo.
encendida, ya que podría haber tensiones peligrosas que podrían provocar lesiones o Vedere GP 16. Il modulo è pesante.
incluso la muerte. VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe
auch GP 16. Das Modul ist sehr schwer.
AVISO: Utilice los procedimientos de seguridad cuando elimine el módulo. Consulte el
WARNING GP 16. El módulo es pesado.
Do not touch the ink reservoir while it is hot.
DANGER: Ne pas toucher au réservoir d'encre tant qu'il est chaud.
AVVERTENZA: non toccare il serbatoio di inchiostro quando è caldo. WARNING
VORSICHT: Den Tintenbehälter erst anfassen, wenn er abgekühlt ist. Do not leave an old stripper blade at the customers site.
AVISO: No toque el depósito de tinta mientras éste esté caliente. DANGER: Ne pas laisser les lames usagées du doigt décolleur sur le site client.
AVVERTENZA: non lasciare mai una vecchia lama di separazione presso la sede del cli-
ente.
VORSICHT: Alte Abstreifklingen nicht am Kundenstandort zurücklassen, sondern
WARNING entsorgen.
Do not attempt any repairs to the power cord or safety ground harness/conductor. AVISO: No deje un conjunto de dedos de despegue antiguo en las instalaciones del cli-
DANGER: Ne pas tenter de réparer le faisceau/conducteur de mise à la masse ou du cor- ente.
don d'alimentation.
AVVERTENZA: non eseguire riparazioni sul cavo dell'alimentazione o sul conduttore di
terra di sicurezza.
VORSICHT: Keine Reparaturen am Netzkabel oder am Schutzleiter vornehmen.
AVISO: No intente reparar el cable de alimentación ni el conductor/mazo de tierra de WARNING
protección. Mandatory safety warning. This procedure must be performed by 2 people. The module
is heavy.
DANGER: Avertissement obligatoire. Cette procédure doit être effectuée par 2 per-
WARNING sonnes. Le module est très lourd.
Do not remove the DADH while the DADH is lowered. In the lowered position the coun- AVVERTENZA: Avviso di sicurezza obbligatorio. A causa della pesantezza del modulo,
terbalance springs are compressed and can cause injury when released. questa procedura deve essere eseguita da due persone.
DANGER: Ne pas retirer le CAD alors qu'il est en position basse. Dans cette position, les VORSICHT: Verbindliche Sicherheitsvorschrift - dieser Vorgang muss von zwei Per-
ressorts compensateurs sont compressés et peuvent entraîner des blessures s'ils se sonen ausgeführt werden, da das Modul sehr schwer ist.
relâchent. AVISO: Aviso de seguridad obligatorio. Este procedimiento debe ejecutarse entre dos
AVVERTENZA: non rimuovere l'alimentatore automatico documenti quando è personas. El módulo pesa mucho.
abbassato. In questa posizione, le molle del contrappeso sono compresse e possono
causare lesioni al rilascio.
VORSICHT: Vorlageneinzug nicht in abgesenkter Position entfernen. Bei abgesenktem WARNING
Vorlageneinzug sind die Ausgleichsfedern zusammengedrückt und können bei Fre- Do not undock the HVF BM from the machine. The HVF BM is unstable when undocked
igabe Verletzungen verursachen. from the machine. Do not show the customer how to undock the HVF BM.

Translated Warnings xx Xerox® ColorQube® 9203 Family
DANGER: Ne déconnectez pas le module HVF BM de la machine. Le module HCSS BM AVVERTENZA: Pulire immediatamente una fuoriuscita di olio per evitare il rischio di
devient instable lorsqu'il est déconnecté de la machine. Ne démontrez pas au client scivolare. Non camminare nell'area contaminata per evitare di diffondere l'area contami-
comment déconnecter le module HCSS BM. nata e di contaminare le calzature. Con le calzature contaminate si corre il rischio di
AVVERTENZA: Non sganciare il modulo HVF BM dalla macchina. Questo modulo non è scivolare.
stabile quando è sganciato dalla macchina. Non mostrare al cliente come sganciare il VORSICHT: Ölflecke unverzüglich entfernen. Bei verschüttetem Öl besteht Rutschge-
modulo HCSS BM. fahr. Ölverschmutzten Bereich nicht betreten. Durch Treten in eine Öllache breitet sich
VORSICHT: Docken Sie nicht den HVF BM von der Maschine ab. Der HCSS BM ist insta- die Verschmutzung aus und die Schuhe werden verunreinigt. Mit öligen Schuhsohlen
bil, wenn er von der Maschine abgedockt ist. Zeigen Sie dem Kunden nicht, wie der besteht Rutschgefahr.
HCSS BM abgedockt wird. AVISO: Limpie de inmediato el aceite derramado. El aceite derramado puede ocasionar
AVISO: No desacople el apilador o grapadora de alta capacidad HVF BM de la máquina. resbalones. No camine en la zona donde ocurrió el derrame. Si camina en ella, se untará
Ésta no es estable cuando se desacopla de la máquina. No muestre al cliente cómo de aceite los zapatos y esparcirá el aceite a otras zonas. Los zapatos con aceite pueden
desacoplar el apilador/grapadora de alta capacidad HCSS BM. ocasionar resbalones
WARNING WARNING
Take care not to topple Tray 5. Tray 5 is unstable when undocked from the machine. Do Do not attempt to mop up the spilt oil with conventional mops and water. This will
not show the customer how to undock Tray 5. spread the contamination and will extend the slip hazard.
DANGER: Attention à ne pas faire tomber le magasin 5. Le magasin 5 n’est pas stable DANGER: Ne pas essuyer avec une éponge ou une serpillère et de l'eau si de l'huile est
lorsqu’il est détaché de la machine. Ne pas montrer au client comment détacher le renversée. Cela étalerait l'huile et augmenterait la zone représentant un risque de chute.
magasin 5. AVVERTENZA: non tentare di pulire una fuoriuscita di olio utilizzando uno spazzolone e
AVVERTENZA: Fare attenzione a non destabilizzare il vassoio 5. Quando è sganciato acqua per evitare di estendere l'area contaminata e aumentare il rischio di scivolare.
dalla macchina, questo vassoio è instabile: non mostrare al cliente come sganciarlo. VORSICHT: Nicht versuchen, ausgetretenes Öl mit einem herkömmlichen Wischlappen
VORSICHT: Behälter 5 nicht umstoßen.Der Behälter ist nach der Trennung vom Gerät und Wasser zu beseitigen. Dadurch wird das Öl verteilt und es besteht eine noch
sehr instabil.Benutzer nicht im Trennen des Behälters vom Gerät einweisen. größere Rutschgefahr.
AVISO: Tenga cuidado de que no se caiga la bandeja 5. Cuando no está acoplada a la AVISO: Absténgase de limpiar el aceite derramado a la manera convencional con una
máquina, la bandeja 5 es inestable.No le muestre al cliente como desacoplar la bandeja fregona y agua, ya que ello sólo provocaría la extensión de la contaminación y aumen-
5. taría el peligro de deslizamiento.
WARNING WARNING
Take care during this procedure. Motors will become hot during normal operation. Wear protective gloves, PL 26.10 Item 5 when using solvents and cleaning agents.
DANGER: Exécuter cette procédure avec précaution. Les moteurs peuvent devenir très DANGER: Porter des gants de protection lors de l'utilisation de solvants et de produits
chauds en fonctionnement normal. de nettoyage, PL 26.10 Item 5.
AVVERTENZA: procedere con cautela durante questa procedura. I motori si riscaldano AVVERTENZA: utilizzare guanti protettivi durante l'impiego di solventi e soluzioni per
molto durante il funzionamento. pulizia PL 26.10 Item 5.
VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, da Motoren im Normalbetrieb heiß VORSICHT: Beim Einsatz von Lösungs- und Reinigungsmitteln Handschuhe tragen PL
werden können. 26.10 Item 5.
AVISO: Tenga cuidado al efectuar este procedimiento. Los motores alcanzan altas tem- AVISO: Póngase guantes de protección cuando utilice disolventes y productos de limp-
peraturas durante su funcionamiento normal. ieza PL 26.10 Item 5.
WARNING WARNING
Immediately clean an oil spill. Spilt oil is a slip hazard. Do not walk in the contaminated Do not switch on the electricity to the machine while a ground circuit is disconnected.
area. Walking in the contaminated area will spread the contamination and contaminate Ground circuits ensure that the machine remains safe during a fault condition.
footwear. Contaminated footwear is a slip hazard. DANGER: Ne pas mettre la machine sous tension si un circuit de mise à la masse est
DANGER: Dans le cas où de l'huile est renversée, nettoyez immédiatement pour éviter déconnecté. Les circuits de mise à la masse permettent de garantir la sécurité de la
tout risque de chute. Évitez de marcher dans la zone où de l'huile a été renversée pour machine lors d'un incident.
ne pas l'étaler sur le sol et prévenir tout risque de chute.

Xerox® ColorQube® 9203 Family xxi Translated Warnings
AVVERTENZA: Non accendere la macchina se uno dei conduttori di terra non è con- AVVERTENZA:Quando si usa la siringa per rimuovere l’olio, indossare i guanti protettivi
nesso. In caso di guasti elettrici, tali conduttori garantiscono la sicurezza del sistema. inclusi nel kit di rimozione dell'olio di silicone.
VORSICHT: Stromzufuhr zum Gerät nicht einschalten, wenn keine Erdung gegeben ist. VORSICHT: Beim Entfernen von Öl mit der Ölabsaugpumpe die im Reinigungsset für die
AVISO: No encienda la máquina mientras esté deconectado algún circuito de tierra. Los Silikonölbeseitigung enthaltenen Schutzhandschuhe tragen.
circuitos de tierra mantienen la seguridad de la máquina en las situaciones de averías o AVISO: Póngase los guantes protectores incluidos en el kit de extracción del aceite de
errores. silicona cuando utilice la jeringa para extraer el aceite.
WARNING WARNING
Do not use the on/off switch as a safety disconnect device. The on/off switch is not a Take care during this procedure. The registration/preheat assembly will become hot
disconnect device. Disconnect the power cord from the supply to isolate the equipment. during normal operation.
DANGER: Ne pas utiliser l'interrupteur comme système d'arrêt d'urgence. Déconnecter DANGER: Exécuter cette procédure avec précaution. Le module de cadrage/préchauff-
le cordon d'alimentation de la prise pour isoler l'équipement. age peut devenir très chaud en fonctionnement normal.
AVVERTENZA: Non usare l'interruttore di accensione/spegnimento come dispositivo di AVVERTENZA: procedere con cautela durante questa procedura. Il complessivo di reg-
sicurezza per il disinserimento dell'elettricità, in quanto l'interruttore non è stato diseg- istrazione/preriscaldamento raggiunge alte temperature durante il funzionamento.
nato per questa funzione. Per isolare la macchina dalla corrente elettrica, scollegare il VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, da das Ausrichtungsmodul/
cavo dell'alimentazione dalla presa a muro. Vorheizaggregat im Normalbetrieb heiß wird.
VORSICHT: Der Netzschalter reicht zur Trennung von der Netzspannung NICHT aus. Um AVISO: Tenga cuidado al realizar este procedimiento, ya que el conjunto de registro/pre-
das Gerät von der Netzspannung zu trennen, den Netzstecker abziehen. calentamiento alcanza una elevada temperatura durante su funcionamiento normal.
AVISO: No utilice el interruptor de encendido/apagado como dispositivo de desconex-
ión seguro. El interruptor de encendido/apagado no es un dispositivo de desconexión.
Para aislar el equipo totalmente, desconecte el cable de alimentación de la toma de cor- WARNING
riente. A warning is used whenever an operating or maintenance procedure, practice, condi-
tion or statement, if not strictly observed, could result in personal injury.
DANGER: Une note Danger est utilisée chaque fois qu'une procédure d'utilisation ou de
WARNING maintenance peut être cause de blessure si elle n'est pas strictement respectée.
USA and Canada. Do not install this machine in a hallway or exit route that does not
AVVERTENZA: Un segnale di avvertenza è utilizzato ogni volta che una procedura oper-
have 1.12 m (44 inches) of space additional to the normal space requirements in front of
ativa o di manutenzione, una pratica, una condizione o un'istruzione, se non stretta-
the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space mente osservata, potrebbe causare lesioni personali.
is needed in front of the machine in hallway and exit routes.
VORSICHT: Weist darauf hin, dass ein Abweichen von den angeführten Arbeits- und
DANGER: États-Unis et Canada. Si cette machine est installée dans un couloir ou une
Wartungsanweisungen gesundheitliche Schäden, möglicherweise sogar schwere Ver-
voie de sortie, 1,12 m (44 pouces) d'espace supplémentaire à l'espace normal doit être
letzungen zur Folge haben kann.
disponible devant la machine conformément aux normes de sécurité d'incendie.
AVISO:Un aviso se utiliza siempre que un procedimiento de operación o mantenimiento,
AVVERTENZA: N/A práctica o condición puede causar daños personales si no se respetan estrictamente.
VORSICHT: N/A
AVISO: Estados Unidos y Canadá. No instale esta máquina en un corredor o ruta de sal-
ida que no tenga 1.12 m (44 pulgadas) de ancho delante de la máquina, sin incluir el
espacio que ocupe la máquina. Este espacio adicional de 1.12 m (44 pulgadas) delante
de la máquina en corredores y rutas de salida es necesario para cumplir los requisitos
de las normas sobre incendios.
WARNING
Wear the protective gloves included in the silicon oil removal kit when using the syringe
to remove the oil.
DANGER: Il est indispensable de porter les gants de protection inclus dans le kit sili-
cone de nettoyage de l’huile lors de l’utilisation de la seringue de pour nettoyer l’huile.

Translated Warnings xxii Xerox® ColorQube® 9203 Family
1 Service Call Procedures
SCP 1 Initial Actions........................................................................................................ 1-3
SCP 2 Call Actions .......................................................................................................... 1-3
SCP 3 Fault Analysis....................................................................................................... 1-4
SCP 4 Subsystem Maintenance...................................................................................... 1-7
SCP 5 Final Actions ........................................................................................................ 1-8
October 2014 Service Call Procedures

Xerox® ColorQube® 9203 Family 1-1
Service Call Procedures October 2014
1-2 Xerox® ColorQube® 9203 Family
SCP 1 Initial Actions SCP 2 Call Actions
Use Service Call Procedures to find a problem with the machine. Use SCP 2 Call Actions during a service call.
Always use SCP 1 Initial Actions to collect information on the machine performance. Do not Procedure
overlook any of the Initial Actions procedures.
1. If this is the first service call to this machine perform the following actions:
a. Check the machine configuration with the customer.
Also refer to GP 33 Machine Features.
Refer to dC131 Read / Write to check the following:
Procedure • Machine speed - Refer to NVM ID 616-003. if incorrect a pre-serialized SIM is
required, obtain through normal channels.
• Product identifier - Refer to NVM ID 616-052 - if required correct within the
WARNING NVM location.
Do not work in a confined space. 1 m (39 inches) space is needed for safe working • Service plan - Refer to NVM ID 606-269 - if required correct in dC136 or dC103.
1. If the reason for the call is an oil spill from the machine, go to GP 27 Cleaning Procedure. b. Check that all the required hardware and software is installed. Check that all the
2. Ask the operator to describe or demonstrate the problem. required hardware and software is enabled.
c. Mark off the hardware options, software options or Tags installed on the Tag matrix
NOTE: If the machine is password protected, login into Service Copy Mode, refer to GP 1 cards.
Service Mode.
d. Enter the machine information and the customer information in the service logbook.
3. If the problem is the result of an incorrect action by the operator, refer the operator to the 2. Check and record the total print count.
user documentation. 3. Review any copy, print and fax samples.
4. Check the steps that follow: 4. Make sure the user access settings are correct. If necessary refer to the user documenta-
a. The power lead is connected to the wall outlet and to the machine. tion.
b. Documents are not loaded in the DADH or on the document glass. 5. To prevent the deletion of the soft machine settings perform an NVM Save from service
c. The paper is loaded correctly. mode on the UI using dC361 NVM Save and Restore in the maintenance routines.
If the paper in the trays does not match the paper specified on the UI, change the 6. If necessary perform GP 17 Network Clone Procedure.
paper or the specification to match.
NOTE: The clone file must be taken whenever the customer changes the network control-
d. All paper trays are closed. ler setting or the system software is changed. Advise the administrator to perform this pro-
e. All covers are closed or installed. cedure at a regular interval.
f. If a telephone line is installed, make sure that the line is connected between the
7. Determine if the printheads require resealing, refer to Mod.TAG 017.
machine and the wall jack.
8. Before switching off the machine or clearing the memory, check for a customer job in the
g. If a telephone line is installed, make sure that the customer telephone line is func-
memory.
tioning.
9. Go to SCP 3 Fault Analysis.
h. That there are sufficient supply of ink sticks.
i. If the problem is media related. Check the relevant area of paper path for scraps of
media or sheets not easily visible to a customer
5. Check the machine service log book for previous actions that are related to this call.
6. Go to SCP 2 Call Actions.

Xerox® ColorQube® 9203 Family 1-3 SCP 1, SCP 2
SCP 3 Fault Analysis
Use SCP 3 Fault Analysis to identify a fault.
Procedure
If an error message or fault code appears, go to the relevant RAP. If necessary refer to OF 4
Status Codes and Messages RAP.
Check the fault history. Refer to GP 2 Fault Codes and History Files. If necessary, go to the rel-
evant RAP.
Check if a Service Code is displayed on the Machine Information tab on the user interface,
refer to OF 17 Service Codes RAP. If necessary perform OF 17 Service Codes RAP
Figure 1 Splash screen
To check for Power on Self Test (POST) errors. Refer to OF 16 Post Error RAP.
• If the UI displays ‘The machine is not available’ or the machine does not come to a ‘Ready
to scan your job’ state. Go to the OF 5 Boot Up Failure RAP.
If a fault code is not displayed use the machine in all modes until the fault is found. Use the list
that follows to find the correct procedure for the machine fault. When the fault is cleared, go to Sleep Mode Problems
SCP 4 Subsystem Maintenance, then SCP 5 Final Actions. • If the machine fails to enter or exit sleep mode, go to the OF 7 Sleep Mode RAP.
• Power Up Problems User Interface Problems
• Sleep Mode Problems • Go to the OF 3 Unresponsive Machine RAP if the machine has the faults that follow:
• User Interface Problems – The machine is silent.
• Messages – There is no information on the user interface.
• Image Quality Problems – There is no LED illumination on the user interface.
• DADH Problems • If the user interface is not illuminated or fails to respond correctly, go to the relevant pro-
• Paper Supply and Paper Feed Problems cedure:
• OCT Problems – OF 2 UI Touch Screen Failure RAP (W/O TAG 006).
• LCSS Problems – OF 18 UI Touch Screen Failure RAP (W/TAG 006).
• HVF, HVF BM, Inserter and Tri-Folder Problems • If the user interface is illuminated, but there is no information, go to the 02-321-00 XEIP
Browser Dead RAP.
• Fax Problems
• If the UI is offset, corrupted or a problem selecting features, refer to GP 32 user Interface
• Other Problems
Panel Diagnostics, check panel calibration and the UI functions.
• Additional Information
Messages
Power Up Problems
• If a message is displayed, but not a fault code, go to OF 4 Status Code and Message
• Go to the OF 3 Unresponsive Machine RAP if the machine has the faults that follow: RAP.
– The machine will not power up. Image Quality Problems
– There is no information on the user interface. • Image quality fault. Go to the IQ 1 Image Quality Entry RAP.
– There is no LED illumination on the user interface. DADH Problems
– All the panel lights are on, the UI touch screen is illuminated and the machine then • If the DADH does not detect the documents in the DADH input tray, go to 05B DADH Doc-
powers off. ument Sensor Failure RAP.
• If the UI display stops on the splash screen, Figure 1, go to OF 16 POST Error RAP. • If the DADH has a fault, but not a fault code, go to the 05A DADH Other Faults RAP.
• If the DADH has detected a document of the wrong size. Perform the procedures that fol-
low:
– 62A Scanning Document Size RAP (W/O TAG 007) or 62C Scanning Document
Size RAP (W/TAG 007).
– 05-257-00 Unknown Document Size RAP.

SCP 3 1-4 Xerox® ColorQube® 9203 Family
Paper Supply and Paper Feed Problems – 12E-171 Copy Damage in the HVF BM RAP.
• For the paper supply faults that do not have a fault code, perform the relevant procedures – 12F-171 Mis-Registration in Stapled and Unstapled Sets RAP.
that follow: – 12G-171 HVF BM Poor Stacking RAP.
– 71A Tray 1 Empty RAP. – 12H-171 Pause To Unload (PTU) RAP.
– 71B Tray 1 Wrong Size Paper RAP. – 12J-171 Inserter Paper Sensing and +5V Supply RAP.
– 72A Tray 2 Empty RAP. – 12K-171 HVF Initialization Failure RAP.
– 72B Tray 2 Wrong Size Paper RAP. – 12L-171 Tri-Folder Not Detected RAP.
– 73A Tray 3 Out Of Paper RAP. – 12N-171 Chad Bin Present and Bin Full RAP.
– 74A Bypass Tray RAP. – 12P-171 Buffer Clamp RAP
– 75B Tray 5 Empty RAP • If a booklet is not stapled or folded correctly go to:
• If the machine produces a multifeed, go to the OF 8 Multifeed RAP. – ADJ 12.6-171 Booklet Compiling Position
OCT Problems – ADJ 12.7-171 Booklet Crease Position
• If the prints adhere to each other in the OCT, check the static brush at the exit rolls PL – ADJ 12.8-171 Booklet Staple Position
10.15 Item 5.
• If the tri-folder paper fold is not in the correct position, perform ADJ 12.2-171 Tri-Folder
LCSS Problems Paper Settings.
• If the machine has an LCSS fault, but not a fault code, perform the relevant procedures Fax Problems
that follow: • For Fax problems with no fault code, perform the relevant procedures that follow:
– 12A-110 Pause to Unload (PTU) Fault RAP. – 20A Fax Entry RAP.
– 12B-110 Bin 1 Overload RAP. – 20B Unable To Send A Fax RAP.
– 12C-110 LCSS Initialization Failure RAP. – 20C Unable To Send A Fax To Some Machines RAP.
– 12D-110 LCSS Power Distribution RAP. – 20D Unable To Receive A Fax RAP.
– 12E-110 LCSS Paper Entry RAP. – 20E Fax Will Not Print RAP.
– 12F-110 LCSS PWB DIP Switch Settings RAP. – 20F Fax Tab Not Available RAP.
– 12G-110 LCSS PWB Damage RAP. – 20G Embedded Fax Checkout RAP.
– 12H-110 Copy Damage in the LCSS RAP. – 20H Embedded Fax PWB Voltage Checkout.
– 12J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. Other Problems
– 12K-110 LCSS Poor Stacking RAP. • Ink leak. Go to the 93B Ink Leak Checkout RAP
– 12L-110 Stapling Prime Failure RAP. • The ink level gauges on the UI do not correlate with the number of ink sticks in the ink
– 12M-110 Staple Head Operation Failure RAP. loader. Refer to OF 9 Ink Stick Count Mismatch.
– 12N-110 Chad Bin Present and Bin Full RAP. • The key plate is in the incorrect position and preventing the loading of the ink sticks. Go to
• If the punched holes are out of position, perform ADJ 12.3-110 Hole Punch Position. the OF 11 Unable to Load Ink Sticks.
• If the machine has the problems that follow, go to the 12F-110 LCSS PWB DIP Switch • Intermittent failure. Go to the OF 10 Intermittent Failure RAP.
Settings RAP: • Machine noise. Go to the OF 1 Unusual Noise RAP.
– False jam clearance messages. • Hot machine. Go to the OF 6 Fans and Air Systems RAP.
– Communication errors between the LCSS and the machine. • Convenience stapler faults. Go to the OF 13 Convenience Stapler RAP.
• If the staples of a stapled set are not correct, go to the 12L-110 Stapling Prime Failure • Machine odour. Go to the OF 6 Fans and Air Systems RAP.
RAP.
• Check the fault history, GP 2 Fault Codes and History Files
HVF, HVF BM, Inserter and Tri-Folder Problems
• Xerox extensible interface platform faults. Go to the OF 14 Xerox Extensible Interface
• If the machine has a fault in the HVF or HVF BM, but with no fault code, perform the rele- Platform RAP.
vant procedures that follow: • Xerox secure access faults. Go to the OF 15 Xerox Secure Access RAP.
– 12A-171 HVF BM Power Distribution RAP. • Network problems, go to the 16A Network Error Entry RAP.
– 12B-171 HVF BM to Machine Communication Interface and BM Present RAP. • If the foreign device is not detected, go to the 03A Foreign Device PWB Fault RAP.
– 12C-171 HVF BM Bin 2 Failure RAP.
– 12D-171 Booklet Quality RAP.

Xerox® ColorQube® 9203 Family 1-5 SCP 3
Additional Information • GP 42 How to Set the IP Address of the PWS
If necessary, refer to the following general procedures and information: • GP 43 How to Change Ethernet Speed
• GP 1 Service Mode • GP 44 How to Disable the Firewall of the PWS
• GP 2 Fault Codes and History Files • GP 45 How to Identify the Different Printhead Connectors
• GP 3 Service Information • GP 46 ColorQube 9201 Low Cost Printhead
• GP 5 Customer Administration Tools
• GP 6 Marking Unit Maintenance Positions
• GP 7 System Grounding Verification
• GP 8 Special Tools and Consumables
• GP 9 User Interface Service Menu Map
• GP 10 How to Check a Motor
• GP 11 How to Check a Sensor
• GP 12 How to Check a Solenoid or Clutch
• GP 13 How to Check a Switch
• GP 14 How to Switch Off the Machine or Switch On the Machine
• GP 15 Location and Function of PWB LEDs
• GP 16 How to Safely Lift or Move Heavy Modules
• GP 17 Network Clone Procedure
• GP 18 Machine Lubrication
• GP 19 Machine SIM Card Matrix
• GP 20 Paper and Media Size Specifications
• GP 21 Installation Space Requirements
• GP 22 Electrical Power Requirements
• GP 23 Environmental Data
• GP 24 Hardware Kit Contents
• GP 25 First Copy / Print Out Time and Power On / Off Time
• GP 26 Restriction of Hazardous Substances (RoHS)
• GP 27 Cleaning Procedure
• GP 28 Marking Unit Assembly Wiring Harnesses
• GP 29 Component Locations
• GP 30 How to Mask Jets / Jet Substitution
• GP 31 How to Open and Close the Stripper Gate
• GP 32 User Interface Panel Diagnostics
• GP 33 Machine Features
• GP 34 Service Plan
• GP 35 Copy and Print Speeds
• GP 36 How to Unlock the Cleaning Unit
• GP 37 Post Part Replacement Routines
• GP 38 How to Set the Date and Time
• GP 39 How to Enable HTTP
• GP 40 Glossary of Terms, Acronyms and Abbreviations
• GP 41 How to Configure the PWS to Ping a Device

SCP 4 Subsystem Maintenance Table 2 HFSI cleaning
Use SCP 4 Subsystem Maintenance to maintain the machine. The

recommended
Procedure cleaning Parts list
Item Component Description frequency reference
Drum fan Drum fan All sheets fed after last 500k feeds PL 94.20 Item 5
WARNING shroud shroud HFSI reset
Ensure that the electricity to the machine is switched off while performing tasks that do Upper JL baf- Upper baffle All sheets fed after last 400k feeds PL 10.10 Item 9
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause fle HFSI reset
death or injury. Moving parts can cause injury.
Go to the correct procedure: Lubrication
• HFSI To lubricate the machine, refer to ADJ 4.1 Machine Lubrication.
• Lubrication
• How to Clean the Machine How to Clean the Machine
HFSI To clean the machine, refer to GP 27 Cleaning Procedure.
The High Frequency Service Items are shown in Table 1 HFSI replacement and Table 2 HFSI
cleaning. To change HFSI settings, refer to dC135 CRU / HFSI Status.
Table 1 HFSI replacement

The
recommended
life for new
component Parts list
Item Component Description installation reference
Tray 1 feed Feed rolls All sheets fed from tray 1 600k feeds PL 81.25 Item 6
after last HFSI reset PL 81.25 Item 9
PL 81.25 Item 11
PL 81.26 Item 11
PL 81.30 Item 11
Bypass tray Bypass tray The total bypass tray 600k feeds PL 74.10 Item 7
feeds feed rolls feeds after the last HFSI PL 74.10 Item 13
reset PL 74.10 Item 14
Tray 5 feeds Tray 5 feed All sheets fed from tray 5 600k feeds PL 81.45 Item 2
rolls after last HFSI reset
Inserter Inserter feed Total Inserter feeds 80k feeds PL 12.310 Item 1
rolls
Transfix strip- Transfix strip- All sheets fed after last 460k feeds PL 10.20 Item 14
per per assembly HFSI reset

Xerox® ColorQube® 9203 Family 1-7 SCP 4
SCP 5 Final Actions
Use SCP 5 Final Actions to complete the service call.
Procedure
Perform the steps that follow:
1. If necessary, perform an NVM Restore from service mode on the UI using dC361 NVM
Save and Restore.
2. If necessary perform GP 17 Network Clone Procedure.
NOTE: The clone file will need to be taken whenever the customer changes the network
controller setting or after the system software is changed.
3. If necessary, go to SCP 4 Subsystem Maintenance.

4. Clear all fault counters, go to GP 1.
5. Check that the Service Code on the Machine Information tab displays 0. If any number
other than 0 is displayed go to OF 17 Service Codes RAP.
6. Empty waste tray and reset waste tray count in the Call Closeout window in service mode.
7. Operate the machine in all modes.
8. Make copies and / or prints from all trays and check the registration and copy quality.
9. Make a proof copy or print of a customer document.
10. If some of the customers selections were changed, return the selections to the customer
settings.
11. Mark off the hardware options, software options or Tags installed on the Tag matrix cards.
12. Perform an NVM Save from service mode on the UI using dC361 NVM Save and Restore
in the maintenance routines.
13. If some changes were made to the configuration or options were added, print the configu-
ration report. Store the configuration report with the machine log book. Discard the previ-
ous version of the configuration report.
14. Make sure the machine and service area are clean. Go to GP 27 Cleaning Procedures.
15. If necessary, provide the customer with training.
16. At the completion of the service call report the value of the usage counters.

2 Status Indicator RAPs
Chain 1 - Standby Power Chain 5 - DADH
01-505-00 Mid Left Door Open RAP ............................................................................... 2-9 05-250-00, 05-251-00 DADH Checksum Error RAP ....................................................... 2-55
01-506-00 Upper Left Door Open RAP ........................................................................... 2-9 05-252-00 DADH Stepper Controller Communications Error.......................................... 2-55
01-510-00 Front Door Open RAP.................................................................................... 2-10 05-253-00, 05-254-00 DADH Communications Error RAP ............................................. 2-56
01-525-00 +24V, +/-12V, +5V Short Circuit and Overload RAP ..................................... 2-10 05-255-00 Late Pre Scan Message RAP ........................................................................ 2-56
01-530-00 +/- 50V Short Circuit and Overload RAP ....................................................... 2-12 05-256-00 Eject Count Error RAP ................................................................................... 2-57
01-535-00 Power Interlock Failed: No Heater Requests RAP ........................................ 2-13 05-257-00 Unknown Document Size RAP ...................................................................... 2-57
01-540-00, 01-544-00 +24V, +/-12V, +5V Failure RAP .................................................. 2-14
05-258-00, 05-307-00 DADH Cover Interlock Open RAP ............................................... 2-59
01-542-00, 01-546-00 50V Failure RAP.......................................................................... 2-15
01A AC Power Distribution RAP ..................................................................................... 2-16 05-259-00, 05-260-00 DADH Active Line or Standby Error RAP .................................... 2-60
01B +3.3V ESTAR Distribution RAP ............................................................................... 2-20 05-300-00 DADH Open RAP........................................................................................... 2-60
01C +3.3V Distribution RAP ............................................................................................ 2-22 05-310-00 Document Too Short RAP ............................................................................. 2-61
01D +5V Distribution RAP ............................................................................................... 2-24 05-330-00, 05-331-00 DADH Feed Sensor Failure RAP ................................................ 2-62
01E +12V Distribution RAP ............................................................................................. 2-27 05-335-00 DADH TAR Sensor Failure RAP.................................................................... 2-64
01F -12V Distribution RAP .............................................................................................. 2-30 05-340-00 DADH Pre Registration Sensor Failure RAP ................................................. 2-65
01G +17V Distribution RAP............................................................................................. 2-31 05-345-00, 05-346-00 DADH Exit Sensor Failure RAP................................................... 2-66
01H +24V Distribution RAP ............................................................................................. 2-31 05-350-00, 05-352-00 DADH CVT Sensor Failure RAP ................................................. 2-67
01J +50V Distribution RAP.............................................................................................. 2-35
05A DADH Other Faults RAP.......................................................................................... 2-68
01K -50V Distribution RAP .............................................................................................. 2-37
01L 0V Distribution RAP.................................................................................................. 2-38 05B DADH Document Sensor Failure RAP..................................................................... 2-69
05C DADH Motor Failure RAP ........................................................................................ 2-69
Chain 2 - User Interface 05D DADH Feed Clutch Failure RAP.............................................................................. 2-70
02-302-00, 02-306-00, 02-308-00 Flash Failure RAP ..................................................... 2-41 05E Damaged Documents RAP...................................................................................... 2-70
02-315-00 Service Registry Bad Data RAP .................................................................... 2-41 05F Platen Down Failure RAP ........................................................................................ 2-71
02-316-00, 02-317-00 SRS Error RAP............................................................................ 2-42 05G DADH Exit RAP ....................................................................................................... 2-72
02-320-00 Data Time Out Error RAP .............................................................................. 2-42
02-321-00 XEIP Browser Dead RAP............................................................................... 2-43 Chain 10 - Transfix and Copy/Print Transportation
02-380-00, 02-381-00 UI Communication Fault RAP...................................................... 2-43 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00, 10-148-00 Post Transfix
02-390-00 Configurable Services RAP ........................................................................... 2-44 Jam RAP ......................................................................................................................... 2-73
10-140-00 to 10-146-00, 10-149-00 to 10-151-00 Exit Jam RAP.................................... 2-75
Chain 3 - Machine Run Control 10-500-00 to 10-540-00 Transfix Error RAP ................................................................... 2-76
03-316-00 CCM Cannot Communicate with IOT RAP .................................................... 2-45 10-545-00 Drum Position Error for Transfix RAP ............................................................ 2-78
03-325-00 System Detects the Machine Clock Failed to Increment During Power On RAP 2-45 10-550-00 Drum Stall During Transfix RAP .................................................................... 2-79
03-331-00, 03-332-00 Main Controller Board Cannot Communicate with ESS RAP...... 2-46 10-555-00 Post Transfix Motor (M4) Over Current RAP ................................................. 2-79
03-338-00 The Main Controller on the CCB / SBC Has Reset RAP ............................... 2-46 10-560-00, 10-565-00 Transfix Motor Over Current RAP ............................................... 2-80
03-346-00 Unable To Communicate With UI RAP .......................................................... 2-47 10-570-00 Stripper Solenoid Over Current RAP ............................................................. 2-81
03-347-00 Main Controller PWB Cannot Communicate with UI PWB RAP .................... 2-47 10-571-00, 10-572-00 Stripper Latch Sensor Error RAP ................................................ 2-82
03-355-00 CCM POST Failure Detected RAP ................................................................ 2-48
03-360-00 CCS POST System Memory Error RAP ........................................................ 2-48 Chain 12-65 - Offset Catch Tray
03-361-00 CCS POST Flash Memory Error RAP ........................................................... 2-49 12-701-00-65 Offset Catch Tray Failure RAP ................................................................. 2-83
03-362-00 CCS Power Fault RAP................................................................................... 2-49
Chain 12-110 - LCSS
03-397-00 System Configuration Recovery Attempt RAP............................................... 2-50
12-024-00-110, 12-025-00-110 Paddle Roll Failure RAP ............................................... 2-85
03-398-00, 03-399-00 SIM Card Fault RAP .................................................................... 2-51
12-043-00-110, 12-046-00-110 Hole Punch Operation Failure RAP .............................. 2-86
03-401-00, 03-403-00 Fax Not Detected RAP ................................................................ 2-51
12-127-00-110 Sheet Late to Hole Punch RAP .............................................................. 2-87
03-417-00 Incompatible Fax Software RAP .................................................................... 2-52
12-151-00-110, 12-152-00-110 Sheet Late to Bin 1 RAP ............................................... 2-87
03-777-00 Power Loss Detected RAP ............................................................................ 2-52
12-171-00-110, 12-172-00-110 Paper Exiting to Bin 0 RAP ........................................... 2-89
03-788-00 CCS Runtime could not Enter Power Saver Mode S3 RAP .......................... 2-53
12-198-00-110 Finisher Stray Sheet Detected RAP ....................................................... 2-90
03-790-00 Timezone Cannot Be Set RAP ...................................................................... 2-53
12-199-00-110 Unexpected Sheet at Finisher Entry RAP............................................... 2-91
03A Foreign Device PWB Fault RAP .............................................................................. 2-54
12-310-00-110, 12-312-00-110, 12-313-00-110 Interlocks RAP..................................... 2-92
October 2014 Status Indicator RAPs

12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector Movement Failure RAP ........... 2-93 12-369-00-171 to 12-377-00-171 HVF Stapler Position and Priming RAP ..................... 2-148
12-371-00-110, 12-372-00-110, 12-378-00-110 Staple Head Unit Movement Failure RAP 2-94 12-392-00-171 to 12-395-00-171 HVF Front Tamper Fault RAP.................................... 2-151
12-392-00-110, 12-393-00-110, 12-394-00-110 Front Tamper Move Failure RAP ........ 2-96 12-396-00-171 to 12-399-00-171 HVF Rear Tamper Fault RAP .................................... 2-152
12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper Move Failure RAP ........ 2-97 12-403-00-171, 12-413-00-171, 12-414-00-171 HVF BM Staple Head 2 and Stapler
12-462-00-110 Bin 1 Movement Failure RAP ................................................................. 2-99 Module RAP .................................................................................................................... 2-153
12-492-00-110 to 12-494-00-110 IME to Finisher Failure RAP ...................................... 2-101 12-415-00-171 HVF BM Crease Roll Gate Home RAP .................................................. 2-154
12-762-00-110, 12-764-00-110, 12-765-00-110 IME to Finisher Communication 12-417-00-171, 12-418-00-171 HVF BM Flapper RAP ................................................... 2-155
Failure RAP ..................................................................................................................... 2-101 12-450-00-171, 12-456-00-171 to 12-459-00-171 HVF Ejector Module RAP ................. 2-156
12-950-00 IME Delivers Sheet Too Early RAP ............................................................... 2-102 12-451-00-171 to 12-455-00-171 HVF Ejector Roll and Lower Paddle Fault RAP ......... 2-157
12A-110 Pause To Unload (PTU) Fault RAP .................................................................. 2-102 12-460-00-171 to 12-462-00-171 HVF Bin 1 Position RAP ............................................ 2-160
12B-110 Bin 1 Overload RAP ......................................................................................... 2-103 12-463-00-171, 12-464-00-171 HVF BM +24V Failure RAP........................................... 2-162
12C-110 LCSS Initialization Failure RAP ........................................................................ 2-103 12-465-00-171 to 12-468-00-171 Paddle Unit Position RAP .......................................... 2-163
12D-110 LCSS Power Distribution RAP ......................................................................... 2-104 12-473-00-171 to 12-478-00-171 Support Finger Position RAP ..................................... 2-165
12E-110 LCSS Paper Entry RAP .................................................................................... 2-106 12-479-00-171 Inserter Paper Length Fault RAP ........................................................... 2-167
12F-110 LCSS PWB DIP Switch Settings RAP .............................................................. 2-106 12-492-00-171 to 12-494-00-171 IME To Finisher Failure RAP ..................................... 2-168
12G-110 LCSS PWB Damage RAP................................................................................ 2-107 12-762-00-171, 12-764-00-171, 12-765-00-171 IME To Finisher Communication
12H-110 Copy Damage in the LCSS RAP ...................................................................... 2-108 Failure RAP..................................................................................................................... 2-169
12J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP .......................... 2-109 12A-171 HVF Power Distribution RAP............................................................................ 2-169
12K-110 LCSS Poor Stacking RAP ................................................................................ 2-109 12B-171 HVF BM to Machine Communications Interface and BM Present RAP ........... 2-172
12L-110 Stapling Prime Failure RAP .............................................................................. 2-110 12C-171 HVF BM Bin 2 Failure RAP .............................................................................. 2-173
12M-110 Staple Head Operation Failure RAP ................................................................ 2-112 12D-171 Booklet Quality RAP......................................................................................... 2-174
12N-110 Chad Bin Present and Bin Full RAP ................................................................. 2-113 12E-171 Copy Damage in the HVF BM RAP .................................................................. 2-178
12F-171 Mis-Registration in Stapled and Unstapled Sets RAP ...................................... 2-178
Chain 12-171 - HVF 12G-171 HVF BM Poor Stacking RAP............................................................................ 2-179
12-024-00-171, 12-025-00-171 HVF Paddle Roller Position RAP .................................. 2-115 12H-171 Pause to Unload (PTU) RAP............................................................................ 2-179
12-044-00-171 to 12-047-00-171 HVF Punch Head Position RAP ................................. 2-116 12J-171 Inserter Paper Sensing and +5V Supply RAP................................................... 2-180
12-056-00-171, 12-057-00-171 Inserter Bottom Plate RAP ............................................ 2-117 12K-171 HVF Initialization Failure RAP .......................................................................... 2-182
12-061-00-171, 12-416-00-171 HVF BM Crease Blade Fault RAP ................................ 2-117 12L-171 Tri-Folder Not Detected RAP ............................................................................ 2-183
12-062-00-171 HVF BM Crease Roll Motor Failure RAP................................................ 2-118 12M-171 Not Used .......................................................................................................... 2-183
12-063-00-171, 12-411-00-171 HVF BM Staple Unit 1 Failure RAP .............................. 2-119 12N-171 Chad Bin Present and Bin Full RAP ................................................................. 2-184
12-065-00-171, 12-383-00-171 HVF BM Backstop Motor Fault RAP ............................. 2-120 12P-171 Buffer Path Clamp Problems RAP.................................................................... 2-185
12-066-00-171, 12-384-00-171, 12-419-00-171, 12-420-00-171 HVF BM Tamper
Fault RAP ........................................................................................................................ 2-121 Chain 16 - Network Controller
12-083-00-171, 12-440-00-171 to 12-444-00-171 HVF Paper Pusher Fault RAP .......... 2-122 16-000-00 to 16-000-26 Cannot Create RPC With ENS RAP ........................................ 2-187
12-113-00-171, 12-114-00-171, 12-190-00-171, 12-192-00-171 HVF BM Entry RAP ... 2-123 16-001-09 to 16-001-90 Unable to Synchronize Startup RAP ........................................ 2-187
12-125-00-171, 12-126-00-171 HVF Entry Sensor RAP................................................. 2-125 16-002-09 to 16-002-19 Unable to Register as RPC RAP .............................................. 2-188
12-141-00-171, 12-142-00-171 HVF Buffer Path Sensor RAP ....................................... 2-126 16-003-09 to 16-003-90 Too Many IPC Handles RAP .................................................... 2-188
12-151-171, 12-152-171 HVF Compiler Exit Sensor RAP .............................................. 2-127 16-004-14 to 16-005-92 RPC Failure to Register RAP ................................................... 2-189
12-157-00-171, 12-158-00-171 HVF Buffer Position Sensor RAP.................................. 2-128 16-006-09, 16-006-19 Cannot Register for Events RAP................................................. 2-189
12-166-00-171 HVF BM Compiler Exit Jam RAP ........................................................... 2-129 16-007-92 to 16-010-99 Invalid IPC / RPC Data RAP .................................................... 2-190
12-171-00-171, 12-172-00-171 HVF Top Tray Exit Sensor Fault RAP........................... 2-130 16-013-14, 16-014-14 Copier Synchronization Error RAP .............................................. 2-190
12-181-00-171, 12-182-00-171 HVF BM Exit Jam RAP ................................................. 2-131 16-015-14, 16-015-19 Data Store Variable Not Set RAP................................................ 2-191
12-183-00-171, 12-184-00-171 HVF BM Paper Jam RAP.............................................. 2-134 16-016-14, 16-016-19 Data Store Initialization Failed RAP ............................................ 2-191
12-185-00-171 to 12-187-00-171 Tri-Folder Exit Sensor and Assist Sensor RAP.......... 2-136 16-017-19 to 16-021-26 Send Event Failure / Could Not Get Host Name RAP.............. 2-192
12-191-00-171, 12-193-00-171, 12-194-00-171, 12-196-00-171 Inserter Paper Jam RAP2-139 16-021-46 Unable to Get Host Name RAP ..................................................................... 2-192
12-198-00-171, 12-199-00-171 HVF Paper Jam RAP .................................................... 2-141 16-023-09, 16-023-26 RPC Call Failure RAP ................................................................. 2-193
12-273-00-171 to 12-277-00-171 Offset Unit Fault RAP................................................. 2-142 16-026-09 to 16-026-92 Memory Allocation Error RAP .................................................. 2-193
12-288-00-171, 12-289-00-171 HVF Nip Split RAP ........................................................ 2-143 16-027-90 Unable to Obtain Queue ID RAP ................................................................... 2-194
12-310-00-171, 12-312-00-171, 12-313-00-171 HVF Docking and Interlocks RAP ....... 2-144 16-028-09, 16-028-90 Unable to Complete RPC Call / Invalid Range RAP ................... 2-194
12-316-00-171, 12-319-00-171 Inserter Interlocks RAP ................................................. 2-145 16-030-19 Unable to Obtain Client RAP ......................................................................... 2-195
12-317-00-171, 12-318-00-171 Tri-folder Interlocks RAP ............................................... 2-146 16-031-09 Invalid Event Notification RAP ....................................................................... 2-195
12-367-00-171, 12-368-00-171, 12-380-00-171 HVF Punch Unit Paper Edge Detect RAP2-147 16-032-19, 16-039-00 NVM Connection Failure / Pthread Create Error RAP ................ 2-196
Status Indicator RAPs October 2014

16-040-92 Semaphore Fault RAP ................................................................................... 2-196 16-608-26 Fault Service Failed to Unbind RAP .............................................................. 2-222
16-048-09 Unable to Set Binding RAP............................................................................ 2-197 16-608-28 to 16-608-67 Unable to Free IPC Resources RAP ........................................ 2-222
16-048-14, 16-048-90 Cannot Set ESS Client Binding RAP........................................... 2-197 16-608-105 Unable Build UI SVC Obtain Client Failed RAP........................................... 2-223
16-048-99 Unable to Set Client Binding RAP.................................................................. 2-198 16-609-07 Unknown Message Received RAP ................................................................ 2-223
16-150-09 Cannot Send Registration Event RAP ........................................................... 2-198 16-609-19, 16-609-105 Too Many IPC Handlers / Invalid RPC Data RAP ..................... 2-224
16-150-14 Unable to Obtain RPC Transport RAP........................................................... 2-199 16-609-26 Fault Service Encountered Error RAP ........................................................... 2-224
16-150-19 Unable to Sync Peer RAP.............................................................................. 2-199 16-609-46 to 16-609-92 Invalid IPC Data Received RAP ............................................... 2-225
16-150-26 Fault Service Failed to Write Log RAP .......................................................... 2-200 16-610-00, 16-610-07 IPC Send Failure RAP................................................................. 2-225
16-150-90 Invalid IPC Request Destination RAP............................................................ 2-200 16-610-09 Cannot Send IPC Message RAP ................................................................... 2-226
16-150-92 Consumer Interface Fault RAP ...................................................................... 2-201 16-610-11 to 16-610-90 Unable to Send IPC Message RAP.......................................... 2-226
16-151-09 to 16-151-19 Invalid IPC Command / SNMP Reg Failure RAP ..................... 2-201 16-610-92 Failure to Send Queue Status RAP ............................................................... 2-227
16-151-26 Fault Service Failed to Get a Log RAP .......................................................... 2-202 16-610-99 Unable to Send IPC Message RAP ............................................................... 2-227
16-151-90 Environment Variable Failure RAP ................................................................ 2-202 16-611-07, 16-611-38 Client Removal Failed RAP ......................................................... 2-228
16-152-09 Internal IPC Failure RAP................................................................................ 2-203 16-611-19 to 16-611-47 Unable to Remove RPC Connection RAP................................ 2-228
16-152-14 Empty Internal Event Failure RAP ................................................................. 2-203 16-611-66 to 16-611-99 Unable to Remove RPC Connection RAP................................ 2-229
16-152-19 Unable to Send Request to SESS RAP......................................................... 2-204 16-612-09 to 16-612-68 Unable to Do Shutdown Sync RAP .......................................... 2-229
16-152-26 Unable to Send Request to SESS RAP......................................................... 2-204 16-613-09 to 16-614-19 DC Sync / Comms Error RAP................................................... 2-230
16-153-09 Unable to Obtain IPC Queue RAP................................................................. 2-205 16-614-47 Invalid Software Upgrade RAP ...................................................................... 2-230
16-153-14 Unable to Initialize Event List RAP ................................................................ 2-205 16-615-35, 16-615-46 Data Store Variable Not Set RAP................................................ 2-231
16-153-19 NVM Save Failure RAP ................................................................................. 2-206 16-615-47 Multiple Software Upgrade File RAP ............................................................. 2-231
16-154-09 ESS Registration Configuration Error RAP.................................................... 2-206 16-615-66 Data Store Variable Not Set RAP .................................................................. 2-232
16-154-14 Cannot Create Internal Event Queue RAP .................................................... 2-207 16-615-67, 16-615-90, 16-616-38, 16-616-46 SESS Data Store Environmental
16-154-19 NVM Read Failure RAP ................................................................................. 2-207 Variable RAP................................................................................................................... 2-232
16-155-19 ESS Failed to Boot from Alternate Disk RAP................................................. 2-208 16-616-47 IPC Message Failure RAP ............................................................................. 2-233
16-156-19 Service Run Loop Failed RAP ....................................................................... 2-208 16-616-67 Submission Of E-mail OR IFax Job Failed RAP ............................................ 2-233
16-160-09 ESS Reg Service Process Death RAP .......................................................... 2-209 16-617-19 RPC Information Corrupt RAP ....................................................................... 2-234
16-161-09, 16-164-09 Cannot Send Reg Event / List Access Failure RAP .................... 2-209 16-617-47 TAR Extraction Failure RAP .......................................................................... 2-234
16-161-09 to 16-164-09 Cannot Send Reg Event / List Access and ESS Services 16-618-47 DLM SPI Extraction Failure RAP ................................................................... 2-235
Failure RAP ..................................................................................................................... 2-210 16-619-14 to 16-619-93 Cannot Unregister From Registration Service RAP ................. 2-235
16-429-00, 16-431-00 Unable to Write to Data Store / Get System Time RAP .............. 2-210 16-620-07 to 16-620-90 Registration Service Failed RAP .............................................. 2-236
16-432-00 Unknown Scheduler Received RAP .............................................................. 2-211 16-620-92, 16-620-93, 16-620-99 Unable to Register With Network Controller
16-433-00 RPC Call Failed RAP ..................................................................................... 2-211 Registration Service RAP................................................................................................ 2-236
16-434-00 Unable to Change Scheduler RAP ................................................................ 2-212 16-621-00, 16-621-07, 16-621-11, 16-621-28, 16-621-35, 16-621-38, 16-621-47, 16-621-66,
16-600-07 to 16-600-67 Cannot Create RPC Connection RAP ...................................... 2-212 16-621-67, 16-621-93, 16-621-99 Unable to Obtain Host Name RAP............................ 2-237
16-601-26 to 16-601-46 Queue Setup / System Control Failed / Invalid UI Info RAP..... 2-213 16-622-07, 16-622-09, 16-622-11, 16-622-14, 16-622-19, 16-622-26, 16-622-28, 16-622-35,
16-601-47 Diagnostics Service Failed IPC Queue Setup RAP ....................................... 2-213 16-622-38, 16-622-46, 16-622-47 Corrupt RPC Table RAP ........................................... 2-237
16-601-66, 16-601-67 Unable to Do Start Up Sync RAP ................................................ 2-214 16-622-66, 16-622-67, 16-622-68 Unable to Register RPC Service RAP ...................... 2-238
16-601-68 Unable to Start Up and Sync RAP ................................................................. 2-214 16-623-35, 16-623-47, 16-624-46 ENS Service Failed to Respond In Time RAP .......... 2-238
16-601-105 Unable Synchronize At Start Up RAP.......................................................... 2-215 16-625-35, 16-625-46, 16-625-66, 16-625-67, 16-625-90 Invalid IPC Type RAP........... 2-239
16-602-07 to 16-603-105 RPC Service Registration Failure RAP .................................. 2-215 16-626-00, 16-626-11, 16-626-38, 16-626-47, 16-626-67 Memory Leak RAP ............... 2-239
16-603-11, 16-603-28 Replace Handler Call Failed RAP ............................................... 2-216 16-628-07, 16-628-09, 16-628-35, 16-628-46, 16-628-66, 16-628-67 Range
16-603-46 to 16-603-67 Too Many IPC Handlers RAP................................................... 2-216 Environment Variable RAP.............................................................................................. 2-240
16-603-68, 16-604-105 Replace Handler Call Failed / Data Store Variable Not Set RAP 2-217 16-629-11, 16-629-26, 16-629-46, 16-629-67, 16-629-68, 16-629-92, 16-629-93
16-603-46, 16-603-105, 16-604-14 RPC Call Failure to ESS Reg Service RAP ............ 2-217 No Acknowledgment For RPC Message RAP ................................................................ 2-240
16-604-38 to 16-605-07 Could Not Register With Reg Service RAP .............................. 2-218 16-630-09, 16-630-26, 16-630-35, 16-630-38, 16-630-46, 16-630-47, 16-630-66, 16-630-67,
16-605-14, 16-605-105 Unable to Unregister As RPC Service / RPC Call Failure RAP. 2-218 16-630-68, 16-630-99 Corrupt RPC RAP........................................................................ 2-241
16-605-26 Fault Service Timed Out Registering RAP..................................................... 2-219 16-631-19, 16-631-46, 16-631-19, 16-633-19, 16-634-46, 16-635-07, 16-635-35,
16-605-35 to 16-605-67 RPC Call Failure to ESS RAP .................................................. 2-219 16-635-46, 16-635-99-16-636-35, 16-636-99 XDR Data Error RAP ............................... 2-241
16-606-07 Cannot Register For Events RAP .................................................................. 2-220 16-637-11, 16-637-26, 16-637-38, 16-637-47, 16-637-66, 16-637-67, 16-637-93,
16-606-105 OS Problem RAP ......................................................................................... 2-220 16-637-95 File Error RAP................................................................................................ 2-242
16-606-35 to 16-606-99 Cannot Register For Events RAP............................................. 2-221 16-638-66, 16-638-67, 16-639-38, 16-639-46, 16-640-28, 16-640-35, 16-640-46,
16-607-19 to 16-608-14 Invalid RPC Data / Unable to Free Resources RAP................. 2-221 16-641-00, 16-641-26, 16-641-46 O/S Failure RAP........................................................ 2-242

16-642-46, 16-642-47, 16-643-19, 16-643-26, 16-643-47, 16-644-11 16-758-35, 16-758-46, 16-758-47, 16-758-66, 16-758-67, 16-758-93, 16-759-09,
Unable To Close File RAP .............................................................................................. 2-243 16-759-14, 16-759-19, 16-759-26 Service Run Loop Failed RAP .................................. 2-257
16-644-11, 16-644-26, 16-644-46, 16-644-47, 16-644-66, 16-644-67, 16-645-11, 1 16-759-46, 16-759-47, 16-759-66, 16-759-67, 16-759-93, 16-760-09, 16-760-14,
6-645-26, 16-645-46, 16-645-47, 16-645-66, 16-645-67 Unable To Read From File RAP 2-243 16-760-19, 16-760-26, 16-760-46 Fail to Enable Process RAP...................................... 2-258
16-646-26, 16-647-19, 16-647-26, 16-649-35, 16-650-35, 16-650-99 16-760-47, 16-760-67, 16-760-68, 16-760-93, 16-760-99, 16-761-09, 16-761-14,
Invalid Service Attribute RAP .......................................................................................... 2-244 16-761-19, 16-761-26, 16-761-46 File Error RAP ........................................................... 2-258
16-651-19, 16-651-35, 16-651-99, 16-652-38, 16-652-99, 16-653-38, 16-654-38, 16-654-99, 16-761-47 to 16-769-95 Other Network Faults 1 RAP .................................................... 2-259
16-655-38, 16-656-38 Register Failure RAP................................................................... 2-244 16-770-09 to 16-779-95 Other Network Faults 2 RAP .................................................... 2-260
16-658-07, 16-659-11, 16-659-28, 16-659-93, 16-659-95, 16-660-95, 16-660-99, 16-780-00 to 16-789-47 Other Network Faults 3 RAP .................................................... 2-261
16-661-95 Parser Utility Open Failure RAP .................................................................... 2-245 16-790-09 to 16-799-47 Other Network Faults 4 RAP .................................................... 2-262
16-662-11, 16-662-28, 16-662-93, 16-662-95, 16-663-28, 16-663-93, 16-663-95 16-800-09 to 16-809-47 Other Network Faults 5 RAP .................................................... 2-263
Parser Utility Template Failed To Parse RAP ................................................................. 2-245 16-810-00 to 16-16-819-47 Other Network Faults 6 RAP ............................................... 2-264
16-664-11, 16-664-28, 16-664-93, 16-664-95, 16-665-95 Parser Utility Closing 16-820-47 to 16-829-47 Other Network Faults 7 RAP .................................................... 2-265
Failure RAP ..................................................................................................................... 2-246 16-830-47 to 16-839-47 Other Network Faults 8 RAP .................................................... 2-265
16-666-11, 16-666-28, 16-666-93, 16-666-95 Parser Utility Invocation Failed RAP....... 2-246 16-840-47 to 16-849-47 Other Network Faults 9 RAP .................................................... 2-266
16-667-11, 16-667-28, 16-667-95, 16-668-47 Parser Utility Set Status Failure RAP ..... 2-247 16-850-47 to 16-859-47 Other Network Faults 10 RAP .................................................. 2-266
16-668-93, 16-668-95 Unable To Determine Local File Statistics RAP .......................... 2-247 16-860-47 to 16-869-47 Other Network Faults 11 RAP .................................................. 2-267
16-669-28, 16-669-93, 16-669-95, 16-670-00 Unable To Write Job Template RAP ...... 2-248 16-870-47 to 16-879-47 Other Network Faults 12 RAP .................................................. 2-267
16-670-11, 16-670-28, 16-670-47, 16-670-93, 16-671-00, 16-671-47 Unable To 16-880-47 to 16-890-47 Other Network Faults 13 RAP .................................................. 2-268
Decode Template File RAP............................................................................................. 2-248 16-891-00, 16-892-00 Edge Server Auto Registration Failed RAP................................. 2-268
16-617-93, 16-671-95, 16-672-09, 16-672-95, 16-673-95, 16-674-00, 16-674-09, 16-900-19 to 16-909-19 Other Network Faults 14 RAP .................................................. 2-269
16-675-00, 16-6700-00, 16-700-35 File Error RAP ......................................................... 2-249 16-910-19 to 16-919-19 Other Network Faults 15 RAP .................................................. 2-269
16-702-95, 16-707-00, 16-709-00 XSA Database Failure RAP ...................................... 2-249 16-930-19 to 16-939-19 Other Network Faults 17 RAP .................................................. 2-270
16-730-35, 16-730-66, 16-740-19, 16-750-07, 16-750-09, 16-750-11 Unable To 16-950-19 to 16-959-19 Other Network Faults 19 RAP .................................................. 2-271
Create Client Handle RAP .............................................................................................. 2-250 16-960-19 to 16-969-19 Other Network Faults 20 RAP .................................................. 2-272
16-718-00 to 16-16-724-00 Hard Disk Partition Full RAP ............................................... 2-250 16-975-19 to 16-979-35 Other Network Faults 21 RAP .................................................. 2-272
16-742-19 Hard Disk ODIO Failure RAP ........................................................................ 2-251 16-980-00 to 16-989-35 Other Network Faults 22 RAP .................................................. 2-273
16-750-66, 16-750-67, 16-750-90 Invalid Request RAP ................................................. 2-251 16-954-19, 16-955-19 Internet Fax Application Registration Error RAP ......................... 2-274
16-750-92, 16-750-93, 16-750-95, 16-751-00, 16-751-07, 16-751-09, 16-751-11, 16-956-19, 16-957-19 E-mail Application Registration Error RAP .................................. 2-274
16-751-14, 16-751-19, 16-751-26 Database Error RAP ................................................. 2-252 16-985-19, 16-986-19 Network Scanning Application Registration Error RAP ............... 2-275
16-751-28, 16-751-35, 16-751-38, 16-751-46, 16-751-66, 16-751-67, 16-751-92, 16-987-19, 16-988-19 Server Fax Application Registration Error RAP........................... 2-275
16-751-93 Unknown Attribute RAP ................................................................................. 2-252 16-989-19 Disk Encryption Operation Failed RAP .......................................................... 2-276
16-752-00, 16-753-00 File Cabinet Application Registration Error RAP ......................... 2-253 16A Network Error Entry RAP......................................................................................... 2-276
16-752-07, 16-752-09, 16-752-14, 16-752-19, 16-752-26, 16-752-28, 16-752-35, 16B FTP or SMB Unable to Connect to Remote Server RAP......................................... 2-277
16-752-46, 16-752-47 Invalid File Details RAP ............................................................... 2-253 16C Remote Directory Lock Failed RAP ......................................................................... 2-279
16-752-66, 16-752-67, 16-752-92, 16-752-93, 16-752-95, 16-753-09, 16-753-14,
16-753-19, 16-753-26, 16-753-28 Scan to FAX Registration Error RAP ........................ 2-254 Chain 19 - Image Processing
16-753-35, 16-753-46, 16-753-47, 16-753-66, 16-753-67, 16-753-90, 16-753-92, 19-300-00 to 19-310-00 Image Disk (HDD 1) Failure RAP ............................................. 2-281
16-753-93, 16-753-95, 16-753-09 Data Store Read Failure RAP ................................... 2-254 19-401-00, 19-402-00 Stress Out of Memory RAP ......................................................... 2-282
16-754-14, 16-754-19, 16-754-26, 16-754-28, 16-754-35, 16-754-46, 16-754-47, 19-403-00 EPC Out of Memory RAP .............................................................................. 2-282
16-754-66, 16-754-67, 16-754-68 OS Error RAP ........................................................... 2-255 19-409-00 Job Integrity Failure RAP ............................................................................... 2-283
16-754-90, 16-754-92, 16-754-92, 16-754-93, 16-754-95, 16-755-00, 16-755-09, 19-410-00 to 19-410-13 Image Structure Failure RAP ................................................... 2-283
16-755-14, 16-755-19, 16-755-26, 16-755-28 Fault Service Error RAP ......................... 2-255 19-750-00 EPC Memory Change Detected RAP ............................................................ 2-284
16-755-35, 16-755-46, 16-755-47, 16-755-67, 16-755-90, 16-755-93, 16-755-99, 19-752-00 Image Rotation Detected RAP....................................................................... 2-284
16-756-09, 16-756-14 Request Error RAP...................................................................... 2-256 19-754-00 Image Disk Change RAP ............................................................................... 2-285
16-756-35, 16-756-46, 16-756-47, 16-756-66, 16-756-67, 16-756-93, 16-757-09, Chain 20 - Fax
16-757-14, 16-757-19, 16-757-26 NVM Corrupt RAP..................................................... 2-256
20-302-00, 20-303-00 Fax Reset Failure RAP................................................................ 2-287
16-757-35, 16-757-46, 16-757-47, 16-757-66, 16-757-67, 16-757-93, 16-758-09, 1
20-305-00 Fax System Low Memory Unrecoverable RAP ............................................. 2-287
6-758-14, 16-758-19, 16-758-26 Unable to Write NVM Value RAP................................ 2-257

20-320-00 Fax Fault Not Cleared by Reset RAP ............................................................ 2-288 Chain 42 - Fans and Cooling
20-322-00 Non-Volatile Device not Installed RAP........................................................... 2-288 42-500-00 Marking Unit Air Solenoid Over Current RAP ................................................ 2-317
20-323-00, 20-324-00 Fax System Memory Low RAP.................................................... 2-289 42-504-00 Enclosure Fan Over Current RAP.................................................................. 2-317
20-327-00 Extended Fax PWB Failure RAP ................................................................... 2-289 42-505-00 Abatement Fan Over Current RAP ................................................................ 2-318
20-331-00, 20-338-00, 20-339-00, 20-341-00 Fax Network Line 1 Fault RAP ............... 2-290
20-332-00, 20-340-00 Fax Network Line 2 Fault RAP .................................................... 2-291 Chain 62 - Scanner
20-342-00 Fax File Integrity Fault RAP ........................................................................... 2-291 62-277-00 Scanner to DADH Communication Fail Entry RAP ........................................ 2-319
20-701-00 Fax Phone Book Download Failed RAP ........................................................ 2-292 62-277-00A Scanner to DADH Communication Fail RAP............................................... 2-319
20-701-00A Fax Phone Book Download Failed RAP (W/O TAG X-001) ........................ 2-292 62-277-00B Scanner to DADH Communication Fail RAP............................................... 2-320
20-701-00B Fax Phone Book Download Failed RAP (W/TAG X-001) ............................ 2-293 62-277-00C Scanner to DADH Communication Fail RAP............................................... 2-320
20-710-00, 20-711-00 Image Overwrite Error RAP......................................................... 2-293 62-310-00 Scanner to Copy Controller/Single Board Controller Communication Fail
20-710-00, 20-711-00A Image Overwrite Error RAP (W/O TAG X-001)......................... 2-294 Entry RAP........................................................................................................................ 2-321
20-710-00, 20-711-00B Image Overwrite Error RAP (W/TAG X-001)............................. 2-294 62-310-00A Scanner to Copy Controller Communication Fail RAP ................................ 2-321
20A Fax Entry RAP ......................................................................................................... 2-295 62-310-00B Scanner to Single Board Controller Communication Fail RAP .................... 2-322
20B Unable To Send A Fax RAP .................................................................................... 2-296 62-310-00C Scanner to Copy Controller Communication Fail RAP................................ 2-323
20C Unable To Send A Fax To Some Machines RAP .................................................... 2-297 62-310-00D Scanner to Single Board Controller Communication Fail RAP.................... 2-323
20D Unable To Receive A Fax RAP ............................................................................... 2-298 62-450-00 to 62-472-00 Calibration Failure Entry RAP................................................... 2-324
20E Fax Will Not Print RAP............................................................................................. 2-299 62-450-00A to 62-472-00A Calibration Failure RAP ....................................................... 2-325
20F Fax Tab Not Available RAP ..................................................................................... 2-300 62-450-00B to 62-472-00B Calibration Failure RAP ....................................................... 2-325
20G Embedded Fax Checkout ........................................................................................ 2-301 62-450-00C to 62-472-00C Calibration Failure RAP....................................................... 2-326
20H Embedded Fax PWB Voltage Checkout (W/O TAG X-001) .................................... 2-302 62-473-00 UART RX Wrap Error Entry RAP................................................................... 2-326
20J Fax Problems on Digital Networks RAP ................................................................... 2-303 62-473-00A UART RX Wrap Error RAP.......................................................................... 2-327
62-473-00B UART RX Wrap Error RAP.......................................................................... 2-327
Chain 22 - System Errors 62-473-00C UART RX Wrap Error RAP.......................................................................... 2-328
22-300-05 to 22-309-04 Other Network Faults 24 RAP .................................................. 2-305 62-474-00, 62-475-00 Stepper Speed/Reset Error RAP................................................. 2-328
22-310-04 to 22-318-04 Other Network Faults 25 RAP .................................................. 2-305 62-476-00 Scan Carriage Home Sensor Entry RAP ....................................................... 2-329
22-315-04 One or More Modules Did Not Respond RAP ............................................... 2-306 62-476-00A Scan Carriage Home Sensor RAP .............................................................. 2-329
22-319-04 IOT Integrity Problem While Printing a Job RAP ........................................... 2-306 62-476-00B Scan Carriage Home Sensor RAP .............................................................. 2-330
22-321-00 SM Failed to Remove Scan to File RAP ........................................................ 2-307 62-476-00C Scan Carriage Home Sensor RAP .............................................................. 2-331
22-321-04 Proposal Response Time Out Error RAP ...................................................... 2-307 62-477-00 to 62-481-00 Timing Errors RAP.................................................................... 2-332
22-325-01 Cleaning Unit Extended Life Mode Entered RAP .......................................... 2-308 62-484-00 Apps Code Not Present RAP......................................................................... 2-333
22-328-00 Incomplete System Information RAP ............................................................. 2-308 62-485-00 +12V Supply Error Entry RAP........................................................................ 2-333
22-330-00 Page Pack PIN Entry Locked RAP ................................................................ 2-309 62-485-00A +12V Supply Error RAP............................................................................... 2-334
22-330-01 List Jobs Request Timed Out Between UI and Copy Controller RAP............ 2-309 62-485-00B +12V Supply Error RAP............................................................................... 2-334
22-330-02 List Jobs Request Timed Out Between Copy Controller and ESS Print 62-485-00C +12V Supply Error RAP .............................................................................. 2-335
Service RAP .................................................................................................................... 2-310 62-486-00 +24V Supply Error Entry RAP........................................................................ 2-335
22-330-03 List Jobs Request Timed Out Between Copy Controller and Scan to File 62-486-00A +24V Supply Error RAP............................................................................... 2-336
Service RAP .................................................................................................................... 2-310 62-486-00B +24V Supply Error RAP............................................................................... 2-337
22-330-04 List Jobs Request Timed Out Between Copy Controller and Scan to Fax 62-486-00C +24V Supply Error RAP .............................................................................. 2-337
Service RAP .................................................................................................................... 2-311 62-487-00 System Phase Lock Loop (PLL) Error RAP ................................................... 2-338
22-330-05 List Jobs Request Timed Out Between Queue Utility and DC Job 62A Scanning Document Size RAP (W/O TAG 007) ...................................................... 2-338
Service RAP .................................................................................................................... 2-311 62B LED Exposure Lamp Failure RAP (W/O TAG 007) ................................................. 2-339
22-330-06 ESS Scan to Distribution Service not Responding to List Jobs RPC Call RAP 2-312 62C Scanning Document Size RAP (W/TAG 007).......................................................... 2-340
22-350-01, 22-350-02 Software Detects Non-valid Xerox SOK RAP.............................. 2-312 62D Exposure Lamp Failure RAP (W/TAG 007) ............................................................. 2-341
22-351-01 to 22-351-03 SOK Write Failure RAP ............................................................ 2-313
22-352-00 Serial Number Missing RAP .......................................................................... 2-313 Chain 70 to 75 - Paper Supply
22-371-00, 22-372-00 Fax Application Registration Error RAP ...................................... 2-314 70-312-00 Tray 1 to Tray 3 Communication Failure RAP ............................................... 2-343
22-701-04 Module Completion Message Received RAP ................................................ 2-314 70-325-00 Lower Left Door Open in Run RAP................................................................ 2-343
22-720-00 Service Registry Bad Data/Corrupted RAP ................................................... 2-315 71-101-00, 71-106-00 Tray 1 Mis-Feed Jam RAP .......................................................... 2-344
22-721-00 No Response From The Service Registry RAP ............................................. 2-315 71-215-00 Tray 1 Elevate Up Failure RAP...................................................................... 2-345
22-750-04 to 22-755-17 Other Network Faults 25 RAP .................................................. 2-316 71-320-00 Tray 1 Open In Run RAP ............................................................................... 2-346
71A Tray 1 Empty RAP ................................................................................................... 2-347

71B Tray 1 Wrong Size Paper RAP ................................................................................ 2-347 89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Failure RAP ....................... 2-392
72-101-00, 72-106-00, 72-110-00 Tray 2 Mis-Feed Jam RAP........................................ 2-348 89-125-00 to 89-128-00, 89-130-00 Media Path Sensor 20 Failure RAP ....................... 2-393
72-215-00 Tray 2 Elevate Up Failure RAP...................................................................... 2-350 89-500-00, 89-502-00 Registration Motor Over Current RAP ......................................... 2-394
72-320-00 Tray 2 Open in Run RAP ............................................................................... 2-351 89-504-00 Registration Sensor Over Current RAP ......................................................... 2-395
72A Tray 2 Empty RAP ................................................................................................... 2-351 89-512-00 to 89-514-00 Registration Scan Error RAP.................................................... 2-396
72B Tray 2 Wrong Size Paper RAP ................................................................................ 2-352 89-520-00 Home Sensor Timeout RAP .......................................................................... 2-397
73-101-00, 73-106-00, 73-110-00 Tray 3 Mis-Feed Jam RAP........................................ 2-353 89-531-00 to 89-534-00 Registration Process Error RAP ............................................... 2-398
73-212-00 Tray 3 Elevate Encoder Failure RAP ............................................................. 2-354 89-540-00 to 89-545-00 Registration Process Error RAP ............................................... 2-399
73-215-00 Tray 3 Hoist Failure RAP ............................................................................... 2-355 89-550-00, 89-551-00 Media Registration Error RAP ..................................................... 2-399
73-320-00 Tray 3 Open in Run RAP ............................................................................... 2-356 89-555-00, 89-556-00 Media Registration Out of Range RAP........................................ 2-400
73-325-00 Feeder HT Drawer Open in Run RAP ........................................................... 2-356 89-561-00 Media Registration Parameters Reset RAP .................................................. 2-401
73A Tray 3 Out of Paper RAP ......................................................................................... 2-357 89-562-00 Incorrect Media RAP...................................................................................... 2-401
74-101-00 Bypass Tray Mis-Feed RAP .......................................................................... 2-357 89-563-00 IOD Alignment Error RAP .............................................................................. 2-402
74-120-00 Bypass Tray Guides Move in Run RAP ......................................................... 2-358 89-564-00 Calibration Image Error RAP ......................................................................... 2-402
74-214-00 Bypass Tray Nudger Failure RAP.................................................................. 2-359 89-565-00, 89-566-00 Scan Measurement Was Out Of Range RAP ............................. 2-403
74A Bypass Tray Size Sensing Problems RAP .............................................................. 2-359 89-567-00 Calibration Scan Detected Floating Point Exception RAP............................. 2-403
75-101-00 Tray 5 Mis-Feed RAP .................................................................................... 2-360
75-212-00, 75-215-00 Tray 5 Elevate Up Failure RAP ................................................... 2-362 Chain 91 - Marking Unit
75-213-00, 75-216-00 Tray 5 Elevate Down Failure RAP............................................... 2-363 91-500-00, 91-600-00 Initial Position Error RAP ............................................................. 2-405
75-312-00 IME to Tray 5 Communication Failure RAP ................................................... 2-364 91-501-00 to 91-502-00 Image Timing Error RAP .......................................................... 2-405
75-320-00 Tray 5 Opened In Run RAP ........................................................................... 2-364 91-503-00 Print Image Data Did Not Arrive From the Controller in Time RAP ............... 2-406
75-325-00 Tray 5 Undocked In Run RAP ....................................................................... 2-365 91-504-00, 91-505-00 Printhead Stitch Motor Over Current RAP................................... 2-406
75A Tray 5 Door Open During Run RAP ........................................................................ 2-365 91-506-00 to 91-509-00 Roll Motor Over Current RAP ................................................... 2-407
75B Tray 5 Empty RAP ................................................................................................... 2-366 91-510-00, 91-511-00 X Axis Motor Over Current RAP .................................................. 2-408
91-512-00, 91-605-00 Marking Unit Motor Short RAP .................................................... 2-409
Chain 82 to 89 - Paper Transport 91-513-00, 91-514-00, 91-581-00, 91-583-00 IOD Drive Error RAP .............................. 2-410
82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82-159-00, 82-164-00 to 82-166-00 91-515-00 Vertical Wiper Motor Over Current RAP ........................................................ 2-411
Media Path Sensor (5) RAP ............................................................................................ 2-367 91-516-00 Low Pressure Assist Over Current RAP ........................................................ 2-412
82-125-00 to 82-133-00, 82-153-00, 82-155-00, 82-160-00, 82-162-00, 82-163-00 91-517-00 Marking Unit Air Pump Over Current RAP..................................................... 2-412
Confirm Sensor (16) RAP ............................................................................................... 2-368 91-519-00 to 91-522-00, 91-655-00 to 91-690-00, 91-807 to 91-811-00
82-132-00, 82-155-00 Media Path Sensor 16 Duplex Mode RAP .................................. 2-369 Printhead NVM Read or Write Error RAP ....................................................................... 2-413
82-133-00 Media Path Sensor 16 Time out from Tray 5 RAP ........................................ 2-371 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to 91-804-00
82-134-00 Media Path Sensor 16 Time-out from Tray 4 RAP ........................................ 2-372 Printhead Thermal Error RAP ......................................................................................... 2-414
82-140-00, 82-142-00 Media Path Sheet Too Wide or Narrow RAP .............................. 2-373 91-559-00 Marking Unit Components Out of Position RAP ............................................ 2-416
82-141-00, 82-147-00, 82-148-00, 82-154-00 Media Path Sensor 14 RAP.................... 2-373 91-560-00 Carriage Selection Time Out RAP ................................................................. 2-417
82-145-00, 82-146-00, 82-150-00, 82-151-00, 82-156-00 Media Path Sensor 14 91-562-00, 91-563-00 Upper Carriage Error RAP .......................................................... 2-418
Time Out in Duplex Mode RAP ....................................................................................... 2-375 91-565-00, 91-566-00 Upper Printhead Restraint Error RAP ......................................... 2-420
82-149-00 Media Path Sensor 14 TE Time Out RAP ..................................................... 2-377 91-567-00 to 91-568-00 Lower Carriage Error RAP ....................................................... 2-420
82-161-00 Early Confirm Timeout RAP........................................................................... 2-379 91-570-00, 91-571-00 Lower Printhead Restraint Error RAP ......................................... 2-422
82-500-00, 82-501-00 Vertical Transport Motor M2 Failure RAP ................................... 2-380 91-572-00, 91-573-00, 91-575-00 Wiper Vertical Error RAP .......................................... 2-422
82-502-00, 82-503-00 Horizontal Transport Motor M6 Failure RAP ............................... 2-381 91-574-00, 91-576-00, 91-598-00 Wiper Horizontal Error RAP ...................................... 2-424
82-507-00, 82-508-00 Nip C and Nip D Release Solenoid Over Current RAP ............... 2-382 91-586-00 Quad Wave Amplifier Short RAP ................................................................... 2-425
82-510-00 Trailer Slowdown Calculation Fail RAP ......................................................... 2-382 91-587-00, 91-588-00 Quad Wave Amplifier Thermal Error RAP ................................... 2-426
83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 Media Path Sensor 13 91-607-00, 91-608-00 Printhead to Drum Error RAP ...................................................... 2-426
Duplex Mode RAP........................................................................................................... 2-383 91-610-00 to 91-613-00 Printhead Wave amp Calibration Error RAP ............................ 2-427
83-112-00, 83-115-00, 83-116-00, 83-117-00, 83-119-00 Media Path Sensor 13 91-614-00 to 91-617-00 Printhead Data Error RAP ........................................................ 2-429
Invert Mode RAP ............................................................................................................. 2-385 91-630-00 IOD Scan Process Failure RAP..................................................................... 2-430
83-120-00 to 83-125-00 Media Path Sensor 17 RAP ..................................................... 2-387 91-631-00 IOD Dark Adjust Failure RAP ........................................................................ 2-430
83-500-00 Output Transport Motor M5 Failure RAP ....................................................... 2-388 91-636-00 IOD in Degraded Mode RAP ......................................................................... 2-431
83-504-00 HPP Diverter Solenoid Failure RAP .............................................................. 2-389 91-637-00 Drum Runout Calibration Needed RAP ......................................................... 2-434
83-506-00 Nip D Release Solenoid Failure RAP ............................................................ 2-389 91-638-00 IOD Detects Chronic Jet Error RAP............................................................... 2-435
88-500-00 to 88-502-00 Preheat Thermal Error RAP ..................................................... 2-390 91-660-00 to 91-663-00, 91-820-00 to 91-823-00 Printhead Link Error RAP ................. 2-437
88-508-00 Registration / Preheat Air Pump Incorrect Current RAP ................................ 2-391 91-669-00 Excessive Skew RAP .................................................................................... 2-438

91-670-00 Scanned Image Out of Sequence RAP ......................................................... 2-438 92-551-00 CIS Interrupt Storm Fault RAP....................................................................... 2-469
91-671-00 Fiducials Not Found RAP............................................................................... 2-439 92-552-00 SBC Interrupt Storm Fault RAP ..................................................................... 2-469
91-672-00 Missing Jets RAP........................................................................................... 2-439 92-550-00, 92-555-00 System Timer Error RAP ............................................................. 2-470
91-673-00 Floating Point Error RAP................................................................................ 2-440 92-554-00 AC Line Failed RAP ....................................................................................... 2-470
91-674-00 to 91-677-00, 91-812-00 to 91-815-00 Printhead Adjustment Error RAP ...... 2-440 92-556-00, 92-557-00, 92-558-00, 92-559-00 ECM Failure RAP ................................... 2-471
91-678-00 to 91-681-00, 91-816-00 to 91-819-00 Printhead Convergence 92-560-00, 92-561-00 Marking Unit Firmware Version Mismatch RAP .......................... 2-471
Adjustment Error RAP ..................................................................................................... 2-441 92-562-00 Drum Driver Firmware Version Mismatch RAP.............................................. 2-472
91-682-00 Ambient Thermistor Error RAP ...................................................................... 2-442 92-563-00 Power Supply Firmware Version Mismatch RAP........................................... 2-472
91-695-00, 91-696-00, 91-697-00 IOD Jet Position Noise RAP...................................... 2-443 92-564-00 Media Path Firmware Version Mismatch RAP............................................... 2-473
91-698-00 to 91-732-00 IOD Excessive Head Misalignment RAP.................................. 2-444 92-565-00 3TM Firmware Version Mismatch RAP.......................................................... 2-473
91-701-00 to 91-705-00 Printhead 1 Converging Error RAP .......................................... 2-446 92-566-00 Tray 5 Firmware Version Mismatch RAP....................................................... 2-474
91-707-00 to 91-711-00 Printhead 2 Converging Error RAP .......................................... 2-447 92-567-00 Copy Controller Software Version Mismatch RAP......................................... 2-474
91-713-00, 91-714-00 Printhead 3 Converging Error RAP ............................................. 2-447 92-568-00 ECM Initialization Error RAP.......................................................................... 2-475
91-715-00 to 91-717-00, 91-719-00 Printhead 4 Converging Error RAP ........................ 2-448 92-569-00 Blackheart Version Mismatch RAP ................................................................ 2-475
91-718-00 IOD, Head X-Position Error RAP ................................................................... 2-448 92-571-00 Software Error RAP ....................................................................................... 2-476
91-721-00, 91-722-00, 91-735-00, 91-736-00 IOD Contamination Error RAP................ 2-449 92-575-00 ADC Out of Range RAP................................................................................. 2-476
91-725-00, 91-726-00, 91-727-00, 91-728-00 IOD Bad Target Scan RAP ..................... 2-449 92-579-00 CDI Submit Sheet Error RAP......................................................................... 2-477
91-730-00 IOD Target Y Position Out Of Far Range RAP .............................................. 2-450 92-581-00 Image Transfer Error RAP ............................................................................. 2-477
91-805-00, 91-806-00 Printhead Communications RAP ................................................. 2-451 92-583-00 Cold Temperature Boot Time-out RAP .......................................................... 2-478
91-824-00 PQM Insufficient Ink RAP .............................................................................. 2-453 92-585-00 LVDS Contone Terminal Error During Image Transfer RAP.......................... 2-478
91-825-00 PQM Insufficient Paper RAP.......................................................................... 2-453 92-586-00 Print Engine Speed Fault RAP....................................................................... 2-479
91-826-00 PQM Insufficient Jets RAP............................................................................. 2-454 92-598-00, 92-599-00, 92-600-00 IME NVRAM Error RAP ............................................ 2-479
91-827-00 PQM Align Needed RAP................................................................................ 2-454 92-803-00, 92-804-00 DSP2 Overlay Error RAP ............................................................ 2-480
91-828-00 PQM Y-Dot Position Needed RAP................................................................. 2-455 92-805-00 Fuse A Blown RAP ........................................................................................ 2-480
91-829-00 PQM Drum Runout Needed RAP .................................................................. 2-455 92-806-00 Fuse B Blown RAP ........................................................................................ 2-481
91-830-00 PQM Uniformity Needed RAP........................................................................ 2-456 92-807-00 Diagnostic Routine Not Implemented RAP .................................................... 2-482
91-831-00 PQM Uniformity Reset Needed RAP ............................................................. 2-456
91-832-00 PQM Empty Waste Tray RAP........................................................................ 2-457 Chain 93 - Ink Delivery
91-833-00 PQM Cleaning Pages Needed RAP .............................................................. 2-457 93-501-00 to 93-516-00 Ink Loader Is Jammed RAP...................................................... 2-483
91-834-00 PQM Tool Not Usable RAP............................................................................ 2-458 93-520-00, 93-521-00, 93-522-00 Ink Melt Reservoir Thermal Error RAP...................... 2-483
91-835-00 PQM Tool Manually Disabled RAP ................................................................ 2-458 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00, 93-533-00
91-836-00 PQM System Busy RAP ................................................................................ 2-459 Ink Melt Error RAP .......................................................................................................... 2-484
91-837-00 PQM Align Calibration Needed RAP.............................................................. 2-459 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Thermistor Error RAP................ 2-485
91-842-00 to 91-845-00 Printhead Nvram Read or Decode Error RAP .......................... 2-460 93-535-00, 93-536-00, 93-537-00 Upper Umbilical Thermal Error RAP ......................... 2-486
91-848-00 to 91-851-00 IOD Align Calibration Error RAP............................................... 2-460 93-538-00, 93-539-00, 93-540-00 Lower Umbilical Thermal Error RAP ......................... 2-487
93-545-00 to 93-548-00 Ink Melt Reservoir Conductivity Error RAP............................... 2-488
Chain 92 - IOT Process Control 93-549-00 to 93-552-00 and 93-557-00 to 93-560-00 Printheads 1 and 3 Printhead
92-505-00, 92-506-00 Marking Unit Communications Error RAP ................................... 2-461 Reservoir Fill Error RAP .................................................................................................. 2-489
92-510-00, 92-511-00 Marking Unit Ink On Drum Communications Error RAP.............. 2-461 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead
92-515-00, 92-516-00 Drum Driver Communications Error RAP .................................... 2-462 Reservoir Fill Error RAP .................................................................................................. 2-492
92-520-00 Power Supply Communications Error RAP.................................................... 2-462 93-565-00 to 93-599-00 and 93-800-00 to 93-812-00 Printheads 1, 2, 3 & 4 Ink Level
92-525-00, 92-526-00 Media Path Communications Error RAP ..................................... 2-463 Sense Error RAP............................................................................................................. 2-494
92-527-00, 92-528-00 ESD Count Exceeded RAP ......................................................... 2-463 93-813-00 to 93-820-00 Ink Melt Reservoir Level Sense Failure RAP ........................... 2-495
92-530-00 3TM Serial Link Error RAP............................................................................. 2-464 93-825-00, 93-892-00 Ink Key Plate Motor Over Current RAP ....................................... 2-496
92-531-00 Paper Tray Module Communications Error RAP ........................................... 2-464 93-871-00 to 93-874-00 Ink Level Sense Error RAP....................................................... 2-496
92-535-00, 92-536-00 Tray 5 Communications Error RAP ............................................. 2-465 93-890-00 Marking Unit Air Solenoid Over Current RAP ................................................ 2-497
92-541-00, 92-570-00 Interrupt Storm Fault RAP ........................................................... 2-465 93-891-00 Ink Transport Over Current RAP.................................................................... 2-497
92-542-00 PS Interrupt Storm Fault RAP........................................................................ 2-466 93-901-00 to 93-904-00 Ink Melt Reservoir Fill Failure RAP........................................... 2-498
92-543-00, 92-544-00 MU Interrupt Storm Faults RAP................................................... 2-466 93-909-00 to 93-924-00 Printhead Reservoir Level Failure RAP.................................... 2-498
92-545-00 DD Interrupt Storm Fault RAP ....................................................................... 2-467 93-933-00 to 93-936-00 Head Purge Failure RAP .......................................................... 2-499
92-546-00, 92-547-00 MP Interrupt Storm Faults RAP ................................................... 2-467 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP .......................................... 2-499
92-548-00 TTM Interrupt Storm Fault RAP ..................................................................... 2-468 93A Ink Melt Reservoir Check......................................................................................... 2-500
92-549-00 PFP Interrupt Storm Fault RAP...................................................................... 2-468 93B Ink Leak Checkout RAP........................................................................................... 2-501

Chain 94 - Ink Transfer 99-497-00 to 99-515-00 PEST Error 19 RAP.................................................................. 2-543
94-504-00, 94-505-00 Cleaning Unit Reservoir Pressure Error RAP.............................. 2-503 99-516-00 to 99-533-00 PEST Error 20 RAP.................................................................. 2-544
94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 Cleaning Unit Over 99-534-00 to 99-548-00 PEST Error 21 RAP.................................................................. 2-545
Current RAP .................................................................................................................... 2-503 99-549-00 to 99-563-00 PEST Error 22 RAP.................................................................. 2-546
94-510-00, 94-512-00 Drum Image Initial Position Error RAP ........................................ 2-504 99-564-00 to 99-580-00 PEST Error 23 RAP.................................................................. 2-548
94-514-00, 94-518-00 Drum Imaging Error RAP ............................................................ 2-504 99-581-00 to 99-595-00 PEST Error 24 RAP.................................................................. 2-549
94-519-00 Drum Imaging Error RAP ............................................................................... 2-505 99-596-00 to 99-610-00 PEST Error 25 RAP.................................................................. 2-550
94-520-00 Cleaning Unit Drive Error RAP ...................................................................... 2-505 99-611-00 to 99-625-00 PEST Error 26 RAP.................................................................. 2-551
94-522-00 Cleaning Unit Motor Stall RAP....................................................................... 2-506 99-626-00 to 99-640-00 PEST Error 27 RAP.................................................................. 2-552
94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP .............................................. 2-507 99-641-00 to 99-655-00 PEST Error 28 RAP.................................................................. 2-553
94-535-00 Drum Driver Command Current Error RAP ................................................... 2-509 99-656-00 to 99-670-00 PEST Error 29 RAP.................................................................. 2-554
94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-00, 94-633-00 99-671-00 to 99-685-00 PEST Error 30 RAP.................................................................. 2-555
Drum Heat Error RAP ..................................................................................................... 2-509 99-686-00 to 99-700-00 PEST Error 31 RAP.................................................................. 2-556
94-545-00 Drum Runout Calibration Error RAP .............................................................. 2-510 99-701-00 to 99-722-00 PEST Error 32 RAP.................................................................. 2-557
94-547-00, 94-555-00 Y-Axis Belt Ratio Error RAP ........................................................ 2-511 99-723-00 to 99-742-00 PEST Error 33 RAP.................................................................. 2-558
94-548-00 Y-Axis Position Error RAP ............................................................................. 2-511 99-743-00 to 99-766-00 PEST Error 34 RAP.................................................................. 2-559
94-549-00 Drum Runout Calibration Error RAP .............................................................. 2-512 99-767-00 to 99-784-00 PEST Error 35 RAP.................................................................. 2-560
94-551-00, 94-552-00, 94-553-00 Drum Y-Axis Error RAP ............................................ 2-512 99-785-00 to 99-804-00 PEST Error 36 RAP.................................................................. 2-561
94-558-00, 94-560-00, 94-562-00, 94-564-00, 94-566-00 99-805-00 to 99-823-00 PEST Error 37 RAP.................................................................. 2-562
Cleaning Unit Position Error RAP ................................................................................... 2-513 99-824-00 to 99-838-00 PEST Error 38 RAP.................................................................. 2-563
94-568-00, 94-570-00, 94-572-00, 94-573-00 Cleaning Unit I/O Error RAP ................... 2-513 99-839-00 to 99-871-00 PEST Error 39 RAP.................................................................. 2-565
94-574-00 Cleaning Unit Sync Error RAP ....................................................................... 2-514 99-872-00 to 99-888-00 PEST Error 40 RAP.................................................................. 2-567
94-610-00 to 94-612-00 Cleaning Unit Error RAP .......................................................... 2-514 99-889-00 to 99-904-00 PEST Error 41 RAP.................................................................. 2-568
94-615-00 Non Xerox Cleaning Unit Detected RAP ....................................................... 2-515 99-905-00 to 99-921-00 PEST Error 42 RAP.................................................................. 2-569
94-616-00 Cleaning Unit Low Oil Detected RAP ............................................................ 2-515 99-922-00 to 99-938-00 PEST Error 43 RAP.................................................................. 2-571
94-617-00, 94-618-00 Oil Pump Error RAP .................................................................... 2-516 99-939-00 to 99-954-00 PEST Error 44 RAP.................................................................. 2-572
94-619 Cleaning Unit Delivery Line Blocked RAP .......................................................... 2-517 99-955-00 to 99-962-00 PEST Error 45 RAP.................................................................. 2-573
94-620-00 Drum Fan Stall RAP ...................................................................................... 2-517 99-992-00 PEST Error 46 RAP ....................................................................................... 2-574
94-621-00 Abatement Fan Stall RAP .............................................................................. 2-518 99-996-00 to 99-999-00 PEST Error 47 RAP.................................................................. 2-574
94-622-00 Cleaning Unit Previously Marked Unusable RAP .......................................... 2-519
94-634-00, 94-635-00 DMU Thermistor Failure RAP...................................................... 2-519
OF - Other Faults
94A Enclosure Fan Error RAP ........................................................................................ 2-520 OF 1 Unusual Noise RAP ............................................................................................... 2-575
94B Drum Drive Control Test Actions RAP ..................................................................... 2-520 OF 2 UI Touch Screen Failure RAP (W/O TAG 006)...................................................... 2-580
OF 3 Unresponsive Machine RAP .................................................................................. 2-581
Chain 99 - PEST OF 4 Status Codes and Messages RAP ......................................................................... 2-586
99-000-00 to 99-070-00 PEST Error 1 RAP.................................................................... 2-523 OF 4a Status Codes in Numerical Order ........................................................................ 2-586
99-071-00 to 99-112-00 PEST Error 2 RAP.................................................................... 2-524 OF 4b Status Messages in Alphabetical Order ............................................................... 2-615
99-113-00 to 99-141-00 PEST Error 3 RAP.................................................................... 2-525 OF 5 Boot Up Failure RAP.............................................................................................. 2-646
99-142-00 to 99-168-00 PEST Error 4 RAP.................................................................... 2-526 OF 6 Fans and Air Systems RAP.................................................................................... 2-650
99-175-00 to 99-218-00 PEST Error 5 RAP.................................................................... 2-527 OF 7 Sleep Mode RAP.................................................................................................... 2-651
99-220-00 to 99-244-00 PEST Error 6 RAP.................................................................... 2-529 OF 8 Multi-feed RAP ....................................................................................................... 2-652
OF 9 Ink Stick Count Mismatch....................................................................................... 2-653
99-245-00 to 99-271-00 PEST Error 7 RAP.................................................................... 2-530
OF 10 Intermittent Failure RAP ....................................................................................... 2-653
99-272-00 to 99-292-00 PEST Error 8 RAP.................................................................... 2-531
OF 11 Unable to Load Ink Sticks .................................................................................... 2-655
99-293-00 to 99-312-00 PEST Error 9 RAP.................................................................... 2-532
OF 12 Not Used .............................................................................................................. 2-656
99-313-00 to 99-329-00 PEST Error 10 RAP.................................................................. 2-533
OF 13 Convenience Stapler RAP ................................................................................... 2-656
99-330-00 to 99-349-00 PEST Error 11 RAP.................................................................. 2-534
OF 14 Extensible Interface Platform RAP ....................................................................... 2-657
99-360-00 to 99-382-00 PEST Error 12 RAP.................................................................. 2-535
OF 15 Xerox Secure Access RAP .................................................................................. 2-657
99-394-00 to 99-413-00 PEST Error 13 RAP.................................................................. 2-536 OF 16 POST Error RAP .................................................................................................. 2-659
99-414-00 to 99-428-00 PEST Error 14 RAP.................................................................. 2-537 OF 17 Service Code RAP ............................................................................................... 2-664
99-429-00 to 99-443-00 PEST Error 15 RAP.................................................................. 2-538 OF 18 UI Touch Screen Failure RAP (W/TAG 006)........................................................ 2-667
99-444-00 to 99-460-00 PEST Error 16 RAP.................................................................. 2-539
99-461-00 to 99-477-00 PEST Error 17 RAP.................................................................. 2-540
99-480-00 to 99-496-00 PEST Error 18 RAP.................................................................. 2-542

01-505-00 Mid Left Door Open RAP 01-506-00 Upper Left Door Open RAP
01-505-00 The mid door interlock switch detects that the mid left door is open. 01-506-00 The upper door interlock switch detects that the upper left door is open.
Initial Actions Initial Actions
WARNING WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Ensure that the electricity to the machine is switched off while performing tasks that do
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
death or injury. Moving parts can cause injury. death or injury. Moving parts can cause injury.
• Check the actuator on the mid left door assembly, PL 70.30 Item 16. If the actuator is • Check the actuator on the upper left door assembly, PL 70.30 Item 18. If the actuator is
damaged, install a new mid left door assembly, PL 70.30 Item 16. damaged, install a new upper left door assembly, PL 70.30 Item 18.
• Make sure the latch springs on the mid left door are installed correctly. Make sure that the • Make sure the latch springs, PL 70.30 Item 20 on the upper left door are installed cor-
mid left door closes correctly. If necessary, install a new mid left door assembly, PL 70.30 rectly. Make sure that the middle left door closes correctly. If necessary, install a new
Item 16. upper left door assembly, PL 70.30 Item 18.
Procedure Procedure
Enter dC330 code 01-101 to check the mid door interlock switch, S01-101, PL 82.10 Item 10. Enter dC330 code 01-100 to check the upper door interlock switch, S01-100, PL 82.10 Item
Actuate S01-101. The display changes. 10. Actuate S01-100. The display changes.
Y N Y N
Go to wiring diagram WD 8.1. Check S01-101. Go to wiring diagram WD 8.1. Check S01-100.
References: References:
• GP 13 How to Check a Switch. • GP 13 How to Check a Switch.
• PJ104, Media Path Driver PWB. • PJ104, Media Path Driver PWB.
• 01C +3.3V Distribution RAP. • 01C +3.3V Distribution RAP.
• 01L 0V Distribution RAP. • 01L 0V Distribution RAP.
Install new components as necessary: Install new components as necessary:
• Mid door interlock switch, PL 82.10 Item 10. • Upper door interlock switch, PL 82.10 Item 10.
• Media path driver PWB, PL 1.15 Item 5. • Media path driver PWB, PL 1.15 Item 5.
Check that S01-101 is installed correctly. Check that S01-100 is installed correctly.

Xerox® ColorQube® 9203 Family 2-9 01-505-00, 01-506-00
01-510-00 Front Door Open RAP 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload
01-510-00 The front door interlock switch detects that the front door is open. RAP
01-525-00 An over current condition has been detected with the +24V, +12V, -12V or +5V
Initial Actions supply.
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause WARNING
death or injury. Moving parts can cause injury. Ensure that the electricity to the machine is switched off while performing tasks that do
• Check the actuator on the front door moulding, PL 81.11 Item 7. If the actuator is dam- not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
aged, install a new front door assembly, PL 81.11 Item 11. death or injury. Moving parts can cause injury.
• Make sure the access magnetic catch, PL 81.11 Item 8 is not missing. Make sure that the Switch off the machine, then switch on the machine, GP 14. Check the PEST fault history,
front door closes correctly. If necessary, install a new front door assembly, PL 81.11 Item dC123. There are hard PEST faults shown.
11. Y N
The yellow LED, Figure 1, illuminates within one minute.
Y N
Procedure Perform the short circuit checks that follow:
Enter dC330 code 01-103 to check the front door interlock switch, S01-103, PL 1.15 Item 7. • +24V Short Circuit Check
Actuate S01-103. The display changes.
• +12V Short Circuit Check
Y N
Go to wiring diagram WD 9.3. Check S01-103. • -12V Short Circuit Check
References: • +5V Short Circuit Check
• GP 13 How to Check a Switch. If no short circuit is found and the supply is still not available, install a new power
• PJ801, Drum Driver PWB. supply unit, PL 1.15 Item 2.
• 01B +3.3V ESTAR Distribution RAP.
Refer to WD 1.4 and WD 9.4 The voltage on PJ902 pin 31 on the Drum driver PWB is
• 01L 0V Distribution RAP.
less than +1.5V.
Install new components as necessary: Y N
• Front door interlock switch, PL 1.15 Item 7. Install a new power supply unit, PL 1.15 Item 2.
• Drum driver PWB, PL 1.15 Item 4.
Install a new drum driver PWB, PL 1.15 Item 4.
Check that S01-103 is installed correctly.
Perform the RAP(s) given by the hard PEST fault code(s).
+24V Short Circuit Check
Procedure
Switch off the machine, GP 14.
Refer to WD 1.4. Disconnect PJDC1 from the power supply unit and check for a short circuit
between pin 11 of the disconnected PJ and the chassis The circuit is good.
Y N
Go to 01H and follow the procedure for the IME controller PWB.
Go to 01H and follow the procedure for the Quad wave amp PWB.
Y N
Go to 01H and follow the procedure for the drum driver PWB.
A
01-510-00, 01-525-00 2-10 Xerox® ColorQube® 9203 Family
A
With PJDC3 still disconnected from the power supply unit, check for a short circuit between pin -12V Short Circuit Check
24 of the disconnected PJ and the chassis The circuit is good.
Y N
Procedure
Go to 01H and follow the procedure for the media path driver PWB. Switch off the machine, GP 14.
Refer to WD 1.5. Disconnect PJDC4 from the power supply unit and check for a short circuit between pin 12 of the disconnected PJ and the chassis The circuit is good.
between pins 17 to chassis and pin 18 to the chassis, with the PJ disconnected The circuit is Y N
good. Go to 01F and follow the procedure for the IME controller PWB.
Y N Go to 01F and follow the procedure for the Quad wave amp PWB.
Go to 01H and follow the procedure for the power distribution PWB.
No short has been found in the +24V circuits, refer to the fault history for an insight into the between pin 16 of the disconnected PJ and the chassis The circuit is good.
fault area, then go to 01H and check that area. Y N
+12V Short Circuit Check Go to 01F and follow the procedure for the drum driver PWB.
Procedure With PJDC3 still disconnected from the power supply unit, check for a short circuit between pin
Switch off the machine, GP 14. 23 of the disconnected PJ and the chassis. The circuit is good.
Refer to WD 1.4. Disconnect PJDC1 from the power supply unit and check for a short circuit Y N
between pin 13 of the disconnected PJ and the chassis The circuit is good. Go to 01F and follow the procedure for the media path driver PWB.
Y N
Go to 01E and follow the procedure for the IME controller PWB. No short has been found in the -12V circuits, refer to the fault history for an insight into the fault
Go to 01E and follow the procedure for the Quad wave amp PWB. area, then go to 01F and check that area.
Procedure
Y N Switch off the machine, GP 14.
Go to 01E and follow the procedure for the drum driver PWB. Refer to WD 1.4. Disconnect PJDC1 from the power supply unit and check for a short circuit
With PJDC3 still disconnected from the power supply unit, check for a short circuit between pin Y N
22 of the disconnected PJ and the chassis The circuit is good. Go to 01D and follow the procedure for the IME controller PWB.
Y N Go to 01D and follow the procedure for the Quad wave amp PWB.
Go to 01E and follow the procedure for the media path driver PWB.
Refer to WD 1.5. Disconnect PJDC4 from the power supply unit and check for a short circuit between pin 19 of the disconnected PJ and the chassis The circuit is good.
between pin 14 of the disconnected PJ and the chassis The circuit is good. Y N
Y N Go to 01D and follow the procedure for the drum driver PWB.
Go to 01E and follow the procedure for the power distribution PWB.
With PJDC3 still disconnected from the power supply unit, check for a short circuit between pin
Check for a short circuit between pin 15 on PJDC4 and the chassis The circuit is good. 20 of the disconnected PJ and the chassis The circuit is good.
Y N Y N
Go to 01E and follow the procedure for the HDD1. Go to 01D and follow the procedure for the media path driver PWB.
Check for a short circuit between pin 16 on PJDC4 and the chassis The circuit is good. Refer to WD 1.5. Disconnect PJDC4 from the power supply unit and check for a short circuit
Y N between pin 13 of the disconnected PJ and the chassis The circuit is good.
Go to 01E and follow the procedure for the HDD2. Y N
Go to 01D and follow the procedure for the power distribution PWB.
No short has been found in the +12V circuits, refer to the fault history for an insight into the
fault area, then go to 01E and check that area. Check for a short circuit between pin 11 on PJDC4 and the chassis The circuit is good.
Y N
Go to 01D and follow the procedure for the HHD1.
Check for a short circuit between pin 12 on PJDC4 and the chassis The circuit is good.

Xerox® ColorQube® 9203 Family 2-11 01-525-00
Y N 01-530-00 +/- 50V Short Circuit and Overload RAP
Go to 01D and follow the procedure for the HHD2.
01-530-00 An over current condition has been detected with the +50V or -50V supply.
The fault is still active.
Y N Procedure
Perform SCP 5 Final Actions.
Install a new power supply unit, PL 1.15 Item 2. WARNING

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Switch off the machine, then switch on the machine, GP 14. Check the PEST fault history,
dC123. There are hard PEST faults shown.
Y N
The red LED, Figure 1, is illuminated.
Y N
Perform the short circuit checks that follow:
• +50V Short Circuit Check.
• -50V Short Circuit Check.
If no short circuit is found and the supply is still not available, install a new power
supply unit, PL 1.15 Item 2.
Refer to WD 1.4 and WD 9.4. The voltage on PJ902 pin 29 on the drum driver PWB
is less than +1.5V.
Y N
Install a new power supply unit, PL 1.15 Item 2.
Power supply unit Yellow LED
Figure 1 Component location
Perform the RAP(s) given by the hard PEST fault code(s).

Procedure
between pin 10 of the disconnected PJ and the chassis. The circuit is good.
Y N
Go to 01J and follow the procedure for the IME controller PWB
Go to 01J and follow the procedure for the Quad wave amp PWB.
between pin 12 of the disconnected PJ and the chassis. The circuit is good.
Y N
Go to 01J and follow the procedure for the media path driver PWB.
With PJDC3 still disconnected from the power supply unit, check for a short circuit between
pins 13 and 14 of the disconnected PJ and the chassis. the circuit is good.
Y N
Go to 01J and follow the procedure for the drum driver PWB.
A
A
No short has been found in the +50V circuits, refer to the fault history for an insight into the 01-535-00 Power Interlock Failed: No Heater Requests RAP
fault area, then go to 01J and check that area.
01-535-00 The IME power interlock has failed because the AC power manager heater requests
are not being updated.
-50V Short Circuit Check
Procedure Procedure
between pin 18 of the disconnected PJ and the chassis. The circuit is good. WARNING
Y N Ensure that the electricity to the machine is switched off while performing tasks that do
Go to 01K and follow the procedure for the IME controller PWB. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Go to 01K and follow the procedure for the Quad wave amp PWB. death or injury. Moving parts can cause injury.
Switch off the machine, then switch on the machine, GP 14.
The fault is still active.
Go to WD 9.3 and check PJ801. The voltage at PJ801 pin 4 on the drum driver PWB
Y N
changes when the switch is actuated/deactuated.
Y N
Refer to GP 13, How to Check a Switch. Check the wiring between the interlock switch
and PJ801 and repair the wiring as necessary, refer to REP 1.1. If necessary, install new
components:
• Front door interlock switch, (S01-103), PL 1.15 Item 7.
Go to 01A AC Power Distribution RAP and check for the correct AC supply. If necessary, install
a new power supply unit, PL 1.15 Item 2.
Power supply unit Red LED

01-540-00, 01-544-00 +24V, +/-12V, +5V Failure RAP Y N
Check the condition of the drum driver power supply interface cable between PJDC2 on
01-540-00 The +24V, +12V, -12V and +5V supplies have shut down unexpectedly.
the power supply unit and PJ902 on the drum driver PWB. It should be correctly and
securely connected at each end, and should be undamaged. This cable carries power
01-544-00 The IME +24V, +12V, -12V and +5V supplies have failed to switch on. control signals from and to the power supply unit. The cable is good.
Y N
Procedure Correct the cable connection or install a new drum driver power supply interface
cable, PL 1.15 Item 10, as necessary.
WARNING Switch off the machine, GP 14. Check pin 24 of PJ902 on the drum driver PWB. Pin 24
Ensure that the electricity to the machine is switched off while performing tasks that do is short circuit to ground.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Y N
death or injury. Moving parts can cause injury. Install a new power supply unit, PL 1.15 Item 2.
Check that the three LEDs on the top of the power supply unit illuminate within one minute of Repair the wiring, REP 1.1.
switch-on, Figure 1. The LEDs illuminate.
Y N Install a new drum driver PWB, PL 1.15 Item 4. The fault is still active.
Either the power supply unit is faulty or there is a short circuit. Refer to WD 9.4 and WD Y N
1.4. Measure the voltage at pin 27 of PJ902 on the drum driver PWB. The voltage should Perform SCP 5 Final Actions.
be greater than +2.5V, indicating the drum driver PWB is enabling the +24V, +12V, -12V
and +5V supplies in the power supply unit. The voltage is greater than +2.5V. Go to 01H +24V Distribution RAP.
Y N Other voltage supplies are inter-dependent. Also refer to the RAP’s that follow:
Check the condition of the drum driver power supply interface cable between PJDC2 • 01D +5V Distribution RAP.
on the power supply unit and PJ902 on the drum driver PWB. It should be correctly • 01E +12V Distribution RAP.
and securely connected at each end, and should be undamaged. This cable carries • 01F -12V Distribution RAP.
power control signals from and to the power supply unit. The cable is good.
Y N
Correct the cable connection or install a new drum driver power supply inter-
face cable, PL 1.15 Item 10, as necessary.
Temporarily install a network cable between PJ403 on the IME Controller PWB and
PJ603 on the drum driver PWB. The fault persists.
Y N
Install a new service loop, PL 92.10 Item 9.
Switch off the machine, GP 14. Check pin 27 of PJ902 on the drum driver PWB. Pin
27 is short circuit to ground.
Y N
Repair the wiring, REP 1.1.
Either the power supply unit is faulty or there is a short circuit. Go to 01-525-00 +24V, +/-
12V, +5V Short Circuit and Overload RAP.
Refer to WD 9.4 and WD 1.4. Measure the voltage at pin 24 of PJ902 on the drum driver PWB.
This can be measured on the top of the connector, while it is connected to the drum driver Power supply unit Three LEDs
PWB. The voltage should be greater than +2.5V, indicating that the power supply is enabled.
The yellow LED on the power supply unit should also be lit, Figure 1. The voltage is greater Figure 1 Component location
than +2.5V.

A B C
01-542-00, 01-546-00 50V Failure RAP Install a new drum driver PWB, PL 1.15 Item 4.
01-542-00 The IME +50V or -50V supply has shutdown unexpectedly.

The control voltages are correct. If the +50V or -50V supplies are still not present, either
there is a power supply unit fault or there is a short circuit. Go to 01-530-00 +/-50V Short
01-546-00 The IME +50V or -50V supply has failed to switch on. Circuit and Overload RAP.
Initial Actions Refer to WD 1.4 and WD 9.4. Check the red LED, Figure 1, is illuminated and the voltage on
If possible, repair all the current listed faults, before performing this procedure, refer to dC123. PJ902 pin 26 on the drum driver PWB is greater than +2.5V. The LED is illuminated and the
voltage is greater than 2.5V.
Fault 01-546-00 Only. If this fault is present after installation of a new wave amp cable, it may Y N
be caused by a misaligned connection to the quad wave amp PWB, causing a short in the 50V Switch off the machine GP 14. Check PJ902 pin 26 on the drum driver PWB. Pin 26 is
supply. Install a new quad wave amp PWB, PL 92.10 Item 3 and wave amp cable, PL 92.10 shorted to ground.
Item 8. Y N
Procedure

WARNING
Switch off the machine GP 14. Refer to WD 1.4 and WD 9.4. Check the condition of the drum
driver power supply interface cable between PJDC2 on the power supply unit and PJ902 on
the drum driver PWB. It should be correctly and securely connected at each end, and should
be undamaged, PL 1.15 Item 10. The ribbon cable is secure and in good condition.
Y N
Correct the cable connection or install a new drum driver power supply interface cable, PL
1.15 Item 10, as necessary.
Switch on the machine GP 14. The fault code is still present.

Y N
Check the 3 LEDs on the power supply are illuminated, Figure 1. The 3 LEDs are on and
remain illuminated after 60 seconds.
Y N Three LEDs
Green = +3.3V ESTAR
Either the power supply unit is not enabled or is faulty or there is a short circuit on the Power supply unit Yellow = +5V, Red = +50V
+50V or -50V output circuits.
NOTE: The voltage on PJ902 at pin 28 must be greater than +2.5V to enable +/-50V out-
puts.
Switch on the machine GP 14. Go to WD 1.4 and WD 9.4. Check the voltage on PJ902
pin 28 on the drum driver PWB. The voltage is greater than +2.5V.
Y N
Refer to WD 1.4 and WD 9.4. Check the drum driver power supply interface cable for
short circuits on PJ902 at pin 28 and pin 29. The cable is good.
Y N
Repair the drum driver power supply interface cable as necessary, REP 1.1. If
necessary, install a new drum driver power supply interface cable, PL 1.15 Item
10.
A B C

01A AC Power Distribution RAP Power to the Power Supply Unit Check:
Use this RAP to diagnose faults with the AC power distribution throughout the machine. Procedure
Check the green LED on top of the power supply, Figure 1. The green LED is lit.
Initial Actions Y N
Check the customer AC supply. The AC supply is good.
Y N
WARNING Inform the customer to resolve the power supply fault.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Check the power cord, PL 1.15 Item 1.
The ink reservoir, PL 93.10 Item 10, is warm.
Switch off the machine, then switch on the machine, GP 14. Check for PEST errors, go to
Y N
dC123 PEST Fault History. If a fault is given, perform the appropriate RAP. If the machine is
Go to:
unresponsive, go to OF 3.
• Main Power Rocker Switch Check:
Procedure • Ink Reservoir Heaters Check:
AC Power is distributed widely throughout this machine. Either work through this RAP or if the
faulty area of the machine is known, select the required check from the list that follows: AC power is present and the power interlocks are operating.
Main Power Rocker Switch Check:
NOTE: If multiple heater failures are noted, the fault is likely to exist in one of the following:
• Marking unit heater PWB supply, WD 9.8. Procedure
• Head thermistors safety circuit, refer to the 99-394-00 to 99-413-00 PEST Error 13 RAP. Switch off the machine, GP 14, disconnect the power cord. Refer to WD 1.1. Disconnect
PJ8AC on the power supply unit and measure the continuity between pins 1 and 2 of the
• WD 1.4, WD 9.2, WD 9.4 and WD 9.6 for IME common heater relay. The line signal must
cable, Continuity is measured when the main power rocker switch is in the on position
be greater than +2.5V to close the relays.
and open circuit is measured when the main power rocker switch is in the off position.
• Check the power supply output for the items that follow: Y N
– Ink melt, refer to Ink Reservoir Heaters Check: If there is no voltage output, install a Check the wiring between PJ8AC on the power supply unit and the main power rocker
new power supply unit, PL 1.15 Item 2. switch and repair as necessary, refer to REP 1.1. If necessary, install new a main power
– Registration pre-heater, refer to Registration/Pre-Heaters Check: If there is no volt- rocker switch, PL 1.15 Item 3.
age output, install a new power supply unit, PL 1.15 Item 2.
– Drum heaters, refer to Drum Heaters Check:. If there is no voltage output, install a Continuity is measured when the main power rocker switch is in off position.
new power supply unit, PL 1.15 Item 2. Y N
There is a short circuit or the switch has failed. Check the wiring between PJ8AC on the
– Marking unit heater PWB supply, refer to Marking Unit Heater PWB Supply Check:. If
power supply unit and the main power switch and repair as necessary, refer to REP 1.1. If
there is no voltage output, install a new power supply unit, PL 1.15 Item 2.
necessary, install new a main power switch, PL 1.15 Item 3.
• Power to the Power Supply Unit Check:
• Main Power Rocker Switch Check: Install a new power supply unit, PL 1.15 Item 2.
• Ink Reservoir Heaters Check:
• Ink Melt Heaters Check: Ink Reservoir Heaters Check:
• Drum Heaters Check: Procedure
• Registration/Pre-Heaters Check: Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
• Thermal Cutout Check: 9.8. Disconnect PJ201 from the marking unit heater PWB. Check the electrical resistance of
• Finisher Supply Check: the ink reservoir heaters, by measuring the resistance across the pins of the PJ201 harness as
• Marking Unit Heater PWB Supply Check: follows:
• Lower Umbilical Heater Check: • Ink reservoir heater 1, pin 1 to pin 3. Expect a cold resistance of approximately 45-55
• Head 1 Reservoir and Jetstack Heaters Check: ohms.
• Head 3 Reservoir and Jetstack Heaters Check: • Ink reservoir heater 2, pin 2 to pin 4. Expect a cold resistance of approximately 45-55
• Upper Umbilical Heater Check: ohms.
• Head 2 Reservoir and Jetstack Heaters Check: The measured resistances are correct.
• Head 4 Reservoir and Jetstack Heaters Check:

01A 2-16 Xerox® ColorQube® 9203 Family
Y N Y N
Go to WD 9.8. Check the wiring between PJ201 on the marking unit heater PWB and the Go to WD 1.2. Check the wiring between PJ5AC on the power supply unit, and PJX to the
ink reservoir heaters. Repair the wiring as necessary, REP 1.1. If necessary, install a new drum heaters. Repair the wiring as necessary, refer to REP 1.1. As necessary, install a
reservoir assembly, PL 93.10 Item 26. new drum, PL 94.20 Item 1.
The ink reservoir heaters are good. If necessary, install a new Marking unit heater PWB, PL Go to Thermal Cutout Check:
92.10 Item 5. Perform SCP 5 Final Actions.
Registration/Pre-Heaters Check:
Ink Melt Heaters Check: Procedure
Procedure Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD 1.2. Disconnect PJ5AC from the power supply unit. Check the electrical resistance of the regis-
1.2. Disconnect PJ5AC from the power supply unit. Check the electrical resistance of the four tration/pre-heaters by measuring the resistance across the pins of the PJ5AC harness as fol-
ink melt heaters by measuring the resistance across the pins of the PJ5AC harness as follows: lows:
• Black ink melt heater, pin 6 to pin 12. Expect a cold resistance of approximately 70-80 • Registration pre-heater 1, pin 3 to pin 9. Expect a cold resistance of approximately 50-60
ohms. ohms.
• Yellow ink melt heater, pin 6 to pin 13. Expect a cold resistance of approximately 70-80 • Registration pre-heater 2, pin 2 to pin 8. Expect a cold resistance of approximately 50-60
ohms. ohms.
• Cyan ink melt heater, pin 7 to pin 1. Expect a cold resistance of approximately 70-80 • Check that pin 8 to the chassis is open circuit.
ohms. • Check that pin 9 to the chassis is open circuit.
• Magenta ink melt heater, pin 7 to pin 11. Expect a cold resistance of approximately 70-80 The measured resistances are correct.
ohms. Y N
• Check that pin 7 to chassis is open circuit. Go to WD 1.2. Check the wiring between PJ5AC on the power supply unit, and PJ140 to
• Check that pin 6 to the chassis is open circuit. the registration preheat assembly. Repair the wiring as necessary, refer to REP 1.1. As
The measured resistances are correct. necessary, install a new registration preheat assembly PL 88.10 Item 1.
Y N
The registration/pre-heaters are good. If necessary, install a new power supply unit, PL 1.15
Go to WD 1.2. Check the wiring between PJ5AC and PJX to the ink melt heaters. Repair
the wiring as necessary, refer to REP 1.1. If necessary, install a new ink loader melt plate Item 2.
assembly, PL 93.10 Item 3.
Thermal Cutout Check:
The ink melt heaters are good. If necessary, install a new power supply unit, PL 1.15 Item 2. Procedure
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
Drum Heaters Check: 1.2. Disconnect PJ5AC harness on the power supply unit. Check the continuity of the thermal
Procedure cutouts on the thermal cutout PWB, by measuring the resistance across the pins of the PJ5AC
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD harness as follows:
• cutout for drum heater 1, pin 4 to pin 14. Expect a short circuit.
1.2. Disconnect PJ5AC from the power supply unit. Check the electrical resistance of the two
drum heaters by measuring the resistance across the pins of the PJ5AC harness as follows: • cutout for drum heater 2, pin 5 to pin 18. Expect a short circuit.
• Drum heater 1 first section, pin 15 to pin 16. Expect a cold resistance of approximately 40- • Check that pin 4 and 5 to the chassis is open circuit.
50 ohms. The measured resistances are correct.
• Drum heater 1 second section, pin 15 to pin 17. Expect a cold resistance of approximately Y N
40-50 ohms. Go to WD 1.2. Check the wiring between PJ5AC on the power supply unit and PJ140 to
• Drum heater 2 first section, pin 10 to pin 19. Expect a cold resistance of approximately 40- the thermal cutout PWB, PL 88.10 Item 11. Repair as necessary, refer to REP 1.1. As
50 ohms. necessary, install a new thermal cutout PWB, PL 94.20 Item 11.
• Drum heater 2 second section, pin 10 to pin 20. Expect a cold resistance of approximately
The thermal cutouts are good. Refer to WD 9.4. Switch on the electricity to the machine, GP
40-50 ohms.
14, and check the voltage on PJ902 pin 1 or pin 2 on the drum driver PWB is greater than
• Check that pin 15 to the chassis is open circuit.
+2.5V. Check the voltage on PJ902 pin 33 on the drum driver PWB is greater than +2.5V. The
• Check that pin 10 to the chassis is open circuit. voltages are good.
The measured resistances are correct. Y N
A

Xerox® ColorQube® 9203 Family 2-17 01A
A
Check the condition of harness between PJDC2 of the power supply unit and PJ 902 of the Lower Umbilical Heater Check:
drum driver PWB. The harness is good.
Y N
Procedure
Repair the harness, REP 1.1. Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
9.8. Disconnect PJ701 from the marking unit heater PWB. Check the electrical resistance of
Install a new power supply unit, PL 1.15 Item 2. the lower umbilical heater, by measuring the resistance across pin 1 to pin 8 of the PJ701 har-
ness, expect a cold resistance of approximately 85-95 ohms. The measured resistance is
Finisher Supply Check: correct.
Y N
Procedure
Verify that the machine is configured for a finisher and that the machine is ready to print. Refer Go to WD 9.8. Check the wiring between PJ701 on the marking unit heater PWB and the
to WD 1.4 and WD 9.4. Check the Finisher On signal from PJDC2, pin 3 on the power supply lower umbilical heater. Repair the wiring as necessary, refer to REP 1.1. If necessary,
unit to PJ902, pin 3 on the drum driver PWB. The signal is good. install new components:
Y N • Umbilical, PL 91.25 Item 10.
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Repair • Marking unit heater PWB, PL 92.10 Item 5.
the wiring as necessary, REP 1.1 or install new wiring, PL 1.15 Item 10. If necessary,
• Power supply unit, PL 1.15 Item 2.
install new components:
The lower umbilical heater is good. If necessary, install a new power supply unit, PL 1.15 Item
• Drum driver PWB, PL 1.15 Item 4. 2.
• Drum driver power supply interface cable (PJ902), PL 1.15 Item 10.
Head 1 Reservoir and Jetstack Heaters Check:
An HVF is installed.
Y N Procedure
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
WD 1.1 and WD 12.1. Check the wiring between PJ3AC on the power supply unit and 9.8. Disconnect PJ701 from the marking unit heater PWB. Check the electrical resistance of
CN1 on the LCSS power supply module, PL 12.75 Item 2. As necessary, repair the wiring, the head 1 reservoir and jetstack heaters, by measuring the resistance across the pins of the
REP 1.1. If necessary, install new components: PJ701 harness as follows:
• LCSS power supply unit, PL 12.75 Item 2. • Head 1 reservoir heater, pin 2 to pin 3. Expect a cold resistance of approximately 95-105
• Power supply unit, PL 1.15 Item 2. ohms.
• Head 1 first half jetstack heater, pin 5 to pin 4. Expect a cold resistance of approximately
NOTE: Verify that no short circuits exist between the line, neutral and ground on the 495-505 ohms.
harness to the finisher, before a new power supply unit is installed.
• Head 1 second half jetstack heater, pin 5 to pin 6. Expect a cold resistance of approxi-
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD mately 495-505 ohms.
1.1 and WD 12.6. Check the wiring between PJ3AC on the power supply unit and CN1 on the • Check that pin 2 to ground and pin 5 to ground are open circuit.
HVF power supply unit, PL 12.140 Item 1. As necessary, repair the wiring, REP 1.1. If neces-
The measured resistances are correct.
sary, install new components:
Y N
• HVF power supply unit, PL 12.140 Item 1. If the correct resistance was not measured, go to WD 9.8. Check the wiring between
• Power supply unit, PL 1.15 Item 2. PJ701 on the marking unit heater PWB and the head 1 reservoir and jet stack heater.
NOTE: Verify that no short circuits exist between the line, neutral and ground on the har- Repair the wiring as necessary, refer to REP 1.1. If necessary, install a new printhead 1,
PL 91.25 Item 2.
ness to the finisher, before a new power supply unit is installed.
The head 1 heaters are good. If necessary, install a new marking unit heater PWB, PL 92.10
Marking Unit Heater PWB Supply Check: Item 5.
Procedure
Refer to WD 1.1 and WD 9.8, check the wiring between PJ4AC on the power supply unit and
PJ101 on the marking unit heater PWB. If necessary, repair the wiring, REP 1.1.

Head 3 Reservoir and Jetstack Heaters Check: Head 2 Reservoir and Jetstack Heaters Check:
Procedure Procedure
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
9.8. Disconnect PJ701 from the marking unit heater PWB. Check the electrical resistance of 9.8. Disconnect PJ401 from the marking unit heater PWB. Check the electrical resistance of
the head 3 reservoir and jetstack heaters, by measuring the resistance across the pins of the the head 2 reservoir and jetstack heaters, by measuring the resistance across the pins of the
PJ701 harness as follows: PJ401 harness as follows:
• Head 3 reservoir heater, pin 9 to pin 10. Expect a cold resistance of approximately 95-105 • Head 2 reservoir heater, pin 2 to pin 3. Expect a cold resistance of approximately 95-105
ohms. ohms.
• Head 3 first half jetstack heater, pin 12 to pin 11. Expect a cold resistance of approxi- • Head 2 first half jetstack heater, pin 5 to pin 4. Expect a cold resistance of approximately
mately 495-505 ohms. 495-505 ohms.
• Head 3 second half jetstack heater, pin 12 to pin 13. Expect a cold resistance of approxi- • Head 2 second half jetstack heater, pin 5 to pin 6. Expect a cold resistance of approxi-
mately 495-505 ohms. mately 495-505 ohms.
• Check that pin 9 and pin 12 to the chassis is open circuit. • Check that pin 2 and pin 5 to the chassis is open circuit.
The measured resistances are correct. The measured resistances are correct.
Y N Y N
Go to WD 9.8. Check the wiring between PJ701 on the marking unit heater PWB and the Go to WD 9.8. Check the wiring between PJ401 on the marking unit heater PWB and the
head 3 reservoir and jet stack heater. Repair the wiring as necessary, refer to REP 1.1. If head 2 reservoir and jet stack heater. Repair the wiring as necessary, refer to REP 1.1. If
necessary, install a new printhead 3, PL 91.25 Item 2. necessary, install a new printhead 2, PL 91.20 Item 2.
The head 3 heaters are good. If necessary, install a new marking unit heater PWB, PL 92.10 The head 2 heaters are good. If necessary, install a new marking unit heater PWB, PL 92.10
Item 5. Re-connect PJ701. Item 5.
Upper Umbilical Heater Check: Head 4 Reservoir and Jetstack Heaters Check:
Procedure Procedure
Switch off the electricity to the machine, GP 14, and disconnect the power cord. Disconnect Switch off the electricity to the machine, GP 14, and disconnect the power cord. Refer to WD
PJ401 from the marking unit heater PWB. Check the electrical resistance of the upper umbili- 9.8. Disconnect PJ401 from the marking unit heater PWB. Check the electrical resistance of
cal heater, by measuring the resistance across the pins of the PJ401 harness as follows: the head 4 reservoir and jetstack heaters, by measuring the resistance across the pins of the
• Upper umbilical heater, pin 1 to pin 7. Expect a cold resistance of approximately 85-95 PJ401 harness as follows:
ohms. • Head 4 reservoir heater, pin 8 to pin 9. Expect a cold resistance of approximately 95-105
• Check that pin 1 and pin 7 to the chassis is open circuit. ohms.
The measured resistances are correct. • Head 4 first half jetstack heater, pin 11 to pin 10. Expect a cold resistance of approxi-
Y N mately 495-505 ohms.
Go to WD 9.8. Check the wiring between PJ401 on the marking unit heater PWB and the • Head 4 second half jetstack heater, pin 11 to pin 12. Expect a cold resistance of approxi-
upper umbilical heater. Repair the wiring as necessary, refer to REP 1.1. If necessary, mately 495-505 ohms.
install a new umbilical, PL 91.20 Item 10. • Check that pin 8 and pin 11 to the chassis is open circuit.
The measured resistances are correct.
The upper umbilical heater is good. If necessary, install a new power supply unit, PL 1.15 Item Y N
2.
Go to WD 9.8. Check the wiring between PJ401 on the marking unit heater PWB and the
head 4 reservoir and jet stack heater. Repair the wiring as necessary, refer to REP 1.1. If
necessary, install a new printhead 4, PL 91.20 Item 2.
The head 4 heaters are good. Re-connect PJ401. If necessary, install a new marking unit
heater PWB, PL 92.10 Item 5.

01B +3.3V ESTAR Distribution RAP
Use this RAP to diagnose +3.3V ESTAR supply and distribution faults in the machine. This
supply is used to power the IME logic circuits. This supply is not to be confused with the +3.3V
supply, which is generated on the power distribution PWB. To diagnose +3.3V faults go to 01C.
Procedure
WARNING
Check the green LED, Figure 1, on top of the power supply unit. This is lit to indicate that the
+3.3V ESTAR supply is available in the power supply unit. The green LED is lit.
Y N
The AC supply is good.
Three LEDs Y N
Green = +3.3V ESTAR Go to 01A AC Power Distribution RAP.
Power supply unit
Yellow = +5V, Red = +50V
Go to the 01A AC Power Distribution RAP. Perform the Main Power Rocker Switch
Check.
Switch off, then switch on the machine, GP 14. Check the PEST fault history, dC123. There
are hard PEST faults shown.
Y N
Check that the +3.3V is within tolerance, +3.3V +/- 2.5% at JDC1 between pin 9 and pin
14.
NOTE: To view the +3.3V ESTAR supply generation, refer to WD 1.3. +3.3V ESTAR is
only distributed on PJDC1 and PJDC3 on the power supply unit. A short circuit on this
output also disables the +17V output.
The +3.3V supply is within tolerance.
Y N
Determine which PWB has the distribution fault, go to PWB Checks.
Perform the RAP(s) given by the hard PEST fault code(s), then return to this RAP.

01A, 01B 2-20 Xerox® ColorQube® 9203 Family
PWB Checks • To view the +3.3V ESTAR distribution from the marking unit heater PWB, refer to WD 9.8.
Check the PWBs below to determine which PWB has the distribution fault. Follow the distribu- • For +3.3V ESTAR faults on the marking unit heater PWB, refer to WD 9.8
tion back to the supply. Repair the wiring, REP 1.1 or install a new PWB or power supply unit, • If necessary, install a new marking unit heater PWB, PL 92.10 Item 5.
PL 1.15 Item 2 as necessary. Refer to GP 15 for the location and function of the LED’s on the Marking Unit Driver PWB:
PWB’s.
• To view the +3.3V ESTAR distribution from the IME controller PWB, refer to WD 9.7.
NOTE: Many PWBs have distribution fuses.
• For +3.3V ESTAR faults on the marking unit driver PWB, refer to:
IME Controller PWB: – WD 9.10
– WD 9.11
• To view the +3.3V ESTAR distribution from the power supply unit to the IME controller
– WD 9.12
PWB, refer to WD 1.4.
• If necessary, install a new marking unit driver PWB, PL 92.10 Item 4.
• For +3.3V ESTAR faults on the IME controller PWB, refer to:
Drum Driver PWB:
– WD 9.5
– WD 9.6 • The +3.3V ESTAR LED on the drum driver PWB is shown in WD 9.2.
– WD 9.7 • To view the +3.3V ESTAR distribution from the power supply unit, to the drum driver PWB,
• The components that follow are driven from +3.3V ESTAR from the IME controller PWB refer to WD 1.5.
– Printheads, PL 91.20 Item 2 or PL 91.25 Item 2 • For +3.3V ESTAR faults on the drum driver PWB, refer to:
– Quad waveamp PWB, PL 92.10 Item 3 – WD 9.2
– Marking unit driver PWB, PL 92.10 Item 4 – WD 9.3
• If necessary, install a new IME controller PWB, PL 92.10 Item 1, or one of the compo- – WD 9.4
nents in the list above. • The +3.3V ESTAR LED on this PWB is shown in WD 9.2.
Media Path Driver PWB: • The components that follow are driven from +3.3V ESTAR from the drum driver PWB:
– Front door interlock switch PL 1.15 Item 7
• To view the +3.3V ESTAR distribution from the power supply unit to the media path driver
– Waste tray sensor PL 91.05 Item 4
PWB, refer to WD 1.5.
• If necessary, install a new drum driver PWB, PL 1.15 Item 4, or one of the components in
• For +3.3V ESTAR faults on the media path driver PWB refer to:
the list above.
– WD 8.1
Quad Waveamp PWB:
– WD 8.2
– WD 8.3. • To view the +3.3V ESTAR distribution from the IME controller PWB to the quad wave amp
– WD 8.4 PWB, refer to WD 9.5.
– WD 8.5 • For +3.3V ESTAR faults on the quad wave amplifier PWB, refer to WD 9.13.
• Repair the wiring as necessary, REP 1.1. • If necessary, install a new quad waveamp PWB, PL 92.10 Item 3.
• The components that follow are driven from +3.3V ESTAR from the media path driver Ink Load Entry PWB:
PWB:
– Upper door interlink PL 82.10 Item 10 • To view the +3.3V ESTAR distribution from the marking unit driver PWB to the ink load
– Vertical transport sensor PL 82.10 Item 7 entry PWB, refer to WD 8.4.
– 3 tray module PL 73.16 • For +3.3V ESTAR faults on the ink load entry PWB, refer to:
– Ink loader door switch PL 93.10 Item 19 – WD 9.17
– Bypass width sensor PL 74.11 Item 6 – WD 9.18
– Potentiometer PL 74.11 Item 10 • If necessary, install a new ink load entry PWB, PL 93.10 Item 8.
– Ink load entry PWB PL 93.10 Item 8 Printhead 1 to 4:
– Tray 5 control PWB PL 75.68 Item 8

• To view the +3.3V ESTAR distribution from the IME controller PWB to the printhead
• If necessary, install a new media path driver PWB, PL 1.15 Item 5, or one of the compo- PWBs, refer to:
nents in the list above.
– WD 9.5
Marking Unit Heater PWB:
– WD 9.6

Xerox® ColorQube® 9203 Family 2-21 01B
• For +3.3V ESTAR faults on the printheads, refer to: 01C +3.3V Distribution RAP
– WD 9.20 Use this RAP to diagnose +3.3V supply and distribution faults. This supply is not to be con-
– WD 9.21 fused with the +3.3 ESTAR supply, which is generated in the power supply unit. Go to 01B to
• The +3.3V ESTAR LEDs on these printheads are shown in: diagnose +3.3V ESTAR faults.
– WD 9.20
– WD 9.21 Procedure
• If necessary, install a new printhead 1 or printhead 3 PL 91.25 Item 2 or install a new
printhead 2 or printhead 4 PL 91.20 Item 2.
3 Tray Module PWB:
WARNING
• To view the +3.3V ESTAR distribution from the media path driver PWB, refer to WD 8.2 Ensure that the electricity to the machine is switched off while performing tasks that do
• For +3.3V ESTAR faults on the 3 tray module PWB, refer to:
– WD 7.3
The green LED is lit on the power supply, Figure 1.
– WD 7.4 Y N
• If necessary, install a new 3 tray module PWB, PL 73.16 Item 4. Go to 01B +3.3V ESTAR Distribution RAP.
Check the PWBs below to determine which PWB has the distribution fault. Follow the distribu-
tion back to the supply. Repair the wiring, REP 1.1 or install a new PWB or power supply unit,
PL 1.15 Item 2 as necessary. Refer to GP 15 for the location and function of the LED’s on the
PWB’s.
To view the +3.3V supply generation, refer to WD 1.6.
Power Distribution PWB:
• For +3.3V faults on the power distribution PWB, refer to WD 1.6.
• If necessary repair the wiring, REP 1.1.
• If necessary, install a new power distribution PWB, PL 3.10 Item 1.
• If necessary, install a new power supply unit, PL 1.15 Item 2
Copy Controller PWB (W/O TAG 006):
• To view the +3.3V distribution from the power distribution PWB, refer to WD 1.6.
• For +3.3V faults on the copy controller PWB, refer to:
– WD 3.1
– WD 3.2
• If necessary, install a new copy controller PWB, PL 3.10 Item 17.
Power supply unit Green LED
Network Controller PWB (W/O TAG 006):
• Check for the presence of the +3.3V supply by viewing CR19, the +3.3V ON LED on the
Figure 1 Component location network controller PWB, refer to WD 1.7.
• For +3.3V faults on the network controller PWB, refer to:
– WD 1.7
• If necessary, install a new network controller PWB, PL 3.10 Item 4.
Single Board Controller PWB (W/TAG 006):
• For +3.3V faults on the single board controller PWB, refer to:
– WD 3.4
– WD 3.5

01B, 01C 2-22 Xerox® ColorQube® 9203 Family
• If necessary repair the wiring, REP 1.1. Registration/Pre-heat Interface PWB
• If necessary, install a new single board controller PWB, PL 3.11 Item 13. • +3.3V is generated within this PWB from the +5V supply. Refer to WD 8.6.
Scanner PWB (W/O TAG 007): • If necessary, install a new registration/pre-heat interface PWB, PL 88.10 Item 10.
• To view the +3.3V distribution from the power distribution PWB, refer to WD 1.8. IOD Pre-amplifier PWB:
• For +3.3 faults on the scanner PWB, refer to: • +3.3V is generated within this PWB from the +5V supply. Refer to WD 9.22.
– WD 6.1 • If necessary, install a new IOD pre-amplifier PWB, PL 94.15 Item 4.
– WD 6.2
– WD 6.3
• If necessary, install a new scanner PWB, PL 62.16 Item 8.
Full Width Array (W/O TAG 007):
• To view the +3.3V distribution from the scanner PWB, refer to WD 6.3.
• For +3.3 faults on the full width array, refer to:
– WD 6.3.
• Install new components as necessary, PL 62.15.
Scanner PWB (W/TAG 007):
• For +3.3 faults on the scanner PWB, refer to:
– WD 6.4
– WD 6.5
– WD 6.6
• If necessary, install a new scanner PWB, PL 62.17 Item 1. Power supply unit Green LED
DADH PWB:
• To view the +3.3V distribution from the DADH PWB, refer to WD 6.3. Figure 1 Component location
• For +3.3 faults on the DADH PWB, refer to:
– WD 5.1.
– WD 5.2.
• If necessary, install a new DADH PWB, PL 5.10 Item 5.
UI PWB (W/O TAG 006):
• To view the +3.3V distribution from the copy controller PWB, refer to WD 3.1.
• For +3.3 faults on the UI PWB, refer to:
– WD 3.1
• If necessary, install a new user interface control PWB, PL 2.10 Item 2 or user interface
status PWB, PL 2.10 Item 4.
UI PWB (W/TAG 006):
• To view the +3.3V distribution from the single board controller PWB, refer to WD 3.4.
• For +3.3 faults on the UI PWB, refer to:
– WD 3.4

Xerox® ColorQube® 9203 Family 2-23 01C
01D +5V Distribution RAP NOTE: Many PWB’s have distribution fuses
Use this RAP to diagnose +5V supply and distribution faults. IME Controller PWB:
Procedure • To view the +5V distribution from the power supply unit, refer to WD 1.4.
• For +5V faults on the IME controller PWB, refer to:
– WD 9.6
WARNING – WD 9.7
Ensure that the electricity to the machine is switched off while performing tasks that do • The marking unit driver PWB PL 92.10 Item 4, is driven from +5V from the IME controller
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause PWB
• Repair the wiring as necessary, REP 1.1
NOTE: To view the +5V supply generation, refer to WD 1.3. • If necessary, install a new IME controller PWB, PL 92.10 Item 1, or a new marking unit
driver PWB PL 92.10 Item 4
The yellow LED on top of the power supply unit, Figure 1, indicates that the +5V supply is
available in the power supply unit. The green LED is lit but the yellow led is extinguished. Drum Driver PWB
Y N
Go to the 01C 3.3V Distribution RAP. • To view the +5V distribution from the power supply unit, refer to WD 1.5
• For +5V faults on the drum driver PWB, refer to:
Switch off, then switch on the machine, GP 14. Check the PEST fault history, dC123. There – WD 9.1
are hard PEST faults shown. – WD 9.2
Y N
– WD 9.3
Check that the +5V is within tolerance, +5V +/- 2% at JDC1 pin 17. Refer to WD 1.4. The
+5V is good. • The components that follow are driven from +5V from the drum driver PWB:
Y N – IOD assembly PL 94.15 Item 1
Install a new power supply unit, PL 1.15 Item 2. – Front transfix motor encoder, part of the front transfix motor, PL 10.20 Item 11
– Rear transfix motor encoder, part of the rear transfix motor, PL 10.20 Item 11
– Front and rear transfix flexure encoder PL 10.20 Item 5
CAUTION – Drum position encoder assembly PL 94.20 Item 8
Do not disconnect or connect PJ’s while the machine has power on, to avoid equipment – Registration/Pre-heat interface PWB PL 88.10 Item 10
damage. – Stripper latch sensor, PL 10.10 Item 17
Check for short circuits. Refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload – Pre exit sensor, PL 10.10 Item 6.
RAP, +5V short circuit check. The circuit is good.
– Cleaning unit motor assembly, PL 94.10 Item 19
Y N
Switch off the machine, GP 14. Disconnect connectors on the power supply to iso- – Cleaning unit home sensor, PL 94.10 Item 17
late the PWB’s that follow: – Post transfix sensor, PL 10.10 Item 6
• PJDC1 to isolate the IME controller PWB. • Repair the wiring as necessary, REP 1.1.
• PJDC3 to isolate drum driver PWB and media path driver PWB. • If necessary, install a new drum driver PWB, PL 1.15 Item 4, or one of the components in
• PJDC4 to isolate the power distribution PWB and HDDs. the list above
Repair the short circuit. Refer to REP 1.1. Install new parts as necessary. Media Path Driver PWB
Determine which PWB has the distribution fault, go to PWB Checks. • To view the +5V distribution from the power supply unit, refer to WD 1.5
• For +5V faults on the media path driver PWB, refer to:
Perform the RAP(s) given by the hard PEST fault code(s), then return to this RAP. – WD 8.1
PWB Checks – WD 8.2
Check the PWBs below to determine which PWB has the distribution fault. Follow the distribu- – WD 8.3
tion back to the supply. Repair the wiring, REP 1.1 or install a new PWB or power supply unit, – WD 8.4
– WD 8.5
PWB’s.
– WD 8.6

01D 2-24 Xerox® ColorQube® 9203 Family
• The +5V LED on this PWB is shown in WD 8.5 • Repair the wiring as necessary, REP 1.1.
• The components that follow are driven from the media path driver PWB: • If necessary, install a new 3 tray module PWB, PL 73.16 Item 4.
– Registration/Pre-heat interface PWB, PL 88.10 Item 10 see below for components Registration/Pre-heat Interface PWB:
driven by this PWB
– Vertical transport sensor, PL 82.10 Item 7 • To view the +5V distribution from the drum driver PWB, refer to WD 9.2.
– Confirm sensor, PL 82.10 Item 7 • To view +5V distribution from the media path driver PWB, refer to WD 8.1
– Vertical transport motor encoder, part of the vertical transport motor, PL 82.10 Item • For +5V faults on the registration/preheat interface PWB, refer to WD 8.6
12 • The components that follow are driven from +5V from the reg/preheat interface PWB:
– 3 Tray module, PL 73.16 and components, see below for components driven by this – Reg/preheat home sensor, part of PL 88.10 Item 10.
PWB – Pre transfix sensor Q89-006. PL 88.10 Item 12.
– Bypass empty sensor, PL 74.10 Item 18 • Repair the wiring as necessary, REP 1.1.
– Bypass feed sensor, PL 74.10 Item 19 • If necessary, install a new Registration/Pre-heat interface PWB, PL 88.10 Item 10, or one
– Bypass nudger home sensor, PL 74.10 Item 18 of the components in the list above
– Tray 5 control PWB, PL 75.68 Item 8 see below for components driven by this PWB Marking Unit Driver PWB:
– OCT PL 12.00 Item 1
• To view the +5V distribution from the IME controller PWB, refer to WD 9.7
– LCSS PWB, PL 12.75 Item 1, see below for components driven by this PWB
• For +5V faults on the marking unit driver PWB, refer to WD 9.10
– HVF PWB PL 12.140 Item 2, see below for components driven by this PWB
• Repair the wiring as necessary, REP 1.1.
– Duplex start sensor PL 10.15 Item 3
• If necessary install a new marking unit driver PWB, PL 92.10 Item 4
– Exit sensor PL 10.15 Item 3
Tray 5 Control PWB:
– Duplex sensor PL 82.15 Item 3
– Horizontal transport motor encoder, part of the horizontal transport motor, PL 82.15 • To view the +5V distribution from the media path driver PWB, refer to WD 8.4.
Item 9
• For +5V faults on the tray 5 control PWB, refer to:
– Duplex end sensor PL 82.15 Item 3
– WD 7.1.
– WD 7.2.
• If necessary, install a new media path driver PWB, PL 1.15 Item 5, or one of the compo-
nents in the list above
• If necessary, install a new tray 5 control PWB, PL 75.68 Item 8.
Power Distribution PWB
• To view the +5V distribution from the power supply unit, refer to WD 1.5.
• To view the +5V distribution from the power distribution PWB, refer to WD 1.6.
• For +5V faults on the power distribution PWB, refer to:
• For +5V faults on the copy controller PWB, refer to WD 3.2.
– WD 1.6
– WD 1.7
• If necessary, install a new copy controller PWB, PL 3.10 Item 17.
– WD 1.8 (W/O TAG 006)
– WD 1.9 (W/TAG 006)
• Repair the wiring as necessary, REP 1.1. • To view the +5V distribution from the power distribution PWB, refer to WD 1.7.
• If necessary, install a new power distribution PWB, PL 3.10 Item 1 (W/O TAG 006), PL • For +5V faults on the network controller PWB refer to WD 1.7.
3.11 Item 1 (W/TAG 006). • If necessary, install a new network controller PWB, PL 3.10 Item 4
3 Tray Module PWB: Single Board Controller PWB (W/TAG 006):
• To view the +5V distribution from the media path driver PWB, refer to WD 8.2. • To view the +5V distribution from the power distribution PWB, refer to WD 1.6.
• For +5V faults on the 3 tray module PWB, refer to: • For +5V faults on the single board controller PWB, refer to:
– WD 7.3. – WD 3.4.
– WD 7.4. – WD 3.5.
– WD 7.5 • If necessary repair the wiring, REP 1.1.
• The +5V LED on this PWB is shown in WD 7.3. • If necessary, install a new single board controller PWB, PL 3.11 Item 13.

Xerox® ColorQube® 9203 Family 2-25 01D
Scanner PWB (W/O TAG 007): NOTE: The +5V supply is generated internally on the cleaning unit PWB, refer to WD 9.19.
• The reed switch assembly (level sensing), part of PL 94.10 Item 21, is driven from +5V
from the cleaning unit PWB:
• For +5V faults on the scanner PWB, refer to:
– WD 6.1. NOTE: The cleaning unit PWB and reed switch are not spared individually, the next high-
est assembly is the cleaning unit.
– WD 6.2.
– WD 6.3. • Repair the wiring as necessary, REP 1.1
• Repair the wiring as necessary, REP 1.1. • If necessary, install a new cleaning unit, PL 94.10 Item 21
• If necessary, install a new scanner PWB, PL 62.16 Item 8. LCSS PWB:
• To view the +5V distribution from the LCSS power supply module, refer to WD 12.1
• To view the +5V distribution from the power distribution PWB, refer to WD 1.9. • For +5V faults on the LCSS, refer to:
• For +5V faults on the scanner PWB, refer to: – WD 12.1
– WD 6.4. – WD 12.2
– WD 6.5 – WD 12.3
– WD 6.6 – WD 12.4
• If necessary repair the wiring, REP 1.1. – WD 12.5
• If necessary, install a new scanner PWB, PL 62.17 Item 1. • Repair the wiring as necessary, REP 1.1.
DADH PWB: • If necessary, install a new LCSS PWB, PL 12.75 Item 1.
HVF PWB:
• Note: This PWB does not have an external +5V supply. +5V is generated on-board from
the +3.3V supply, as shown in WD 5.2. • To view the +5V distribution from the HVF power supply module, refer to WD 12.6.
• For +5V faults on the DADH PWB, refer to: • For +5V faults on the HVF, refer to:
– WD 5.1. – WD 12.6
– WD 5.2. – WD 12.7
• Repair the wiring as necessary, REP 1.1. – WD 12.8
• If necessary, install a new DADH PWB, PL 5.10 Item 5. – WD 12.9
HDD 1 (W/O TAG 006): – WD 12.10
– WD 12.11
• To view the +5V distribution from the power supply unit, refer to WD 1.5 – WD 12.12
• For +5V faults on HDD 1, refer to WD 3.3 – WD 12.13
• If necessary, install a new HDD copy controller assembly, PL 3.10 Item 2. – WD 12.14
HDD 1 (W/TAG 006): – WD 12.15
• To view the +5V distribution from the power supply unit, refer to WD 1.5
• If necessary, install a new HVF PWB, PL 12.140 Item 2.
• For +5V faults on HDD 1, refer to WD 3.6
BM PWB (Booklet Maker):
• If necessary, install a new HDD single board controller assembly, PL 3.11 Item 2.
HDD 2 (W/O TAG 006): • To view the +5V distribution from the HVF PWB, refer to WD 12.6.
• For +5V faults on the BM, refer to:
• To view the +5V distribution from the supply unit, refer to WD 1.5
– WD 12.16
• For +5V faults on HDD 2, refer to WD 1.7
– WD 12.17
• If necessary, install a new HDD network controller assembly, PL 3.10 Item 2
– WD 12.18
Cleaning Unit PWB:
– WD 12.19
• For +5V faults on the cleaning unit PWB, refer to WD 9.19 • Repair the wiring as necessary, REP 1.1.
• If necessary, install a new BM PWB, PL 12.175 Item 10.

Tri-folder PWB: 01E +12V Distribution RAP
Use this RAP to diagnose +12V supply and distribution faults.
• To view the +5V distribution from the BM PWB, refer to WD 12.6.
• For +5V faults on the tri-folder PWB, refer to WD 12.20.
Procedure
• If necessary, install a new tri-folder PWB, PL 12.205 Item 16.
Inserter PWB: WARNING
• To view the +5V distribution from the HVF PWB, refer to WD 12.14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• For +5V faults on the inserter PWB, refer to: death or injury. Moving parts can cause injury.
– WD 12.21
NOTE: To view the +12V supply generation, refer to WD 1.3.
– WD 12.22
• Repair the wiring as necessary, REP 1.1. The yellow LED on top of the power supply unit, Figure 1, indicates that the +5V supply is
available in the power supply unit. The +5V and +12V supplies are generated from the -12V/
• If necessary, install a new inserter PWB, PL 12.310 Item 9.
+24V supply in the power supply unit. The yellow LED is lit.
OCT PWB: Y N
• To view the +5V distribution from the media path driver PWB, refer to WD 8.5.
• For +5V faults on the OCT, refer to WD 12.23. Check that the +12V is within tolerance, +12V +/- 5% at JDC1 pin 13. The +12V is good.
• Repair the wiring as necessary, REP 1.1. Y N
• If necessary, install a new OCT, PL 12.00 Item 1. Install a new power supply unit, PL 1.15 Item 2.
CAUTION
Do not disconnect or connect PJ’s while the machine has power on. to avoid equipment dam-
age.
Check for short circuits. Refer to the 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload
RAP, +5V short circuit check. The circuit is good.
Y N
Switch off the machine, GP 14. Disconnect connectors on the power supply to isolate the
PWB’s that follow:
• PJDC1 to isolate the IME controller PWB.
• PJDC3 to isolate drum driver PWB and media path driver PWB.
Repair the short circuit. Refer to REP 1.1. Install new parts as necessary.
PWB’s.
Power supply unit Yellow LED NOTE: Many PWBs have distribution fuses.
IME Controller PWB:

Figure 1 Component location • To view the +12V distribution from the power supply unit, refer to WD 1.4.
– WD 9.5
– WD 9.6
– WD 9.7
• The items that follow are driven from +12V from the IME controller PWB:

Xerox® ColorQube® 9203 Family 2-27 01D, 01E
– Printing heads, PL 91.25 Item 2, PL 91.25 Item 2. • If necessary, install a new cleaning unit, PL 94.10 Item 21.
– Marking unit driver PWB PL 92.10 Item 4. NOTE: The cleaning unit PWB is not spared individually, the next highest assembly is the
• Repair the wiring as necessary, REP 1.1. cleaning unit.
• If necessary, install a new IME controller PWB, PL 92.10 Item 1, or one of the items in the
list above. Media Path Driver PWB:
Marking Unit Driver PWB:
• To view the +12V distribution from the IME controller PWB, refer to WD 9.7.
– WD 8.1
• For +12V faults on the marking unit driver PWB, refer to:
– WD 8.5
– WD 9.10
• The components that follow are driven from +12V from the media path driver PWB:
– WD 9.12
– Exit illuminator, PL 10.15 Item 16.
• The solenoid patch PWB, PL 93.10 Item 9 is driven from +12V from the marking unit
driver PWB – Horizontal illuminator, PL 82.15 Item 11.
• Repair the wiring as necessary, REP 1.1. – Registration/preheat illuminator PWB, PL 82.15 Item 17.
• If necessary, install a new marking unit driver PWB, PL 92.10 Item 4. – Registration/preheat interface PWB PL 88.10 Item 10.
Solenoid Patch PWB: • Repair the wiring as necessary, REP 1.1.
• To view the +12V distribution from the marking unit driver PWB, refer to WD 9.12. • If necessary, install a new media path driver PWB, PL 1.15 Item 5, or one of the items in
• For +12V faults on the solenoid patch PWB, refer to WD 9.14. the list above.
• The components that follow are driven from +12V from the solenoid patch PWB: Registration/Pre-heat Interface PWB:
– Reservoir pump PL 93.10 Item 11. • To view the +12V distribution from the drum driver PWB, refer to WD 9.2.
– LPA valve solenoid PL 93.10 Item 15. • To view +12 V distribution from media path driver PWB, refer to WD 8.1.
• Repair the wiring as necessary, REP 1.1. • For +12V faults on the registration/pre-heat interface PWB, refer to WD 8.6.
• If necessary, install a new solenoid patch PWB, PL 93.10 Item 9, or one of the items in the • The components that follow are driven from +12V from the reg/preheat interface PWB:
list above. – Registration scan bar Q89-005, PL 88.10 Item 2.
Drum Driver PWB: – Registration/preheat air pumps MOT88-008, PL 88.10 Item 5.
• To view the +12V distribution from the power supply unit, refer to WD 1.5. • Repair the wiring as necessary, REP 1.1.
• For +12V faults on the drum driver PWB, refer to: • If necessary, install a new registration/pre-heat interface PWB, PL 88.10 Item 10, or one
– WD 9.2 of the items in the list above
– WD 9.3 Power Distribution PWB:
– WD 9.4
• For +12V faults on the power distribution PWB, refer to:
• The +12V LED on this PWB is shown in WD 9.2.
– WD 1.6
• The components that follow are driven from +12V from the drum driver PWB:
– WD 1.7
– Enclosure Fan, PL 1.15 Item 6.
– WD 1.8 (W/O TAG 006)
– Marking unit cooling fan, PL 1.15 Item 23.
– WD 1.9 (W/TAG 006)
– Abatement fan assembly, PL 94.20 Item 11.
– Cleaning unit, PL 94.10 Item 21.
• If necessary, install a new power distribution PWB, PL 3.10 Item 1.
– Stripper Jam Clearance LED assembly, PL 10.10 Item 10
– Registration/preheat Interface PWB, PL 88.10 Item 10
• For +12V faults on the copy controller PWB, refer to:
• If necessary, install a new drum driver PWB, PL 1.15 Item 4, or one of the items in the list
above. – WD 3.1
Cleaning Unit: – WD 3.2

• To view the +12V distribution from the drum driver PWB, refer to WD 9.4. – WD 3.3
• For +12V faults on the cleaning unit PWB, refer to WD 9.19. • Repair the wiring as necessary, REP 1.1.
• Repair the wiring as necessary, REP 1.1. • If necessary, install a new copy controller PWB, PL 3.10 Item 17.

01E 2-28 Xerox® ColorQube® 9203 Family
• To view the +12V distribution from the power distribution PWB, refer to WD 1.7. HDD 1 (W/O TAG 006):
• For +12V faults on the network controller PWB refer to WD 1.7. • To view the +12V distribution from the power supply unit, refer to WD 1.5.
• If necessary, install a new network controller PWB, PL 3.10 Item 4. • For +12V faults on HDD 1, refer to WD 3.3.
Single Board Controller PWB (W/TAG 006): • If necessary, install a new HDD copy controller assembly, PL 3.10 Item 2.
• To view the +3.3V distribution from the power distribution PWB, refer to WD 1.6. HDD 1 (W/TAG 006):
• For +3.3V faults on the single board controller PWB, refer to: • To view the +12V distribution from the power supply unit, refer to WD 1.5.
– WD 3.4 • For +12V faults on HDD 1, refer to WD 3.6.
– WD 3.5 • If necessary, install a new HDD single board controller assembly, PL 3.11 Item 2.
• If necessary repair the wiring, REP 1.1. HDD 2 (W/O TAG 006):
• If necessary, install a new single board controller PWB, PL 3.11 Item 13. • To view the +12V distribution from the power supply unit, refer to WD 1.5.
Scanner PWB (W/O TAG 007): • For +12V faults on HDD 2, refer to WD 1.7.
• To view the +12V distribution from the power distribution PWB, refer to WD 1.8. • If necessary, install a new HDD network controller assembly, PL 3.10 Item 2.
• For +12V faults on the scanner PWB, refer to: Quad Waveamp PWB:
• To view the +12V distribution from the IME controller PWB, refer to WD 9.5.
– WD 6.1
• For +12V faults on quad waveamp PWB, refer to WD 9.13.
– WD 6.3
• The scan carriage, PL 62.15 Item 6, is driven from +12V from the scanner PWB:
• If necessary, install a new quad waveamp PWB, PL 92.10 Item 3.
Printheads 1 to 4
• To view the +12 V distribution from the IME controller PWB, refer to WD 9.5 and WD 9.6.
Full Width Array (W/O TAG 007):
• For +12V faults on the printhead, refer to WD 9.20 and WD 9.21.
• To view the +12V distribution from the scanner PWB, refer to WD 6.3.
• If necessary, install a new printhead PL 91.20 Item 2 or PL 91.25 Item 2.
• For +12V faults on the full width array, refer to WD 6.3.
• Install new components as necessary, PL 62.15.
– WD 6.4
– WD 6.5
– WD 6.6
UI PWB (W/O TAG 006):
• To view the +12V distribution from the copy controller PWB, refer to WD 3.2.
• For +12V faults on the UI PWB, refer to WD 3.2.
UI PWB (W/TAG 006): Power supply unit Yellow LED
• To view the +12V distribution from the single board controller PWB, refer to WD 3.4.
• For +12V faults on the UI PWB, refer to: Figure 1 Component location
– WD 3.4

Xerox® ColorQube® 9203 Family 2-29 01E
01F -12V Distribution RAP • If necessary, install a new IME controller PWB, PL 92.10 Item 1, or one of the items in the
list above.
Use this RAP to diagnose -12V supply and distribution faults.
Drum Driver PWB:
Procedure • To view the -12V distribution from the power supply unit, refer to WD 1.5.
• For -12V faults on the drum driver PWB, refer to:
– WD 9.2
WARNING • Repair the wiring as necessary, REP 1.1.
Ensure that the electricity to the machine is switched off while performing tasks that do • If necessary, install a new drum driver PWB, PL 1.15 Item 4.
• To view the -12V distribution from the IME controller PWB, refer to WD 9.7.
• For -12V faults on the marking unit driver PWB, refer to WD 9.10.
CAUTION • Repair the wiring as necessary, REP 1.1.
Do not disconnect or connect PJ’s while the machine has power on. to avoid equipment damage. • If necessary, install a new marking unit driver PWB, PL 92.10 Item 4.
NOTE: To view the -12V supply generation, refer to WD 1.3. Quad Waveamp PWB:
The yellow LED on top of the power supply unit, Figure 1, indicates that the +5V supply is
• For -12V faults on quad waveamp PWB, refer to WD 9.13.
available in the power supply unit. The +5V and +12V supplies are generated from the -12V/
+24V supply in the power supply unit. The yellow LED is lit. • Repair the wiring as necessary, REP 1.1.
Y N • If necessary, install a new quad waveamp PWB, PL 92.10 Item 3.
Go to the 01-540-00, 01-544-00 +24V, +/-12V, +5V Failure RAP. Printheads 1 to 4
• To view the -12 V distribution from the IME controller PWB, refer to WD 9.5, WD 9.6 and
Check that the -12V is within tolerance, -12V +/- 5% at JDC1 pin 12. The -12V is good.
WD 9.7.
Y N
Check for short circuits. Refer to the 01-525-00 +24V, +\-12V, +5V Short Circuit and Over- • For -12V faults on the printhead, refer to WD 9.20 and WD 9.21.
load RAP, -12V short circuit check. • If necessary, install a new printhead PL 91.20 Item 2 or PL 91.25 Item 2.
Media Path Driver PWB
NOTE: The -12V supply is protected via a foldback circuit. A short circuit will result in 0V
output, but the power supply will not switch off. Removing the short will restore -12V out- NOTE: The media path driver PWB receives -12V from the harness but it is not connected.
put from the power supply.
If a short circuit is found, disconnect connectors on the power supply unit to isolate the
PWB’s that follow:
• PJDC1 to isolate the IME controller PWB.
• PJDC3 to isolate drum driver PWB and media path driver PWB.
PWB’s.
IME Controller PWB:
• To view the -12V distribution from the power supply unit, refer to WD 1.4.
• For -12V faults on the IME controller PWB, refer to:
– WD 9.5
– WD 9.6
– WD 9.7
• The components that follow are driven from -12V from the IME controller PWB.
– Print heads, PL 91.25 Item 2, PL 91.25 Item 2.
– Quad waveamp PWB PL 92.10 Item 3. Power supply unit Yellow LED

01F 2-30 Xerox® ColorQube® 9203 Family
01G +17V Distribution RAP 01H +24V Distribution RAP
Use this RAP to diagnose +17V supply and distribution faults. Use this RAP to diagnose +24V supply and distribution faults.
Procedure NOTE: This supply is not to be confused with the +17V supply, which is shown in WD 1.5.
Procedure
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do WARNING
Check the power distribution PWB. Follow the distribution back to the supply. Repair the wiring,
REP 1.1 or install a new PWB or power supply unit, PL 1.15 Item 2 as necessary.
NOTE: To view the +17V supply generation, refer to WD 1.5. CAUTION

NOTE: The voltage of this supply varies. At start up, the output is +17V unregulated and an Do not disconnect or connect PJ’s while the machine has power on. to avoid equipment dam-
average of about +17V can be measured. During the normal run mode, the output of this sup- age.
ply rises to +24V. The supply then drops back to +17V unregulated during the sleep mode. If NOTE: To view the +24V supply generation, refer to WD 1.3.
the yellow LED is lit on the power supply, the output should be about +24V.
Check the PEST fault history, dC123. There are hard PEST faults shown.
Power distribution PWB: Y N
Check the LEDs on top of the power supply unit, Figure 1. The yellow LED is lit.
• To view the +17V distribution from the power supply unit, refer to WD 1.5. Y N
NOTE: A short circuit on this output also disables the +3.3V ESTAR output. The green LED is lit.
Y N
NOTE: A short circuit on the +3.3V may result in the +17V output being disabled from Go to the 01C 3.3V Distribution RAP
overload.
Check for short circuits. Refer to the 01-525-00 +24V, +/-12V, +5V Short Circuit and
NOTE: A missing or invalid power normal signal (refer to WD 8.2) may result in an over-
Overload RAP, +24V short circuit check.
load on the +17V output, causing the supply to be disabled.
Switch off the machine, GP 14. Disconnect the following connectors on the power
• For +17V faults on the power distribution PWB, refer to: supply to isolate the PWB’s that follow:
– WD 1.5 • PJDC1 to isolate the IME controller PWB.
– WD 1.6 • PJDC3 to isolate the drum driver PWB and media path driver PWB.
– WD 1.7 • PJDC4 to isolate the power distribution PWB and HDDs.
• If necessary, install a new power distribution PWB, PL 3.10 Item 1. A short circuit exists.
Y N
Either the power supply unit is faulty or there is a short circuit. Refer to WD 9.4
and WD 1.4. Measure the voltage at pin 27 of PJ902 on the drum driver PWB.
The voltage should be greater than +2.5V, indicating the drum driver PWB is
enabling the +24V, +12V, -12V and +5V supplies in the power supply unit. The
voltage is greater than +2.5V.
Y N
Check the condition of the drum driver power supply interface cable
between PJDC2 on the power supply unit and PJ902 on the drum driver
PWB. It should be correctly and securely connected at each end, and
should be undamaged. This cable carries power control signals from and
to the power supply unit. The cable is good.
Y N
Install a new drum driver power supply interface cable, PL 1.15 Item
10, as necessary.
A B C D E

Xerox® ColorQube® 9203 Family 2-31 01G, 01H
A B C D E
Switch off the machine, GP 14. Check pin 27 of PJ902 on the drum driver Solenoid Patch PWB:
PWB. Pin 27 is short circuit to ground.
Y N • To view the +24V distribution from the marking unit driver PWB, refer to WD 9.12.
Install a new drum driver PWB, PL 1.15 Item 4. • For +24V faults on the solenoid patch PWB, refer to:
– WD 9.14
– WD 9.15
Install a new power supply unit, PL 1.15 Item 2. • The components that follow are driven from +24V from the solenoid patch PWB:
– Purge solenoid valves 1 to 4 SOL93-059, 060, 061, 062, part of PL 93.10 Item 10.
Repair the wiring, REP 1.1. Install new components as necessary. – Black ink solenoid valves 5 to 8 SOL063,064, 065, 066, part of PL 93.10 Item 10
– Yellow ink solenoid valves 9 to 12,SOL067, 068, 069, 070, part of PL 93.10 Item 10
Check that the +24V is within tolerance, +24.5V +/- 5%, (+23.275V to +25.725V), at JDC1
– Cyan ink solenoid valves 13 to 16 SOL071, 072, 073, 074, part of PL 93.10 Item 10
pin 11. Refer to WD 1.4. The +24V is good.
Y N – Magenta ink solenoid valves 17 to 20 SOL075, 076, 077, 078, part of PL 93.10 Item
Install a new power supply unit, PL 1.15 Item 2. 10
Determine which PWB has the supply fault, go to PWB Checks. • If necessary, install a new solenoid patch PWB, PL 93.10 Item 9.
Power Distribution PWB:
PWB Checks • To view the +24V distribution from the power supply unit, refer to WD 1.5.
Check the PWBs below to determine which PWB has the distribution fault. Follow the distribu- • For +24V faults on the power distribution PWB, refer to:
– WD 1.6
– WD 1.7
PWB’s.
– WD 1.8 (W/O TAG 006)
NOTE: Many PWBs have distribution fuses. – WD 1.9 (W/TAG 007)
IME Controller PWB:
• If necessary, install a new power distribution PWB, PL 3.10 Item 1
• To view the +24V distribution from the power supply unit, refer to WD 1.4. Scanner PWB (W/O TAG 007):
• To view the +24V distribution from the power distribution PWB, refer to WD 1.8
– WD 9.6
– WD 9.7
– WD 6.1
• The marking unit driver PWB, PL 92.10 Item 4, is driven from +24V from the IME control-
ler PWB – WD 6.2
• Repair the wiring as necessary, REP 1.1 • The components that follow are driven from +24V from the scanner PWB:
• If necessary, install a new IME controller PWB, PL 92.10 Item 1. – LED exposure lamp(s), PL 62.15 Item 2.
Marking Unit Driver PWB: • Repair the wiring as necessary, REP 1.1
• If necessary, install a new scanner PWB, PL 62.16 Item 8
• To view the +24V distribution from the IME controller PWB, refer to WD 9.7. Scanner PWB (W/TAG 007):
• For +24V faults on the marking unit driver PWB, refer to:
– WD 9.10 • To view the +24V distribution from the power distribution PWB, refer to WD 1.9.
– WD 9.12 • For +24V faults on the scanner PWB, refer to:
• The solenoid patch PWB PL 93.10 Item 9 is driven from +24V from the marking unit driver – WD 6.4.
PWB: – WD 6.5
• Repair the wiring as necessary, REP 1.1. – WD 6.6
• If necessary, install a new marking unit driver PWB, PL 92.10 Item 4. • If necessary repair the wiring, REP 1.1.

01H 2-32 Xerox® ColorQube® 9203 Family
DADH PWB: – T3 feed motor MOT73-001, PL 81.30 Item 22.
– 3 tray transport motor MOT70.025, PL 73.16 Item 3.
• To view the +24V distribution from the power distribution PWB, refer to WD 1.8 (W/O TAG
– Tray up limit switch, S73-384, PL 81.30 Item 25.
006) or WD 1.9 (W/TAG 006).
– Tray 3 elevate motor, MOT73-0023, PL 73.16 Item 2.
• For +24V faults on the DADH PWB, refer to:
– WD 5.1
• If necessary, install a new 3 tray module PWB, PL 73.16 Item 4
– WD 5.2
Drum Driver PWB:
• The components that follow are driven from +24V from the DADH PWB:
– DADH CVT motor MOT05-099, PL 5.25 Item 9. • To view the +24V distribution from the power supply unit, refer to WD 1.5
– DADH feed motor MOT05-074, PL 5.15 Item 16. • For +24V faults on the drum driver PWB, refer to:
– DADH duplex solenoid SOL05-100, PL 5.30 Item 3. – WD 9.1
– Nudger motor MOT05-098, PL 5.15 Item 5. – WD 9.2
– DADH feed clutch CL05-062, PL 5.15 Item 9. • The components that follow are driven from +24V from the drum driver PWB:
– DADH cover interlock switch S05-212, PL 5.15 Item 11. – Drum fan MOT42-064, PL 94.20 Item 4.
• Repair the wiring as necessary, REP 1.1 – Cleaning unit delivery pump, part of PL 94.10 Item 21.
• If necessary, install a new DADH PWB, PL 5.10 Item 5. – Cleaning unit return reservoir pump, part of PL 94.10 Item 21.
Media Path Driver PWB: – Cleaning unit PWB, part of PL 94.10 Item 21.
• If necessary, install a new drum driver PWB, PL 1.15 Item 4.
Tray 5 Control PWB:
– WD 8.2
– WD 8.3 • To view the +24V distribution from the media path driver PWB, refer to WD 8.4.
– WD 8.4 • For +24V faults on the tray 5 control PWB, refer to:
– WD 8.5 – WD 7.1.
• The components that follow are driven from +24V from the media path driver PWB: – WD 7.2.
– Bypass feed motor (M7) MOT74-420, PL 74.10 Item 2. • The components that follow are driven from +24V from the tray 5 control PWB:
– 3 tray module PWB PL 73.16 Item 4. – Tray 5 transport motor MOT75.018, PL 81.40 Item 2.
– Tray 5 control PWB PL 75.68 Item 8. – Elevator motor MOT75-019, PL 75.68 Item 4.
– OCT PL 12.00 Item 1. – Upper limit switch S75-412, PL 75.68 Item 12.
– LCSS PWB PL 12.75 Item 1. – Tray down limit switch S75-415, PL 75.70 Item 2.
– HVF PWB PL 12.140 Item 2. – Feed motor MOT75-117, PL 81.40 Item 3.
• Repair the wiring as necessary, REP 1.1. • Repair the wiring as necessary, REP 1.1.
• If necessary, install a new media path driver PWB, PL 1.15 Item 5 • If necessary, install a new tray 5 control PWB, PL 75.68 Item 8.
3 Tray Module PWB: LCSS PWB:
• To view the +24 distribution from the media path driver PWB, refer to WD 8.2 • To view the +24V distribution from the LCSS power supply module, refer to WD 12.1.
• For +24V faults on the three trays module PWB, refer to: • For +24V faults on the LCSS, refer to:
– WD 7.3 – WD 12.1
– WD 7.4 – WD 12.3
– WD 7.5 – WD 12.4
• The +24V LED on this PWB is shown in WD 7.3 – WD 12.5
• The components that follow are driven from +24V from the 3 tray module PWB: • The components that follow are driven from +24V from the LCSS PWB:
– T1 feed / elevator motor MOT71-002, PL 81.25 Item 22. – Docking interlock switch S12-177, PL 12.15 Item 2.
– T2 feed / elevator motor MOT72-001, PL 81.26 Item 22. – Front door interlock switch S12-303, PL 12.75 Item 5.

Xerox® ColorQube® 9203 Family 2-33 01H
– Transport motor 1 MOT12-223, PL 12.40 Item 2. – Ejector motor MOT12-236, part of PL 12.110 Item 2.
– SH1 motor MOT12-247, part of PL 12.55 Item 5. – Ejector roll motor MOT12-233, part of PL 12.110 Item 2.
– SU1 motor MOT12-249, part of PL 12.55 Item 5. – Pressing & support motor MOT12-323, PL 12.110 Item 9.
– Transport motor 2 MOT12-224, PL 12.60 Item 5. – Front tamper motor MOT12-226, PL 12.125 Item 6.
– Paddle roll motor MOT12-237, PL 12.25 Item 10. – Punch unit motor MOT12-245, part of PL 12.125 Item 19.
– Punch head motor MOT12-243, PL 12.20 Item 2. – Punch head motor MOT12-244, part of PL 12.125 Item 19.
– Front tamper motor MOT12-226, part of PL 12.45 Item 1. • Repair the wiring as necessary, REP 1.1.
– Rear tamper motor MOT12-227, part of PL 12.45 Item 1. • If necessary, install a new HVF PWB, PL 12.140 Item 2.
– Bin 1 upper limit switch S12-190, PL 12.30 Item 3. BM PWB (Booklet Maker):
– Top cover interlock switch S12-197, PL 12.75 Item 6.
– Bin 1 lower limit switch S12-191, PL 12.35 Item 1. • To view the +24V distribution from the HVF PWB, refer to WD 12.6.
– Bin 1 elevator motor MOT12.-241, PL 12.30 Item 8. • For +24V faults on the BM, refer to:
• Repair the wiring as necessary, REP 1.1. – WD 12.17.
• If necessary, install a new LCSS PWB, PL 12.75 Item 1. – WD 12.19.
HVF PWB: • The components that follow are driven from +24V from the BM PWB:
– BM SH1 motor MOT12-254, part of PL 12.185 Item 7.
• To view the +24V distribution from the HVF power supply module, refer to WD 12.6. – BM SH2 motor MOT12-275, part of PL 12.185 Item 7.
• For +24V faults on the HVF, refer to: – BM compiler motor MOT 12-251, PL 12.175 Item 1.
– WD 12.6 – BM backstop motor MOT 12-255, PL 12.160 Item 4.
– WD 12.7. – BM tamper 1 motor MOT12-256, PL 12.155 Item 3.
– WD 12.8 – BM stack hold solenoid SOL12-259 (1 of 2), PL 12.165 Item 17.
– WD 12.9 – BM stack hold solenoid SOL12-259 (2 of 2), PL 12.165 Item 17.
– WD 12.10. – BM conveyor drive motor MOT12-274, PL 12.190 Item 4.
– WD 12.13 – BM crease roll gate motor MOT12-273, PL 12.175 Item 8.
– BM crease roll motor MOT12-253, PL 12.175 Item 12.
– WD 12.14
– BM crease blade motor MOT12-252, PL 12.170 Item 3.
– WD 12.15
– BM flapper motor MOT12-271, PL 12.175 Item 1.
• The components that follow are driven from +24V from the HVF PWB:
– Transport motor 1 MOT12-223, PL 12.120 Item 2.
• If necessary, install a new BM PWB, PL 12.175 Item 10.
– Buffer motor MOT12-262, PL 12.120 Item 1.
Tri-folder PWB:
– Nip split motor MOT12-164, PL 12.125 Item 15.
– Transport motor 2 MOT12-224, PL 12.120 Item 1. • To view the +24V distribution from the BM PWB, refer to WD 12.6.
– BM diverter solenoid SOL12-258, PL 12.120 Item 4. • For +24V faults on the tri-folder PWB, refer to WD 12.20.
– Exit diverter solenoid SOL12-225, PL 12.120 Item 4. • The components that follow are driven from +24V from the tri folder PWB:
– Bypass feed motor MOT12-263, PL 12.120 Item 2. – Tri folder top cover interlock switch S12-210, PL 12.215 Item 3.
– Set clamp solenoid SOL12-056, PL 12.120 Item 4. – Tri folder front door interlock switch S12-209, PL 12.215 Item 2.
– Docking interlock switch S12-177, PL 12.100 Item 16. – Tri folder diverter solenoid SOL12-267, PL 12.215 Item 16.
– Front door interlock switch S12-303, PL 12.115 Item 28. – Tri folder assist gate solenoid SOL12-268, PL 12.215 Item 8.
– Top cover interlock switch S12-197, PL 12.115 Item 24. – Tri folder drive clutch CL12-269, PL 12.205 Item 9.
– Paddle unit motor MOT12-239, PL 12.120 Item 6. • Repair the wiring as necessary, REP 1.1.
– Paddle roll motor MOT12-238, part of PL 12.115 Item 2. • If necessary, install a new tri-folder PWB, PL 12.205 Item 16.
– Paper pusher motor MOT12-265, PL 12.115 Item 13. Inserter PWB:
– Bin 1 elevator motor MOT12-241, PL 12.105 Item 10.
– Stapler gate safety switch S12-319, PL 12.115 Item 17. • To view the +24V distribution from the HVF PWB, refer to WD 12.14.
– Rear tamper motor MOT12-227, PL 12.110 Item 19. • For +24V faults on the inserter PWB, refer to:
– Staple head 1 motor MOT12-247, part of PL 12.110 Item 12. – WD 12.21
– Stapler unit 1 motor MOT12-249, PL 12.110 Item 27. – WD 12.22

• The components that follow are driven from +24V from the inserter PWB: 01J +50V Distribution RAP
– Inserter top cover interlock switch S12-178, PL 12.305 Item 8. Use this RAP to diagnose +50V supply and distribution faults.
– Inserter jam cover interlock switch S12-179, PL 12.300 Item 18.
– Inserter clutch CL12-260, PL 12.310 Item 3. Procedure
– Inserter motor MOT12-261, PL 12.315 Item 1.
• If necessary, install a new inserter PWB, PL 12.310 Item 9. WARNING
OCT PWB: Ensure that the electricity to the machine is switched off while performing tasks that do
• To view the +24V distribution from the media path driver PWB, refer to WD 8.5. death or injury. Moving parts can cause injury.
• For +24V faults on the OCT PWB, refer to WD 12.23. To view the +50V generation, refer to WD 1.3.
Check the red LED on top of the power supply unit, Figure 1, that indicates that the +50V sup-
• The OCT offset motor MOT12-300, part of PL 12.00 Item 1, is driven from +24V from the
ply is available in the power supply unit. The red LED is lit and the AC supply is good.
inserter PWB
Y N
• Repair the wiring as necessary, REP 1.1. Install a new power supply unit, PL 1.15 Item 2.
• If necessary, install a new OCT, PL 12.00 Item 1.
Cleaning Unit: Check the PEST fault history, dC123. There are hard PEST faults shown.
Y N
• To view the +24V distribution from the drum driver PWB, refer to WD 9.2 Check that the +50V is within tolerance, +50V +/- 2% at JDC1 pin 10. Refer to WD 1.4.
• For +24V faults on the cleaning unit PWB, refer to WD 9.19 The +50V is good.
Y N
• The cleaning unit solenoid valve, part of PL 94.10 Item 21, is driven from +24V from the
cleaning unit PWB:
• Repair the wiring as necessary, REP 1.1. Determine which PWB has the supply fault. Go to PWB Checks.
• If necessary, install a new cleaning unit, PL 94.10 Item 21.
NOTE: The cleaning unit PWB is not spared individually, the next highest assembly is the
cleaning unit. PWB Checks
PWB’s.
NOTE: Many PWBs have distribution fuses.
IME Controller PWB:
– WD 9.5
– WD 9.6
– WD 9.7
• The components that follow are driven from +50V from the IME controller PWB:
– Marking unit driver PWB PL 92.10 Item 4.
– Quad Waveamp PWB PL 92.10 Item 3.
Power supply unit LEDs • If necessary, install a new IME controller PWB, PL 92.10 Item 1.

Xerox® ColorQube® 9203 Family 2-35 01H, 01J
Media Path Driver PWB:
– WD 8.1
– WD 8.3
– WD 8.5
• The +50V LED on this PWB is shown in WD 8.5.
• The components that follow are driven from +50V from the media path driver PWB:
– Nip C release solenoid SOL82-007, PL 82.15 Item 4.
– HPP diverter solenoid SOL83-004, PL 82.15 Item 5.
– Exit / duplex diverter solenoid SOL83-006, PL 10.15 Item 14.
– Nip D release solenoid SOL82-008, PL 70.30 Item 13.
• If necessary, install a new media path driver PWB, PL 1.15 Item 5.
Drum Driver PWB:
1. To view the +50V distribution from the power supply unit, refer to WD 1.5. Power supply unit Red LED
2. For +50V faults on the drum driver PWB, refer to WD 9.2.
3. The +50V LED on this PWB is shown in WD 9.2. Figure 1 Component location
4. The stripper solenoid SOL10-021, PL 10.10 Item 3, is driven from +50V from the drum
driver PWB:
5. Repair the wiring as necessary, REP 1.1.
6. If necessary, install a new drum driver PWB, PL 1.15 Item 4.
Quad Waveamp PWB:
1. To view the +50V distribution from the IME controller PWB, refer to WD 9.5.
2. For +50V faults on quad waveamp PWB, refer to WD 9.13.
4. If necessary, install a new quad waveamp PWB, PL 92.10 Item 3.
1. To view the +50V distribution from the IME controller PWB, refer to WD 9.7.
2. For +50V faults on the marking unit driver PWB, refer to:
• WD 9.10
• WD 9.11
3. The Waste tray lock solenoid SOL91-044, PL 91.10 Item 17, is driven from +50V from the
marking unit driver PWB:
5. If necessary, install a new marking unit driver PWB, PL 92.10 Item 4.

01J 2-36 Xerox® ColorQube® 9203 Family
01K -50V Distribution RAP Quad Waveamp PWB:
Use this RAP to diagnose -50V supply and distribution faults.
• For -50V faults on quad waveamp PWB, refer to WD 9.13.
Procedure • Repair the wiring as necessary, REP 1.1.
• If necessary, install a new quad waveamp PWB, PL 92.10 Item 3.
WARNING
To view the -50V generation, refer to WD 1.3.
Check the condition of the drum driver power supply interface cable between PJDC2 on the
power supply unit and PJ902 on the drum driver PWB. It should be correctly and securely con-
nected at each end, and should be undamaged. This cable carries power control signals from
and to the power supply unit. The cable is good.
Y N
Install a new drum driver power supply interface cable, PL 1.15 Item 10.
Check the red LED on top of the power supply unit, Figure 1 that indicates that the +50V sup-
ply is available in the power supply unit. The red LED is lit.
Y N
The red LED is extinguished and the AC supply is good. Check the PEST fault history,
dC123. There are hard PEST faults shown.
Y N
Perform the 01-542-00, 01-546-00, 50V Failure RAP. Power supply unit Red LED

Check that the -50V is within tolerance, -50V +/- 2% at JDC1 pin 18. Refer to WD 1.4. The -
50V is good.
Y N
PWB’s.
IME Controller PWB:
• To view the -50V distribution from the power supply unit, refer to WD 1.4.
• For -50V faults on the IME controller PWB, refer to:
– WD 9.5
– WD 9.6
• The quad waveamp PWB PL 92.10 Item 3 is driven from -50V from the IME controller
PWB.
• If necessary, install a new IME controller PWB, PL 92.10 Item 1.

Xerox® ColorQube® 9203 Family 2-37 01K
01L 0V Distribution RAP Copy Controller PWB (W/O TAG 006):
Use this RAP to diagnose 0V faults. • Refer to WD 3.1, WD 3.2 and WD 3.3.
Procedure • If necessary, install a new copy controller PWB, PL 3.10 Item 17 or associated compo-
nents.
Copy Controller PWB (W/TAG 006):
WARNING • Refer to WD 3.4, WD 3.5 and WD 3.6.
Ensure that the electricity to the machine is switched off while performing tasks that do • Repair the wiring as necessary, REP 1.1.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • If necessary, install a new single board controller PWB, PL 3.11 Item 13 or associated
death or injury. Moving parts can cause injury. components.
Important: 0V return lines are connected together and to the chassis, both inside the UI Control PWB, Touch Screen and UI Status PWB:
power supply units and at the PWBs.
• Refer to WD 3.1 (W/O TAG 006) or WD 3.4 (W/TAG 006). If necessary, install new com-
ponents from the list that follows:
To measure the continuity of a 0V line between the power supply unit and a PWB, isolate the
line concerned by disconnecting the PJs at both ends. In this way there will be no misleading – UI control PWB, PL 2.10 Item 2.
parallel paths. As necessary, repair the wiring, REP 1.1 or install a new harness. The same – Touch screen, PL 2.10 Item 3.
applies between the power distribution PWB and other PWBs. – UI status PWB, PL 2.10 Item 4.
– LCD to PWB harness, PL 2.10 Item 11.
To check the connection of a 0V line to chassis via the power supply unit, connect the PJ at the
– UI control to UI status harness, PL 2.10 Item 9.
power supply unit only, disconnect from the PWB, and measure the continuity to the chassis.
As necessary, repair the wiring, REP 1.1 or install a new power supply unit, PL 1.15 Item 2. • Repair the wiring as necessary, REP 1.1.
• If necessary, install a new user interface control PWB.
To check the connection of a 0V line to chassis via the PWB, connect the power PJ at the PWB • If necessary, install a new touch screen, PL 2.10 Item 3.
only, disconnect from the power supply unit, and measure the continuity to the chassis. If nec- • If necessary, install a new user interface status PWB, PL 2.10 Item 4.
essary repair the wiring or install a new PWB.
Foreign Device Interface PWB:
To check the 0V line between a PWB and a component, (sensor, motor, etc.), disconnect the • Refer to WD 3.3 (W/O TAG 006) or WD 3.6 (W/TAG 006).
PWB PJ, then check the wiring for condition, short circuits, open circuits etc. As necessary, • Repair the wiring as necessary, REP 1.1
repair the wiring, REP 1.1, install a new harness, component or PWB. • If necessary, install a new foreign device interface PWB, PL 3.10 Item 18, or associated
components.
This procedure lists the wiring diagrams that show the occurrence of 0V lines. Select the sus- DADH PWB:
pect area from the list, check the wiring for condition, short circuits and open circuits. Repair
• Refer to WD 5.1 and WD 5.2
the wiring as necessary, REP 1.1 or install a new harness or faulty component.
Power Supply Unit: • If necessary, install a new DADH PWB, PL 5.10 Item 5, or associated components.
• Refer to WD 1.3, WD 1.4 and WD 1.5. Scanner PWB (W/O TAG 007):
• Repair the wiring as necessary, REP 1.1. • Refer to WD 6.1, WD 6.2 and WD 6.3
• If necessary install a new power supply unit, PL 1.15 Item 2. • Repair the wiring as necessary, REP 1.1
Power Distribution PWB: • If necessary, install a new scanner PWB, PL 62.16 Item 8, or associated components.
• Refer to WD 1.6, WD 1.7 and WD 1.8 (W/O TAG 006) or WD 1.9 (W/TAG 006). Scanner PWB (W/TAG 007):
• Repair the wiring as necessary, REP 1.1. • Refer to WD 6.4, WD 6.5 and WD 6.6.
• If necessary install a new power supply unit, PL 1.15 Item 2. • Repair the wiring as necessary, REP 1.1
Network Controller PWB (W/O TAG 006): • If necessary, install a new scanner PWB, PL 62.16 Item 8, or associated components.
• Refer to WD 1.7 Tray 5 Control PWB:
• Repair the wiring as necessary, REP 1.1 • Refer to WD 7.1 and WD 7.2
• If necessary, install a new network controller PWB, PL 3.10 Item 4, or associated compo- • Repair the wiring as necessary, REP 1.1.
nents. • If necessary, install a new tray 5 control PWB PL 75.68 Item 8, or associated components.

01L 2-38 Xerox® ColorQube® 9203 Family
3 Tray Module PWB: Cleaning Unit PWB:
• Refer to WD 7.3, WD 7.4 and WD 7.5 • Refer to WD 9.19
• Repair the wiring as necessary, REP 1.1. • Repair the wiring as necessary, REP 1.1.
• If necessary, install a new 3 tray module PWB, PL 73.16 Item 4, or associated compo- • If necessary, install a new cleaning unit PWB, PL 94.10 Item 21, or associated compo-
nents nents.
Media Path Driver PWB: Printheads 1, 2, 3 and 4 PWBs:
• Refer to WD 8.1, WD 8.2, WD 8.3, WD 8.4 and WD 8.5. • Refer to WD 9.20 and WD 9.21
• Repair the wiring as necessary, REP 1.1. • Repair the wiring as necessary, REP 1.1
• If necessary, install a new media path driver PWB, PL 1.15 Item 5 or associated compo- • If necessary, install a new printhead 1, 2, 3 or 4 PWB, PL 91.20 Item 3 and PL 91.25 Item 3.
nents. IOD Pre-amplifier PWB:
Drum Driver PWB: • Refer to WD 9.22
• Refer to WD 9.1, WD 9.2, WD 9.3 and WD 9.4. • Repair the wiring as necessary, REP 1.1.
• Repair the wiring as necessary, REP 1.1 • If necessary, install a new IOD assembly, PL 94.15 Item 1, or associated components.
• If necessary, install a new drum driver PWB, PL 1.15 Item 4, or associated components LCSS PWB:
IME Controller PWB: • The LCSS low voltage power comes from its own power supply module as shown in WD
• Refer to WD 1.1, WD 9.5, WD 9.6 and WD 9.7 12.1. Refer to WD 12.1, WD 12.2, WD 12.3, WD 12.4 and WD 12.5
• Repair the wiring as necessary, REP 1.1 • Repair the wiring as necessary, REP 1.1.
• If necessary, install a new IME controller PWB, PL 92.10 Item 1, or associated compo- • If necessary, install a new LCSS power supply module, PL 12.75 Item 2, LCSS PWB, PL
nents. 12.75 Item 1, or associated components.
Marking Unit Heater PWB: HVF Control PWB:
• Refer to WD 9.8 • The HVF low voltage power comes from its own power supply module as shown in WD
• Repair the wiring as necessary, REP 1.1 12.6. Refer to WD 12.6, WD 12.7, WD 12.8, WD 12.9, WD 12.10, WD 12.11, WD 12.12,
WD 12.13, WD 12.14 and WD 12.15
• If necessary, install a new marking unit heater PWB, PL 92.10 Item 5, or associated com-
ponents. • Repair the wiring as necessary, REP 1.1
Marking Unit Driver PWB: • If necessary, install a new HVF PWB, PL 12.140 Item 2, or associated components.
• Refer to WD 9.9, WD 9.10, WD 9.11 and WD 9.12 BM PWB (Booklet maker):
• Repair the wiring as necessary, REP 1.1 • The BM low voltage power comes from the HVF power supply module as shown in WD
• If necessary, install a new marking unit driver PWB, PL 92.10 Item 4, or associated com- 12.6. Refer to WD 12.6, WD 12.16, WD 12.17, WD 12.18 and WD 12.19.
ponents. • Repair the wiring as necessary, REP 1.1.
Quad Waveamp PWB: • If necessary, install a new BM PWB, PL 12.175 Item 10, or associated components.
• Refer to WD 9.13 Tri-folder PWB:
• Repair the wiring as necessary, REP 1.1 • The tri-folder low voltage power comes from the HVF power supply module as shown in
WD 12.6. Refer to WD 12.6 and WD 12.20
• If necessary, install a new quad waveamp PWB, PL 92.10 Item 3, or associated compo-
nents. • Repair the wiring as necessary, REP 1.1.
Solenoid Patch PWB: • If necessary, install a new tri-folder PWB, PL 12.205 Item 16, or associated components.
• Refer to WD 9.14, WD 9.15 and WD 9.16 Inserter PWB:
• Repair the wiring as necessary, REP 1.1 • The inserter low voltage power comes from the HVF power supply module as shown in
WD 12.14. Refer to WD 12.14, WD 12.21 and WD 12.22
• If necessary, install a new reservoir, PL 93.10 Item 10, or associated components.
Ink Load Entry PWB:
• If necessary, install a new inserter PWB, PL 12.310 Item 9, or associated components.
• Refer to WD 9.17 and WD 9.18
OCT PWB:
• The OCT low voltage power comes from the media path driver PWB, as shown in WD 8.5.
• If necessary, install a new ink load entry PWB, PL 93.10 Item 8, or associated compo-
nents. Refer to WD 8.5 and WD 12.23.
• If necessary, install a new OCT, PL 12.00 Item 1, or media path driver PWB, PL 1.15 Item 5.

Xerox® ColorQube® 9203 Family 2-39 01L
01L 2-40 Xerox® ColorQube® 9203 Family
02-302-00, 02-306-00, 02-308-00 Flash Failure RAP 02-315-00 Service Registry Bad Data RAP
02-302-00 Flash rewrite failure. 02-315-00 Service registry bad or corrupted data
02-306-00 Flash erase failure. Procedure

02-308-00 Flash download failure.
WARNING
Procedure Ensure that the electricity to the machine is switched off while performing tasks that do
WARNING 1. Switch the machine off, then switch on the machine, GP 14.
1. Switch the machine off, then switch on the machine, GP 14.

Xerox® ColorQube® 9203 Family 2-41 02-302-00, 02-306-00, 02-308-00, 02-315-00
02-316-00, 02-317-00 SRS Error RAP 02-320-00 Data Time Out Error RAP
02-316-00 SRS returns to LUI invalid fields, invalid data or missing data. 02-320-00 UI does not receive requested data from the CCM within the specified time out win-
dow.
02-317-00 LUI gets not response from SRS.
Procedure
Procedure
WARNING
WARNING Ensure that the electricity to the machine is switched off while performing tasks that do
Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause death or injury. Moving parts can cause injury.
death or injury. Moving parts can cause injury. 1. Switch the machine off, then switch on the machine, GP 14.

02-316-00, 02-317-00, 02-320-00 2-42 Xerox® ColorQube® 9203 Family
02-321-00 XEIP Browser Dead RAP 02-380-00, 02-381-00 UI Communication Fault RAP
02-321-00 The user interface has detected that the EIP (Extensible Interface Platform) browser 02-380-00 Communication via H-H USB net path connection between NC and UI panel is not
does not respond, or is known to be not working. working
Procedure 02-381-00 Communication via USB connection between CC and UI panel is not working.
Procedure
WARNING
CAUTION
Before a new user interface assembly is installed, identify the machine software level (GP 4).
Check the compatibility of the software on the new user interface assembly. Install the software CAUTION
to meet the customer machine requirements. Use the Customer Administration Tool (CAT), GP Before a new user interface assembly is installed, identify the machine software level (GP 4).
5. Check the compatibility of the software on the new user interface assembly. Install the software
Perform the following steps: to meet the customer machine requirements. Use the Customer Administration Tool (CAT), GP
1. Switch off the machine, then switch on the machine, GP 14. 5.
Perform the following steps:
NOTE: If the UI is unavailable, the power down request cannot be confirmed. The
1. Switch off the machine, then switch on the machine, GP 14.
machine will power down automatically after 60 seconds.
NOTE: If the UI is unavailable, the power down request cannot be confirmed. The
2. Ensure the Custom Services button is enabled on the user interface, as detailed in the
machine will power down automatically after 60 seconds.
System Administrator’s Guide. If necessary, re-load the software set, GP 4 Machine Soft-
ware. 2. For machines W/O TAG 006, refer to WD 3.1. Check the communications cable between
3. Check that the machine is communicating with the network, for example by sending a PJ905 on the UI PWB to PJ19 on the copy controller PWB. If necessary, repair the wiring,
print job. If necessary, check the network cable and check with the customer that their REP 1.1, or install a new user interface harness, PL 2.10 Item 7. Check that the copy con-
network and web browser are running correctly. troller PWB is correctly and securely connected to the network controller PWB. If neces-
sary, install new components:
4. For machines W/O TAG 006, refer to WD 3.1. Check the communications cable between
PJ905 on the UI PWB to PJ19 on the copy controller PWB. If necessary, repair the wiring, • Copy controller PWB, PL 3.10 Item 17.
REP 1.1, or install a new user interface harness, PL 2.10 Item 7. Check that the copy con- • User interface control PWB, PL 2.10 Item 2.
troller PWB is correctly and securely connected to the network controller PWB. If neces- 3. For machines W/TAG 006, refer to WD 3.4. Check the communications cable between
sary, install new components: PJ905 on the UI PWB to PJ19 on the single board controller PWB. If necessary, repair the
• Network controller PWB, PL 3.10 Item 4. wiring, REP 1.1, or install a new user interface harness, PL 2.10 Item 7. If necessary,
• Copy controller PWB, PL 3.10 Item 17. install new components:
• User interface control PWB, PL 2.10 Item 2. • Single board controller PWB, PL 3.11 Item 13.
5. For machines W/TAG 006, refer to WD 3.4. Check the communications cable between • User interface control PWB, PL 2.10 Item 2.
PJ905 on the UI PWB and PJ19 on the single board controller PWB. If necessary, repair
the wiring, REP 1.1, or install a new user interface harness, PL 2.10 Item 7. If necessary,
install new components:
• Single board controller PWB, PL 3.11 Item 13.
• User interface control PWB, PL 2.10 Item 2.

Xerox® ColorQube® 9203 Family 2-43 02-321-00, 02-380-00, 02-381-00
02-390-00 Configurable Services RAP
02-390-00 During power up all configurable services have not achieved a stable state after 5
minutes from power up.
Procedure
WARNING
2. Reload the software set, GP 4 Machine Software.

02-390-00 2-44 Xerox® ColorQube® 9203 Family
03-316-00 CCM Cannot Communicate with IOT RAP 03-325-00 System Detects the Machine Clock Failed to
03-316-00 The communications between the copy controller PWB through the media path Increment During Power On RAP
PWB and to the IME controller PWB have failed.
03-325-00 The software has detected that the machine clock has not incremented within
1.5sec during the power on self test operation.
Initial Actions
Initial Actions
WARNING
death or injury. Moving parts can cause injury. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• If the fault occurs during a software upgrade, wait 15 minutes for the software program- death or injury. Moving parts can cause injury.
ming operation to complete, before performing the next action.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
• Switch off the machine, then switch on the machine, GP 14. domly, the cause may be due to electrical noise. Go to OF 10 intermittent Failure RAP.
domly, the cause may be due to electrical noise. Go to OF 10 intermittent Failure RAP. Procedure
Procedure NOTE: The machine may continue to boot with this fault, but printing may be disabled. The sta-
tus code, 03-505 is raised with this fault code.
1. For machines W/O TAG 006, switch off the machine, GP 14. Ensure all the connectors on
the copy controller PWB, PL 3.10 Item 17, media path driver PWB, PL 1.15 Item 5 and the 1. Switch off the machine, then switch on the machine, GP 14.
IME controller PWB, PL 92.10 Item 1 are correctly and securely seated. Switch on the 2. Re-load the software set, GP 4.
machine, GP 14.
3. For machines W/O TAG 006, if necessary, install a new copy controller PWB, PL 3.10
For machines W/TAG 006, switch off the machine, GP 14. Ensure all the connectors on Item 17.
the single board controller PWB, PL 3.11 Item 13, media path driver PWB, PL 1.15 Item 5 For machines W/TAG 006, if necessary, install a new single board controller PWB, PL
and the IME controller PWB, PL 92.10 Item 1 are correctly and securely seated. Switch
3.11 Item 13.
on the machine, GP 14.
4. For machines W/O TAG 006, if necessary, install a new NVM PWB, PL 3.10 Item 21 and
2. If the fault was detected during a software upgrade. Re-load the software set, GP 4
battery PL 3.10 Item 22.
Machine Software.
For machines W/TAG 006, if necessary, install a new NVM PWB, PL 3.11 Item 17 and
3. For machines W/O TAG 006, go to WD 3.2, WD 8.2, WD 8.4 and WD 9.5. Check the wir- battery PL 3.11 Item 18.
ing between PJ20 on the copy controller PWB and PJ402 on the media path driver PWB.
Check the wiring between PJ408 on the media path driver PWB and PJ402 on the IME
controller PWB. Repair the wiring as necessary, REP 1.1. If necessary, install new com-
ponents:
• Drawer service loop harness, PL 3.10 Item 20.
• Copy controller PWB, PL 3.10 Item 17.
• Media path driver PWB, PL 1.15 Item 5.
• IME Controller PWB, PL 92.10 Item 1.
For machines W/TAG 006, go to WD 3.5, WD 8.2, WD 8.4 and WD 9.5. Check the wiring
between PJ20 on the single board controller PWB and PJ402 on the media path driver
PWB. Check the wiring between PJ408 on the media path driver PWB and PJ401 on the
IME controller PWB. Repair the wiring as necessary, REP 1.1. If necessary, install new
components:
• SBC drawer service loop harness, PL 3.11 Item 16.
• Single Board controller PWB, PL 3.11 Item 13.
• Service loop, PL 92.10 Item 9.

03-331-00, 03-332-00 Main Controller Board Cannot 03-338-00 The Main Controller on the CCB / SBC Has Reset
Communicate with ESS RAP RAP
03-331-00 The copy controller cannot communicate with the network controller. 03-338-00 System detects that the software in the copy controller PWB / single board control-
ler PWB has been reset. This was due either to the watch dog timing out or the software writing
03-332-00 The copy controller was unable to communicate with the network controller after 12 to an illegal address.
minutes.
Initial Actions
NOTE: On W/TAG 006 machines, the main controller and network controller are integral com-
ponents of the single board controller PWB.
Initial Actions WARNING

WARNING death or injury. Moving parts can cause injury.
Ensure that the electricity to the machine is switched off while performing tasks that do • Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to the OF 10 intermittent Failure RAP.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran- Procedure
domly, the cause may be due to electrical noise. Go to the OF 10 intermittent Failure RAP. 1. Switch off the machine, then switch on the machine, GP 14.
2. Re-load the software set, GP 4 Machine Software.
Procedure 3. For machines W/O TAG 006, install new components as necessary:
1. Switch off the machine, then switch on the machine, GP 14. • Copy controller PWB, PL 3.10 Item 17.
2. For machines W/O TAG 006, remove then re-install the network controller PWB. Ensure it • Network controller PWB, PL 3.10 Item 4.
is fully and correctly inserted in PJ7 on the copy controller PWB. For machines W/TAG 006, install new components as necessary:
3. For machines W/TAG 006, check that the network connection to the single board control- • Single Board controller PWB, PL 3.11 Item 13.
ler PWB, PJ227, is correctly inserted.
5. For machines W/O TAG 006, install new components as necessary:
• Network controller PWB, PL 3.10 Item 4.
6. For machines W/TAG 006, install a new single board controller PWB, PL 3.11 Item 13.
7. For additional information, refer to Eureka TIPs for Corrupted Machine Software, Print
Files or Print Drivers and CBC PWB Overheating Caused by Bad Coolong Fan.

03-346-00 Unable To Communicate With UI RAP 03-347-00 Main Controller PWB Cannot Communicate with
03-346-00 Unable to re-establish communication with the UI after 30 seconds. UI PWB RAP
03-347-00 The copy controller PWB/single board controller PWB to UI control PWB communi-
Procedure cations have failed.
Initial Actions
WARNING
1. Switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
2. Reload the software set, GP 4 Machine Software. death or injury. Moving parts can cause injury.
• Switch off the machine, then switch on the machine, GP 14.
domly, the cause may be due to electrical noise. Go to OF 10 intermittent Failure RAP.
Procedure
the copy controller PWB, PL 3.10 Item 17 and the UI control PWB, PL 2.10 Item 2 are cor-
rectly and securely seated. Switch on the machine, GP 14.
For machines W/TAG 006, switch off the machine, GP 14. Ensure all the connectors on
the single board controller, PL 3.11 Item 13 and the UI control PWB, PL 2.10 Item 2 are
correctly and securely seated. Switch on the machine, GP 14.
3. For machines W/O TAG 006, go to WD 3.1. and WD 3.2. Check the wiring between PJ19
on the Copy Controller PWB and PJ900, PJ901 and PJ905 on the UI Control PWB.
Repair the wiring as necessary, REP 1.1. If necessary, install a new user interface har-
ness, PL 2.10 Item 7.
For machines W/TAG 006, go to WD 3.4. and WD 3.5. Check the wiring between PJ19 on
the single board controller PWB and PJ900, PJ901 and PJ905 on the UI Control PWB.
Repair the wiring as necessary, REP 1.1. If necessary, install a new user interface har-
ness, PL 2.10 Item 7.
For machines W/TAG 006, install new components as necessary:
• Single Board controller PWB, PL 3.11 Item 13.

03-355-00 CCM POST Failure Detected RAP 03-360-00 CCS POST System Memory Error RAP
03-355-00 The software has detected a CCM POST failure during the NVM integrity test / NVM 03-360-00 The copy control software has detected a system memory error during power on
battery failure. self test. The system memory is mounted directly on the copy controller PWB/single board con-
troller PWB.
Initial Actions
Initial Actions
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Ensure that the electricity to the machine is switched off while performing tasks that do
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran- death or injury. Moving parts can cause injury.
domly, the cause may be due to electrical noise. Go to OF 10 intermittent Failure RAP. • Switch off the machine, then switch on the machine, GP 14.
• Check that the NVM battery is located correctly and in good condition. • Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
Procedure
Procedure
NOTE: The machine may continue to boot with this fault, but printing may be disabled. The sta-
1. For machines W/O TAG 006, switch off the machine, GP 14. Ensure the memory PWB is
tus code, 03-505 is raised with this fault code.
correctly and securely seated on the copy controller PWB PL 3.10 Item 17. Switch on the
1. Switch off the machine, then switch on the machine, GP 14. machine, GP 14.
2. Re-load the software set, GP 4. For machines W/TAG 006, switch off the machine, GP 14. Ensure the memory PWB is
3. For machines W/O TAG 006, if necessary, install a new NVM PWB, PL 3.10 Item 21 and correctly and securely seated on the single board controller PWB PL 3.11 Item 13. Switch
battery PL 3.10 Item 22. on the machine, GP 14.
For machines W/TAG 006, if necessary, install a new NVM PWB, PL 3.11 Item 17 and 2. Re-load the software set, GP 4 Machine Software.
battery PL 3.11 Item 18. 3. For machines W/O TAG 006, if necessary, install a new copy controller PWB, PL 3.10
4. For machines W/O TAG 006, if necessary, install a new copy controller PWB, PL 3.10 Item 17.
Item 17. For machines W/TAG 006, if necessary, install a new single board controller PWB, PL
For machines W/TAG 006, if necessary, install a new single board controller PWB, PL 3.11 Item 13.
3.11 Item 13.

03-361-00 CCS POST Flash Memory Error RAP 03-362-00 CCS Power Fault RAP
03-361-00 The copy control software has detected a flash memory error during power on self 03-362-00 The copy controller software has failed to exit from a timer loop and has detected
test. that this is caused by an abnormal power condition.
WARNING WARNING
• Switch off the machine, then switch on the machine, GP 14. • Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran- • Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF 10 intermittent Failure RAP. domly, the cause may be due to electrical noise. Go to OF 10 intermittent Failure RAP.
Procedure Procedure
1. For machines W/O TAG 006, switch off the machine, GP 14. Ensure the memory PWB is 1. Switch off the machine, then switch on the machine, GP 14.
correctly and securely seated on the copy controller PWB PL 3.10 Item 17. Switch on the 2. For machines W/O TAG 006, check the wiring and connections between the power supply
machine, GP 14. unit, the power distribution PWB and the copy controller PWB. Repair the wiring as nec-
For machines W/TAG 006, switch off the machine, GP 14. Ensure the memory PWB is essary, REP 1.1.
correctly and securely seated on the single board controller PWB PL 3.11 Item 13. Switch For machines W/TAG 006, check the wiring and connections between the power supply
on the machine, GP 14. unit, the power distribution PWB and the single board controller PWB. Repair the wiring
2. Re-load the software set, GP 4 Machine Software. as necessary, REP 1.1.
3. For machines W/O TAG 006, if necessary, install a new copy controller PWB, PL 3.10 3. Perform the appropriate procedure:
Item 17. • For machines W/O TAG 006, go to the following RAPs and check the low voltage
For machines W/TAG 006, if necessary, install a new single board controller PWB, PL supplies to the copy controller PWB:
3.11 Item 13. – 01C +3.3V Distribution RAP.
– 01D +5V Distribution RAP.
– 01E +12V Distribution RAP.
– 01G +17V Distribution RAP.
– 01H +24V Distribution RAP.
– 01L 0V Distribution RAP
As necessary, repair the wiring, REP 1.1, or install new components as necessary:
– Power distribution PWB, PL 3.10 Item 1.
– Harness PDB to CCB (16 way power), PL 3.10 Item 12.
– Copy controller PWB, PL 3.10 Item 17.
– Power supply unit, PL 1.15 Item 2.
• For machines W/TAG 006, go to the following RAPs and check the low voltage sup-
plies to the single board controller PWB:
– 01C +3.3V Distribution RAP.
– 01E +12V Distribution RAP.
– 01G +17V Distribution RAP.

As necessary, repair the wiring, REP 1.1, or install new components as necessary: 03-397-00 System Configuration Recovery Attempt RAP
– Power distribution PWB, PL 3.11 Item 1. 03-397-00 System configuration is lost and an attempted recovery made (from SIM).
– Single board controller PWB, PL 3.11 Item 13.
– Harness PDB to SBC (PJ17), PL 3.11 Item 10. Initial Actions
– Harness PDB to SBC (PJ18), PL 3.11 Item 11.
– Power supply unit, PL 1.15 Item 2.
WARNING
Procedure
2. Check that the SIM is installed.
3. Check for damage to the SIM:
• Enter dC131.
• Select CCS NVM ID 616-3 Product Configuration.
• Check that the value is set to 112 or 113 or 114. If the value is set to 47, 48 or 49, the
SIM is missing or damaged. Escalate the problem to your national technical special-
ist to obtain a new serialized SIM card that is compatible with the machine.
4. Check that the SIM card is a valid option for this machine, GP 19. If there is a mismatch
between the SIM card and the machine then the two are not compatible. Obtain a SIM
card that is compatible with this machine.
5. For machines W/O TAG 006, if necessary, install new components:
• NVM PWB, PL 3.10 Item 21.
• SIM, PL 3.10 Item 29.
For machines W/TAG 006, if necessary, install new components:
• SIM, PL 3.11 Item 21.
6. Perform an NVM restore, refer to NVM Save and Restore, dC361.
7. If an NVM restore cannot be completed perform the following:
• Enter dC131.
• Set the market region. Enter CCS NVM ID 616-1, set value to appropriate market
region.
• Enter Service Admin.
a. Press and hold the # key, * key and the Stop key.
b. Enter the passcode 2732. Touch the Enter button on the UI.
c. Select machine status / Paper Management / Tray Contents
d. Set the tray 3 contents as appropriate to the machine location A4 or 8.5 x 11 inch.
8. Reset counters and exit diagnostics.

03-398-00, 03-399-00 SIM Card Fault RAP 03-401-00, 03-403-00 Fax Not Detected RAP
03-398-00 SIM card serial number mismatch between the option and the machine 03-401-00 The basic (embedded) fax PWB has not been detected or confirmed.
03-399-00 SIM card data cannot be processed by the machine. 03-403-00 Extended fax PWB has not been confirmed or detected. This is for information only.
The machine does not have an extended fax PWB.
Procedure
Procedure
WARNING
1. Switch off the machine, then switch on the machine, GP 14. death or injury. Moving parts can cause injury.
2. Check that the machine serial number is correct, refer to dC132. 1. Switch off the machine, then switch on the machine, GP 14.
3. Check that the SIM card is a valid option for this machine, GP 19. There is a mismatch 2. Check that the embedded Fax PWB, PL 20.05 Item 4 has been installed.
between the SIM card and the machine and the two are not compatible. Obtain a SIM 3. For machines W/O TAG 006, check that the software module, PL 3.10 Item 9 is inserted
card that is compatible with this machine. correctly.
NOTE: A pre-serialized SIM card will be required. Escalate the request through normal 4. For machines W/TAG 006, check that the software module, PL 3.11 Item 7 is inserted cor-
rectly.
channels.
5. Perform the Initial Actions in 20A Fax Entry RAP.
NOTE: The SIM card is also referred to as the product enablement key. 6. Go to 20G Embedded Fax Checkout.
4. For machines W/O TAG 006, if necessary, install new components: 7. If necessary, install a new embedded Fax PWB, PL 20.05 Item 4.
• Product enablement key, PL 3.10 Item 29. 8. If necessary, re-load the software set, GP 4 Machine Software.
• Copy controller PWB, PL 3.10 Item 17. 9. For machines W/O TAG 006, if necessary, install new components:
For machines W/TAG 006, if necessary, install new components: • Software module, PL 3.10 Item 9,
• Product enablement key, PL 3.11 Item 22. • Copy controller PWB, PL 3.10 Item 17.
• Single board controller PWB, PL 3.11 Item 13. For machines W/TAG 006, if necessary, install new components:
• Software module, PL 3.11 Item 7,

03-417-00 Incompatible Fax Software RAP 03-777-00 Power Loss Detected RAP
03-417 The fax software version supplied at power up is not compatible with the image pro- 03-777-00 This fault code in the fault history file indicates that the system has previously
cessing software. detected a power input loss.
Procedure Procedure
WARNING WARNING
Switch off the machine, then switch on the machine, GP 14. 1. Check with the customer that the AC mains (line) input power supply is not experiencing
interruptions.
Perform the following: 2. Check with the customer that the machine does not share a power supply with any other
• Reload the software set, GP 4, Machine Software. equipment. Sharing a power supply may cause the safety over current device to switch off
• As necessary, install new components: the electrical supply to the machine. This would cause a 03-777-00 fault. If possible,
ensure the machine is connected to a dedicated power supply.
– Embedded Fax PWB, PL 20.05 Item 4.
3. Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
– Extended Fax PWB, PL 20.05 Item 2.
4. Go to 01A AC Power Distribution RAP and check the power input circuit and its connec-
tors.

03-788-00 CCS Runtime could not Enter Power Saver 03-790-00 Timezone Cannot Be Set RAP
Mode S3 RAP 03-790-00 At power up the Timezone is not valid due to NVM corruption, or OS file system
problem. Timezone overridden to GMT: DST disabled.
03-788 The copy control software could not enter power save mode. The copy control software
was unable to update its parameters from the UI, when the machine previously came out of the
sleep mode. It was then unable to re-enter the sleep mode, S3. Procedure
Procedure
WARNING
WARNING not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Ensure that the electricity to the machine is switched off while performing tasks that do death or injury. Moving parts can cause injury.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Reset the time zone in customer domain tools, refer to GP 5.
1. Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
3. For machines W/O TAG 006, go to WD 3.1 and check the wiring between PJ19 on the
Copy Controller PWB and PJ900, PJ901 and PJ905 on the UI Control PWB. Repair the
wiring as necessary, REP 1.1.
4. For machines W/TAG 006, go to WD 3.4 and check the wiring between PJ19 on the single
board controller PWB and PJ900, PJ901 and PJ905 on the UI Control PWB. Repair the

A
03A Foreign Device PWB Fault RAP Disconnect the foreign device. Install a temporary shorting link between pins 2 and 3 on the
foreign device interface harness bulkhead connector. Check the voltage at pin 2. 0V is mea-
Use this RAP when the foreign interface device is not detected.
sured.
Y N
Initial Actions For machines W/O TAG 006, install a new foreign device interface PWB, PL 3.10 Item 18.
For machines W/TAG 006, install a new foreign device interface PWB, PL 3.11 Item 14.
WARNING Install a temporary shorting link between pins 1 and 3 on the foreign device interface harness
Ensure that the electricity to the machine is switched off while performing tasks that do bulkhead connector. Check the display. The machine is enabled.
death or injury. Moving parts can cause injury. For machines W/O TAG 006, install new components as necessary:
• Install a new foreign device interface PWB, PL 3.10 Item 18.
CAUTION
Do not show the customer how to install a temporary shorting link. Do not leave a shorting link • Install a new foreign device interface PWB, PL 3.11 Item 14.
installed.
• For machines W/O TAG 006, ensure the foreign interface PWB, PL 3.10 Item 18 is The enable circuits are working correctly.
securely connected to the copy controller PWB, PL 3.10 Item 17.
NOTE: Currently the signals used for billing, e.g. machine function, premium tray, etc. cannot
• For machines W/TAG 006, ensure the foreign device interface PWB, PL 3.11 Item 14 is
be adequately measured with a standard meter.
securely connected to the single board controller PWB, PL 3.11 Item 13.
Procedure
(USSG/XCL only) Check the operation of the foreign interface device using a foreign interface
test tool, PL 26.10 Item 14 in conjunction with the 7655/65/75 indicator/instruction chart. If a
foreign interface test tool is not available/suitable, perform the procedure that follows:
For machines W/O TAG 006, refer to WD 3.3. Check the foreign device interface harness, PL
3.10 Item 30.
For machines W/TAG 006, refer to WD 3.6. Check the foreign device interface harness, PL
3.11 Item 22. The harness is good.
Y N
For machines W/O TAG 006, perform the following as necessary:
• Repair the harness, REP 1.1.
• Install a new foreign device interface harness, PL 3.10 Item 30.
For machines W/TAG 006, perform the following as necessary:
• Repair the harness, REP 1.1.
• Install a new foreign device interface harness, PL 3.11 Item 23.
NOTE: Do not attempt to repair the harness from the bulkhead connector to the foreign
device.
For machines W/O TAG 006, check the +3.3V supply to PJ13 at pins 1, 5, 9, 16 and 22 on the
Copy Controller PWB.
For machines W/TAG 006, check the +3.3V supply to PJ13 at pins 1, 5, 9, 16 and 22 on the
single board controller PWB. The +3.3V supply is good.
Y N
Check the +3.3V distribution. Refer to:
• 01C +3.3V Distribution RAP.
A
05-250-00, 05-251-00 DADH Checksum Error RAP 05-252-00 DADH Stepper Controller Communications Error
05-250-00 The DADH flash memory is corrupted. A kernel checksum error has been detected. 05-252-00 DADH PWB to stepper motors communications have failed.
05-251-00 The DADH flash memory is corrupted. An application checksum error has been Initial Actions
detected.

Ensure that the electricity to the machine is switched off while performing tasks that do Switch off, then switch on the machine, GP 14.
Procedure
Switch off, then switch on the machine, GP 14.
1. Switch off the machine, GP 14. Ensure all the connectors on the DADH PWB, PL 5.10
Item 5, are correctly and securely seated. Switch on the machine, GP 14.
Procedure 2. Go to WD 5.1. Check the wiring between PJ181 on the DADH PWB and the feed motor, PL
1. Re-load the software set, GP 4 Machine Software. 5.15 Item 16 and the CVT motor, PL 5.25 Item 9. Repair the wiring as necessary, REP 1.1.
2. If necessary, install a new DADH PWB, PL 5.10 Item 5. 3. Install new components as necessary:
• DADH feed motor, PL 5.15 Item 16.
• DADH CVT motor, PL 5.25 Item 9.
• DADH PWB, PL 5.10 Item 5.

05-253-00, 05-254-00 DADH Communications Error RAP 05-255-00 Late Pre Scan Message RAP
05-253-00 The DADH PWB to copy controller PWB / single board controller PWB communica- 05-255-00 The DADH pre scan status message was not received in time.
tions have failed.
05-254-00 The DADH PWB to copy controller PWB / single board controller PWB communica-
Procedure
tions are out of sequence.

Ensure that the electricity to the machine is switched off while performing tasks that do 1. Switch off, then switch on the machine, GP 14.
Procedure
the DADH PWB, PL 5.10 Item 5, scanner PWB, PL 62.16 Item 8 and the copy controller
PWB, PL 3.10 Item 17 are correctly and securely seated. Switch on the machine, GP 14.
2. For machines W/TAG 006, switch off the machine, GP 14. Ensure all the connectors on
the DADH PWB, PL 5.10 Item 5, scanner PWB, PL 62.17 Item 1 and the single board
controller PWB, PL 3.11 Item 13 are correctly and securely seated. Switch on the
machine, GP 14.
3. If the fault was detected during a software upgrade. Re-load the software set, GP 4
Machine Software.
4. For machines W/O TAG 006, go to WD 3.1, WD 5.2 and WD 6.4. Check the wiring
between PJ188 on the DADH PWB and PJ921 on the scanner PWB. Check the wiring
between PJ922 on the scanner PWB and PJ15 on the copy controller PWB. Repair the
5. For machines W/TAG 006, go to WD 3.4, WD 5.2 and WD 6.1. Check the wiring between
PJ188 on the DADH PWB and PJ921 on the scanner PWB. Check the wiring between
PJ922 on the scanner PWB and PJ15 on the single board controller PWB. Repair the wir-
ing as necessary, REP 1.1.
• DADH communication/power cable, PL 5.10 Item 6.
• Scanner communication/power cable, PL 62.10 Item 12.
• Scanner PWB, PL 62.16 Item 8.
7. For machines W/TAG 006, install new components as necessary:
• DADH communication/power cable, PL 5.10 Item 6.
• Scanner video harness, PL 62.17 Item 3.
• DADH/IIT Power connection, PL 62.17 Item 15.

05-256-00 Eject Count Error RAP 05-257-00 Unknown Document Size RAP
05-256-00 The number of ejections from the DADH did not match the number of feeds. 05-257-00 The DADH has failed to detect the document size during pre-feed.
Procedure Initial Actions
WARNING WARNING
1. Switch off, then switch on the machine, GP 14. • Make sure that a bright light is not above the DADH input tray. Refer to TAG D-007 and
check size sensor 1 and size sensor 2. If necessary, adjust the position of the machine.
• Remove all documents from the DADH and input tray.
• Make sure that the sensors and the area around the sensors are clean.
Procedure
NOTE: The DADH width sensor is a potentiometer. The arm on the potentiometer is attached
to the width guides. This gives a variable voltage to indicate the paper width setting.
Enter dC330 code 05-221 to check the DADH tray size sensor 1 Q05-221, PL 5.35 Item 8.
Actuate Q05-221. The display changes.
Y N
Go to Wiring Diagram WD 5.2. Check Q05-221.
References:
• P/J190, DADH PWB.
• 01D +5V Distribution RAP.
• DADH tray size sensor 1, PL 5.35 Item 8.
Enter dC330 code 05-222 to check the DADH tray size sensor 2 Q05-222, PL 5.35 Item 8.
Actuate Q05-222. The display changes.
Y N
References:
• DADH tray size sensor 2, PL 5.35 Item 8.

A
Open the DADH top cover. Enter dC330 code 05-204 to check the DADH feed sensor, Q05-
204, PL 5.15 Item 2. Actuate Q05-204. The display changes.
Y N
DADH width sensor
Go to Wiring Diagram WD 5.1. Check Q05-204. Q05-095
References:
• DADH feed sensor, PL 5.15 Item 2.
Enter dC330 code 05-206 to check the DADH pre-reg sensor, Q05-206, PL 5.25 Item 1. Actu-
ate Q05-206. The display changes.
Y N Arm
References:
• DADH pre-reg sensor, PL 5.25 Item 1.
Completely open the DADH width guides. Go to WD 5.2. Measure the voltage at P/J190 pin 8.
Completely close the DADH width guides. The voltage changes from approximately 3.3V to
approximately 0V.
Y N
Remove the DADH input tray assembly, PL 5.35 Item 1. Make sure the arm of the DADH
width sensor is installed correctly, Figure 1. Check the mechanical operation of the width
guides. If necessary, install a new DADH width sensor, PL 5.35 Item 11.
Go to dC131. Check that the IIT DADH NVM parameters for the detection of the size of paper
are correct.
• DADH sensor replacement kit W/TAG D-007, PL 31.11 Item 17.

05-258-00, 05-307-00 DADH Cover Interlock Open RAP
05-258-00 The DADH cover interlock switch detects that the top cover is open during initializa- Actuator
tion.
05-307-00 The DADH cover interlock switch detects that the top cover is open.
Initial Actions
WARNING
• Remove all documents from the DADH.
• Check the switch actuator on the DADH cover, Figure 1. If the actuator is damaged, install
a new DADH top cover, PL 5.20 Item 15.
• Make sure the latch springs, PL 5.20 Item 7 are installed correctly. Make sure that the top
cover closes correctly. If necessary, install a new top access cover assembly, PL 5.20
Item 17.
• Check that the EPC memory PWB, PL 3.10 Item 28, is correctly seated.
NOTE: dC640 can be used to isolate a defective EPC memory PWB. In the case of a
defective EPC PWB the procedure will stop at 99% of completion then the system will
hang. With a good EPC memory PWB the dC640 procedure will complete within 20 sec-
onds. DADH cover interlock switch,
S05-212
Procedure
Enter dC330 code 05-212 to check the DADH cover interlock switch, Figure 1, S05-212. Actu-
ate S05-212. The display changes.
Y N Figure 1 Component location
Go to Wiring Diagram WD 5.1. Check S05-212.
References:
• GP 13 How to Check a Switch.
• 01H +24V Distribution RAP.
• DADH cover interlock switch, PL 5.15 Item 11.
Check that S05-212 is installed correctly.

05-259-00, 05-260-00 DADH Active Line or Standby Error 05-300-00 DADH Open RAP
RAP 05-300-00 The platen down sensor detects that the DADH is open during run.
05-259-00 The DADH active line is in the wrong state during the scan
Initial Actions
05-260-00 The DADH is not in standby at the start of the job.

Ensure that the electricity to the machine is switched off while performing tasks that do Check that the DADH platen down sensor magnet, PL 5.10 Item 10 is installed and aligned
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause correctly to the platen down sensor.
NOTE: The DADH has two magnets, the magnet on the left front corner of the DADH actuates
• Switch off, then switch on the machine, GP 14.
the platen down sensor, refer to PL 5.10 Item 10.
Procedure Procedure
1. For machines W/O TAG 006 and W/O TAG 007, go to WD 5.2 and WD 6.1. Check the wir- Enter dC330 code 62-019 to check the platen down sensor, Q62-019, PL 62.16 Item 5. Open
ing between PJ188 on the DADH PWB and PJ921 on the scanner PWB. Repair the wiring and close the DADH. The display changes.
as necessary, REP 1.1. Y N
2. For machines W/TAG 006 and W/TAG 007, go to WD 5.2 and WD 6.4. Check the wiring For machines W/O TAG 006 and W/O TAG 007 go to Wiring Diagram WD 6.2. Check
between PJ188 on the DADH PWB and PJ921 on the scanner PWB. Repair the wiring as Q62-019.
necessary, REP 1.1. References:
3. For machines W/O TAG 006 and W/TAG 007, go to WD 5.2 and WD 6.4. Check the wiring • GP 13 How to Check a Switch.
between PJ188 on the DADH PWB and PJ921 on the scanner PWB. Repair the wiring as • PJ927, Scanner PWB.
necessary, REP 1.1. • 01C +3.3V Distribution RAP.
4. If necessary, install a new DADH PWB, PL 5.10 Item 5. • 01L 0V Distribution RAP.
• Platen down sensor, PL 62.16 Item 5.
For machines W/TAG 006 and W/TAG 007, go to Wiring Diagram WD 6.5. Check Q62-
019.
References:
• PJ927, scanner PWB.
For machines W/O TAG 006 and W/TAG 007, go to Wiring Diagram WD 6.5. Check Q62-
019.
References:
• PJ927, scanner PWB.
A
A
• 01L 0V Distribution RAP. 05-310-00 Document Too Short RAP
Install new components as necessary: 05-310-00 The DADH detects a document that is shorter than 110mm.
• Scanner PWB, PL 62.17 Item 1. Initial Actions
Perform the steps that follow. Install new components as necessary:
• Check that Q62-019 is installed correctly. WARNING
• Check the DADH frame for distortion, go to ADJ 5.2. If the DADH frame is distorted, install Ensure that the electricity to the machine is switched off while performing tasks that do
a new DADH, PL 5.10 Item 9. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Make sure that the documents are longer than 110 mm (4.3 inches).
• Check for toner contamination on and in the locality of the DADH feed sensor Q05-204,
PL 5.15 Item 2.
Procedure
If the documents are longer than 110mm, go to the procedures that follow:
• 05-330-00, 05-331-00 CVT - DADH Feed Sensor Failure RAP.
• 05-335-00 DADH TAR Sensor Failure RAP.
• 05-350-00, 05-352-00 DADH CVT Sensor Failure RAP.
• 05-340-00 CVT-DADH Pre-Reg Sensor Failure RAP.

A
05-330-00, 05-331-00 DADH Feed Sensor Failure RAP Enter dC330 code 05-074 to run the DADH feed motor, MOT05-074. MOT05-074 runs.
Y N
05-330-00 The DADH feed sensor does not detect the lead edge of the document within the
Go to the 05C DADH Motor Failure RAP.
correct time after the feed motor runs.
While MOT 05-074 runs, stack the code 05-062 to energize the DADH feed clutch, CL05-062.
05-331-00 The DADH feed sensor does not detect the trail edge of the document within the
correct time. NOTE: The feed clutch disengages after 30 seconds. The feed motor stops after 3 minutes.
CL05-062 energizes, the nudger rolls and the feed rolls rotate.
Initial Actions Y N
• Go to the 05D DADH Feed Clutch Failure RAP and check CL05-062.
WARNING
• ADJ 5.1 DADH Drive Belt Adjustment.
Enter dC330 code 05-098, to run the DADH nudger motor. The feed roll assembly lowers,
then raises after 10 seconds.
• Remove all documents from the DADH. Y N
• Make sure that the customer is not using damaged documents. If the DADH damages the Go to Wiring Diagram WD 5.1. Check the nudger motor.
documents, go to the 05E Damaged Documents RAP. References:
• Clean the DADH feed sensor, PL 5.15 Item 2, and the area around the sensor, Figure 2. • GP 10 How to Check a motor.
• Check that the feed roll assembly is installed correctly, refer to REP 5.14. • P/J183, DADH PWB and P/J201.
• Check that the CVT roll is installed correctly, refer to REP 5.15. • 01H +24V Distribution RAP.
• Make sure that the feed rolls are clean and rotate freely, refer to ADJ 5.4. If necessary, • 01L 0V Distribution RAP.
install a new feed roll assembly, PL 5.15 Item 1 or feed roll assembly cover, PL 5.15 Item Install new components as necessary:
21.
• DADH nudger motor, PL 5.15 Item 5.
• Go to dC135 CRU/HFSI Status. Check the count of the DADH feed roll set. If the count is
• DADH feed assembly, PL 5.15 Item 18.
near end of life, install a new feed roll assembly, PL 5.15 Item 1.
• Check the operation of the feed yoke, Figure 1. Make sure that the feed yoke shaft is
under the moulded clip of the feed housing. Make sure that the feed yoke spring, PL 5.15
Item 7 is connected to the feed housing and to the feed yoke.
• Check that the DADH feed sensor, Q05-204 is installed correctly, Figure 2. If necessary,
• Make sure that the front feed gate, PL 5.15 Item 12 and the rear feed gate, PL 5.15 Item
install a new feed roll assembly, PL 5.15 Item 1.
13 are locked in the down position.
• Ensure the feed motor drive belt and DADH CVT motor belt are tensioned correctly, ADJ
• Check the DADH CVT sensor and actuator for damage, PL 5.20 Item 12.
5.1.
• When large documents are fed (A3 or 11x17 inch), check the items that follow:
Procedure
– Check that the DADH CVT motor rotates freely, refer to the 05C DADH Motor Failure
Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Hold the DADH RAP.
cover interlock switch closed, PL 5.15 Item 11. Enter dC330 code 05-204 to check the DADH
– Check the CVT motor drive belt, refer to ADJ 5.1 DADH Drive Belt Adjustment.
feed sensor, Q05-204. Actuate Q05-204. The display changes.
Y N – Check that the CVT roll is clean and rotates freely, refer to ADJ 5.4.
Go to Wiring Diagram WD 5.1. Check Q05-204. – If necessary install a new DADH feed motor, PL 5.25 Item 9.
References: • Go to the 05D DADH Feed Clutch Failure RAP and check CL05-062.
• GP 11 How to Check a Sensor. • Make sure that the size of the documents are sensed correctly. Refer to the 05-257-00
• P/J184, DADH PWB. Document Size Sensor Failure RAP.
• DADH feed sensor, PL 5.15 Item 2.
A
Clip CVT motor MOT 05-099
Top cover interlock switch
Feed motor
MOT05-074
Feed yoke and
spring
Feed clutch
CL05-062
Feed yoke shaft
Front and rear feed

gates
P/J201
Nudger motor DADH feed sensor Feed roll assembly
MOT 05-098 Q05-204
Front and rear

feed gates

05-335-00 DADH TAR Sensor Failure RAP • Make sure that the takeaway roll is clean and rotates freely, refer to ADJ 5.4.
• Make sure that the takeaway roll idlers are clean and rotate freely, refer to ADJ 5.4.
05-335-00 The DADH TAR sensor does not detect the lead edge of the document within the
correct time. • Check the takeaway roll static eliminator and ground harness, PL 5.35 Item 7.
• Make sure that the DADH ground harness is connected correctly, PL 5.10 Item 11.
Initial Actions • ADJ 5.1 Feed Motor Drive Belt Adjustment.
• DADH takeaway roll, PL 5.35 Item 6.
WARNING
• DADH top access cover assembly, PL 5.20 Item 17.
death or injury. Moving parts can cause injury. If the fault continues, make sure that documents correctly continue past the previous sensor in
the document path. Refer to the 05-330-00, 05-331-00 DADH Feed Sensor Failure RAP.
• Clean the feed rolls, refer to ADJ 5.4. If necessary, install a new feed roll assembly, PL
5.15 Item 1.
Procedure
NOTE: To get access to the DADH TAR sensor, remove the DADH top cover, PL 5.20 Item 15.
Open the DADH top cover. Enter dC330 code 05-096 to check the DADH TAR sensor, Q05-
096, PL 5.20 Item 11. Actuate Q05-096. The display changes.
Y N
References:
• P/J186, DADH PWB and P/J191.
• 01C +3.3V Distribution PWB.
• DADH TAR sensor, PL 5.20 Item 11.
Remove the DADH rear cover, PL 5.10 Item 1. Hold the DADH cover interlock switch closed,
PL 5.15 Item 11. Enter dC330 code 05-074 to run the DADH feed motor, MOT05-074, PL 5.15
Item 16. MOT05-074 runs.
Y N
The takeaway roll rotates.

Y N
Perform the steps follow:
• Check the feed motor drive belt, PL 5.35 Item 5.
• ADJ 5.1 Feed Motor Drive Belt Adjustment.
• Check the takeaway roll and pulley, PL 5.35 Item 6 and PL 5.35 Item 15, refer to GP 7.

• Check that the DADH TAR sensor, Q05-096 is installed correctly.
• Go to the 05D DADH Feed Clutch Failure RAP and check the DADH feed clutch.

A
05-340-00 DADH Pre Registration Sensor Failure RAP The fault only occurs in duplex mode.
Y N
05-340-00 The DADH pre registration sensor does not detect the lead edge of the document
Go to Final Actions.
within the correct time.
This fault can be caused by the DADH feed motor running too slowly in reverse. Refer to the
Initial Actions 05C DADH Motor Failure RAP. If the fault continues, go to Final Actions.
Final Actions
WARNING
• Check that Q05-206 is installed correctly, PL 5.25 Item 1.
death or injury. Moving parts can cause injury. • Make sure that the CVT idler rolls are clean and rotate freely, refer to ADJ 5.4.
• Remove all documents from the DADH. • Make sure that the CVT roll is clean, refer to ADJ 5.4.
• Remove the DADH top cover assembly, PL 5.20 Item 16. Make sure the harnesses are • Make sure the feed motor drive belt and the DADH CVT motor drive belt are tensioned
routed correctly and away from the document path, Figure 1. correctly, ADJ 5.1.
Procedure • DADH CVT roll, PL 5.25 Item 5.
• DADH top access cover assembly, PL 5.20 Item 17.
NOTE: To access the DADH pre registration sensor, remove the DADH top cover, PL 5.20 Item
If the fault continues, make sure that documents correctly exit the previous sensor in the docu-
15.
ment path. Refer to the 05-350-00, 05-352-00 DADH CVT Sensor Failure RAP.
Open the top access cover assembly. Enter dC330 code 05-206 to check the DADH pre regis-
tration sensor, Q05-206, PL 5.25 Item 1. Actuate Q05-206. The display changes.
Y N
Go to Wiring Diagram WD 5.1. Check Q05-206. Ground harness
References:
• 01C +3.3V Distribution PWB.
• DADH pre registration sensor, PL 5.25 Item 1.
PL 5.15 Item 11. Enter dC330 code 05-099 to check the DADH CVT motor, MOT05-099, PL
5.25 Item 9. MOT05-099 runs.
Y N
DADH pre registration
sensor Q05-206
The CVT roll rotates.
Y N
Perform the steps that follow: Sensor harness
• Check the DADH CVT motor drive belt, PL 5.25 Item 11.
• Check the DADH CVT motor tension spring. Make sure that the DADH CVT motor
drive belt tension is correct, ADJ 5.1.
• Check the CVT roll pulley, PL 5.25 Item 17.
If necessary, install a new DADH CVT roll, PL 5.25 Item 5.
A

A
05-345-00, 05-346-00 DADH Exit Sensor Failure RAP If necessary, install a new DADH CVT roll, PL 5.25 Item 5.
05-345-00 The DADH exit sensor does not detect the lead edge of the document within the
NOTE: The exit roll idlers remain lowered for 30 seconds.
correct time in the forward mode.
Enter dC330 code 05-100 to energize the DADH duplex solenoid, SOL05-100, PL 5.30 Item 3,
05-346-00 The DADH exit sensor does not detect the trail edge of the document within the cor- to lower the exit roll idlers PL 5.30 Item 6. The exit roll idlers lower.
rect time in the forward mode. Y N
Initial Actions • Go to Wiring diagram WD 5.1. Check SOL05-100.
References:
– GP 12 How to Check a Solenoid or Clutch.
WARNING
– P/J181, DADH PWB and P/J205.
death or injury. Moving parts can cause injury. – 01L 0V Distribution RAP.
• Remove all documents from the DADH exit tray. Raise the DADH, remove all documents • Check the baffle assembly link arm, PL 5.30 Item 11. Make sure that the link arm is
that are wound around the CVT roll. connected correctly to the DADH duplex solenoid, refer to REP 5.5.
• Make sure that the customer has set the document width guides correctly. Install new components as necessary:
• DADH duplex solenoid, PL 5.30 Item 3.
Procedure • DADH PWB, PL 5.10 Item 5.
• Lower baffle assembly, PL 5.30 Item 14.
NOTE: The DADH exit sensor is a reflective type sensor.
Enter dC330 code 05-209 to check the DADH exit sensor, Q05-209, PL 5.30 Item 13. Raise Enter dC330 code 05-074 to run the DADH feed motor, MOT05-074, PL 5.15 Item 16.
the DADH. Actuate Q05-209. The display changes. MOT05-074 runs.
Y N Y N
Go to Wiring diagram WD 5.2. Check Q05-209. Go to the 05C DADH Motor Failure RAP.
References:
The exit roll rotates.
Y N
• P/J189, DADH PWB. Perform the steps that follow:
• 01D +5V Distribution RAP. • Check the feed motor drive belt, PL 5.35 Item 5.
• 01L 0V Distribution RAP. • Check the feed motor tension spring, PL 5.15 Item 17. Check the feed motor drive
Install new components as necessary: belt tension, ADJ 5.1.
• DADH exit sensor, PL 5.30 Item 13. • Check the exit roll and pulley, PL 5.35 Item 6 and PL 5.35 Item 15.
The fault only occurs in duplex mode.
Close the DADH. Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Y N
Hold the DADH cover interlock switch closed. Enter dC330 code 05-099 to run the DADH CVT Go to Final Actions.
motor, MOT05-099, PL 5.25 Item 9. MOT05-099 runs.
Y N NOTE: During normal operation, the exit roll idlers remain raised (closed) in simplex mode. In
Go to the 05C DADH Motor Failure RAP. duplex mode, the exit roll idlers remain raised unless the document is longer than 280mm (11
inches). The exit roll idlers raise and lower while feeding longer documents in duplex mode.
Exit diagnostics mode. Close the DADH top cover. Make two copies in duplex mode. Check
Y N
that the second document is held in the feed rolls, PL 5.15 Item 1, until the first document is fed
into the output tray. The feed rolls held the second document.
• Check the DADH CVT motor DADH CVT motor drive belt, PL 5.25 Item 11. Y N
• Check the DADH CVT motor tension spring, PL 5.25 Item 10. Make sure the DADH Go to the 05D DADH Feed Clutch Failure RAP.
CVT motor drive belt tension is correct, ADJ 5.1.
• Check the CVT roll pulley, PL 5.25 Item 17. Go to Final Actions.
A
Final Actions 05-350-00, 05-352-00 DADH CVT Sensor Failure RAP
Perform the steps that follow: 05-350-00 The DADH CVT sensor does not detect the lead edge of the document within the
• For 05-345-00 and 05-346-00 faults: correct time in the forward mode.
– Check that the pre-scan idlers are clean and rotate freely, refer to ADJ 5.4.
05-352-00 The DADH CVT sensor does not detect the lead edge of the document within the
– Check that the post-scan idlers are clean and rotate freely, refer to ADJ 5.4.
correct time in the reverse mode.
– Check the CVT ramp assembly for damage and rough edges, PL 62.10 Item 5.
– Check the duplex gate for damage and rough edges, PL 5.25 Item 12. Initial Actions
– Check that the DADH exit sensor, Q05-209 is installed correctly, PL 5.30 Item 13.
– Make sure that the DADH ground harness is connected correctly, PL 5.10 Item 11.
– Make sure the DADH feed motor drive belt and DADH CVT motor drive belt are ten- WARNING
sioned correctly, ADJ 5.1. Ensure that the electricity to the machine is switched off while performing tasks that do
Install new components as necessary: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
– Top access cover assembly, PL 5.20 Item 17. death or injury. Moving parts can cause injury.
– Lower baffle assembly, PL 5.30 Item 14. Remove all documents from the DADH.
• For 05-346-00 faults:
– Make sure that the exit rolls are clean and rotate freely, refer to ADJ 5.4. Procedure
– Make sure that the exit roll idlers are clean and rotate freely, refer to ADJ 5.4. NOTE: To get access to the DADH CVT sensor, remove the DADH top cover, PL 5.20 Item 15.
– Make sure the tension springs on the exit roll shaft are in the correct position, refer to
Enter dC330 code 05-097 to check the DADH CVT sensor Q05-097, PL 5.20 Item 12. Actuate
REP 5.5
Q05-097. The display changes.
– Check the exit roll static eliminator and ground harness, PL 5.35 Item 7. Y N
– Check the restack arm for damage or rough edges, PL 5.35 Item 3. Go to Wiring diagram WD 5.1. Check Q05-097.
If necessary, install a new DADH exit roll, PL 5.35 Item 6. References:
If the fault continues, make sure that all documents correctly exit the previous sensor in the • GP 11 How to Check a Sensor.
document path. Refer to the 05-340-00 DADH Pre-Reg Sensor Failure RAP. • P/J186 and P/J191, DADH PWB.
• DADH CVT sensor, PL 5.20 Item 12.
PL 5.15 Item 11. Enter dC330 code 05-099 to check the DADH CVT motor, MOT05-099, PL
5.25 Item 9. MOT05-099 runs.
Y N

Y N
• Check the DADH CVT motor drive belt, PL 5.25 Item 11.
• Check the DADH CVT motor tension spring. Make sure that the DADH CVT motor
drive belt tension is correct, ADJ 5.1.
• Check the CVT roll pulley, PL 5.25 Item 17.
If necessary, install a new DADH CVT roll, PL 5.25 Item 5.

A
The fault only occurs in duplex mode (fault code 05-352-00). 05A DADH Other Faults RAP
Y N
This RAP gives the additional information on common DADH problems. Perform the RAP for
Go to Final Actions.
all current fault codes before this RAP is performed.
NOTE: The exit roll idlers remain lowered for 30 seconds.
Procedure
Enter dC330 code 05-100 to check the DADH duplex solenoid, SOL05-100. Energize SOL05-
Go to the correct RAP:
100 to lower the exit roll idlers, PL 5.35 Item 6. The exit roll idlers lower.
Y N • 05B DADH Document Sensor Failure RAP.
Go to Wiring Diagram WD 5.1. Check SOL05-100. • 05C DADH Motor Failure RAP.
References: • 05D DADH Feed Clutch Failure RAP.
• GP 12 How to Check a Solenoid or Clutch. • 05E Damaged Documents RAP.
• P/J181, DADH PWB. • 05F Platen Down Failure RAP.
• 01H +24V Distribution RAP. • 05G DADH Exit RAP
• DADH duplex solenoid, PL 5.30 Item 3.
NOTE: During normal operation, the exit roll idlers remain raised (closed) in simplex mode. In
duplex mode, the exit roll idlers remain raised unless the document is longer than 280mm (11
inches). The exit roll idlers raise and lower while feeding longer documents in duplex mode.
Exit the diagnostics mode. Close the DADH top cover. Make two copies in duplex mode.
Check that the second document is held in the feed rolls until the first document is fed into the
output tray. The feed rolls held the second document.
Y N
Go to the 05D DADH Feed Clutch Failure RAP.
The fault is caused if the DADH feed motor runs too slowly in reverse, refer to the 05C DADH
Motor Failure RAP. If the fault continues, go to Final Actions.
Final Actions
Perform the steps that follow. Install new components as necessary:
• Check that the CVT roll is clean and rotates freely, refer to ADJ 5.4.
• Check the DADH CVT sensor, PL 5.20 Item 12 is installed correctly.
• Check the takeaway roll static eliminator and ground harness, PL 5.35 Item 7.
• Make sure that the DADH ground harness is connected correctly, PL 5.10 Item 11.
• Make sure the feed motor drive belt tension is correct, ADJ 5.1.
If the fault continues, make sure that documents correctly exit the previous sensor in the docu-
ment path. Refer to the 05-335-00 DADH TAR Sensor Failure RAP.

05-350-00, 05-352-00, 05A 2-68 Xerox® ColorQube® 9203 Family
05B DADH Document Sensor Failure RAP 05C DADH Motor Failure RAP
Initial Actions Procedure
• Clean the DADH document sensor, PL 5.35 Item 19 and the area around the sensor.
WARNING
• The DADH document sensor can fail to detect the last document in a document set if
static electricity is on the input tray. If necessary, clean the input tray with antistatic fluid, Ensure that the electricity to the machine is switched off while performing tasks that do
refer to ADJ 5.4. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Go to the correct procedure:
Procedure
• DADH Feed Motor Failure
• DADH CVT Motor Failure
WARNING DADH Feed Motor Failure
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause NOTE: In duplex mode, the DADH feed motor runs in the forward and reverse direction. The
duplex mode component control code is provided to reverse the drive of the feed motor.
Enter dC330 code 05-102 to check the DADH document sensor, Q05-102, PL 5.35 Item 19. NOTE: When referring to Wiring Diagram WD 5.1, the Motor on (pulses) +24V indicated on
The display changes. PJ204, will read +12V on a digital meter.
Y N
Go to Wiring Diagram WD 5.1. Check the DADH feed motor, MOT05-074, PL 5.15 Item 16.
References:
References:
• GP 10 How to Check a Motor.
• DADH document sensor, PL 5.35 Item 19.
• DADH feed motor, PL 5.15 Item 16.
If the problem continues, install new components as necessary: DADH CVT Motor Failure
• DADH document sensor, PL 5.35 Item 19. Go to WD 5.1. Check the DADH CVT motor, MOT05-099, PL 5.25 Item 9.
NOTE: When referring to Wiring Diagram WD 5.1, the Motor on (pulses) +24V indicated on
PJ203, will read +12V on a digital meter.
References:
• DADH CVT motor, PL 5.25 Item 9.

Xerox® ColorQube® 9203 Family 2-69 05B, 05C
05D DADH Feed Clutch Failure RAP 05E Damaged Documents RAP
Use this RAP when the DADH feed clutch does not operate correctly. Use this RAP if the documents get damaged by the DADH.
Also use this RAP if the feed clutch energizes at the wrong time in duplex mode, which causes: Procedure
• Mis-feeds.
• The feed rolls to reverse and eject the original documents into the DADH input tray.
Procedure WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1. If the DADH damages the underside of the documents mid-way along the lead edge,
death or injury. Moving parts can cause injury. install a new feed roll assembly, PL 5.15 Item 1.
Go to Wiring Diagram WD 5.1. Check the DADH feed clutch, CL05-062, PL 5.15 Item 9. 2. ADJ 5.2 DADH height adjustment.
3. Check the input tray for damage, PL 5.35 Item 1.
References: • Make sure that the document width guides move freely.
• GP 12 How to Check a Solenoid or Clutch. • Check that the takeaway roll assembly, PL 5.35 Item 17 and exit roll assembly, PL
• P/J183, DADH PWB and P/J202. 5.35 Item 6 for damage and contamination, refer to ADJ 5.4.
• 01H +24V Distribution RAP. • Check the restack arm for damage, PL 5.35 Item 3.
• 01L 0V Distribution RAP. 4. Open the DADH top access cover assembly, PL 5.20 Item 17.
Install new components as necessary: • Check the document path for damage.
• DADH feed clutch, PL 5.15 Item 9, or the alternative DADH feed clutch and spacer kit W/ • Check the takeaway roll idlers and CVT roll idlers, PL 5.20 Item 3 for damage. Make
TAG D-005, PL 5.15 Item 28. sure the idlers are clean and rotate freely, refer to ADJ 5.4.
• DADH PWB, PL 5.10 Item 5. 5. Raise the DADH. Lower the baffle assembly, Figure 1.
• DADH feed assembly, PL 5.15 Item 18. • Remove any pieces of paper.
• Check the duplex gate, PL 5.25 Item 12 for damage. Make sure the duplex gate
moves freely.
• Check the CVT roll, PL 5.25 Item 5 for damage. If necessary, clean the CVT roll,
ADJ 5.4.
• Check the pre-scan idlers, PL 5.25 Item 6 and post scan idlers, PL 5.30 Item 4 for
damage. Make sure the idlers are clean and rotate freely, refer to ADJ 5.4.
• Check the document path for damage.
• Check the baffle assembly, PL 5.30 Item 14 for damage.
• Check the exit roll idlers for damage, PL 5.30 Item 6. Make sure the idlers are clean
and rotate freely, ADJ 5.4.
6. Check the CVT ramp assembly, PL 62.10 Item 5 for damage.
7. Make sure that the customers documents are within the specification, refer to GP 20.

05D, 05E 2-70 Xerox® ColorQube® 9203 Family
05F Platen Down Failure RAP
Use this RAP when the platen down sensor does not respond to opening and closing the
Baffle assembly DADH.
Procedure
Go to 05-300-00 DADH Open RAP.
Duplex gate
CVT roll
Post scan idlers
Pre-scan idlers

Xerox® ColorQube® 9203 Family 2-71 05E, 05F
05G DADH Exit RAP
Use this RAP if the original documents are not stacking correctly when exiting the DADH or
duplex copies are jamming when they are fed back into the DADH.
Procedure
Perform the following:
1. Use a cleaning cloth dampened with water to clean the takeaway roll assembly, PL 5.35
Item 17. If necessary, install a new takeaway roll assembly.
2. Make sure that the takeaway roll assembly, PL 5.35 Item 17 is correctly grounded. Refer
to GP 7 System Grounding Verification.

05G 2-72 Xerox® ColorQube® 9203 Family
10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00, • If the displayed fault code is 10-112-00, check the drum stripper blade assembly, PL
10.12 Item 3 for damage or contamination. Refer to REP 10.21 Stripper Blade, Gate and
10-148-00 Post Transfix Jam RAP Baffle. Install new components as required.
10-110-00 Timing sensor 11 detects that the sheet is too long. • If the displayed fault code is 10-112-00, check that the white gear of the stripper solenoid
10-111-00 Timing sensor 11 detects that the sheet is too short. assembly has not come adrift, PL 10.10 Item 3.
• Check for multifeeds. If there are multifeeds, go to the OF 8 Multifeed RAP.
10-112-00 The lead edge is late to timing sensor 11.
• If glossy media is used, instruct the customer to feed the media from the bypass tray and
10-113-00 The trail edge is late from timing sensor 11. select glossy for the media type.
10-125-00 Timing sensor 12 detects that the sheet is too long.
Procedure
10-126-00 Timing sensor 12 detects that the sheet is too short.
Refer to Figure 1. Lower the drum stripper gate and baffle assembly, GP 31. Check that the
10-127-00 The lead edge was late to timing sensor 12. stripper blade shaft is not broken and installed correctly. Slide the shaft forwards and back-
10-128-00 The trail edge was late from timing sensor 12. wards and feel for the shaft to engage on the detent. Raise the stripper blade into the operating
position. Check that the stripper blade shaft lock is engaging correctly at the front and rear.
10-147-00 The lead edge is early to timing sensor 11. The stripper blade latch mechanism is good.
10-148-00 The lead edge is early to timing sensor 12. Y N
Install new stripper components as necessary, PL 10.10, PL 10.12.
Initial Actions
Check the drum stripper blade timing. Print three copies of TP 14 Drum Stripper Blade Test
Page. Stripper blade timing is good.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Check the stripper solenoid SOL10-021 PL 10.10 Item 3. Refer to 10-570-00 Stripper
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Solenoid Over Current RAP.
Cheat the front door interlock. Enter dC330 code 10-018 to run the post transfix motor (M4), PL
10.10 Item 5. The motor runs.
WARNING Y N
Go to WD 8.2. Check the post transfix motor (M4). Refer to:
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If
• PJ303, Media path driver PWB.
• 01J +50V Distribution RAP.
WARNING • 01L 0V Distribution RAP.
Take care during this procedure. Sharp edges may be present that can cause injury. Install new components as necessary:
• Check that the media loaded into the trays matches the UI display. • Post transfix motor (M4), PL 10.10 Item 5.
• Check for obstructions in the paper path. • Media path driver PWB, PL 1.15 Item 5.
• Check for a build up of paper fragments and paper dust accumulation on the underside of
the RALPH assembly. Observe roller drive J, PL 10.10 Item 1 and roller drive L, PL 10.10 Item 2.
• Check the jam clearance guide 3b is latched correctly, PL 10.12 Item 1. NOTE: If the displayed fault code is 10-128-00 on a high print count machine. Clean the roller
• Ensure that the springs for both the front and rear latch forks, PL 10.10 Item 14, are not drive J and roller drive L. If the 10-128-00 jam rate decreases after cleaning replace both the J
broken or fallen off. & L drive rollers.
• Ensure that the springs are orientated the correct way. The longer end hook of the spring
The rollers rotate.
should be hooked from under the stripper cam, PL 10.10 Item 18.
Y N
• If the displayed fault code is 10-112-00, check the transfix stripper blade, PL 10.20 Item Check the gear drive, drive gears and roller drives, PL 10.10.
14 for damage. Refer to REP 10.6 Transfix Blade. Install new components as required. If necessary, install new components:
• Go to dC135 CRU/HFSI Status. Check the count of the transfix stripper. If the count is • Drive gears, PL 10.10 Item 13.
near end of life, install a new transfix stripper blade, PL 10.20 Item 14.
• Gear drive, PL 10.10 Item 4.
• Roller drive J, PL 10.10 Item 1.
A

Xerox® ColorQube® 9203 Family 2-73 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-
A B
• Roller drive L, PL 10.10 Item 2. Install new components as necessary:
• Nip D release solenoid, PL 70.30 Item 13.
Unlatch the stripper gate, GP 31. Enter dC330 code 10-015, post transfix sensor (11), Q10-
015, PL 10.10 Item 6. Manually actuate Q10-015. The display changes.
Y N
Re-enter the dC330 codes 82-007 and 82-008. Check that nip C and nip D open fully and close
Go to WD 9.3. Check the post transfix sensor (11), Q10-015. Refer to:
fully when the solenoids energize and de-energize. The nips operate correctly.
• GP 11 How to Check a Sensor. Y N
• PJ802, Drum driver PWB. Check for obstructions. Install new components as necessary:
• 01D +5V Distribution RAP. • Horizontal paper path components, PL 82.15.
• 01L 0V Distribution RAP. • Left hand upper door components, PL 70.30.
Run dC625 Registration / Preheat Calibration. If the fault persists, check the following:
• Post transfix sensor (11), PL 10.10 Item 6.
• Roller drive L, PL 10.10 Item 2.
Enter dC330 code 10-016 pre exit sensor (12), Q10-016, PL 10.10 Item 6. Manually actuate • Gear drive, PL 10.10 Item 4.
Q10-016. The display changes. • Stripper gate and baffle assembly, PL 10.12 Item 1.
Y N
Go to WD 9.3. Check the pre exit sensor (12), Q10-016. Refer to:
Stripper blade lock Detent in shaft
(Front and rear)
• PJ801, Drum driver PWB.
• Pre exit sensor (12), PL 10.10 Item 6. Closed
Enter dC330 code 82-007 to energize the nip C release solenoid, SOL82-007, PL 82.15 Item
4. SOL82-007 energizes.
Y N
Go to WD 8.1. Check the nip C release solenoid, SOL82-007. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• 01L 0V Distribution RAP. Open
• Nip C release solenoid, PL 82.15 Item 4.
Enter dC330 code 82-008 to energize the nip D release solenoid, SOL82-008, PL 70.30 Item
13, SOL82-008 energizes.
Y N Stripper blade shaft
Go to WD 8.3. Check the nip D release solenoid, SOL82-008. Refer to:
Figure 1 Component Location
B
10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10- 2-74 Xerox® ColorQube® 9203 Family
A
10-140-00 to 10-146-00, 10-149-00 to 10-151-00 Exit Jam • Media Path Driver PWB, PL 1.15 Item 5.
RAP Enter dC330 code 83-006 exit duplex diverter solenoid, SOL83-006, PL 10.15 Item 14. Press
10-140-00 Timing sensor 15 detects that the sheet is too long. Start. SOL83-006 energizes.
Y N
10-141-00 Timing sensor 15 detects that the sheet is too short. Go to WD 8.1. Check SOL83-006. Refer to:
10-142-00 Timing sensor 15 detects that the sheet is too long after invert.
10-143-00 Timing sensor 15 detects that the sheet is too short after invert.
10-144-00 The lead edge is late to timing sensor 15. Install new components as necessary:
• Exit / duplex diverter solenoid, PL 10.15 Item 14.
10-145-00 The trail edge is late from timing sensor 15.
10-146-00 The lead edge is late to timing sensor 15 after invert. The diverter gate moves and retracts freely within one second.
Y N
10-149-00 The lead edge is early to timing sensor 15.
Check the operation and condition of the diverter gate. If necessary install new diverter
gate components, PL 10.15, or install a new exit paper path assembly, PL 10.15 Item 19,
10-150-00 The lead edge is early to timing sensor 15 after invert.
as necessary.
10-151-00 The trail edge is late from timing sensor 15 after invert. Enter dC330 code 10-018 Post transfix motor (M4) MOT10-018. MOT10-018 runs.
Y N
Initial Actions Go to WD 8.2. Check MOT10-018. Refer to:
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 01L 0V Distribution RAP.
death or injury. Moving parts can cause injury. Install new components as necessary:
• Check that the media loaded into the trays matches the UI display. • Post transfix motor (M4), PL 10.10 Item 5.
• Check for obstructions in the paper path. • Media path driver PWB, PL 1.15 Item 5.
• Check the jam clearance guide 3b and 4a are latched correctly
Enter dC330 code 83-001 exit motor (M5), MOT83-001. MOT83-001 runs.
• Check for multifeeds. If there are multifeeds, go to the OF 8 Multifeed Rap.
Y N
• If glossy media is used, instruct the customer to feed the media from the bypass tray and Go to WD 8.2. Check MOT83-001. Refer to:
select glossy for the media type.
Procedure
Cheat the front door interlock. Enter dC330 code 10-017 exit sensor (15), Q10-017, PL 10.15
Item 3. Raise and lower handle 4a to actuate Q10-017. The display changes.
Y N Install new components as necessary:
Go to WD 8.5. Check Q10-017. Refer to: • Exit motor (M5), PL 10.15 Item 11.
• GP 11 How to Check a Sensor. • Media path driver PWB, PL 1.15 Item 5.
The exit paper path rolls rotate.
Y N
• 01L 0V Distribution RAP. Check the drive belt, pulleys and drive gears on the exit paper path assembly, PL 10.15.
Install new components as necessary: If necessary, install new components:
• Exit sensor (15), PL 10.15 Item 3. • Roller nip N, PL 10.15 Item 1.
A B

Xerox® ColorQube® 9203 Family 2-75 10-140-00 to 10-146-00, 10-149-00 to 10-151-00
B
• Roller nip P, PL 10.15 Item 6. 10-500-00 to 10-540-00 Transfix Error RAP
• Pulley 3mm driven, PL 10.15 Item 7. 10-500-00 Insufficient force is detected by the front transfix flexure encoder.
• Belt 3mm (112T), PL 10.15 Item 8.
• Belt 3mm (92T), PL 10.15 Item 9. 10-505-00 Insufficient force is detected by the rear transfix flexure encoder.
• Pulley 3mm (21T one way), PL 10.15 Item 10. 10-511-00 The transfix assembly is out of position.
• Drive gear, PL 10.15 Item 12.
10-512-00 Transfix unloading is not detected in time.
Check the following:
10-516-00 Transfix flexure encoder reading does not change during transfix homing (for possi-
NOTE: If only short edge feed media is jamming replace roller drive J, PL 10.10 Item 1 and ble future use).
roller drive L, PL 10.10 Item 2.
10-517-00 Transfix out of position during unload (for possible future use).
• The bearings, shafts and rolls on the exit paper path assembly, PL 10.15.
• Roller nip N, PL 10.15 Item 1. 10-521-00 Transfix load front position error.
10-522-00 Transfix load rear position error.
• Roller nip P, PL 10.15 Item 6.
10-523-00 Transfix unload front position error.
10-524-00 Transfix unload rear position error.
10-525-00 Transfix motor failure.
10-530-00 Transfix gap set failure.
10-535-00 The transfix load gain/offset calibration is inconsistent with expected value.
10-536-00 Transfix calibration NVM reset error.
10-537-00 The front transfix flexure encoder did not reach home position on time.
10-538-00 The rear transfix flexure encoder did not reach home position on time.
10-540-00 The transfix task was late.
Initial Actions
WARNING
• Ensure that the ground wire is connected at the front of the transfix roller.
Procedure
Enter dC978 Transfix Calibration Values. Check the calibration values against the label on the
front of the drum frame, Figure 1. The calibration values match.
Y N
Enter the correct transfix load values in NVM. Run test prints to verify that the problem is
corrected. Perform SCP 5 Final Actions.
A
A B
NOTE: To move the transfix roller onto the drum rotate the transfix gear counterclockwise. c. Drum driver PWB, PL 1.15 Item 4.
Open the front door but do not cheat the interlock switch, then switch off the machine, GP 14. d. Transfix roller harness, PL 1.15 Item 20.
Use a screwdriver to manually rotate the transfix gear, Figure 2. This action will move the e. Drum driver to front components harness, PL 1.15 Item 4.
transfix roller. Move the transfix roller onto, then off the drum. Perform the action at the front
and rear. Enter dC330 codes 10-019 and 10-020 to run the front and rear transfix motors. When the
• Check that the transfix mechanisms operate smoothly. Watch for the transfix roller or motor runs the transfix drive arm will move up and down approximately 10 times. The motors
encoder moving up and down. Check that the effort to move the front and rear transfix run.
mechanisms is similar. Y N
Go to WD 9.1. Check the relevant motor. Refer to:
NOTE: The transfix motors will give some resistance to movement. If the transfix mecha- • GP 10 How to Check a Motor.
nisms move without any resistance, this indicates a problem. • PJ401, Drum driver PWB.
• While the transfix roller is away from the drum, spin the roller. Check that the roller spins • 01J +50V Distribution RAP.
freely without binding or generating unusual noise. • 01L 0V Distribution RAP.
• Check there are no cracks in the transfix bearing carrier and the front transfix linkage Install new components as necessary:
assembly in the area were the transfix bearing is located, PL 10.20 Item 8 and PL 10.20 • Transfix motor, PL 10.20 Item 11.
Item 3.
• Check that the gear train and the transfix bearings are good. Check for excessive move-
ment between the linkage arm and the pin. This is caused by missing or worn bushing Enter dC962 Transfix Load Test and run the test. The transfix load test passed.
inside the front or rear transfix linkage assembly. Install new components as necessary, Y N
PL 10.20 Item 8 and PL 10.20 Item 10. If errors are indicated, check out the fault description displayed.
The transfix components are good.
Y N If the fault still occurs, perform the following:
Install new transfix components as necessary, PL 10.20. 1. For fault codes 10-500 or 10-505, make sure that the relevant transfix encoder screws are
tight and the relevant transfix encoder is secured to the frame.
Switch on the machine, GP 14. Check dC123 PEST Fault History if a fault is displayed. Enter
2. Recheck the fault code description, use it to aid in identifying which link assembly is at
dC140 Analog Monitor. Use a screwdriver to manually rotate the front and rear transfix gears. fault. Inspect for worn or damaged gears and check for a cracked linkage. Install new
Monitor all encoders:
components as necessary:
• 10-010 Rear transfix flexure encoder.
• Front compound gear, PL 10.20 Item 7.
• 10-011 Rear transfix motor encoder.
• Front transfix linkage assembly, PL 10.20 Item 8.
• 10-012 Front transfix flexure encoder.
• Rear compound gear, PL 10.20 Item 9.
• 10-013 Front transfix motor encoder.
• Rear transfix linkage assembly, PL 10.20 Item 10.
NOTE: It is important that all the above listed transfix encoders are monitored. A front 3. Check the transfix roll ground wire, refer GP 7 System Grounding Verification. Refer to
transfix encoder may over compensate for a faulty rear transfix encoder. This can cause dC122 Fault History and check for ESD failures, 92-527-00, 92-528-00.
the machine to display a front transfix encoder error.
The display changes between 0 and 65535 for all 4 transfix encoders.
Y N
1. For transfix flexture encoders, ensure that the two fasteners that secure the encoder
are tight and firmly capture the encoder.
2. Refer to WD 9.1 and WD 9.3. Check and the wiring between the drum driver PWB Calibration label for front and
and the encoder. Repair the wiring as necessary, REP 1.1. Refer to: rear transfix values
• PJ 401, PJ 501, PJ 801, Drum Driver PWB.
• 01D +5V Distribution RAP
• 01L 0V Distribution RAP
Install new components as necessary: Figure 1 Calibration label
a. Transfix flexure encoder, PL 10.20 Item 5.
b. Transfix motor, PL 10.20 Item 11.
B

Xerox® ColorQube® 9203 Family 2-77 10-500-00 to 10-540-00
10-545-00 Drum Position Error for Transfix RAP
10-545-00 The drum was not at the correct position to start the transfix operation.
Rear transfix motor and
encoder
Initial Actions
Rear transfix flexure WARNING

encoder
CAUTION
Use care when working near the drum. The drum can be damaged easily, which will cause
Front transfix motor and print quality defects.
encoder • Switch off, then switch on the machine, GP 14.
• Check for damage or debris that restricts drum or drum encoder movement.
Screwdriver slot (also at Front transfix flexure Procedure

rear) encoder Install a new IME controller PWB, PL 92.10 Item 1.
Figure 2 Transfix component locations

10-500-00 to 10-540-00, 10-545-00 2-78 Xerox® ColorQube® 9203 Family
10-550-00 Drum Stall During Transfix RAP 10-555-00 Post Transfix Motor (M4) Over Current RAP
10-550-00 The drum stalled during transfix. 10-555-00 The post transfix motor M4 is taking too much current.

Check that the print media loaded into all of the trays matches the UI display for each tray. If
necessary correct the settings or load the correct media.
WARNING
NOTE: Media that is too thick will cause drive errors, if the machine is not expecting thick Ensure that the electricity to the machine is switched off while performing tasks that do
media. For media specification refer to GP 20 not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Procedure Manually rotate roller drive J and L, Figure 1. Check that the rollers rotate freely and are free of
Perform the following: defects or debris. The rollers are good.
1. GP 7 System Ground Check. Y N
Clean the rollers, GP 27 or install new rollers PL 10.10 Item 1 and PL 10.10 Item 2.
2. dC625 Registration/Preheat Calibration.
3. Go to 94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP. Enter dC330 10-018 to run the post transfix motor (M4), (MOT10-018), PL 10.10 Item 5. The
motor runs.
Y N
Go to WD 8.2. Check the post transfix motor (M4). Refer to:
• Post transfix motor (M4), PL 10.10 Item 5
If the error persists, install new components as necessary.

• Post transfix motor M4 PL 10.10 Item 5

10-560-00, 10-565-00 Transfix Motor Over Current RAP
10-560-00 Front transfix motor over current.
Roller drive J
10-565-00 Rear transfix motor over current.
Post transfix motor Procedure

Go to the 10-500-00 to 10-540-00 Transfix Error RAP.
Roller drive L

10-570-00 Stripper Solenoid Over Current RAP
10-570-00 Stripper solenoid over current. Stripper blade lock Detent in shaft
(Front and rear)
Initial Actions
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Closed
WARNING
Take care during this procedure. The stripper blade is very sharp and can cause injury.
WARNING
Open
• Check the harness leading to the stripper solenoid, PL 10.10 Item 3.
Procedure
Refer to Figure 1. Lower the stripper gate and baffle assembly, GP 31. Check that the stripper
blade shaft is installed correctly. Slide the shaft forwards and backwards and feel for the shaft
to engage on the detent. Raise the stripper blade into the operating position. Check that the Stripper blade shaft
stripper blade shaft lock is engaging correctly at the front and rear. The stripper blade latch
mechanism is good.
Y N
Install new stripper components as necessary, PL 10.10, PL 10.12. Figure 1 Component location
Enter dC330 code 10-021 to energize the stripper solenoid, SOL10-021, PL 10.10 Item 3.
The solenoid energizes.
Y N
Go to Wiring Diagram WD 9.2. Check the stripper solenoid.
Refer to:
• GP 12, How to Check a Solenoid.
• P/J601, Drum driver PWB.
• Stripper solenoid assembly, PL 10.10 Item 3.
Check for obstructions that could prevent the stripper solenoid from engaging the stripper
blade. Install new components as necessary, PL 10.10, PL 10.12.

A B
10-571-00, 10-572-00 Stripper Latch Sensor Error RAP Go to Wiring Diagram WD 9.3. Check the stripper latch sensor, Q10-014.
Refer to:
10-571-00 Stripper latch sensor time out.
• GP 11, How to Check a Sensor
10-572-00 Stripper latch bad sensor state. • P/J801 Drum driver PWB.
Initial Actions • 01L 0V Distribution RAP.
• Stripper latch sensor, PL 10.10 Item 17.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Check all components in the stripper system for damage, PL 10.10. Pay special attention to:
• Front latchfork, PL 10.10 Item 11
• Back latchfork, PL 10.10 Item 12.
WARNING • Return spring, PL 10.10 Item 14.
Take care during this procedure. The stripper blade is very sharp and can cause injury. • Stripper latch cam, PL 10.10 Item 15.
Install new components as necessary, PL 10.10.
WARNING
• Unlatch, then fully latch the stripper blade, GP 31.
• Ensure that the front and back latch fork return springs, PL 10.10 Item 14, are not unfas-
tened or broken.
Procedure
Enter the dC330 code 10-014 to monitor the stripper latch sensor, PL 10.10 Item 17. Stack
dC330 code 10-023 to run the post transfix motor (M4), PL MOT10-018, PL 10.10 Item 5 in
reverse to latch the stripper gate. MOT10-018 runs.
Y N
Go to Wiring Diagram WD 8.2. Check MOT10-018.
Refer to:
• GP 10, How to Check a Motor.
• P/J303, Media Path Driver PWB.
• Post transfix motor (M4), PL 10.10 Item 5.
Stack the code 10-025 to run the post transfix motor (M4) to unlatch the stripper gate. The
sensor display changes.
Y N
Remove the post transfix motor (M4) and the gear drive, refer to REP 10.8. Check for
damage. The gear drive is good.
Y N
A B
12-701-00-65 Offset Catch Tray Failure RAP
12-701 The offset catch tray (OCT) fails to offset the paper stack. Sensor actuator
Initial Actions
WARNING
OCT index sensor
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Q12-212
• Check that the offset catch tray is correctly installed and there is no obstruction to prevent
movement between offset positions. If the tray is damaged, install a new OCT PL 12.00 OCT feed offset motor
Item 1. MOT12-300
Procedure
1. Go to Wiring Diagram WD 12.23, check the OCT wiring.
2. Repair the wiring or install a new OCT, PL 12.00 Item 1.
4. Check the OCT feed offset motor, Figure 1.
5. Check the gears and rack for damage, rotational failure and foreign material.
6. Check the OCT index sensor, Figure 1.
7. Check the OCT tray 90% full sensor, Figure 1.
8. Check the communication link between the OCT and the media path driver board PWB,
WD 8.5 and WD 12.23.
9. Check the sensor actuator.
If necessary, install new components:
• OCT module, PL 12.00 Item 1
Perform SCP 5 Final Actions RAP.
OCT tray 90% full sensor

Q12-211

Xerox® ColorQube® 9203 Family 2-83 12-701-00-65
12-701-00-65 2-84 Xerox® ColorQube® 9203 Family
A
12-024-00-110, 12-025-00-110 Paddle Roll Failure RAP Refer to:
12-024-00-110 The paddle is not at the home position. • 12G-110 LCSS PWB Damage RAP.
12-025-00-110 The paddle fails to rotate. • P/J310, LCSS PWB.
NOTE: The paddle is in the home position when the sensor flag is located between the sensor
jaws. If a jam occurs in the compiler, bin 1 will not be available.
NOTE: With reference to WD 12.3 component control codes; • Paddle roll motor, PL 12.25 Item 10.
Code 12-237 drives the paddle roll motor until the paddle wheel shaft assembly is at the home • LCSS PWB, PL 12.75 Item 1.
position.
Code 12-238 runs the paddle roll motor. Enter dC330 code 12-238 and stack the code 12-186, to actuate the paddle roll motor home
sensor Q12-186. The display cycles high/low.
Initial Actions Y N
Go to WD 12.4. Check Q12-186.
Refer to:
WARNING • 12G-110 LCSS PWB Damage RAP.
Ensure that the electricity to the machine is switched off while performing tasks that do • GP 11, How to Check a Sensor.
• P/J314, LCSS PWB.
WARNING Install new components as necessary:
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the • Paddle roll motor home sensor, PL 12.25 Item 11.
machine. Do not show the customer how to un-dock the LCSS. • LCSS PWB, PL 12.75 Item 1.
• That there is no paper or other obstructions in the vicinity of the paddle. Perform SCP 5 Final Actions.
• The paddle roll position sensor bracket is holding the sensor in the correct position, i.e.
the flag is in the middle of the sensor gap and the sensor does not touch any moving com-
ponents.
• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
the compiler capacity can be exceeded. Refer to 12J-110 Mis-Registration in Stapled Sets
and Non-stapled Sets RAP.
• Check the position of the paddles. With the paddle roll in the home position both sets of
paddles must be within the output cover, if they are not, refer to REP 12.12-110 Paddle
Wheel Shaft Assembly. If any of the paddles are out of alignment to other paddles, install
a new paddle wheel shaft assembly, PL 12.25 Item 4.
• LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Settings RAP.
Procedure
NOTE: All LCSS interlocks must be made to supply +24V to the motors.
NOTE: In diagnostics, actuating any LCSS sensor or switch can change the displayed state on
the UI. Make sure that the correct sensor or switch is tested.
Run the paddle roll motor MOT 12-238, PL 12.25 Item 10. Enter dC330 codes 12-237 paddle
roll motor home position and 12-238 paddle roll motor run. The paddle rotates correctly.
Y N
Go to WD 12.3. Check the paddle roll motor MOT12-238.
A

Xerox® ColorQube® 9203 Family 2-85 12-024-00-110, 12-025-00-110
A
12-043-00-110, 12-046-00-110 Hole Punch Operation Failure Install new components as necessary:
• Punch head present sensor, PL 12.20 Item 1.
RAP
• LCSS PWB, PL 12.75 Item 1.
12-043-00-110 The hole punch fails to perform a punch cycle.
Enter dC330 code 12-194 to actuate the punch head home sensor Q12-194, PL 12.20 Item 1.
12-046-00-110 The hole punch is not at the home position. The display changes.
Y N
Initial Actions Go to WD 12.2, check Q12-194.
Refer to:
• 12G-110 LCSS PWB Damage RAP.
WARNING • GP 11 How to Check a Sensor.
Ensure that the electricity to the machine is switched off while performing tasks that do • P/J307, LCSS PWB.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 12D-110 LCSS Power Distribution RAP.
death or injury. Moving parts can cause injury. • 01L 0V Distribution RAP
• Punch head home sensor, PL 12.20 Item 1.
WARNING • LCSS PWB, PL 12.75 Item 1.
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the
machine. Do not show the customer how to un-dock the LCSS. Enter dC330 code 12-244. The punch cycles.
Y N
• Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Set-
Go to WD 12.3, check the hole punch motor MOT12-243, PL 12.20 Item 2.
tings RAP.
Refer to:
• Check that the hole punch is present and correctly installed.
• Check the frame of the hole punch unit is not bent. The rear upright of the hole punch unit • GP 10, How to Check a Motor.
frame must be at 90 degrees to the base of the hole punch unit, PL 12.20 Item 3.
• Check that the punch has not jammed in the down position. This can occur with transpar- • 12D-110 LCSS Power Distribution RAP.
encies and labels.
NOTE: The home position of the punch unit is when the cut-out in the actuator is between Install new components as necessary:
the punch head home sensor jaws. • Punch head motor assembly, PL 12.20 Item 2.
NOTE: With reference to WD 12.3 component control codes; • LCSS PWB, PL 12.75 Item 1.
Code 12-243 moves the hole punch to the home position. NOTE: The chad bin collects the pieces of paper cut out by the hole punch. The chad bin level
Code 12-244 cycles the hole punch until time-out. sensor will not operate if the tray is incorrectly installed. Ensure the chad bin is fully inserted
and the lever engages in the slot.
Procedure
Enter dC330 code 12-193. Actuate the chad bin level sensor Q12-193, using a strip of paper,
Go to WD 12.2. Check the link between P/J307 pins 10 and 11, LCSS PWB. The link is good.
PL 12.20 Item 7. The display changes.
Y N
Y N
Repair the wiring or connector.
Refer to:
Enter dC330 code 12-195 to actuate the punch head present sensor Q12-195, PL 12.20 Item
1. The display changes. • 12G-110 LCSS PWB Damage RAP.
Y N • GP 11 How to Check a Sensor.
Go to WD 12.2. Check Q12-195. • P/J307, LCSS PWB.
Refer to: • 12D-110 LCSS Power Distribution RAP.
• 12G-110 LCSS PWB Damage RAP. • 01L 0V Distribution RAP
• GP 11 How to Check a Sensor. Install new components as necessary:
• P/J307, LCSS PWB. • Chad bin level sensor, PL 12.20 Item 7.
• 12D-110 LCSS Power Distribution RAP. • LCSS PWB, PL 12.75 Item 1.
A
12-043-00-110, 12-046-00-110 2-86 Xerox® ColorQube® 9203 Family
12-127-00-110 Sheet Late to Hole Punch RAP 12-151-00-110, 12-152-00-110 Sheet Late to Bin 1 RAP
12-127-00-110 Sheet late at the punch sensor. 12-151-00-110 The trailing edge of the sheet is late to the compile exit sensor, Q12-106.
Initial Actions 12-152-00-110 The leading edge of the sheet is late to the compile exit sensor, Q12-106.
Initial Actions
WARNING
WARNING
machine. Do not show the customer how to un-dock the LCSS. WARNING
Check the following: Take care not to topple the LCSS. The LCSS is unstable when un-docked from the
machine. Do not show the customer how to un-dock the LCSS.
• The LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Settings
RAP. NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized.
• Ensure the paper tray guides are set to the correct position for the size of paper in the Paper is fed to bin 1 when the diverter gate solenoid is de-energized.
tray.
• For a paper jam at the entrance to the LCSS. Check that there is no obstruction that
would prevent a sheet from arriving in position for punching, refer to the 12H-110 Copy • LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Settings RAP.
Damage in the LCSS RAP. • Ensure the paper tray guides are set to the correct position for the size of paper in all
• The punch sensor 1, Q12-078 for chad debris, PL 12.20 Item 7. trays.
• The tensioner on the intermediate paper drive belt. Check that the tensioner is free to
Procedure move and that the tensioner pulley is free to rotate. If necessary re-lubricate the tensioner
and tensioner pulley, REP 12.3-110. Refer to GP 18 Machine Lubrication.
NOTE: The tensioner arm and the tensioner pulley require different lubricants, refer to
REP 12.3-110 for details
Enter dC330 code 12-078 to actuate the punch sensor Q12-078. The display changes.
• That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the
Y N
motor shaft.
Refer to: • All the transport drive belts are correctly fitted, are in a good condition and correctly ten-
• 12G-110 LCSS PWB Damage RAP. sioned, refer to ADJ 12.4-110.
• GP 11, How to Check a Sensor. • All the transport rolls and idler pulleys are free to rotate.
• P/J307, LCSS PWB. • The diverter gate and linkage for free movement.
• 12D-110 LCSS Power Distribution RAP • A paper jam in the path to bin 1, to the compiler, and for poor stacking on bin 1.
• 01L 0V Distribution RAP • Ensure that the LCSS is fully latched to the machine, refer to REP 12.13-110.
Install new components as necessary: • Torn paper fragments from a previous jam clearance action.
• Punch sensor, PL 12.20 Item 7. • Clean punch sensor 1, PL 12.20 Item 7. To access punch sensor 1, refer to REP 12.7-
110.
NOTE: Punch sensor 1 should be cleaned even if a hole punch unit is not installed as it
Perform SCP 5 Final Actions. actively monitors paper path jams.
Refer to the 12H-110 Copy Damage in the LCSS RAP and the 12J-110 Mis-Registration in Sta-
pled Sets and Non-Stapled Sets RAP.

Xerox® ColorQube® 9203 Family 2-87 12-127-00-110, 12-151-00-110, 12-152-00-110
Procedure Y N
Go to WD 12.1. Check MOT12-223.
NOTE: All LCSS interlocks must be made to supply +24V to the motors. Refer to:
Figure 1. Enter dC330 code 12-224 to run the transport motor 2 MOT12-224. The motor runs. • 12G-110 LCSS PWB Damage RAP.
Y N • GP 10, How to Check a Motor.
Go to WD 12.3. Check MOT12-224. • P/J305, LCSS PWB.
Refer to:
• 12D-110 LCSS Power Distribution RAP.
• GP 10, How to check a motor.
• Transport motor 1, PL 12.40 Item 2.
Install new components as necessary: If the fault is still present, perform 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper
• Transport motor 2, PL 12.60 Item 5. Move Failure RAP.
• LCSS PWB, PL 12.75 Item 1. NOTE: A software problem can cause the machine to incorrectly display the fault code 12-152-
00-110.
Figure 1. Enter dC330 code 12-225 to the exit diverter solenoid S12-225. The diverter
solenoid energizes.
Y N
Go to WD 12.2. Check SOL12-225.
Refer to:
• GP 12, How to Check a Solenoid or Clutch.
• Exit diverter solenoid, PL 12.60 Item 12. Compile exit
sensor Q12-106
Figure 1. Enter dC330 code 12-106 to actuate the compile exit sensor Q12-106. The display
changes.
Y N
Refer to: Exit diverter
solenoid
• 12G-110 LCSS PWB Damage RAP. S12-225
• GP 11, How to Check a sensor.
• 12D-110 LCSS Power Distribution RAP. Transport motor 2
MOT12-224
Transport motor 1 MOT12-223
• Compiler exit sensor, PL 12.65 Item 4.
Figure 1. Enter dC330, code 12-223 to run the transport motor 1, MOT12-223. The motor Figure 1 Component location
runs.

12-171-00-110, 12-172-00-110 Paper Exiting to Bin 0 RAP NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized.
12-171-00-110 The leading edge of the sheet is late to the top exit sensor. Paper is fed to bin 1 when the diverter gate solenoid is de-energized.
Procedure
12-172-00-110 The trailing edge of the sheet is late from the top exit sensor.
Initial Actions Enter dC330 code 12-224 to run transport motor 2 MOT12-224, Figure 1. The motor runs.
Y N
WARNING Refer to:
Ensure that the electricity to the machine is switched off while performing tasks that do • 12G-110 LCSS PWB Damage RAP.
WARNING • 01L 0V Distribution RAP
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Install new components as necessary:
machine. Do not show the customer how to un-dock the LCSS. • Transport motor 2, PL 12.60 Item 5.
Check the following: • LCSS PWB, PL 12.75 Item 1.
• Ensure the paper tray guides are set to the correct position for the size of paper in the Enter dC330 code 12-225 to energize the exit diverter solenoid S12-225, Figure 1. The
tray. diverter gate solenoid energizes.
Y N
• The tensioner on the intermediate paper drive belt. Check that the tensioner is free to
move and that the tensioner pulley is free to rotate. If necessary lubricate the tensioner
Refer to:
and tensioner pulley, REP 12.3-110. Refer to GP 18 Machine Lubrication.
NOTE: The tensioner arm and the tensioner pulley require different lubricants, refer to • GP 12, How to Check a Solenoid.
REP 12.3-110.
• The drive pulleys on both transport motor 1 and 2 are secure and do not slip on the motor • 12D-110 LCSS Power Distribution RAP.
shaft. • 01L 0V Distribution RAP
• All the transport drive belts are correctly fitted, are in a good condition and correctly ten- Install new components as necessary:
sioned, refer to ADJ 12.4-110.
• Exit diverter solenoid, PL 12.60 Item 12.
• All he transport rolls and idler pulleys are free to rotate.
• The diverter gate and linkage for free movement.
• A paper jam in the path to bin 0. Enter dC330 code 12-107 to actuate the top tray exit sensor Q12-107, Figure 1. The display
• Torn paper fragments from a previous jam clearance action. changes.
• A paper jam in the path to the top tray. If the jams occur shortly after install. Check the gap Y N
between the entry guide cover, PL 12.70 Item 5 and the paper guide PL 12.60 Item 10. If Go to WD 12.4.Check Q12-107.
the gap is less than 1 mm, adjust or install a new entry guide cover. Refer to the replace- Refer to:
ment procedure in REP 12.15-110. • 12G-110 LCSS PWB Damage RAP.
Refer to the 12H-110 Copy Damage in the LCSS RAP and the 12J-110 Mis-Registration in Sta- • GP 11, How to Check a Sensor.
pled Sets and Non-Stapled Sets RAP. • P/J313, LCSS PWB.
• Top tray exit sensor, PL 12.60 Item 11.

A
Enter dC330 code 12-223 to run the transport motor 1, MOT12-223, Figure 1 The motor 12-198-00-110 Finisher Stray Sheet Detected RAP
runs.
12-198-00-110 A stray sheet was detected in the finisher, after a jam clearance.
Y N
Refer to: Initial Actions
WARNING
• 12D-110 LCSS Power Distribution RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• 01L 0V Distribution RAP death or injury. Moving parts can cause injury.
Install new components as necessary: • Check for a jam or other obstruction in the LCSS paper path.
• Transport motor 1, PL 12.40 Item 2. • Check the paper path for damage.
Procedure
Lower the paper entry guide assembly, PL 12.40 Item 8, to access the entry sensor. Enter
dC330 code 12-077, actuate the entry sensor, Q12-077, PL 12.70 Item 3. The display
changes.
Y N
Top tray exit Refer to:
sensor Q12-107
• GP 11, How to Check a Sensor.
• Entry sensor, PL 12.70 Item 3.
Enter dC330 code 12-078 to actuate the punch sensor 1, Q12-078, PL 12.20 Item 7. The
display changes.
Y N
Exit diverter
solenoid
Transport motor 2 S12-225 Refer to:
MOT12-224 • 12G-110 LCSS PWB Damage RAP.
Transport motor 1 • 12D-110 LCSS Power Distribution RAP.
MOT12-223 • 01L 0V Distribution RAP.
• Punch sensor 1, PL 12.20 Item 7.
Enter dC330 code 12-107 to actuate the top tray exit sensor, Q12-107, PL 12.60 Item 11. The
display changes.

12-171-00-110, 12-172-00-110, 12-198-00-110 2-90 Xerox® ColorQube® 9203 Family
Y N 12-199-00-110 Unexpected Sheet at Finisher Entry RAP
Go to WD 12.4.Check Q12-107.
12-199-00-110 The leading edge of the sheet detected at finisher entry, without first receiving a
Refer to:
paper at IOT exit sensor command.
• GP 11, How to Check a Sensor. Initial Actions
• 01L 0V Distribution RAP. WARNING
Install new components as necessary: Ensure that the electricity to the machine is switched off while performing tasks that do
• Top tray exit sensor, PL 12.60 Item 11. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Enter dC330 code 12-106 to actuate the compiler exit sensor Q12-106, PL 12.65 Item 4. The
display changes.
WARNING
Y N Take care not to topple the LCSS. The LCSS is unstable when un-docked from the
Go to WD 12.4. Check Q12-106. machine. Do not show the customer how to un-dock the LCSS.
Refer to:
• 12G-110 LCSS PWB Damage RAP. CAUTION
• GP 11, How to Check a sensor. Do not connect the output device power cord directly to the AC wall outlet. The output device
• P/J313, LCSS PWB. cannot operate without the machine. The machine controls the distribution of electricity to the
• 12D-110 LCSS Power Distribution RAP. output device for correct power on and power off sequencing.
• 01L 0V Distribution RAP. Check the following:
Install new components as necessary: • LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Settings RAP.
• Compiler exit sensor, PL 12.65 Item 4. • Check the fault history file for related fault codes.
• LCSS PWB, PL 12.75 Item 1. • Check that the communication harness from the finisher to the IME is secure.
• Check the size of paper in the paper trays is correct.
Procedure
1. Switch off the machine, the switch on the machine, GP 14.
2. Check the communication harness. Repair the wiring as necessary, REP 1.1.
3. Un-dock the LCSS, REP 12.13-110, Check the paper path for obstructions and damage.
Cheat the docking interlock switch.
4. Check the entry sensor GP 11. Enter dC330 code 12-077 to actuate the entry sensor
Q12-077, PL 12.70 Item 3.
5. Go to WD 12.1. Check the wiring and PJ connections between the entry sensor and
PJ304 on the LCSS PWB.
If necessary install new components:

12-310-00-110, 12-312-00-110, 12-313-00-110 Interlocks • Go to WD 12.1. Check the wiring between P/J 302 and the docking interlock switch.
• If necessary, install a new docking interlock switch, PL 12.15 Item 2.
RAP
12-310-00-110 The docking interlock is open during run mode.
12-312-00-110 Top Cover Interlock RAP
Check the top cover interlock switch S12-197, PL 12.75 Item 6, as follows:
12-312-00-110 The top cover interlock is open during run mode. • Check the switch actuator.
• Enter dC330 code 12-197 to actuate the top cover interlock switch. If the display does not
12-313-00-110 The front door interlock is open during run mode.
change, refer to:
Initial Actions – GP 13, How to Check a switch
– P/J315, LCSS PWB.
• Go to WD 12.4. Check the wiring between P/J315 and the top cover interlock switch.
WARNING • If necessary install a new top cover interlock switch, PL 12.75 Item 6.
12-313-00-110 Front Door Interlock RAP
death or injury. Moving parts can cause injury. Check the front door interlock switch S12-303, PL 12.75 Item 5, as follows:
• Check the switch actuator.
• Enter dC330 code 12-303 to actuate the front door interlock switch. If the display does not
WARNING change, refer to:
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the – GP 13, How to Check a switch
machine. Do not show the customer how to un-dock the LCSS. – P/J302, LCSS PWB.
• Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Set- • Go to WD 12.1. Check the wiring between P/J302 and the front door interlock switch.
tings RAP. • If necessary install a new front door interlock switch, PL 12.75 Item 5.
• Check the following: Perform SCP 5 Final Actions.
– The LCSS is docked to the machine.
– The LCSS front door is closed.
– The LCSS top cover is closed.
Procedure
Go to WD 12.1. Check for +24V on P/J 302 pin 1. If the voltage is not present, refer to 12D-110
LCSS Power Distribution RAP and 01L 0V Distribution RAP.
Go to the appropriate RAP:

• 12-310-00-110 Docking Interlock RAP
• 12-312-00-110 Top Cover Interlock RAP
• 12-313-00-110 Front Door Interlock RAP
12-310-00-110 Docking Interlock RAP
Un-dock the LCSS REP 12.13-110. Check the docking interlock S12-177, PL 12.15 Item 2, as
follows:
• Check the interlock actuator on the machine is not damaged or missing.
NOTE: The wiring harness passes underneath the docking interlock switch housing. If
this harness is not correctly positioned, the switch can be mis-located, giving intermittent
docking interlock problems.
• Enter dC330 code 12-177 to actuate the docking interlock. If the display does not change,
refer to:
– GP 13, How to Check a Switch
– P/J302, LCSS PWB.

A
12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector Install new components as necessary:
• Ejector out sensor, PL 12.50 Item 3.
Movement Failure RAP
12-340-00-110 The ejector is not at the home position.
Enter dC330 code 12-184 to actuate the ejector home sensor Q12-184, PL 12.50 Item 3. The
12-341-00-110 The ejector is not at the out position.
display changes.
Y N
12-342-00-110 The ejector fails to perform a cycle of operation.
Refer to:
NOTE: A cycle of operation for the ejector is to cycle from the home position to the out position
and back to the home position. • 12G-110 LCSS PWB Damage RAP.
Initial Actions • P/J304, LCSS PWB.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Ejector home sensor, PL 12.50 Item 3.
death or injury. Moving parts can cause injury. • LCSS PWB, PL 12.75 Item 1.
Enter dC330 code 12-236 to check the movement of the ejector, PL 12.50 Item 1. The ejec-
WARNING tor motor cycles.
Y N
Check that the large tie-wrap around the motor of the ejector assembly has not cut
through the motor wires and caused a short circuit to the case of the motor. If necessary
• Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Set- cut the tie-wrap, then tape and isolate the wires. The ejector motor cycles.
tings RAP. Y N
• Un-dock the LCSS, REP 12.13-110, Check for any obstructions that would prevent the Go to WD 12.1. Check the ejector motor home MOT12-234.
ejector from moving. Cheat the docking interlock switch. Refer to:
• Lubricate the LCSS ejector shafts and slide bearings. Refer to ADJ 4.1 Machine Lubrica- • 12G-110 LCSS PWB Damage RAP.
tion. • GP 10, How to Check a Motor.
Procedure • 12D-110 LCSS Power Distribution RAP.
NOTE: All LCSS interlocks must be made to supply +24V to the motors. • 01L 0V Distribution RAP
NOTE: With reference to WD 12.1 component control codes;
• Ejector assembly, PL 12.50 Item 1.
Code 12-234 moves the ejector assembly to the home position.
Code 12-235 moves the ejector assembly to the out position.
Code 12-236 cycles the ejector until time-out. The ejector cycles noisily, colliding with the end stops.
Enter dC330 code 12-185 to actuate the ejector out sensor Q12-185, PL 12.50 Item 3. The Y N
display changes. Check the stapler to ensure the staples are correctly formed. Mis-formed staples can
Y N cause the set to hang in the stapler causing ejector movement failures. The staples are
Go to WD 12.1. Check Q12-185. correctly formed.
Refer to: Y N
Clear the staple head of any mis-formed staples, then check the operation of the sta-
pler. If necessary, install a new staple head unit, PL 12.55 Item 5.
• P/J304, LCSS PWB. If the ejector is still not moving, install a new ejector assembly, PL 12.50 Item 1.
• 12D-110 LCSS Power Distribution RAP. Perform SCP 5 Final Actions.
A B

B
Go to WD 12.1. +5v is available at P/J 304 between pins 7 and 8. 12-371-00-110, 12-372-00-110, 12-378-00-110 Staple Head
Y N
Go to the 12D-110 LCSS Power Distribution RAP and 01L 0V Distribution RAP. Unit Movement Failure RAP
12-371-00-110 The staple head unit fails to move.
Connect a service meter at P/J 304 between pins 8 and 9. Slowly rotate the ejector motor
encoder. The voltage changes between +5V and 0V. 12-372-00-110 The staple head unit is not at the home position.
Y N
Go to WD 12.1. Check the wiring and connectors between the ejector motor encoder sen- 12-378-00-110 The staple head unit is not indexed correctly.
sor and the LCSS PWB. If necessary repair the wiring, REP 1.1. If the wiring is good,
install a new ejector motor encoder sensor, PL 12.50 Item 3. NOTE: The home position is when the staple head unit is at the corner stapling position (fully
to the front of the LCSS and rotated through 45 degrees).
Perform the 12G-110 LCSS PWB Damage RAP. If necessary install a new LCSS PWB, PL
12.75 Item 1. Initial Actions
WARNING
WARNING
tings RAP.
• Un-dock the LCSS from the machine, REP 12.13-110, move the ejector assembly fully to
the right, manually move the stapler unit along the full length of the track using the green
thumb-wheel. Check the home sensor flag and the two dual position flags for damage,
see NOTE. Check for damage or obstructions that would prevent the stapling unit from
moving. If necessary, install a new staple head unit, PL 12.55 Item 5 or a new stapler
traverse assembly, PL 12.55 Item 1.
NOTE: For dual position stapling, the SU1 front index sensor uses two flags.
• Dock the LCSS to the machine.
Procedure
NOTE: With reference to WD 12.3, component control codes;

Code 12-249 increments the stapling unit motor in the forward direction.
Code 12-045 increments the stapling unit motor in the reverse direction.
Code 12-250 cycles the stapling unit between home, first and second stapling positions.
Enter dC330 code 12-235 to move the ejector assembly fully to the right, PL 12.50 Item 1.
Enter code 12-250. The stapling unit cycles back and forth along the track.
Y N
Go to WD 12.3. Check the SU1 motor, MOT12-249.
Refer to:
A
12-340-00-110, 12-341-00-110, 12-342-00-110, 12-371- 2-94 Xerox® ColorQube® 9203 Family
A
• Figure 1, Component location.
• Stapler traverse assembly, PL 12.55 Item 1.
Enter dC330 code 12-135. Actuate the stapler home sensor Q12-135 by moving the stapler
unit to and from the home position, using the green thumb-wheel. The display changes.
Y N
Refer to: SU1 Motor
• 12G-110 LCSS PWB Damage RAP. MOT12-249
• GP 11. How to check a sensor.
• Figure 1.
Staple head
• 01L 0V Distribution RAP unit
Install new components as necessary: Stapler index sensor
Q12-168
• Stapler home sensor, PL 12.55 Item 3.
• LCSS PWB, PL 12.75 Item 1. Stapler home
sensor Q12-135
Enter dC330 code 12-235 to move the ejector assembly fully to the right. Enter code 12-168.
Actuate the stapler index sensor Q12-168 by moving the stapler unit to and from the flag posi-
tion (approximately 115mm (4.5 inches) from the front of the track), using the green thumb-
wheel. The display changes. Figure 1 Component location
Y N
Refer to:
• Stapler index sensor, PL 12.55 Item 3.

12-392-00-110, 12-393-00-110, 12-394-00-110 Front Tamper Procedure
Move Failure RAP NOTE: All LCSS interlocks must be made to supply +24V to the motors.
12-392-00-110 Front tamper fails to move from the home position. NOTE: With reference to WD 12.3 component control codes;
Code 12-226 moves the front tamper to the home position.
12-393-00-110 Front tamper fails to return to the home position.
Code 12-228 moves the front tamper inboard (away from home).
12-394-00-110 Front tamper does not return to the away home position. Code 12-230 moves both tampers to the A4 LEF position.
Code 12-231 moves both tampers to the 8.5 x 11 LEF position.
Initial Actions Code 12-232 Cycles the tampers in and out until time-out.
Enter dC330 codes 12-226 and 12-228 alternately. The front tamper moves between the
WARNING home and inboard positions.
Y N
Go to WD 12.3. Check the front tamper motor, MOT12-226, PL 12.45 Item 1.
Refer to:
WARNING • P/J312, LCSS PWB.
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the • 12D-110 LCSS Power Distribution RAP.
machine. Do not show the customer how to un-dock the LCSS. • 01L 0V Distribution RAP
• Check for damage or obstructions that would prevent the tamper assembly from operating Install new components as necessary:
correctly. If necessary, install a new tamper assembly, PL 12.45 Item 1. • Tamper assembly, PL 12.45 Item 1.
• Jams can be caused by removing prints from bin 1 before the machine has finished print- • LCSS PWB, PL 12.75 Item 1.
ing. If the tampers are touched while they are moving, they may stall and cause the
machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher Enter dC330 code 12-180 to actuate the front tamper home sensor, Q12-180, PL 12.45 Item
and the tray 3 and tray 4 to paper path interface. 3. The display changes.
• Jams can also be caused if the tray settings do not match the paper in the trays. Make Y N
sure the tray settings are correct. Go to WD 12.3. Check Q12-180.
• Check the condition and the tension of the front tamper drive belt. Tensioning is achieved Refer to:
by a spring on the motor, the motor should be free to move. • 12G-110 LCSS PWB Damage RAP.
• If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob- • GP 11 How to Check a Sensor.
ably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor. • P/J312, LCSS PWB.
– Check the paper for defects that could degrade the tamping operation e.g. curl,
paper condition, buckling or paper type. Refer to IQ 1 Image Quality Entry RAP.
– Check the operation of the paddle roll, refer to 12-024-00-110, 12-025-00-110 Pad-
dle Roll Failure RAP. • Tamper assembly, PL 12.45 Item 1.
– Check the operation of the bin 1 upper level sensor, refer to 12-462-00-110 Bin 1 • LCSS PWB, PL 12.75 Item 1.
Movement Failure RAP. NOTE: The front tamper home sensor is bonded onto the tamper unit and is not
– Refer to the 12J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. replaceable. Therefore, failure of this sensor will require the replacement of the
– Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch tamper assembly.
Settings RAP.
Enter dC330 code 12-182 to actuate the front tamper away sensor, Q12-182, PL 12.45 Item 3.
The display changes.
Y N
Refer to:
A
A
• GP 11, How to Check a Sensor. 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear Tamper
Move Failure RAP
12-396-00-110 Rear tamper fails to move from the home position.
Install new components as necessary: 12-397-00-110 Rear tamper fails to return to the home position.
• Front tamper away sensor, PL 12.45 Item 3.
• LCSS PWB, PL 12.75 Item 1. 12-398-00-110 Rear tamper fails to move from the away home position.
Perform SCP 5 Final Actions. Initial Actions
WARNING
WARNING
• Check for damage or obstructions that would prevent the tamper assembly from operating
correctly. If necessary, install a new tamper assembly, PL 12.45 Item 1.
• Jams can be caused by removing prints from bin 1 before the machine has finished print-
ing. If the tampers are touched while they are moving, they may stall and cause the
machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher
and the tray 3 and tray 4 to paper path interface.
• Jams can also be caused if the tray settings do not match the paper in the trays. Make
sure the tray settings are correct.
• Check the condition of the rear tamper drive belt and that it is correctly tensioned. Ten-
sioning is achieved by a spring on the motor, the motor should be free to move.
• If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob-
ably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor.
– Check the paper for defects that could degrade the tamping operation e.g. curl,
paper condition, buckling or paper type. Refer to IQ 1 Image Quality Entry RAP.
– Check the operation of the paddle roll, refer to 12-024-00-110, 12-025-00-110 Pad-
dle Roll Failure RAP.
– Check the operation of the bin 1 upper level sensor, refer to 12-462-00-110 Bin 1
Movement Failure RAP.
– Refer to the 12J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.
– Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch
Settings RAP.

Xerox® ColorQube® 9203 Family 2-97 12-392-00-110, 12-393-00-110, 12-394-00-110, 12-
A
Procedure • GP 11, How to Check a Sensor.
NOTE: With reference to WD 12.3 component control codes; • 01L 0V Distribution RAP
Code 12-227 moves the rear tamper to the home position. Install new components as necessary:
Code 12-229 moves the rear tamper inboard (away from home). • Rear tamper away sensor, PL 12.45 Item 3.
Code 12-230 moves both tampers to the A4 LEF position. • LCSS PWB, PL 12.75 Item 1.
Code 12-231 moves both tampers to the 8.5 x 11 LEF position.
Code 12-232 Cycles the tampers in and out until time-out. Perform SCP 5 Final Actions.
Enter dC330 codes 12-227 and 12-229 alternately. The rear tamper moves between the
home and inboard positions.
Y N
Go to WD 12.3. Check the rear tamper motor, MOT12-227, PL 12.45 Item 1.
Refer to:
• Tamper assembly, PL 12.45 Item 1.
Enter dC330 code 12-181 to actuate the rear tamper home sensor, Q12-181, PL 12.45 Item 3.
Y N
Refer to:
• Tamper assembly, PL 12.45 Item 1.
NOTE: The rear tamper home sensor is bonded onto the tamper unit and is not
replaceable. Therefore, failure of this sensor will require the replacement of the
tamper assembly.
Enter dC330 code 12-183 to actuate the rear tamper away sensor, Q12-183, PL 12.45 Item 3.
Y N
Refer to:
A
12-396-00-110, 12-397-00-110, 12-398-00-110, 2-98 Xerox® ColorQube® 9203 Family
12-462-00-110 Bin 1 Movement Failure RAP Procedure
12-462-00-110 Bin 1 failed to leave the bin 1 upper level sensor during stacking or failed to ini- NOTE: All LCSS interlocks must be made to supply +24V to the motors.
tialise correctly.
NOTE: The home position of bin 1 is when the bin is just lower than the stack level sensor. See the UI. Make sure that the correct sensor or switch is tested.
the final actions at the end of the procedure.
Remove the LCSS rear cover. Enter dC330 code 12-192 to actuate the bin 1 motor encoder
Two sensors and two switches monitor the level of paper in bin 1 and the position of the tray: sensor Q12-192 PL 12.30 Item 11, then slowly rotate the encoder disk by hand. The display
• The bin 1 upper level sensor, detects the top of the paper stack in bin 1, or the empty bin changes.
1, PL 12.35 Item 3. Y N
• The bin 1 90% full sensor, detects when the tray has descended to a position where the Go to WD 12.1. Check Q12-192.
tray is 90% full, PL 12.30 Item 5. Refer to:
• Bin 1 upper limit switch, prevents over travel, S12-190, PL 12.30 Item 3. • 12G-110 LCSS PWB Damage RAP.
• Bin 1 lower limit switch, prevents over travel, S12-191, PL 12.35 Item 1. • GP 11 How to Check a Sensor.
Code 12-241 elevates bin 1 to the home position.
Code 12-059 elevates bin 1 incrementally up.
Code 12-060 elevates bin 1 incrementally down.
• Bin 1 motor encoder sensor Q12-192, PL 12.30 Item 11.
Code 12-242 cycles bin 1 up and down until time-out.
Initial Actions
Enter dC330 code 12-242. Bin 1 cycles down and up.
Y N
WARNING Go to WD 12.5. Check the bin 1 elevator motor, MOT12-241, PL 12.30 Item 8.
Refer to:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 12G-110 LCSS PWB Damage RAP.
death or injury. Moving parts can cause injury. • GP 10 How to Check a Motor.
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Install new components as necessary:
• Bin 1 elevator motor, PL 12.30 Item 8.
• Check for a physical obstruction that would prevent bin 1 from moving, such as an item of
furniture. Enter dC330 code 12-188 to actuate the bin 1 upper level sensor Q12-188, PL 12.35 Item 3.
• Check that bin 1 is level front to back, if necessary perform ADJ 12.1-110 LCSS Bin 1 The display changes.
Level. Y N
• Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Set- Go to WD 12.4. Check Q12-188.
tings RAP. Refer to:
• Refer to the 12J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. • 12G-110 LCSS PWB Damage RAP.
• If there is a large jam of paper above bin 1, this has probably been caused by poorly • GP 11 How to Check a Sensor.
stacked sets failing to actuate the bin 1 upper level sensor. • P/J314, LCSS PWB.
Perform the relevant check: • 12D-110 LCSS Power Distribution RAP.
• If paper is overflowing the tray when it is at the lower limit, check the tray 90% full sensor. • REP 12.13-110 LCSS Un-docking.
• If paper cannot be fed to bin 1 when it is at the highest position, check the bin 1 upper • 01L 0V Distribution RAP
level sensor. Install new components as necessary:
Check the front and rear bin 1 drive belts. If necessary install new components, PL 12.30 Item 1. • Bin 1 upper level sensor, PL 12.35 Item 3.
A

A
• LCSS PWB, PL 12.75 Item 1. • The bin 1 elevator motor MOT12-241 lowers the tray until the bin 1 upper level sensor,
Q12-188 is de-actuated.
Enter dC330 code 12-190 to actuate the bin 1 upper limit switch S12-190, PL 12.30 Item 3. • The Bin 1 elevator motor raises the tray until the paper stack height actuates the Bin 1
The display changes. upper level sensor, then the Bin 1 elevator motor lowers the tray to continue the cycle.
Y N
• When the tray is emptied, the tray returns to the home position. The tray is elevated until
Go to WD 12.4. Check S12-190.
the bin 1 upper level sensor, Q12-188 is made. The tray is then lowered until the bin 1
Refer to: upper level sensor, Q12-188 is just cleared. In the home position the bin 1 upper limit
• 12G-110 LCSS PWB Damage RAP. switch, S12-190 is actuated.
• Bin 1 upper limit switch, PL 12.30 Item 3.
Enter dC330 code 12-191 to actuate the bin 1 lower limit switch S12-191, PL 12.35 Item 1.
Y N
Refer to:
• 12D-110 LCSS Power Generation RAP.
• REP 12.13-110 LCSS Un-docking.
• Bin 1 lower limit switch, PL 12.35 Item 1.
Enter dC330 code 12-187 to actuate the bin 1 90% full sensor Q12-187, PL 12.30 Item 5. The
display changes.
Y N
Refer to:
• 12D-110, LCSS Power Distribution RAP.
• Bin 1 90% full sensor, PL 12.30 Item 5.
As final actions, check the following sequence of operation:

• Paper is delivered to the tray until the bin 1 upper level sensor, Q12-188 is actuated.

12-492-00-110 to 12-494-00-110 IME to Finisher Failure RAP 12-762-00-110, 12-764-00-110, 12-765-00-110 IME to
12-492-00-110 CDI Communications failure with the finisher Finisher Communication Failure RAP
12-762-00-110 Communications failure between the IME and the finisher
12-493-00-110 The finisher failed to cycle up.
12-764-00-110 The IME cannot detect a finisher plugged in.
12-494-00-110 The finisher failed to return a prep time to the IME within 1 second.
12-765-00-110 The IME has detected an incompatible / unknown finisher.
Initial Actions
Initial Actions
WARNING
WARNING
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the WARNING
• Switch off the machine, then switch on the machine machine. Do not show the customer how to un-dock the LCSS.
• Check that the communication harness from the finisher is plugged in to the IME. • Fault 12-762-00 only. Check the fault history, dC122. If any other fault occurred at the
same time as the 12-762-00 fault, perform the relevant RAP.
Procedure • Check that the communication harness from the finisher is plugged in to the IME.
Refer to in line connector PJ904 and to WD 8.5. Switch the machine off, GP 14 and disconnect • Check that the actuator, PL 12.15 Item 7 is attached to the right hand machine frame and
PJ904 on the back of the image processing module. Reconnect PJ904 and switch the machine is making the docking interlock.
on, GP 14. If the fault is still present check for damaged pins on PJ904 and on the media path • Check that the LCSS has initialized correctly, refer to 12C-110 LCSS Initialization Failure
driver PWB. Install new components as required. RAP.
Procedure
Refer to in line connector PJ904 and to WD 8.5. Switch the machine off, GP 14 and disconnect
PJ904 on the back of the image processing module. Reconnect PJ904 and switch the machine
on, GP 14. If the fault is still present check for damaged pins on PJ904 and on the media path
driver PWB. Install new components as required.

Xerox® ColorQube® 9203 Family 2-101 12-492-00-110 to 12-494-00-110, 12-762-00-110, 12-
12-950-00 IME Delivers Sheet Too Early RAP 12A-110 Pause To Unload (PTU) Fault RAP
12-950-00 IME delivers sheet to finisher before the finisher preparation time has expired. Use this RAP when the pause to unload (PTU) feature fails to operate.
Initial Actions
Procedure
WARNING
1. If a single action occurs, take no action.
2. For multiple switch off the machine, then switch on the machine, GP 14.If the fault WARNING
remains, reinstall software, GP 4. Take care not to topple the LCSS. The LCSS is unstable when un-docked from the

RAP.
Procedure
Enter dC330 code 12-324 to illuminate the PTU LED PL 12.75 Item 3. The LED is illumi-
nated.
Y N
Go to WD 12.4. Disconnect PJ312. +2V is available at PJ312 between pins B10 and
B12 when the code is entered.
Y N
Perform the 12G-110 LCSS PWB Damage RAP. If necessary install a new LCSS
PWB, PL 12.75 Item 1.
Check the wiring between the LCSS PWB and the pause to unload PWB. The wiring is
good.
Y N
Repair the wiring.
Install a new pause to unload PWB, PL 12.75 Item 3.
Enter dC330 code 12-208 to actuate the PTU switch S12-208. The display changes.
Y N
Go to WD 12.4. Check the wiring between the LCSS PWB and the pause to unload PWB.
The wiring is good.
Y N
Repair the wiring.
Refer to the 12G-110 LCSS PWB Damage RAP. Install new components as necessary:
• Pause to unload PWB, PL 12.75 Item 3.

12-950-00, 12A-110 2-102 Xerox® ColorQube® 9203 Family
12B-110 Bin 1 Overload RAP 12C-110 LCSS Initialization Failure RAP
Use this RAP to resolve a fault on the bin 1 90% full sensor. When an initialization command is received from the machine, the units are initialized in two
stages:
Procedure • The following units are initialized sequentially:
1. If the staple head is not at the home position, it is driven to the home position
2. If the stapling unit is not at the home position, it is driven to the home position
WARNING
3. If the ejector is not at the home position, it is driven to the home position
• The following units are then initialized simultaneously:
death or injury. Moving parts can cause injury. 1. If the front tamper is not at the home position, it is driven to the home position
2. If the rear tamper is not at the home position, it is driven to the home position
3. If the hole punch is not at the home position, it is driven to the home position
WARNING 4. If the paddle is not at the home position, it is driven to the home position
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the 5. If the stacker is not at the home position, it is driven to the home position
NOTE: The staple cartridge must be fully pushed home.
Enter dC330 code 12-187 to actuate the bin 1 90% full sensor Q12-187, PL 12.30 Item 5. The
display changes. Initial Actions
Y N
Refer to:
WARNING
• GP 11, How to Check a sensor. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• P/J316, LCSS PWB. death or injury. Moving parts can cause injury.
• 12D-110 LCSS Power Generation RAP.
• Bin 1 90% full sensor, PL 12.30 Item 5.
WARNING
• LCSS PWB, PL 12.75 Item 1. Take care not to topple the LCSS. The LCSS is unstable when un-docked from the
CAUTION
Do not install a new LCSS PWB until the cause of the damage to the old LCSS PWB has been
determined, go to 12G-110 LCSS PWB Damage RAP.
Check the fuse on the LCSS PWB, If the fuse (F1) is good, continue at the procedure. If the
fuse not good, install a new LCSS PWB, PL 12.75 Item 1.
Check the LCSS PWB DIP switch settings, refer to 12F-110 LCSS PWB DIP Switch Settings
RAP.
Remove the LCSS covers, REP 12.1-110, so that the units can be viewed. Cheat the front door
interlock switch and the top cover interlock switch. Check that LED 2 is illuminated, this shows
that all interlocks are made. If the LED fails to illuminate, go to 12-310-00-110, 12-312-00-110,
12-313-00-110 Interlocks RAP.
Procedure
Figure 1. Check that the software heartbeat is present on LED 1. The LED should flash twice
per second if the LCSS software is running. If necessary re-load the LCSS software, refer to
GP 4 Machine Software.

Xerox® ColorQube® 9203 Family 2-103 12B-110, 12C-110
If the initialization sequence fails to place any unit at the home position, refer to the appropriate 12D-110 LCSS Power Distribution RAP
RAPs:
The LCSS has an integral power supply providing +24V and +5V supplies to the LCSS PWB.
• Front tamper not at home, refer to 12-392-00-110, 12-393-00-110, 12-394-00-110 Front
The AC power for the LCSS power supply comes from the LVPS and base module of the
Tamper Move Failure RAP
machine.
• Rear tamper not at home, refer to 12-396-00-110, 12-397-00-110, 12-398-00-110, Rear
Tamper Move Failure RAP.- Procedure
• Paddle not at home, refer to 12-024-00-110, 12-025-00-110 Paddle Roll Failure RAP.
• Bin 1 not at home, refer to 12-462-00-110 Bin 1 Movement Failures RAP.
• Punch not at home, refer to 12-043-00-110, 12-046-00-110 Hole Punch Operation Failure WARNING
RAP Ensure that the electricity to the machine is switched off while performing tasks that do
• Staple head not at home, refer to 12M-110 Staple Head Operation Failure RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Stapling unit not at home, refer to 12-371-00-110, 12-372-00-110, 12-378-00-110 Staple death or injury. Moving parts can cause injury.
Head Unit Movement Failure RAP.
• Ejector not at home, refer to 12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector
Movement Failure RAP.
WARNING
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
WARNING
CAUTION
Do not connect the finisher power cord directly to the AC wall outlet. The finisher cannot oper-
ate without the machine. The machine controls the distribution of electricity to the finisher for
correct power on and power off sequencing.
Close or cheat all the LCSS interlocks. Refer to GP 15 for the location and function of the
LED’s on the PWB’s. The LED’s on the LCSS PWB are illuminated, PL 12.75 Item 1.
Y N
+24V is available at Fuse (F1) on the LCSS PWB.
Y N
LED 1 Go to WD 12.1. +24V is available at P/J300 between pins 1 and 3, also between
pins 2 and 4.
Y N
Disconnect P/J 300. +24V is available at P/J300 between pins 1 and 3, also
between pins 2 and 4 on the end of the harness.
Fuse Y N
(F1) Loosen the 4 screws and lift the power supply module away from the
LED 2 LCSS frame, PL 12.75 Item 2. Go to WD 12.1. ACL is available at CN1
between pins 1 and 3.
Y N
Go to the 01A AC Power RAP and check the AC output voltages.
Check the wiring between CN2 and P/J 300. The wiring is good.
Figure 1 LED location Y N
Repair the wiring.
Install a new power supply module, PL 12.75 Item 2.
A B C D
12C-110, 12D-110 2-104 Xerox® ColorQube® 9203 Family
A B C D A B
Check for a short circuit or an overload in the wiring or components connected • If the voltage drops below +22V, switch off the machine, GP 14. Re-check the
to the +24V on the LCSS PWB. Repair the wiring as necessary, REP 1.1. component and harness for overheating or short circuits. Install new compo-
nents as necessary.
Go to WD 12.4 +24V is available at PJ315 pin 5 on the LCSS PWB.
Y N Perform the 12G-110 LCSS PWB Damage RAP, if necessary install a new LCSS PWB,
Go to the 12-310-00-110, 12-312-00-110, 12-313-00-110 Interlocks RAP. PL 12.75 Item 2.
Go to WD 12.1. +5V is available at P/J300 between pins 5 and 7, also between pins 6 and
8.
WARNING Y N
Do not install a fuse of a different type or rating. Installing the wrong type or Disconnect P/J300. +5V is available at P/J300 between pins 5 and 7, also between
rating of fuse can cause overheating and a risk of fire. pins 6 and 8 on the end of the harness.
Perform the following: Y N
• Switch off the machine, GP 14. Loosen the 4 screws and lift the power supply module away from the LCSS frame.
Go to WD 12.1. ACL is available at CN1 between pins 1 and 3.
• Go to WD 12.1. Disconnect the +24V harness to the docking interlock switch,
Y N
S12-177.
• Go to WD 12.1. Disconnect the +24V harness to the front door interlock switch,
S12-303. Check the wiring between CN2 and P/J300. The wiring is good.
• Go to WD 12.4. Disconnect the +24V harness to the top cover interlock switch, Y N
S12-197. Repair the wiring.
• Go to WD 12.1. Disconnect the +24V harness to the transport motor 1, MOT12-
223. Install a new power supply module, PL 12.75 Item 2.
• Go to WD 12.3. Disconnect the +24V harness to the transport motor 2, MOT12-
224. Check for a short circuit or overload in the wiring or components connected to +5V on the
LCSS PWB. Repair the wiring as necessary, REP 1.1.
• Go to WD 12.3. Disconnect the +24V harness to the SU1 motor SU1 motor,
MOT12-249.
Perform the 12G-110 LCSS PWB Damage RAP. If necessary install a new LCSS PWB, PL
• Go to WD 12.3. Disconnect the +24V harness to the paddle roll motor, MOT12- 12.75 Item 1.
238.
• Go to WD 12.4. Disconnect the +24V harness to the bin 1 lower limit switch,
S12-191.
• Go to WD 12.3. Disconnect the +24V harness to the front tamper motor
MOT12-226.
• Go to WD 12.3. Disconnect the +24V harness to the rear tamper motor MOT12-
227.
• Go to WD 12.5. Disconnect the +24V harness to the bin 1 elevator motor
MOT12-241.
• Go to WD 12.5. Disconnect the +24V harness to the bin 1 lower limit switch,
S12-191.
• Go to WD 12.3 Disconnect the +24V harness to the hole punch motor, MOT12-
243.
• Go to WD 12.2 Disconnect the +24V harness to the staple head 1 motor,
MOT12-247.
• Check each harness for short circuits and overheating, GP 7.
• Install new components as necessary.
• Install a new fuse F1 on the LCSS PWB, switch on the machine, GP 14.
• Monitor the voltage at the left end of the fuse and re-connect the circuits one at
a time. Energize the re-connected components using dC330 control codes.
A B

Xerox® ColorQube® 9203 Family 2-105 12D-110
12E-110 LCSS Paper Entry RAP 12F-110 LCSS PWB DIP Switch Settings RAP
The leading edge of the sheet is late to the entry sensor Q12-077, PL 12.70 Item 3. To show the correct settings for the DIP switches on the LCSS PWB.
WARNING WARNING
WARNING WARNING
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Take care not to topple the LCSS. The LCSS is unstable when un-docked from the
machine. Do not show the customer how to un-dock the LCSS. machine. Do not show the customer how to un-dock the LCSS.
Refer to the 12H-110 Copy Damage in the LCSS RAP. Problems that can result from incorrect DIP switch settings are:
• False jam clearance instructions for the LCSS and/or the machine exit area.
• Communication errors between the LCSS and machine.
• Erratic behavior of the LCSS.
• Ensure the paper tray guides are set to the correct position for the size of paper in the
Check the DIP switch settings, Figure 1. If necessary, switch off the machine, GP 14. Correct
tray. the DIP switch setting, then switch on the machine, GP 14.
• Check the input guide for damage or wear that could cause paper to jam.
• Paper jam in the machine to LCSS paper path, ADJ 12.2-110 Machine to LCSS Align- NOTE: Some LCSS PWBs have only one dip switch. If the LCSS PWB has only one dip
ment. switch, all switches should be in the off position.
• IOT exit path and feed rolls.
• Feeding performance from a paper tray loaded with a new ream of paper.
Procedure
Lower the paper entry guide assembly, PL 12.40 Item 8, to access the entry sensor. Enter
dC330 code 12-077 to actuate the entry sensor Q12-077. The display changes.
Y N
Refer to:
Figure 1 DIP switch settings
Make sure that the paper correctly continues past the previous sensor in the paper path. Refer
to the 10-140-00 to 10-146-00, 10-149-00 to 10-151-00 Exit Jam RAP.

12E-110, 12F-110 2-106 Xerox® ColorQube® 9203 Family
12G-110 LCSS PWB Damage RAP
Use this RAP to determine the cause of damage to the LCSS PWB, so that the cause can be
repaired before a new LCSS PWB is installed.
Initial Actions
WARNING
WARNING
Check the fuse on the LCSS PWB. If the fuse is good, continue at the procedure. If the fuse not
good, install a new LCSS PWB, PL 12.75 Item 1.
Procedure
The LCSS PWB can be damaged by a component connected to it going short-circuit. If a new
LCSS PWB is installed and power applied to the machine, the new LCSS PWB will be dam-
aged in the same way. The cause of the damage must be found by following this procedure.
Remove the LCSS PWB and inspect the components shown in Figure 1 for damage. The dam-
age to the component may be in the form of a crack, a small crater or a burnt patch. Refer to
Table 1 to locate the component causing the damage to the LCSS PWB.
Figure 1 LCSS PWB components
Table 1 LCSS PWB Drive Components

LCSS PWB Driven Normal resistance Spared part and
component component measurement +/- 10% references
U9 Rear tamper PJ312 pin A1 to A3 = 29 ohms. Tamper assembly, PL 12.45
motor pin A1 to A4 = 29 ohms. pin A2 to Item 1. 12-396-00-110, 12-
A5 = 29 ohms. pin A2 to A6 = 29 397-00-110, 12-398-00-110,
ohms. RAP
U8 Staple head PJ308 pin A8 to A10 = 20 ohms. Staple head unit, PL 12.55
motor pin A9 to A11 = 20 ohms Item 5. 12M-110 RAP
U7 Front tamper PJ312 pin A7 to A9 = 29 ohms. Tamper assembly, PL 12.45
motor pin A7 to A10 = 29 ohms. pin A8 Item 1. 12-392-00-110, 12-
to A11 = 29 ohms. pin A8 to A12 393-00-110, 12-394-00-110
= 29 ohms. RAP
U13 Transport PJ305 pin 1 to 4 = 4 ohms. pin 1 Transport motor 1, PL 12.40
motor 1 to 5 = 4 ohms. pin 2 to 6 = 4 Item 2. 12-171-00-110, 12-
ohms. pin 2 to 3 = 4 ohms. 172-00-110 RAP

Xerox® ColorQube® 9203 Family 2-107 12G-110
Table 1 LCSS PWB Drive Components 12H-110 Copy Damage in the LCSS RAP
LCSS PWB Driven Normal resistance Spared part and Use this RAP to identify and correct the causes of copy damage in the LCSS.
component component measurement +/- 10% references
U15 Transport PJ309 pin 1 to 4 = 1.3 ohms. pin Transport motor 2, PL 12.60 Procedure
motor 2 1 to 5 = 1.3 ohms. pin 2 to 6 = 1.3 Item 5. 12-171-00-110, 12-
ohms. pin 2 to 7 = 1.3 ohms. 172-00-110 RAP
U4 Hole punch PJ311 pin 1 to 2 = 6 ohms Hole punch motor, PL 12.20 WARNING
motor Item 2. 12-043-00-110, 12- Ensure that the electricity to the machine is switched off while performing tasks that do
046-00-110 RAP not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
U2 Paddle motor PJ310 pin 1 to 3 = 29 ohms. pin 1 Paddle motor assembly, PL death or injury. Moving parts can cause injury.
to 4 = 29 ohms. pin 2 to 5 = 29 12.25 Item 10. 12-024-00-
ohms. pin 2 to 6 = 29 ohms. 110, 12-025-00-110 RAP
U1 SU1 motor PJ308 pin B9 to B11 = 20 ohms. Stapler traverse assembly, WARNING
(stapler index- pin B9 to B12 = 20 ohms. pin B10 PL 12.55 Item 1. 12-371-00- Take care not to topple the LCSS. The LCSS is unstable when un-docked from the
ing) to B13 = 20 ohms. pin B10 to 110, 12-372-00-110, 12-378- machine. Do not show the customer how to un-dock the LCSS.
B14 = 20 ohms. 00-110 RAP Check the following:
U12 Ejector motor PJ303 pin 1 to 2 = 8 ohms Ejector assembly, PL 12.50 • Look for torn paper in the LCSS paper path. Torn fragments can pass through the IOT and
Item 1. 12-340-00-110, 12- LCSS paper path without causing a problem until they finally wedge themselves at some
341-00-110, 12-342-00-110 point. A likely place for a piece of paper to be wedged is at the hole punch assembly,
RAP where the top and bottom guides form the narrowest part of the paper path.
Q4, B5, Diverter gate PJ306 pin 1 to pin 2 = 74 ohms Diverter gate solenoid, PL • Ensure that the shaft diverter assembly, PL 12.60 Item 13, operates correctly and has full
R93, R95 solenoid 12.60 Item 12. 12-171-00- movement.
110, 12-172-00-110 RAP
• Ensure that the hole punches park at the fully open position. If they protrude even slightly,
U14 Bin 1 elevator PJ318 pin 1 to 2 = 7.7 ohms Bin 1 elevator motor, PL a jam will occur in the narrow paper path of the hole punch.
motor 12.30 Item 8. 12-462-00-110
• Ensure that the jam clearance guide, PL 12.70 Item 6, closes and latches correctly. Check
RAP
that the magnet at the rear is located and functions correctly. Check the clip at the front is
positioned correctly, PL 12.70 Item 7.
NOTE: If difficulty is found in connecting the service meter probes to the connector headers on
• Ensure that all idler rolls in the LCSS paper path are free to rotate, particularly those on
the LCSS PWB, refer to the RAP quoted in Table 1 and make the measurement at another
the jam clearance guide, where the paper turns through 90 degrees.
point in the harness to the driven component.
• Ensure that the paper path ribs of the jam clearance guide, PL 12.70 Item 6, and the entry
If the defective driven component is found using the table checks, disconnect the connector guide cover, PL 12.70 Item 5, are free of scores and nicks. Check also for contamination
closest to the driven component, then check the driven component again to identify any short and glue from label stock.
circuit in the wiring to the driven component. Repair the wiring or install new parts as neces-
sary.
If the defective driven component can not be found using the table checks, refer to GP 7, check
each driven component to ensure that it is not seized. Motors should rotate reasonably easily.
Solenoid armatures should slide easily in the coil. Also check the drive components to ensure
that they rotate easily, if necessary install new parts.
When the a new driven component has been installed or the defective drive components have
been repaired, install a new LCSS PWB, PL 12.75 Item 1.

12G-110, 12H-110 2-108 Xerox® ColorQube® 9203 Family
12J-110 Mis-Registration in Stapled Sets and Non-Stapled 12K-110 LCSS Poor Stacking RAP
Sets RAP Use this RAP to find the cause of poor stacking in the LCSS.
Use this RAP to identify and correct the causes of mis-registration in stapled sets, resulting in
staples missing some sheets in the set, or poorly registered non-stapled sets. Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Check the following;
death or injury. Moving parts can cause injury. • Look for sets that are not dropping back fully in bin 1 and therefore not operating the bin 1
level sensor:
– Large paper sizes should not be stacked on top of small paper sizes.
WARNING – Ensure that the paper stack in each paper tray has been fanned.
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the – Turn over the paper stack in each paper tray.
– Ensure that all paper or other copy stock being used is within the size and weight
The most likely cause of mis-registration is paper condition and/or damage such as curl, wrin- specifications. Refer to GP 20 Paper and Media Size Specifications.
kle, creases, dog ears, etc.
– Try using a fresh ream of paper.
Curl, wrinkle and creases are probably caused in the IOT, go to IQ 1 Image Quality Entry RAP. – Ensure that the edge guides of all paper trays are adjusted correctly for the paper
For other copy/print damage and dog ears, go to the 12H-110 Copy Damage in the LCSS RAP. size and that the trays are fully closed.
– Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL
Check the following: 12.10 Item 13.
• Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 12.10 • Labels must not be fed to bin 1, feed all labels bin 0 only.
Item 13.
• It is recommended that transparencies are fed to bin 0 whenever possible.
• Turn over the paper stack in the tray in use.
• Check that bin 1 is level front to back. If necessary perform ADJ 12.1-110 LCSS Bin 1
• Use a new ream of paper in the tray in use.
Level.
• Paper type especially recycled paper can lead to registration problems. Try changing to a
• Check that the bin 1 upper level sensor Q12-188 is working correctly. Refer to the 12-462-
different brand or type of paper.
00-110 Bin 1 Movement Failure RAP.
• Ensure that the guides in the paper trays are correctly set and reported on the UI for the
• Check the operation of the front and rear tampers. Refer to 12-392-00-110, 12-393-00-
paper size loaded.
110, 12-394-00-110 Front Tamper Move Failure RAP and 12-396-00-110, 12-397-00-110,
• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
12-398-00-110, Rear Tamper Move Failure RAP.
the compiler capacity can be exceeded.
• Check that the output device is not near an air conditioning or ventilation output duct. Air
• Check for obstructions in the compiler.
flow across the output bins can cause poor stacking.
• Ensure that the paddle roll operates correctly and that the paddles are not damaged. The
paddles should park completely inside the top section of the compiler, with the shorter
paddle in a vertical position. If all of the paddles are out of position, check the paddle roll
position sensor, PL 12.25 Item 11, the flag, PL 12.25 Item 7 and the paddle motor assem-
bly, PL 12.25 Item 10. If only one paddle is mis-aligned with the others, it can be re-posi-
tioned by hand (they are not bonded to the shaft).
• Ensure that the tampers operate correctly, i.e. are not stalling or losing position during the
job. Inspect the tampers for damage, if necessary install new parts. PL 12.45.
• Inspect the bin 1 entry nips for roll damage. The idlers should be held against the rubber
driving rolls and they should be free to rotate within their support springs. If necessary,
install new parts, PL 12.65.
• Inspect the four spring loaded guides on the output cover, PL 12.10 Item 7. Ensure that
they are correctly located and are free to move up and down.

Xerox® ColorQube® 9203 Family 2-109 12J-110, 12K-110
A
12L-110 Stapling Prime Failure RAP NOTE: If the SH1 priming sensor does not see staples in the primed position, the staple head
cycles a number of times to prime the staple head. This occurs when the LCSS interlocks are
Use this RAP when the staples in the stapling head are not primed.
made.
Initial Actions Follow the customer instruction label inside the LCSS front door to remove the staple cartridge,
slide out the top sheet of staples from the cartridge, to expose a fresh sheet of staples on the
top of the stack. Ensure the forming plate is fully closed, Figure 2. Install the staple cartridge
WARNING and close the door. The stapler will now cycle a few times to feed and prime the new sheet of
staples. Open the door and remove the staple cartridge. Examine the sheet of staples that
have been fed to the staple forming part of the stapler, by opening the forming plate, Figure 3.
The first two staples have been partially formed.
Y N
Install a new staple cartridge, PL 26.10 Item 16 and repeat the check. If the first two sta-
ples are not partially formed install a new staple head unit, PL 12.55 Item 5. Perform SCP
WARNING 5 Final Actions
machine. Do not show the customer how to un-dock the LCSS. Install a new staple head unit, PL 12.55 Item 5. Perform SCP 5 Final Actions.
tings RAP.
• Check the following:
– The staple cartridge has staples in it and is correctly installed,
– The leading staples in the staple head have been primed, Figure 3.
– Check that the sheets of staples in the cartridge are feeding one at a time. If staple
sheets overlap, they will jam in the cartridge. If necessary, install a new staple car-
tridge, PL 26.10 Item 16.
NOTE: The term “priming” refers to 2 staples at the front of the cartridge, that have been pre-
formed automatically by the action of the stapler, refer to Figure 3.
NOTE: The SH 1 low staples sensor, SH 1 cartridge sensor, SH 1 home sensor and the SH 1
priming sensor are all integral to the staple head unit. These sensors can be checked using
component control codes but they cannot be exchanged as components.
Procedure
Figure 1. Enter dC330 code 12-196 to actuate the SH1 paper sensor Q12-196. The display
changes.
Y N
Refer to:
• GP 11, How to Check a Sensor. SH1 paper sensor
• PJ308, LCSS PWB. Q12-196
Staple head unit
• SH1 paper sensor, PL 12.55 Item 4. Figure 1 Component location
A
12L-110 2-110 Xerox® ColorQube® 9203 Family
Primed staples
Staples
Forming plate
closed
Forming plate open
Figure 2 Staple cartridge closed Figure 3 Staple cartridge open

Xerox® ColorQube® 9203 Family 2-111 12L-110
A
12M-110 Staple Head Operation Failure RAP • GP 13, How to Check a Switch.
Use this RAP when the staple head fails to cycle or the staple head is not at the home position. • P/J 308, LCSS PWB.
NOTE: The home position is with the jaws of the staple head fully open. • 01L 0V Distribution RAP.
Initial Actions
• Staple head unit, PL 12.55 Item 5.
WARNING
WARNING
CAUTION
Do not run code 12-247 without 2 sheets of paper in the stapler jaws. Running this code with-
out the paper in position can cause damage to the machine.

RAP.
• The staple head unit is correctly installed PL 12.55 Item 5.
NOTE: With reference to WD 12.2, component control codes;

Code 12-247 cycles the staple head 1 motor.
Code 12-248 reverses the staple head 1 motor to the home position.
Procedure
NOTE: After repairing the fault using this RAP, switch off the machine, then switch on the
machine, GP 14, to enable operation of the staple head.
Place two sheet of paper in the stapler jaws then enter dC330 code 12-247 to cycle the staple
head once. Enter code 12-248 to reverse the staple head to the home position. The staple
head operates as expected.
Y N
Go to WD 12.2. Check the wiring and connectors between the LCSS PWB and the staple
head The wiring is good.
Y N
Repair the wiring.
Refer to:
A
12M-110 2-112 Xerox® ColorQube® 9203 Family
12N-110 Chad Bin Present and Bin Full RAP
Use this RAP when there is a false indication of a missing or full chad bin.
Initial Actions
WARNING
• Check that the chad bin is fully inserted.
• Check that the actuator for the chad bin level sensor engages in the slot of the chad bin.
• Check that the sensor hole in the side of the chad bin is clear of obstructions.
Procedure
Enter dC330 code 12-193. Actuate the chad bin level sensor Q12-193, using a strip of paper,
PL 12.20 Item 7. The display changes.
Y N
Go to WD 12.2. Check the chad bin level sensor Q12-193.
Refer to:
• Chad bin level sensor, PL 12.20 Item 7.

Xerox® ColorQube® 9203 Family 2-113 12N-110
12N-110 2-114 Xerox® ColorQube® 9203 Family
12-024-00-171, 12-025-00-171 HVF Paddle Roller Position
RAP
12-024-00-171 The paddle roller has failed to return to the home position.
12-025-00-171 The paddle roller has failed to move from the home position. Pusher
Paddle roll
home sen-
Initial Actions sor
Q12-186
WARNING
Check for damage or any obstruction that would prevent paddle movement. If necessary,
install new components.
Procedure
Enter dC330, code 12-238, paddle roll motor run, to check the movement of the paddle, Figure
1. The paddle turns.
Y N
Paddle roll
Go to WD 12.10. Check the wiring and repair as necessary, REP 1.1. Check the paddle motor
roller motor, MOT12-238. Refer to: MOT12-238
• 12A-171 HVF Power Distribution RAP.
• Paddle unit, PL 12.115 Item 2.
• HVF PWB, PL 12.140 Item 2.
Stack the code 12-186, paddle roll home sensor, Q12-186. The display changes as the pad-
dle rotates.
Y N
Go to WD 12.9. Check the wiring and repair as necessary, REP 1.1. Check the paddle
roller home sensor, Q12-186. Refer to:
Figure 1 Components

A
12-044-00-171 to 12-047-00-171 HVF Punch Head Position • GP 10 How to Check a Motor.
RAP
12-044-00-171 The punch head has failed to return to the home position within the required time.
12-045-00-171 The punch head has failed to move from the home position within the required time. • Hole punch module, PL 12.125 Item 19.
12-046-00-171 The punch unit has failed to return to the home position within the required time. • HVF PWB, PL 12.140 Item 2.
12-047-00-171 The punch unit has failed to move from the home position within the required time. Enter dC330, code 12-114 for the punch unit home sensor and stack the code 12-245 or 12-
246 to take the punch unit motor to home, then away from home. Observe the condition of the
Initial Actions sensor on the UI. The display changes.
Y N
Go to WD 12.12. Check the wiring from the sensor to the PWB. Repair as necessary,
WARNING REP 1.1. Check the punch unit home sensor, Q12-114. Refer to:
Ensure that the electricity to the machine is switched off while performing tasks that do • GP 11 How to Check a Sensor.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 12A-171 HVF Power Distribution RAP.
Check the punch head area for any obstruction or damage that could prevent the free move- Install new components as necessary:
ment of the head or the unit. If necessary, install new components.
• Hole punch module, PL 12.125 Item 19.
Procedure
Enter dC330, code 12-244 for the punch head motor, MOT12-244, Figure 1. The control code
12-243, punch head move home, can also be used The motor runs.
Y N Punch head motor,
Go to WD 12.24. Check the wiring from the motor to the PWB. Repair as necessary, REP MOT12-244
1.1. Check the punch head motor, MOT12-244. Refer to:
Punch head home
• 12A-171 HVF Power Distribution RAP. sensor, Q12-194
• HVF PWB, PL 12.140 Item 2. Punch unit home
sensor, Q12-114
Enter dC330, code 12-194 for the punch head home sensor and stack the code 12-244 for the
punch head motor. Observe the condition of the sensor on the UI. The display changes.
Y N Punch unit motor,
Go to WD 12.12. Check the wiring from the sensor to the PWB. Repair as necessary, MOT12-245
REP 1.1. Check the punch head home sensor, Q12-194. Refer to:
Enter dC330, code 12-245 for the motor to travel in the forward direction, or enter the code 12-
246 for the motor to travel in the reverse direction. The motor runs.
Y N
Go to WD 12.24. Check the wiring from the motor to the PWB. Repair as necessary, REP
1.1. Check MOT12-245. Refer to:
A
12-044-00-171 to 12-047-00-171 2-116 Xerox® ColorQube® 9203 Family
12-056-00-171, 12-057-00-171 Inserter Bottom Plate RAP 12-061-00-171, 12-416-00-171 HVF BM Crease Blade Fault
12-056-00-171 The inserter bottom plate has failed to return to the home position. RAP
12-057-00-171 The inserter bottom plate has failed to lift. 12-061-00-171 The crease blade has failed to clear the crease blade home sensor.
Initial Actions 12-416-00-171 The crease blade has failed to return to the home position.
Initial Actions
WARNING
• Turn the crease blade knob (6d) PL 12.150 Item 4 to ensure that the crease blade mech-
anism is free to move. If necessary, clear any paper jam in the area of the blade.
death or injury. Moving parts can cause injury. • Ensure that the crease blade assembly is level front to back and is installed correctly,
refer to REP 12.36-171.
Check that the bottom plate area is clear and that there is no damage or obstructions. Install
new components as necessary. • Check the following parts for damage:
– Crease blade assembly, PL 12.170 Item 13.
Procedure – Drive gear, PL 12.170 Item 6.
Enter dC330, code 12-261 for the inserter motor MOT12-261. The motor runs. – Connecting rods, PL 12.170 Item 9.
Y N
– Crank, PL 12.170 Item 8.
Go to WD 12.14 and WD 12.22. Check the wiring from the inserter motor PL 12.315 Item
1to the HVF PWB PL 12.140 Item 2. Repair as necessary, REP 1.1. Check the inserter
motor, MOT12-261. Refer to: Procedure
• 01L 0V Distribution RAP WARNING
Install new components as necessary: Keep away from the crease blade mechanism when working in close proximity to the
booklet maker while the machine is powered on. The crease blade mechanism activates
• Inserter Motor, PL 12.315 Item 1.
quickly and with great force.
Enter dC330, code 12-085 for the inserter bottom plate sensor, then actuate the inserter bot-
tom plate sensor Q12-085. The display changes. WARNING
Go WD 12.13 and WD 12.21. Check the wiring from the inserter bottom plate sensor PL not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
12.300 Item 16 to the HVF PWB PL 12.140 Item 2. Repair as necessary, REP 1.1. Check death or injury. Moving parts can cause injury.
the inserter bottom plate sensor, Q12-085. Refer to: Enter dC330 code 12-214. Actuate the BM crease blade home sensor Q12-214, PL 12.170
• GP 11 How to Check a Sensor. Item 1, by rotating the crease blade knob PL 12.150 Item 4, so that the actuator moves into
• 12A-171 HVF Power Distribution RAP. and out of the BM crease blade home sensor. The display changes.
• 01L 0V Distribution RAP Y N
Install new components as necessary: Go to WD 12.16. Check Q12-214.
• Inserter bottom plate sensor, PL 12.300 Item 16. Refer to:
• HVF PWB, PL 12.140 Item 2. • GP 11 How to Check a Sensor.
Enter dC330, code 12-315 for the inserter pickup sensor, then actuate the inserter pick sensor • 12A-171 HVF Power Distribution RAP.
Q12-315 PL 12.310 Item 10. The display changes. • 01L 0V Distribution RAP
Y N
Go to WD 12.14, WD 12.21 and WD 12.22. Check the wiring from the inserter pickup sen-
sor PL 12.310 Item 10 to the HVF PWB. Check the inserter pickup sensor. Refer to: • BM PWB, PL 12.175 Item 10.
• GP 11 How to Check a Sensor. • BM crease blade home sensor, PL 12.170 Item 1.
Enter dC330 code 12-215. Actuate the BM crease blade motor encoder sensor Q12-215, PL
• Inserter pickup sensor, PL 12.310 Item 10.
12.170 Item 1 by slowly rotating the crease blade knob PL 12.150 Item 4. The display
• HVF PWB, PL 12.140 Item 2. changes.

Y N 12-062-00-171 HVF BM Crease Roll Motor Failure RAP
Go to WD 12.16. Check the BM crease blade motor encoder, Q12-215.
12-062-00-171 The HVF BM crease roll motor has failed to run.
Refer to:
• GP 11 How to Check a Sensor. Initial Actions
• 12A-171 HVF Power Distribution RAP. Clear any paper jam in the area of the crease rolls.
Procedure
• BM PWB, PL 12.175 Item 10.
• BM crease blade motor encoder sensor, PL 12.170 Item 1. WARNING
Keep away from the crease blade mechanism when working in close proximity to the
Enter dC330, code 12-252 to run the BM crease blade motor, MOT12-252, PL 12.170 Item 3. booklet maker while the machine is powered on. The crease blade mechanism activates
The motor runs. quickly and with great force.
Y N
Go to WD 12.18. Check MOT 12-252.
Refer to: WARNING
• GP 10 How to Check a Motor. Ensure that the electricity to the machine is switched off while performing tasks that do
• 12A-171 HVF Power Distribution RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• 01L 0V Distribution RAP death or injury. Moving parts can cause injury.
Install new components as necessary: Release the crease roll nip pressure by moving the crease roll handle (6c), PL 12.150 Item 5,
• BM crease blade motor assembly, PL 12.170 Item 3. fully counter clockwise. Remove the BM right hand cover, PL 12.185 Item 15, to access the
crease rolls. Enter dC330 code 12-216. Actuate the BM crease roll motor encoder sensor by
• BM PWB, PL 12.175 Item 10.
rotating the crease rolls slowly by hand. The display changes.
Y N
The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces-
Go to WD 12.17. Check the BM crease roll motor encoder sensor, Q12-216, PL 12.175 Item 9.
sary install new components.
Refer to:
• BM PWB, PL 12.175 Item 10.
• BM crease roll motor encoder sensor, PL 12.175 Item 9.
Enter dC330, code 12-253 to run the BM crease roll motor, MOT12-253, PL 12.175 Item 12.
The motor runs.
Y N
Go to WD 12.18. Check the BM crease roll motor, MOT12-253.
Refer to:
• BM crease roll motor, PL 12.175 Item 12.
• BM PWB, PL 12.175 Item 10.
sary install new components:
• BM crease roll motor, PL 12.175 Item 12.
• BM PWB, PL 12.175 Item 10

A
12-063-00-171, 12-411-00-171 HVF BM Staple Unit 1 Failure Install new components as necessary:
• BM staple head 1, PL 12.185 Item 7.
RAP
• BM PWB, PL 12.175 Item 10.
12-063-00-171 The HVF BM staple unit 1 has failed to leave the home position.
Enter dC330, code 12-254 to run the BM SH1 motor. The staple head cycled.
12-411-00-171 The HVF BM staple unit 1 has failed to return to the home position.
Y N
Go to WD 12.16 and WD 12.19. Check the wiring and connectors.
Initial Actions The wiring and connectors are good.
Y N
Repair the wiring or connectors, REP 1.1.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Install a new BM staple head 1, PL 12.185 Item 7.
death or injury. Moving parts can cause injury. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces-
• Check that there is no damage or obstruction that would prevent the stapling unit from sary install new components:
cycling. • BM staple head 1, PL 12.185 Item 7.
• Check that the sheets of staples in the cartridge are feeding one at a time. If staple sheets • BM PWB, PL 12.175 Item 10.
overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, PL
12.185 Item 8.
• Check for jammed staples in the stapler head.
• Ensure that the customer job does not exceed the capacity of the booklet maker. Refer to
12D-171 Booklet Quality RAP for booklet maker quality specifications.
Procedure
Enter dC330, code 12-217 to check the BM staple head (SH) carrier closed sensor, Q12-217,
PL 12.185 Item 18. Open and close the staple head carrier. The display changes.
Y N
Go to WD 12.16. Check the BM SH carrier closed sensor, Q12-217.
Refer to:
• BM Stapler head carrier closed sensor, PL 12.185 Item 18.
• BM PWB, PL 12.175 Item 10.
Remove the HVF front door, refer to REP 12.1-171 HVF Covers. Pull out the BM module.
Remove the staple head 1 cover, PL 12.185 Item 14. Enter dC330, code 12-218 to check the
BM SH1 home switch. Manually rotate the staple head to actuate the BM SH1 home switch.
Y N
Go to WD 12.16. Check the BM SH 1 home switch, S12-218.
Refer to:
• GP 13, How to Check a Switch.
A
A
12-065-00-171, 12-383-00-171 HVF BM Backstop Motor Install new components as necessary:
• BM backstop motor, PL 12.160 Item 4.
Fault RAP
• BM PWB, PL 12.175 Item 10.
12-065-00-171 The HVF BM backstop motor fails to move.
Enter dC330 code 12-259 to energize the BM stack hold solenoid, SOL12-259, PL 12.165 Item
12-383-00-171 The HVF BM backstop is not at the home position.
17. The solenoid energizes.
Y N
Initial Actions Go to WD 12.17. Check the BM stack hold solenoid, SOL12-259.
Refer to:
WARNING
• Check for a jam or other obstruction that could prevent the backstop mechanism from • BM PWB, PL 12.175 Item 10.
moving. • Back stop assembly, PL 12.165 Item 18.
• Check the following items:
– Damaged BM back stop drive belt, PL 12.160 Item 7.
– Damaged BM back stop belt, PL 12.165 Item 15.
• BM backstop guide home sensor, PL 12.160 Item 18.
– Damaged pulley, PL 12.160 Item 5.
– Damaged pulley on the BM back stop drive shaft, PL 12.165 Item 14.
– Damaged pulley on the BM back stop idler shaft, PL 12.160 Item 13. • BM PWB, PL 12.175 Item 10.
– The BM back stop drive belt is tensioned correctly. Refer to REP 12.20-171.
– The BM back stop belt is tensioned correctly. Refer to REP 12.26-171.

Code 12-255 runs the BM backstop motor to the A4 position.
Procedure
Enter dC330 code 12-204. Actuate the BM guide home sensor, Q12-204, PL 12.160 Item 18.
Y N
Refer to:
• BM guide home sensor, PL 12.160 Item 18.
• BM PWB, PL 12.175 Item 10.
Enter dC330, code 12-255 to run the BM backstop motor, MOT12-255, PL 12.160 Item 4. The
motor runs.
Y N
Go to WD 12.17. Check MOT12-255
Refer to:
A
A
12-066-00-171, 12-384-00-171, 12-419-00-171, 12-420-00- The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces-
171 HVF BM Tamper Fault RAP • BM tamper 1 home sensor, PL 12.155 Item 1.
12-066-00-171 The HVF BM tamper has failed to clear the home sensor. • BM tamper 1 motor, PL 12.155 Item 3.
• BM PWB, PL 12.175 Item 10.
12-384-00-171 The HVF BM tamper is not at the home sensor.
12-419-00-171 The HVF BM tamper home fault.
12-420-00-171 The HVF BM tamper move fault.
Initial Actions
WARNING
• Check for a jam or other obstruction that could prevent the tamper mechanism from mov-
ing.
• Check for damaged tamper components, PL 12.155.
Procedure
Enter dC330 code 12-205. Actuate the BM tamper 1 home sensor, Q12-205, PL 12.155 Item
1. The display changes.
Y N
Go to WD 12.18. Check Q12-205
Refer to:
• BM PWB, PL 12.175 Item 10.
• BM tamper 1 home sensor, PL 12.155 Item 1.
Enter dC330, code 12-256, to run the BM tamper 1 motor, MOT12-256, PL 12.155 Item 3.
The motor runs.
Y N
Refer to:
• BM PWB, PL 12.175 Item 10.
• BM tamper 1 motor, PL 12.155 Item 3.
A
A
12-083-00-171, 12-440-00-171 to 12-444-00-171 HVF Paper • HVF Control PWB PL 12.140 Item 2.
Pusher Fault RAP Enter dC330, code 12-092. Manually actuate the paper pusher upper sensor, Q12-092, PL
12-083-00-171 The paper pusher motor has stalled. 12.115 Item 16. The display changes.
Y N
12-440-00-171 The paper pusher has failed to return to the home, (upper) position. Go to WD 12.9. Check Q12-092.
Refer to:
12-441-00-171 The paper pusher has failed to move from the home, (upper) position. • GP 11 How to Check a Sensor.
12-442-00-171 The paper pusher has failed to return to the away, (lower) position.
12-443-00-171 The paper pusher has failed to move from the away, (lower) position. Install new components as necessary:
• Paper pusher upper sensor, PL 12.115 Item 16.
12-444-00-171 The stapler gate safety switch has failed. • HVF Control PWB PL 12.140 Item 2.
Initial Actions Enter dC330, code 12-094. Manually actuate the paper pusher lower sensor, Q12-094, PL
12.115 Item 16. The display changes.
Y N
WARNING Refer to:
Ensure that the electricity to the machine is switched off while performing tasks that do • GP 11 How to Check a Sensor.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 12A-171 HVF Power Distribution RAP
• Check for a jam or other obstruction that could prevent the paper pusher from moving. Install new components as necessary:
• Check for damaged paper pusher components. • Paper pusher lower sensor, PL 12.115 Item 16.
• HVF Control PWB PL 12.140 Item 2.
Procedure
Enter dC330, code 12-265 to run the paper pusher motor, MOT12-265, PL 12.115 Item 13. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces-
The motor runs. sary install new components:
Y N • Paper pusher upper / lower sensor, PL 12.115 Item 16.
Go to WD 12.10. Check MOT12-265 • Paper pusher motor assembly, PL 12.115 Item 13.
Refer to:
• Sensor assembly, PL 12.115 Item 22.
• Paper pusher motor, PL 12.115 Item 13.
Go to WD 12.11. Check the stapler gate safety switch S12-319.

Refer to:
• GP 13 How to check a switch.
• P/J304, HVF Control PWB, PL 12.140 Item 2.
The switch is good.
Y N
Install new components as necessary.
• Sensor assembly, PL 12.115 Item 22.
A
12-083-00-171, 12-440-00-171 to 12-444-00-171 2-122 Xerox® ColorQube® 9203 Family
A
12-113-00-171, 12-114-00-171, 12-190-00-171, 12-192-00-171 Enter dC330, code 12-263 to run the bypass feed motor, MOT12-263, Figure 1. The motor
runs.
HVF BM Entry RAP Y N
12-113-00-171 The paper leading edge is late arriving at the HVF booklet exit sensor. Go to WD 12.8. Check the bypass feed motor, MOT 12-263.
Refer to:
12-114-00-171 The paper trailing edge is late leaving the HVF booklet exit sensor. • GP 10 How to Check a Motor.
12-125-00-171 The entry sensor is not turned on within a specified time.
12-190-00-171 The paper leading edge is late arriving at the BM entry sensor. Install new components as necessary:
• Bypass feed motor, PL 12.120 Item 2.
12-192-00-171 The paper trailing edge is late leaving the BM entry sensor. • HVF PWB, PL 12.140 Item 2.
Initial Actions Check the drive belt on the motor. The drive belt is good.
Y N
Install a new drive belt, PL 12.120 Item 8.
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Enter dC330, code 12-089. Manually actuate the BM entry sensor, Q12-089, Figure 2. The
from the customer supply while performing tasks that do not need electricity. Electricity display changes.
can cause death or injury. Moving parts can cause injury. Y N
• Check for a jam or other obstruction in the bypass transport.
Refer to:
• Check for a jam or other obstruction in the BM paper entry guide.
Procedure
Enter dC330, code 12-087. Manually actuate the HVF booklet exit sensor, Q12-087, Figure 1.
Y N • BM entry sensor, PL 12.150 Item 16.
Go to WD 12.7. Check Q12-087. • HVF PWB, PL 12.140 Item 2.
Refer to:
• GP 11 How to Check a Sensor. Enter dC330, code 12-251 to run the BM compiler motor, MOT12-251, Figure 2. The motor
runs.
Y N
• 01L 0V Distribution RAP Go to WD 12.17. Check MOT12-251.
Install new components as necessary: Refer to:
• HVF booklet exit sensor, PL 12.135 Item 3. • GP 10 How to Check a Motor.
• HVF PWB, PL 12.140 Item 2. • 12A-171 HVF Power Distribution RAP
Enter dC330, code 12-258. Energize the BM diverter solenoid SOL12-258, Figure 1. The
solenoid energizes.
Y N • BM compiler motor, PL 12.175 Item 1.
Go to WD 12.8. Check SOL12-258. • HVF PWB, PL 12.140 Item 2.
Refer to:
• GP 12 How to Check a Solenoid or Clutch. Lower the stapler bracket assembly, Figure 2. Enter dC330 code 12-170 BM paper present
sensor, Q12-170. Actuate Q12-170. The display changes.
Y N
• 01L 0V Distribution RAP Go to WD 12.18. Check Q12-170.
• BM diverter solenoid, PL 12.120 Item 4. • GP 11 How to Check a Sensor.
• HVF PWB, PL 12.140 Item 2. • 12A-171 HVF Power Distribution RAP.
A B
B
• BM paper present sensor, PL 12.185 Item 5. BM entry sensor
Q12-089
• BM PWB, PL 12.175 Item 10.
BM compiler
Check the drive belt on the motor. The drive belt is good. motor,
Y N MOT12-251
Install a new drive belt, PL 12.175 Item 15.
• HVF booklet exit sensor, PL 12.135 Item 3.
• BM diverter solenoid, PL 12.120 Item 4.
• BM diverter gate, PL 12.125 Item 9.
• BM compiler motor, PL 12.175 Item 1.
BM diverter solenoid,
SOL12-258
BM paper present sensor,

Q12-170
HVF booklet exit sensor, Stapler bracket assembly

Q12-087
Bypass Feed motor

MOT12-263
Figure 1 Component location Figure 2 Component location

12-125-00-171, 12-126-00-171 HVF Entry Sensor RAP • Transport motor 1, PL 12.120 Item 2.
12-125-00-171 The entry sensor is not turned on within a specified time. • HVF PWB, PL 12.140 Item 2.
If the fault remains, make sure that the paper correctly continues past the previous sensor in
12-126-00-171 The paper trailing edge is late leaving the entry sensor. the paper path. Refer to the 10-140-00 to 10-146-00, 10-149-00 to 10-151-00 Exit Jam RAP.
Initial Actions
WARNING
• Check for a jam or other obstruction in the entrance guide.
• Check the entrance guide for damage.
Procedure
Enter dC330, code 12-077. Manually actuate the entry sensor, Q12-077, PL 12.135 Item 2.
Y N
Refer to:
Enter dC330, code 12-263 to run the bypass feed motor, MOT12-263, PL 12.120 Item 2. The
motor runs.
Y N
Go to WD 12.8. Check MOT 12-263
Refer to:
Check the transport motor 1 belt. The belt is good.

Y N
Install a new transport motor 1 belt, PL 12.120 Item 7.
• Entry sensor, PL 12.135 Item 2

A
12-141-00-171, 12-142-00-171 HVF Buffer Path Sensor RAP • 01L 0V Distribution RAP
12-141-00-171 The paper trailing edge is late leaving the buffer path sensor. Install new components as necessary:
• Buffer motor, PL 12.120 Item 1.
12-142-00-171 The paper leading edge is late arriving at the buffer path sensor. • HVF PWB, PL 12.140 Item 2.
Initial Actions Check the buffer feed motor belt, PL 12.120 Item 9. The drive belt is good.
Y N
Install a new buffer feed motor belt, PL 12.120 Item 9.
WARNING
death or injury. Moving parts can cause injury. • Buffer path sensor, PL 12.135 Item 2.
• Check for a jam or other obstruction in buffer path transport. • Buffer motor, PL 12.120 Item 1.
• Check the paper guide for damage. • HVF PWB, PL 12.140 Item 2.
Procedure
Enter dC330, code 12-321. Manually actuate the buffer path sensor, Q12-321, PL 12.135 Item
Y N
Refer to:
• Buffer path sensor, PL 12.135 Item 2.
Enter dC330, code 12-258. Energize the BM diverter solenoid SOL12-258, PL 12.120 Item 4.
The solenoid energizes.
Y N
Refer to:
• BM diverter solenoid, PL 12.120 Item 4.
• HVF PWB, PL 12.140 Item 2
Enter dC330, code 12-262 to run the buffer motor, MOT12-262, PL 12.120 Item 1. The motor
runs.
Y N
Refer to:
A
A
12-151-171, 12-152-171 HVF Compiler Exit Sensor RAP • 01L 0V Distribution RAP
12-151-00-171 The paper trailing edge is late leaving the compiler exit sensor. Install new components as necessary:
12-152-00-171 The paper leading edge is late arriving at the compiler exit sensor. • HVF PWB, PL 12.140 Item 2.
Initial Actions Check the transport motor 2 drive belt. The drive belt is good.
Y N
Install a new transport motor 2 drive belt, PL 12.120 Item 10.
WARNING
death or injury. Moving parts can cause injury. • Compiler exit sensor, PL 12.135 Item 2.
• Check for a jam or other obstruction in the paper guide. • Exit diverter solenoid, PL 12.120 Item 4.
• Check the paper guide for damage. • Diverter gate, PL 12.125 Item 7.
Procedure
Enter dC330, code 12-106. Manually actuate the compile exit sensor, Q12-106, Figure 1. The Exit diverter solenoid,
display changes. SOL12-225
Y N
Go to WD 12.7. Check the sensor, Q12-106. Compile exit sensor
Refer to: (Q12-106)
Enter dC330, code 12-225. Energize the exit diverter solenoid SOL12-225, Figure 1. The
solenoid energizes.
Y N
Refer to:
Transport motor 2 - Exit
Install new components as necessary: (MOT12-224)
Enter dC330, code 12-224 to run the transport motor 2, MOT 12-224, Figure 1. The motor
runs.
Y N Figure 1 Component location
Go to WD 12.8. Check the transport motor 2, MOT 12-224.
Refer to:
A
12-157-00-171, 12-158-00-171 HVF Buffer Position Sensor Y N
RAP Refer to:
12-157-00-171 The paper leading edge is late arriving at the buffer position sensor. • GP 10 How to Check a Motor.
12-158-00-171 The paper trailing edge is late leaving the buffer position sensor.
Initial Actions Install new components as necessary:
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Check the bypass feed motor drive belt, PL 12.120 Item 8. The drive belt is good.
death or injury. Moving parts can cause injury. Install a new bypass feed motor drive belt, PL 12.120 Item 8.
• Check for a jam or other obstruction in inserter transport.
• Check the paper guide for damage. sary install new components:
• Buffer position sensor, PL 12.135 Item 2.
Procedure • Transport motor 1, PL 12.120 Item 2.
Enter dC330, code 12-086. Manually actuate the buffer position sensor, Q12-086, PL 12.135 • HVF PWB, PL 12.140 Item 2.
Item 2. The display changes.
Y N
Refer to:
Enter dC330, code 12-223 transport motor 1, to check that the motor runs. The motor runs.
Y N
Go to WD 12.7. Check the wiring and repair as necessary, REP 1.1. Check MOT12-223.
Refer to:
Check the transport motor 1 drive belt, PL 12.120 Item 7. The drive belt is good.
Y N
Install a new transport motor 1 drive belt, PL 12.120 Item 7.
Enter dC330, code 12-263 to run the bypass feed motor, MOT12-263, PL 12.120 Item 2. The
motor runs.

A
12-166-00-171 HVF BM Compiler Exit Jam RAP Unlatch the entrance baffle assembly, PL 12.150 Item 22. Run again MOT12-251. The BM
entry roll rotates.
12-166-00-171 The trail edge is late leaving the BM compiler exit sensor.
Y N
Check the following components:
Initial Actions • BM compiler motor belt, PL 12.175 Item 15.
• BM entry roll pulley, PL 12.150 Item 14.
WARNING • BM entry roll, PL 12.150 Item 15.
Ensure that the electricity to the machine is switched off while performing tasks that do Install new components as necessary.
death or injury. Moving parts can cause injury. Make a 60 page booklet (15 sheets of paper). Check that the top sheet of paper has not been
torn from the booklet. The booklet is good.
• If necessary, remove any paper from the booklet maker.
Y N
• Check that there is no damage or obstruction in the booklet compiling area or the paper Check that the components in the lower crease roll gear and clutch assembly are cor-
path to the booklet compiling area. rectly installed. Refer to the replacement procedure in REP 12.52-171 BM Crease Rolls,
• Check that the stapler bracket assembly, PL 12.185 Item 10, is correctly latched. Gears and Bearings.
• Check the operation of the BM tampers, refer to the 12-066-00-171, 12-384-00-171, 12-
419-00-171, 12-420-00-171 HVF BM Tamper Failure RAP. If the tampers are operating Perform SCP 5 Final Actions.
correctly, go to ADJ 12.5-171 Booklet Tamping and check the tampers are correctly
adjusted.
Procedure
Lower the stapler bracket assembly, Figure 1. Enter dC330 code 12-170 BM paper present
sensor, Q12-170. Actuate Q12-170. The display changes.
Y N
Refer to:
• BM paper present sensor, PL 12.185 Item 5.
• BM PWB, PL 12.175 Item 10.
Go to WD 12.18. Check the connectors and harness between PJ568 and PJ556. Refer to REP
1.1. The wiring and connectors are good.
Y N
Repair the wiring, REP 1.1 or install new components as necessary.
Enter dC330 code 12-251 BM compiler motor, MOT12-251. MOT12-251 runs.

Y N
Refer to:
Install new components as necessary
• BM compiler motor, PL 12.175 Item 1.
• BM PWB, PL 12.175 Item 10.
A
12-171-00-171, 12-172-00-171 HVF Top Tray Exit Sensor
Fault RAP
12-171-00-171 The paper leading edge is late arriving at the top exit sensor.
BM entry roll
12-172-00-171 The paper trailing edge is late leaving the top exit sensor.
Initial Actions
BM compiler motor,
MOT12-251 WARNING
• Check for a jam or other obstruction in the paper guide.
• Check the paper guide for damage.
Procedure
Enter dC330, code 12-107. Manually actuate the top tray exit sensor, Q12-107, PL 12.135 Item
Y N
Refer to:
Enter dC330, code 12-225. Energize the exit diverter solenoid SOL12-225, PL 12.120 Item 4.
BM paper present sensor, The solenoid energizes.
Q12-170 Y N
Refer to:
Stapler bracket assembly • 01L 0V Distribution RAP
Enter dC330, code 12-224 to run the transport motor 2, MOT12-224, PL 12.120 Item 1. The
motor runs.
Figure 1 Component location Y N
Go to WD 12.8. Check MOT12-224
A
A
Refer to: 12-181-00-171, 12-182-00-171 HVF BM Exit Jam RAP
• GP 10 How to Check a Motor. 12-181-00-171 The lead edge is late arriving at the BM exit sensor.
• 01L 0V Distribution RAP 12-182-00-171 The trail edge is late leaving the BM exit sensor.
• Transport motor 2, PL 12.120 Item 1. Initial Actions
Check the transport motor 2 drive belts (A) & (B). The drive belts are good. WARNING
Install a new transport motor 2 drive belt (A) PL 12.120 Item 10 and/or transport motor not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
drive belt (B), PL 12.120 Item 11. death or injury. Moving parts can cause injury.
• Turn the crease blade knob (6d) to ensure that the crease blade mechanism is free to
The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces- move. If necessary, clear any paper jam in the exit area.
sary install new components: • For 12-182-00 faults. Remove and re-seat the BM staple cartridge. Check for miss-
• Top exit sensor, PL 12.135 Item 3. formed staple which may cause the sheet to snag and skew.
• Diverter exit gate, PL 12.125 Item 7. Procedure
• Transport motor 2, PL 12.120 Item 1. Enter dC330 code 12-215. Actuate the BM crease blade motor encoder sensor, Q12-215, Fig-
• HVF PWB, PL 12.140 Item 2. ure 1 by rotating the crease blade knob (6d). The display changes.
Y N
Refer to:
• BM PWB, PL 12.175 Item 10.
• BM crease blade motor encoder sensor, PL 12.170 Item 1.
Release the crease roll nip pressure by moving the crease roll handle fully counter clockwise.
Remove the BM right hand cover, PL 12.185 Item 15 to access the crease rolls. Enter dC330
code 12-216. Actuate the BM crease roll motor encoder sensor by rotating the crease rolls
slowly by hand. The display changes.
Y N
Refer to:
• BM PWB, PL 12.175 Item 10.
Enter dC330 code 12-213. Actuate the BM exit sensor, Q12-213, Figure 2. The display
changes.

A
Y N • 12A-171 HVF Power Distribution RAP.
Go to WD 12.18. Check Q12-213. • 01L 0V Distribution RAP
Refer to:
• BM crease roll gate motor, PL 12.175 Item 8.
• BM PWB, PL 12.175 Item 10.
Install new components as necessary: The BM module has a tri-folder module installed.
• BM PWB, PL 12.175 Item 10. Y N
The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If
• BM exit sensor, PL 12.185 Item 17.
necessary install a new BM PWB, PL 12.175 Item 10.
Enter dC330, code 12-253 to run the BM crease roll motor, MOT12-253. The motor runs.
Check the drive coupler, PL 12.205 Item 17 is engaged with the BM crease roll motor encoder
Y N
disc, PL 12.175 Item 13. The coupler and encoder are correctly engaged.
Refer to: Y N
Align the drive coupler, refer to REP 12.68-171 Tri-folder Drive Install Kit.
• 12A-171 HVF Power Distribution RAP. Check the drive assembly for wear, damage, contamination and misalignment, PL 12.205 Item
• 01L 0V Distribution RAP 12. The condition of the drive assembly is good.
• BM crease roll motor, PL 12.175 Item 12. Install a new drive assembly, PL 12.205 Item 12.
• BM PWB, PL 12.175 Item 10.

Check the condition of the drive belt, PL 12.205 Item 11. The drive belt is good.
Y N
Enter dC330, code 12-253 to run the BM crease roll motor, MOT12-253. The motor drives Install a new tri-folder install kit, PL 12.205 Item 14.
the gears.
Y N
Install new components as necessary: sary install a new BM PWB, PL 12.175 Item 10.
• Crease roll drive train gears, PL 12.180.
Enter dC330, code 12-252 to run the BM crease blade motor, MOT12-252. The motor runs.
Y N
Refer to:
• BM crease blade motor, PL 12.170 Item 3.
• BM PWB, PL 12.175 Item 10
NOTE: The BM crease roll gate motor has two component control codes:
12-273 cycles the crease roll gate.
12-276 opens the crease roll gate.
Enter dC330, code 12-273 to cycle the BM crease roll gate motor, MOT12-273. The motor
runs.
Y N
Refer to:
A
BM crease roll gate motor, MOT12-273
BM crease blade
motor encoder
sensor, Q12-215
BM exit sensor, Q12-213
BM crease blade motor,

MOT12-252
BM crease roll motor, MOT12-253
BM crease roll motor encoder, Q12-216

A
12-183-00-171, 12-184-00-171 HVF BM Paper Jam RAP Refer to:
12-183-00-171 The BM PWB has detected an unexpected sheet in the booklet maker paper • GP 11 How to Check a Sensor.
path. • 12A-171 HVF Power Distribution RAP.
12-184-00-171 The BM PWB has detected a stray sheet in the booklet maker paper path after Install new components as necessary:
jam clearance.
• BM PWB, PL 12.175 Item 10.
• BM entry sensor, PL 12.150 Item 16.
Initial Actions
The HVF has a tri-folder.
Y N
WARNING The fault may be intermittent, check the wiring, REP 1.1. If necessary install a new BM
Ensure that the electricity to the machine is switched off while performing tasks that do PWB, PL 12.175 Item 10.
death or injury. Moving parts can cause injury. Enter dC330 code 12-164. Manually actuate the tri-folder entry sensor, Q12-164, Figure 3.
• Check for a jam or other obstruction in the booklet maker paper path. The display changes.
• Check the paper path for damage. Y N
Go to WD 12.19 and WD 12.20. Check Q12-164. Check the wiring between PJ602 pin 10
on the tri-folder control PWB and PJ563 pin 1 on the BM PWB.
Procedure Refer to:
Enter dC330 code 12-170. Manually actuate the BM paper present sensor, Q12-170, Figure 1. • GP 11 How to Check a Sensor.
Y N
Go to WD 12.18. Check Q12-170. • 01L 0V Distribution RAP
Refer to: Install new components as necessary:
• GP 11 How to Check a Sensor. • Tri-folder entry sensor, PL 12.215 Item 11.
• 12A-171 HVF Power Distribution RAP. • Tri-folder control PWB, PL 12.205 Item 16.
• 01L 0V Distribution RAP • BM PWB, PL 12.175 Item 10.
The fault may be intermittent, check the wiring, REP 1.1. If necessary install a new BM PWB,
• BM PWB, PL 12.175 Item 10.
PL 12.175 Item 10.
• BM paper present sensor, PL 12.185 Item 5.
Enter dC330 code 12-213. Manually actuate the BM exit sensor, Figure 2. The display
changes.
Y N
Refer to:
• BM PWB, PL 12.175 Item 10.
• BM exit sensor, PL 12.185 Item 17.
Enter dC330 code 12-089. Manually actuate the BM entry sensor, Q12-089, Figure 1. The
display changes.
Y N
A
BM entry sensor,
Q12-089
BM exit sensor, Q12-213
BM paper present sensor,

Q12-170

12-185-00-171 to 12-187-00-171 Tri-Folder Exit Sensor and
Assist Sensor RAP
12-185-00-171 The lead edge is late arriving at the tri-folder exit sensor.
12-186-00-171 The trail edge is late leaving the tri-folder exit sensor.
12-187-00-171 The lead edge is late arriving at the tri-folder assist gate sensor.
Initial Actions
WARNING
• Check for a jam or other obstruction in the tri-folder.
Tri-folder entry sensor • Check the tri-folder for damage.
Q12-164
Procedure
Enter dC330 code 12-165. Manually actuate the tri-folder assist gate sensor, Q12-165, Figure
Y N
Go to WD 12.19 and WD 12.20. Check Q12-165.
Refer to:
• Tri-folder assist gate sensor, PL 12.215 Item 6.
• Tri-folder control PWB, PL 12.205 Item 16.
• BM PWB, PL 12.175 Item 10.
Enter dC330 code 12-166. Manually actuate the tri-folder exit sensor, Q12-166, Figure 2. The
display changes.
Y N
Go to WD 12.19 and WD 12.20. Check Q12-166.
Refer to:
• Tri-folder exit sensor, PL 12.215 Item 12.
• BM PWB, PL 12.175 Item 10.
A
12-183-00-171, 12-184-00-171, 12-185-00-171 to 12- 2-136 Xerox® ColorQube® 9203 Family
A B
Enter dC330 code 12-267 to energize the tri-folder diverter solenoid, SOL12-267. The sole- Install new components as necessary:
noid energizes. • BM crease roll motor, PL 12.175 Item 12.
Y N
• BM PWB, PL 12.175 Item 10.
Go to WD 12.19 and WD 12.20. Check SOL12-267.
Refer to:
Perform SCP 5 Final Actions
Install new components as necessary: Tri-folder crease roll
• Tri-folder diverter solenoid, PL 12.215 Item 16. clutch, CL12-269
• BM PWB, PL 12.175 Item 10.
Enter dC330 code 12-268 to energize the tri-folder assist gate solenoid, SOL12-268, Figure 1.
The solenoid energizes. Tri-folder assist gate
Y N sensor, Q12-165
Go to WD 12.19 and WD 12.20. Check SOL12-268.
Refer to:
• Tri-folder assist gate solenoid, PL 12.215 Item 8.
• BM PWB, PL 12.175 Item 10.
Enter dC330 code 12-269 to energize the tri-folder crease roll clutch, CL12-269, Figure 1. The
clutch energizes.
Y N Tri-folder assist gate Tri-folder diverter
Go to WD 12.19 and WD 12.20. Check CL12-269. solenoid, SOL12-268 solenoid, SOL12-267
Refer to:
• 12A-171 HVF Power Distribution RAP. Figure 1 Component location
• Tri-folder crease roll clutch, PL 12.205 Item 9.
• BM PWB, PL 12.175 Item 10.
Enter dC330, code 12-273 to run the BM crease roll motor, MOT12-253, Figure 3. The motor
runs.
Y N
Refer to:
B
Xerox® ColorQube® 9203 Family 2-137 12-185-00-171 to 12-187-00-171
Tri-folder exit
sensor, Q12-166
BM crease roll motor,

MOT12-253

A
12-191-00-171, 12-193-00-171, 12-194-00-171, 12-196-00- • 12A-171 HVF Power Distribution RAP.
171 Inserter Paper Jam RAP
12-191-00-171 The leading edge is late arriving at the inserter standby sensor.
• Inserter TE sensor, PL 12.310 Item 11.
12-193-00-171 The trailing edge is late leaving the inserter standby sensor. • Inserter PWB, PL 12.310 Item 9.
12-194-00-171 The leading edge is late arriving at the inserter pickup sensor.
Enter dC330 code 12-083. Manually actuate the inserter LE sensor, Q12-083, Figure 1. The
12-196-00-171 The trailing edge is late leaving the inserter pickup sensor. display changes.
Y N
Fault code 12-191-00 may also be generated where a fault in the inserter causes jamming in Go to WD 12.13 and WD 12.21. Check Q12-083.
the IME. Refer to:
Initial Actions • 12A-171 HVF Power Distribution RAP.
WARNING
• Inserter LE sensor, PL 12.310 Item 11.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Inserter PWB, PL 12.310 Item 9.
death or injury. Moving parts can cause injury. • HVF PWB, PL 12.140 Item 2.
• Check for a jam or other obstruction in the inserter.
Enter dC330 code 12-316. Manually actuate the inserter acceleration sensor Q12-316, Figure
• Check the inserter for damage.
• Check the condition of the inserter feed rolls. Use a cloth dampened with water to clean Y N
the rolls. If necessary, install a new inserter pickup assembly, PL 12.310 Item 1. Go to WD 12.13, WD 12.21 and WD 12.22. Check the sensor.
• Go to dC135 CRU/HFSI Status. Check the count of the inserter feed roller set. If the count Refer to:
is near end of life, install a new inserter pickup assembly, PL 12.310 Item 1. • GP 11 How to Check a Sensor.
Procedure • 01L 0V Distribution RAP
Enter dC330 code 12-315. Manually actuate the inserter pickup sensor, Q12-315, Figure 1. Install new components as necessary:
• Inserter acceleration sensor, PL 12.300 Item 10.
Y N
Go to WD 12.14, WD 12.21 and WD 12.22 Check Q12-315. • Inserter PWB, PL 12.310 Item 9.
Refer to: • HVF PWB, PL 12.140 Item 2.
Enter dC330 code 12-320. Manually actuate the inserter standby sensor Q12-320. The volt-
age changes.
• 01L 0V Distribution RAP Y N
Install new components as necessary: Go to WD 12.14. Check the sensor.
• Inserter pickup sensor, PL 12.310 Item 10. Refer to:
• Inserter PWB, PL 12.310 Item 9. • GP 11 How to Check a Sensor.
• HVF PWB, PL 12.140 Item 2. • 12A-171 HVF Power Distribution RAP.
Enter dC330 code 12-084. Manually actuate the inserter TE sensor, Q12-084, Figure 1. The Install new components as necessary:
display changes.
• Inserter standby sensor, PL 12.135 Item 2.
Y N
Go to WD 12.13 and WD 12.21. Check Q12-084. • HVF PWB, PL 12.140 Item 2.
Refer to:
Enter dC330 code 12-260 to energize the inserter clutch CL12-260. The clutch energizes.
A
Y N
Go to WD 12.14, WD 12.21 and WD 12.22. Check CL 12-260.
Inserter clutch, Inserter pickup sensor
Refer to:
CL12-260 Q12-315
• 12A-171 HVF Power Distribution RAP. Inserter TE sensor
• 01L 0V Distribution RAP Q12-084
Install new components as necessary: Inserter LE Sensor
• Inserter clutch, PL 12.310 Item 3. Q12-083
• Inserter PWB, PL 12.310 Item 9.
Enter dC330, code 12-261 to run the inserter motor, MOT12-261. The motor runs.
Y N
Go to WD 12.14 and WD 12.22. Check MOT12-261.
Refer to:
Install new components as necessary: Inserter acceleration
sensor
• Inserter motor, PL 12.315 Item 1.
Q12-316
Inserter motor,
Perform SCP 5 Final Actions MOT12-261
Inserter Standby
Sensor Q12-320

A
12-198-00-171, 12-199-00-171 HVF Paper Jam RAP • 01L 0V Distribution RAP
12-198-00-171 A stray sheet was detected in the finisher, after a jam clearance. Install new components as necessary:
• Buffer path sensor, PL 12.135 Item 2.
12-199-00-171 An unexpected sheet has been detected in the finisher. • HVF PWB, PL 12.140 Item 2.
Initial Actions Enter dC330, code 12-106. Manually actuate the compile exit sensor, Q12-106, Figure 1. The
display changes.
Y N
WARNING Go to WD 12.7. Check Q12-106.
Refer to:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • GP 11 How to Check a Sensor.
death or injury. Moving parts can cause injury. • 12A-171 HVF Power Distribution RAP
• Check for a jam or other obstruction in the HVF paper path. • 01L 0V Distribution RAP
• Check the paper path for damage. Install new components as necessary:
Procedure • HVF PWB, PL 12.140 Item 2.
Enter dC330, code 12-077. Manually actuate the entry sensor, Q12-077, Figure 1. The dis-
play changes. Enter dC330, code 12-107. Manually actuate the top tray exit sensor, Q12-107, Figure 1. The
Y N display changes.
Go to WD 12.7. Check Q12-077. Y N
Refer to: Go to WD 12.7. Check Q12-107.
Refer to:
Enter dC330, code 12-086. Manually actuate the buffer position sensor, Q12-086, Figure 1.
The display changes. HVF BM machines only, enter dC330, code 12-087. Manually actuate the HVF booklet exit
Y N sensor, Q12-087, Figure 1. The display changes.
Go to WD 12.7. Check Q12-086. Y N
Refer to: Go to WD 12.7. Check Q12-087.
Refer to:
• HVF booklet exit sensor, PL 12.135 Item 3.
• HVF Control PWB PL 12.140 Item 2.
Enter dC330, code 12-321. Manually actuate the buffer path sensor, Q12-321, Figure 1. The
display changes. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces-
Y N sary install new components.
Refer to:
A
12-273-00-171 to 12-277-00-171 Offset Unit Fault RAP
12-273-00-171 Offset unit does not find its initialization point.
Top tray exit 12-274-00-171 Offset unit does not return to home position.
sensor Q12-107
12-275-00-171 Offset unit does not move out of home position.
12-276-00-171 Offset unit does not return to away home position.
12-277-00-171 Offset unit does not move out of away home position.
NOTE: The above fault codes are not applicable to the 9201/9202/9203 series of machines.
.
Compile exit
sensor
Q12-106
Buffer path sensor

Q12-321
Entry sensor
Q12-077 HVF booklet exit sensor
Q12-087
Buffer position sensor
Q12-086

12-198-00-171, 12-199-00-171, 12-273-00-171 to 12- 2-142 Xerox® ColorQube® 9203 Family
12-288-00-171, 12-289-00-171 HVF Nip Split RAP Y N
12-288-00-171 The nip split has failed to operate.
Refer to:
12-289-00-171 The nip split has failed to return to the home position.
Initial Actions • 01L 0V Distribution RAP
• Nip split sensor, PL 12.135 Item 1.
WARNING • HVF PWB, PL 12.140 Item 2.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform SCP 5 Final Actions.
• Check for a jam or other obstruction in the nip split.
• Check the nip split for damage.
Nip split sensor,
Q12-091
Procedure
Enter dC330, code 12-264 to run the nip split motor, MOT12-264, Figure 1. The nip-split
mechanism can be heard.
Y N
Go to WD 12.8. Check the resistance across the pins of the nip split motor. The resis-
tance is approximately 22 ohms.
Y N
Install a new nip split motor, PL 12.125 Item 15.
Check MOT12-264. Refer to:

Nip home sensor, Nip split motor,
Q12-088 MOT12-264
• Nip split motor, PL 12.125 Item 15.
REAR VIEW
Enter dC330 code 12-088. Manually actuate the nip home sensor, Q12-088, Figure 1. The
display changes.
Y N
Refer to:
• 12A-171 HVF Power Distribution RAP. Figure 1 Component location
• Nip home sensor, PL 12.135 Item 1.
• HVF control PWB, PL 12.140 Item 2.
Enter dC330 code 12-091. Manually actuate the nip split sensor, Q12-091. The display
changes.

12-310-00-171, 12-312-00-171, 12-313-00-171 HVF Docking 12-303-00-171 Front Door Interlock
and Interlocks RAP Check the front door interlock switch, S12-303, Figure 1.
• Check the switch actuator on the inside of the front door is not damaged.
12-310-00-171 The finisher was detected to be undocked in the run mode.
• Enter dC330, code 12-303 actuate the switch and check the display.
12-312-00-171 The top cover interlock was detected open during a run. Refer to:
– GP 13 How to Check a Switch.
12-313-00-171 The finisher front door interlock was detected open during a run.
– WD 12.8.
• Check the wiring, REP 1.1.
Initial Actions
• If necessary, install a new front door interlock switch, PL 12.115 Item 28.
WARNING
• Ensure the HVF is correctly docked to the machine and all interlocks are closed.
• Check the interlock actuator for damage.
Procedure
Go to the relevant procedure:
• 12-177-00-171 Docking Interlock
• 12-197-00-171 Top Cover Interlock
• 12-303-00-171 Front Door Interlock
12-177-00-171 Docking Interlock
Check the docking interlock switch, S12-177, Figure 1.
• Check the switch actuator mounted on the machine is correctly installed and un-broken.
• Enter dC330, code 12-177, actuate the switch and check the display.
Refer to:
– WD 12.8.
• Check the wiring.
• If necessary, install new components:
– Docking interlock switch, PL 12.100 Item 16.
12-197-00-171 Top Cover Interlock
Check the top cover interlock switch, S12-197, Figure 1.
• Check the switch actuator is not damaged.
Refer to:
– WD 12.8.
• If necessary, install a new top cover interlock switch, PL 12.115 Item 24.

12-316-00-171, 12-319-00-171 Inserter Interlocks RAP
12-316-00-171 The inserter top cover interlock was detected open in the run mode.
12-319-00-171 The inserter left hand door was detected open in the run mode.
Initial Actions
WARNING
Check that the inserter top cover and left hand door can be fully closed and that the interlocks
are actuated. Remove any obstruction as necessary.
Top cover interlock switch
S12-197
Procedure
• 12-316-00-171 Inserter Top Cover Interlock
• 12-319-00-171 Inserter Jam Cover Interlock
12-316-00-171 Inserter Top Cover Interlock
Check the inserter top cover interlock switch, S12-178, Figure 1.
• Check the switch actuator mounted on the machine is correctly installed and un-broken.
Refer to:
– WD 12.14 and WD 12.21.
• If necessary, install new components:
– Inserter top cover interlock switch, PL 12.305 Item 8.
12-319-00-171 Inserter Jam Cover Interlock
Check the inserter jam cover interlock switch, S12-179, Figure 1.
• Check the switch actuator is not damaged.
• Enter dC330, code 12-179 actuate the switch and check the display.
Refer to:
– WD 12.14 and WD 12.21.
Front door interlock switch, • Check the wiring, REP 1.1.
Docking interlock, S12-177 S12-303 • If necessary, install a new inserter jam cover interlock switch, PL 12.300 Item 18.

12-317-00-171, 12-318-00-171 Tri-folder Interlocks RAP
12-317-00-171 The tri-folder top cover interlock was detected open during a run.
12-318-00-171 The tri-folder front door interlock was detected open during a run.
Initial Actions
WARNING
Check that the tri-folder top cover and front door can be fully closed and that the interlocks are
actuated. Remove any obstruction as necessary.
Procedure
Figure 1. The two yellow, +24V interlock LEDs on the BM PWB will extinguish if a tri-folder
interlock is open.
Check that the yellow, +24V interlock LED on the BM control PWB is lit. The LED is lit.
Y N
Go to WD 12.9, WD 12.17, WD 12.19, WD 12.20. Check the wiring and repair as neces-
sary, REP 1.1. Check the tri-folder top cover interlock switch and the tri-folder front door
interlock switch, S12-209. Refer to:
Inserter jam cover interlock, Inserter top cover interlock, • GP 13 How to Check a Switch.
S12-179 S12-178
• Tri-folder top cover interlock switch, PL 12.215 Item 3.
Figure 1 Component location • Tri-folder front door interlock switch, PL 12.215 Item 2.
• Tri-folder PWB, PL 12.205 Item 16.
• BM PWB, PL 12.175 Item 10.
Enter dC330, code 12-209 tri-folder front door interlock switch, S12-209. Open the tri-folder
front door. The display changes.
Y N
Go to WD 12.19 and WD 12.20. Check the wiring and repair as necessary, REP 1.1.
Check the tri-folder front door interlock, S12-209. Refer to:
• Tri-folder front door interlock switch, PL 12.215 Item 2.
• Tri-folder PWB, PL 12.205 Item 16.
• BM PWB, PL 12.175 Item 10.
A
A
Enter dC330, code 12-210 tri-folder top cover interlock sensor, Q12-210. Open the tri-folder 12-367-00-171, 12-368-00-171, 12-380-00-171 HVF Punch
top cover. The display changes.
Y N Unit Paper Edge Detect RAP
Go to WD 12.19 and WD 12.20. Check the wiring and repair as necessary, REP 1.1. 12-367-00-171 The punch unit failed to detect the edge of the A4 LE feed paper.
Check the tri-folder top cover interlock sensor, Q12-210. Refer to:
12-368-00-171 The punch unit failed to detect the edge of the 8.5”x 11” SE feed paper.
• 12A-171 HVF Power Distribution RAP. 12-380-00-171 The punch unit failed to detect the edge of the 8.5”x11” LE feed paper.
• 01L 0V Distribution RAP Initial Actions
• Tri-folder top cover interlock sensor, PL 12.200 Item 10.
• Tri-folder PWB, PL 12.205 Item 16. WARNING
• BM PWB, PL 12.175 Item 10. Ensure that the electricity to the machine is switched off while performing tasks that do
Perform SCP 5 Final Actions. death or injury. Moving parts can cause injury.
• Check that the paper path through the punch is clear, Figure 1.
Tri-folder top cover Tri-folder top cover • Check the punch module is seated at the rear or the machine.
interlock switch interlock sensor • Check that a ColorQube punch unit is installed. A ColorQube unit has 3 sensors on the
Q12-210
unit, Figure 1.
Procedure
Figure 1. Punch sensor 1, Q12-078 detects 8.5”x11” LE feed paper. Punch sensor 2, Q12-075
detects 8.5”x11” SE feed paper. Punch sensor 3, Q12-076 detects A4 LE feed paper.
Enter dC330, enter the relevant code then actuate and check each of the three punch sensors.
• code 12-078 for punch sensor 1.
Y N
Go to WD 12.12 for punch sensor 1 or WD 12.24 for punch sensors 2 & 3. Check the wir-
ing and repair as necessary, REP 1.1. Refer to:
Tri-folder front door
interlock switch, S12- • Punch sensor 1, 2 or 3, PL 12.125 Item 17.
209 • HVF PWB, PL 12.140 Item 2.
Enter dC330, code 12-223 transport motor 1, to check that the motor runs. The motor runs.
Y N
Refer to:
A
A
Check the transport motor 1 drive belt, PL 12.120 Item 7. The drive belt is good. 12-369-00-171 to 12-377-00-171 HVF Stapler Position and
Y N
Install a new transport motor 1 drive belt, PL 12.120 Item 7. Priming RAP
12-369-00-171 The stapler return end home failure.
Enter dC330, code 12-245 punch unit motor, to check that the motor runs. The motor runs.
Y N 12-370-00-171 The stapler end home failure.
Refer to: 12-371-00-171 The stapler did not move from the home position within the required time.
• 12A-171 HVF Power Distribution RAP. 12-372-00-171 The stapler did not return to the home position within the required time.
12-373-00-171 The stapler did not enter the mid home position.
• Hole punch module, PL 12.125 Item 19. 12-374-00-171 The stapler did not leave the mid home position.
12-375-00-171 The stapler jaw did not enter the home position.
12-376-00-171 The stapler jaw did not leave the home position.
12-377-00-171 A stapler priming failure was detected.
Initial Actions
WARNING
Transport motor 1 death or injury. Moving parts can cause injury.
drive belt
CAUTION
Do not run code 12-247 without 2 sheets of paper in the stapler jaws. Running this code with-
out the paper in position can cause damage to the machine.
Punch sensor
1 (Q12-078) If stapling has failed, perform the following:
• Check that the staple head unit is correctly installed.

• Check that the staple cartridge has staples in it and is correctly installed in the staple
head.
• Check that the leading staples in the staple head have been primed.
• Check that the sheets of staples in the cartridge are feeding one at a time. If staple sheets
Punch sensor
overlap, they will jam in the cartridge. If necessary, install a new cartridge.
2 (Q12-075) Punch sensor Transport motor 1
3 (Q12-076) (MOT12-223)
REAR VIEW Procedure
NOTE: Sensors Q12-133, Q12-134, Q12-317 and Q12-318 are integral to the staple head unit
and although they can be checked they are not spared separately.
Figure 1 and Figure 2 show the locations of the components.
Enter dC330, code 12-249 to run the stapler unit 1 motor, MOT12-249 and send it to the
inboard end of the machine. The motor runs.

A B
Go to WD 12.15. Check MOT12-249. • Stapler gate safety switch, PL 12.115 Item 17.
Refer to: • HVF PWB, PL 12.140 Item 2.
• GP 10 How to Check a Motor. Go to WD 12.14. Check MOT12-247.
• 12A-171 HVF Power Distribution RAP. Refer to:
• 01L 0V Distribution RAP • GP 10 How to Check a Motor.
Install new components as necessary: • 12A-171 HVF Power Distribution RAP.
• Stapler assembly, PL 12.110 Item 14. • 01L 0V Distribution RAP
• HVF PWB, PL 12.140 Item 2. Install new components as necessary:
• Stapler assembly, PL 12.110 Item 14.
With the stapler unit still at the inboard end, enter dC330, code 12-135. Manually actuate the
stapler unit home sensor, Q12-135 Figure 2. The display changes.
Remove the stapled paper and raise the paper pusher fully upwards. Go to WD 12.10. +5V is
Y N
Go to WD 12.10. Check Q12-135. available at T502 between pins 1 and 4, also between pin 1 and 7 on the staple head.
Y N
Refer to:
Check the wiring between T502 and PJ301. The wiring is good.
Y N
• 12A-171 HVF Power Distribution RAP. Repair the wiring, REP 1.1.
Install a new HVF PWB, PL 12.140 Item 2.
Enter dC330, code 12-134 actuate the stapler priming sensor, Q12-134, by removing and
• Stapler unit home sensor, PL 12.110 Item 15.
installing the staple cartridge. The display changes.
Y N
Go to WD 12.10. Check for a change in signal level at PJ301 pin 9 when Q12-134 is
Enter dC330, code 12-045 to send the stapler unit to the outboard end of the machine. Enter
being actuated. The signal level changes.
code 12-176, stapler unit mid home sensor. Manually actuate the stapler unit mid home sensor,
Y N
Q12-176, Figure 2. The display changes. Check the wiring between PJ301 pin 9 and the stapler unit. The wiring is good.
Y N
Y N
Refer to:
• GP 11 How to Check a Sensor. Install a new stapler assembly, PL 12.110 Item 14.
• 12A-171 HVF Power Distribution RAP Install a new HVF PWB, PL 12.140 Item 2.
• 01L 0V Distribution RAP Enter dC330, code 12-317 actuate the stapler cartridge sensor, Q12-317, by removing and
Install new components as necessary: installing the staple cartridge. The display changes.
• Stapler unit mid home sensor, PL 12.110 Item 15. Y N
• HVF PWB, PL 12.140 Item 2. Go to WD 12.10. Check for a change in signal level at PJ301 pin 10 when Q12-317 is
Place two sheets of paper in the stapler jaws. Raise the finisher top cover. Figure 1, fully lower Y N
the paper pusher, then lower the top cover. Enter dC330, code 12-247 to run the staple head 1 Check the wiring between PJ301 pin 10 and the stapler unit. The wiring is good.
motor, MOT12-247. The motor runs. Y N
Y N Repair the wiring, REP 1.1.
Enter dC330, code 12-319, stapler gate safety switch. Manually actuate the stapler gate Install a new stapler assembly PL 12.110 Item 14.
safety switch. The display changes.
Y N Install a new HVF PWB, PL 12.140 Item 2.
Go to WD 12.11. Check S12-319. With the 2 sheets of paper still in place enter dC330 code 12-318 to monitor the staple jaw
Refer to: home sensor Q12-318, stack the code 12-247 to cycle the staple head. The display changes.
• GP 13 How to Check a Switch. Y N
• 12A-171 HVF Power Distribution RAP. Go to WD 12.10, check for a change in signal level at PJ301 pin 12, while code 12-247 is
• 01L 0V Distribution RAP running. The signal level changes.
A B C
C
Y N
Check the wiring between PJ301 pin 12 and the stapler unit. The wiring is good.
Y N
Repair the wiring, REP 1.1. Stapler unit mid home
sensor, Q12-176
Install a new stapler assembly, PL 12.110 Item 14.
Enter dC330, code 12-133, actuate the low staples sensor, Q12-133, by removing and install-
ing the staple cartridge. The display changes.
Y N
Go to WD 12.10, check for a change in signal level at PJ301 pin 13 when Q12-133 is
Y N
Check the wiring between PJ391 pin 13 and the staple head unit. The wiring is
good.
Y N
Repair the wiring REP 1.1.
Install a new stapler assembly, PL 12.110 Item 14.
sary install new components.
Paper pusher
Stapler unit home

Stapler gate safety sensor, Q12-135
switch, S12-319

A
12-392-00-171 to 12-395-00-171 HVF Front Tamper Fault Stack the dC330 code 12-182, tamper front away sensor, Q12-182. Move the tamper using the
control codes 12-226 and 12-228. The display changes.
RAP Y N
12-392-00-171 The front tamper did not move from the home position. Go to WD 12.15. Check the wiring and repair as necessary, REP 1.1. Check Q12-182.
Refer to:
12-393-00-171 The front tamper did not return to the home position. • GP 11 How to Check a Sensor.
12-394-00-171 The front tamper did not enter the away position.
12-395-00-171 The front tamper did not move from the away position.
• Tamper front away sensor, PL 12.135 Item 1.
Initial Actions • HVF PWB, PL 12.140 Item 2.

WARNING
• Check for damage or obstructions that would prevent the front tamper from operating cor-
rectly.
• Jams can be caused if the tray settings do not match the paper in the trays. Make sure the
tray settings are correct.
Procedure
Figure 1 shows the location of the components.
Enter dC330, code 12-228 to move the tamper inboard, then enter 12-226 to move the tamper
outboard. The tamper moves.
Y N
Go to WD 12.15. Check the wiring and repair as necessary, REP 1.1. Check the front
tamper motor home, MOT12-226. Refer to:
• Front tamper motor, PL 12.125 Item 6.
Tamper front away Tamper front home Front tamper
sensor, Q12-182 sensor, Q12-180 motor, MOT12-226
Stack the dC330 code 12-180, front tamper home sensor, Q12-180. Move the tamper using the
control codes 12-226 and 12-228. The display changes.
Y N
Go to WD 12.15. Check the wiring and repair as necessary, REP 1.1. Check Q12-180.
Refer to: Figure 1 Component location
• Tamper front home sensor, PL 12.135 Item 1.
A
12-396-00-171 to 12-399-00-171 HVF Rear Tamper Fault Y N
RAP Refer to:
12-396-00-171 The rear tamper tray did not move from the home position. • GP 11 How to Check a Sensor.
12-397-00-171 The rear tamper tray did not return to the home position. • 12A-171 HVF Power Distribution RAP.
12-398-00-171 The rear tamper tray did not move from the away position.
12-399-00-171 The rear tamper tray did not return to the away position. • Rear tamper away sensor, PL 12.110 Item 15.
Initial Actions • HVF PWB, PL 12.140 Item 2.

WARNING
• Check for damage or obstructions that would prevent the rear tamper from operating cor-
rectly.
• Check that the drive belt is securely in position, Figure 1.
• Jams can be caused if the tray settings do not match the paper in the trays. Make sure the
tray settings are correct.
Procedure
Enter the dC330 code, 12-229 to move the rear tamper inboard. (The code 12-227 can be
used to move the rear tamper outboard.) The tamper moves.
Y N Rear tamper motor Rear tamper Rear tamper
Go to WD 12.14. Check the wiring and repair as necessary, REP 1.1. Check the rear home, MOT12-227 away sensor, home sensor,
tamper motor, MOT12-227. Refer to: Q12-183 Q12-181
• Rear tamper motor, PL 12.110 Item 19.
Stack the dC330 code, 12-181, rear tamper home sensor, Q12-181. Move the rear tamper
motor using the code 12-229. The display changes.
Y N
Refer to:
• Rear tamper home sensor, PL 12.110 Item 15.
Enter the dC330 code, 12-183, rear tamper away sensor. Use a piece of paper inserted from the
rear of the machine to actuate the rear tamper away sensor, Q12-183. The display changes.

A
12-403-00-171, 12-413-00-171, 12-414-00-171 HVF BM Install new components as necessary:
• BM staple head 2, PL 12.185 Item 7.
Staple Head 2 and Stapler Module RAP
• BM PWB, PL 12.175 Item 10.
12-403-00-171 The booklet maker staple head 2 motor has failed to move.
Enter dC330, code 12-275 to run the BM SH2 motor. The staple head cycled.
12-413-00-171 The booklet maker staple head 2 is not detected in the home position.
Y N
Go to WD 12.16 and WD 12.19. Check the wiring and connectors.
12-414-00-171 The booklet maker stapler module is not detected in the home (staple head
The wiring and connectors are good.
closed) position during hard / soft initialize, or at set boundary.
Y N
Repair the wiring or connectors, REP 1.1.
Initial Actions
Install a new BM staple head 2, PL 12.185 Item 7.
WARNING The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.1. If neces-
Ensure that the electricity to the machine is switched off while performing tasks that do sary install new components:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • BM staple head carrier closed sensor, PL 12.185 Item 18.
death or injury. Moving parts can cause injury. • BM staple head 2 assembly, PL 12.185 Item 7.
• Check that there is no damage or obstruction that would prevent the stapling unit from • BM PWB, PL 12.175 Item 10.
cycling.
• Check that the sheets of staples in the cartridge are feeding one at a time. If staple sheets
overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, PL
12.185 Item 8.
• Ensure that the customer job does not exceed the capacity of the booklet maker. Refer to
12D-171 Booklet Quality RAP for booklet maker quality specifications.
Procedure
Enter dC330, code 12-217 to check the BM staple head carrier closed sensor, Q12-217, Figure
1. Open and close the staple head carrier. The display changes.
Y N
Refer to:
• BM staple head carrier closed sensor, PL 12.185 Item 18.
• BM PWB, PL 12.175 Item 10.
BM staple head carrier
Remove the HVF front door, refer to REP 12.1-171 HVF Covers. Pull out the BM module. closed sensor, Q12-217
Remove the staple head 2 cover, PL 12.185 Item 14. Enter dC330, code 12-220 to check the
BM SH2 home switch. Manually rotate the staple head to actuate the BM SH2 home switch.
Y N BM staple head 2
Go to WD 12.16. Check the BM SH 2 home switch, S12-220. assembly
Refer to:
• GP 13, How to Check a Switch.
A
12-415-00-171 HVF BM Crease Roll Gate Home RAP
12-415-00-171 The crease roll gate is not at the home position.
Initial Actions
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do BM crease gate home sensor,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Q12-222
• Check for a jam or other obstruction that can prevent the crease roll gate mechanism from
moving.
• Check the following parts for damage:
– Crease roll gate rack gears, PL 12.180 Item 8. BM crease roll gate
– Crease roll gate racks, PL 12.180 Item 14. motor, MOT12-273
Procedure
Enter dC330 code 12-222. Actuate the BM crease roll gate home sensor, Q12-222, Figure 1.
Y N
Refer to:
• BM PWB, PL 12.175 Item 10. Figure 1 Component location
• BM crease roll gate home sensor, PL 12.175 Item 9.
NOTE: The BM crease roll gate motor has two component control codes:
12-273 cycles the crease roll gate.
12-276 opens the crease roll gate.
Enter dC330, code 12-273 to cycle the BM crease roll gate motor, MOT12-273. The motor
runs.
Y N
Refer to:
• BM PWB, PL 12.175 Item 10.
• BM crease roll gate motor, PL 12.175 Item 8.
sary install a new BM PWB, PL 12.175 Item 10.

12-417-00-171, 12-418-00-171 HVF BM Flapper RAP
12-417-00-171 The booklet maker flapper did not return to the home position.
12-418-00-171 The booklet maker flapper did not move from the home position.
Initial Actions
WARNING
Check for damage or obstructions that would prevent the BM flapper from rotating.
Procedure
NOTE: All HVF BM interlocks must be made to supply +24V to the motors.
Enter dC330, code 12-271 to check the BM flapper motor, MOT12-271, Figure 1. The BM
flapper rotates.
Y N
Refer to:
• 12A-171, HVF Power Distribution RAP.
• BM flapper motor, PL 12.175 Item 1.
• BM PWB, PL 12.175 Item 10.
Flapper home
• BM flapper, PL 12.150 Item 23. BM Flapper motor,
sensor, Q12-207
MOT12-271
Enter dC330, code 12-207. Actuate the flapper home sensor, Q12-207. The display
changes.
Y N
Refer to:
Install new components as necessary: Figure 1 Component location
• Flapper home sensor, PL 12.150 Item 12.
• BM PWB, PL 12.175 Item 10.

A
12-450-00-171, 12-456-00-171 to 12-459-00-171 HVF Ejector Install new components as necessary:
Module RAP
12-450-00-171 The ejector module motor has stalled
Exit diagnostics mode, selecting the re-boot option. This returns the ejector module to the
12-456-00-171 The ejector module did not return to the home position.
home position.
Enter the dC330 code, 12-185, ejector out sensor, Q12-185.
12-457-00-171 The ejector module did not move from the home position.
Stack the dC330 code, 12-249 to move the stapler unit inboard. The display changes.
Y N
12-458-00-171 The ejector module did not return to the out position. Go to WD 12.11. Check the wiring and repair as necessary, REP 1.1. Check the ejector
out sensor, Q12-185. Refer to:
12-459-00-171 The ejector module did not move from the out position.
Initial Actions
WARNING • Ejector assembly, PL 12.110 Item 2.
Ensure that the electricity to the machine is switched off while performing tasks that do • HVF PWB, PL 12.140 Item 2.
death or injury. Moving parts can cause injury. Exit the diagnostics mode, selecting the re-boot option. This returns the ejector module to the
• Check for damage or obstructions that would prevent the ejector module from operating home position.
correctly. Enter the dC330 code 12-096, ejector motor encoder sensor, Q12-096.
Stack the dC330 code, 12-249 to move the stapler unit inboard. The display changes condi-
• Check ribbon cable on ejector for kinks and potential breaks in the strips.
tion for a few seconds.
• Go to 12K-171 HVF Initialization Failure RAP to determine when the fault occurs. Y N
• Check harness to ejector unit and the plugs under the unit. Go to WD 12.11. Check the wiring and repair as necessary, REP 1.1. Check Q12-096.
Refer to:
Procedure • GP 10 How to Check a Motor.
Figure 1 shows the location of the components. • 12A-171, HVF Power Distribution RAP.
Enter the dC330 code 12-184, ejector home sensor, Q12-184. • 01L 0V Distribution RAP
Stack the dC330 code 12-249 to move the stapler unit inboard. This action moves the stapler Install new components as necessary:
unit inboard, and moves the ejector module to the out position. The display changes. • Ejector assembly, PL 12.110 Item 2.
Y N
The ejector module moved to the out position.
Y N
Go to WD 12.15. Check the wiring and repair as necessary, REP 1.1. Check the
ejector motor, MOT12-236. Refer to:
Go to WD 12.11. Check the wiring and repair as necessary, REP 1.1. Check the ejector
home sensor, Q12-184. Refer to:
A
12-451-00-171 to 12-455-00-171 HVF Ejector Roll and
Lower Paddle Fault RAP
12-451-00-171 The ejector roll motor has stalled.
12-452-00-171 The ejector roll did not return to the home position.
12-453-00-171 The ejector roll did not move from the home position.
12-454-00-171 The lower paddle has failed to return to the home position.
12-455-00-171 The lower paddle has failed to move from the home position.
Initial Actions
WARNING
• Check for any damage or obstructions that would prevent the ejector roll and lower paddle
from operating correctly.
Procedure
Ejector motor, Figure 1, Figure 2 and Figure 3 show the component locations.
MOT12-236 Enter dC330 code, 12-242 to lower the bin 1 stacker tray.
Enter dC330 code 12-249, staple unit 1 forward. This moves the ejector module to the out posi-
tion.
Enter dC330 code 12-098, ejector plate home sensor, Q12-098. Manually turn the ejector belts
a few centimetres. The display changes.
Y N
Refer to:
Ejector motor encoder sen- Enter the dC330 code 12-097, ejector roll motor encoder sensor, Q12-097. Enter the code, 12-
sor, Q12-096 Ejector out sensor,
Ejector home sensor, 233 to rotate the ejector roll motor one cycle of the ejector plates in the forward direction. The
Q12-185
Q12-184 display changes.
Y N
The ejector roll motor turned.
Y N
Figure 1 Component location Go to WD 12.15. Check the wiring and repair as necessary, REP 1.1. Check
MOT12-233. Refer to:
A B
Xerox® ColorQube® 9203 Family 2-157 12-450-00-171, 12-456-00-171 to 12-459-00-171, 12-
A B
roll motor encoder sensor, Q12-097. Refer to:
Enter dC330 code 12-099, ejector lower paddle home sensor. Rotate the lower paddle
upwards and inwards for one full rotation, Figure 3. The voltage changes from a logic high
to a low, and then back to high.
Y N
lower paddle home sensor, S12-099. Refer to:
• 12A-171, HVF Power Distribution RAP. Ejector roll motor
• 01L 0V Distribution RAP MOT12-233
Enter dC330 code 12-202, Ejector paper present sensor, Q12-202. Actuate the ejector paper
present sensor by placing a sheet of paper on the ejector module. The display changes.
Y N
paper present sensor, Q12-202. Refer to:
• Ejector assembly, PL 12.110 Item 2. Ejector roll motor encoder Ejector plate home
sensor, Q12-097 sensor, Q12-098

Rotate paddle 1 Ejector paper
complete turn present sensor
Ejector lower
paddle home
sensor, S12-
099
RIGHT UNDER-SIDE VIEW OF EJECTOR

A B
12-460-00-171 to 12-462-00-171 HVF Bin 1 Position RAP Install new components as necessary:
12-460-00-171 Bin 1 motor has stalled. • Bin 1 upper limit switch, PL 12.105 Item 7.
12-461-00-171 Bin 1 did not actuate the bin 1 upper level sensor during stacking.
If the tray is not at the lower limit, enter the dC330 code 12-191, bin 1 lower limit switch.
12-462-00-171 Bin 1 did not leave the bin 1 upper level sensor during stacking or the stacker Manually actuate the switch, Figure 1. The display changes.
failed to initialize correctly. Y N
Go to WD 12.13. Check the wiring and repair as necessary, REP 1.1. Check S12-
Initial Actions 191. Refer to:
Ensure that the electricity to the machine is switched off while performing tasks that do Install new components as necessary:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Bin 1 lower limit switch, PL 12.105 Item 7.
• Check that bin 1 is not damaged and there are no obstructions that would prevent bin 1
from moving. Go to WD 12.10. Check the wiring and repair as necessary, REP 1.1. Check the bin 1 ele-
• Press the pause to unload button (PTU) to lower bin 1. Press again the pause to unload vator motor, MOT12-241. Refer to:
button to raise bin 1. • GP 10 How to Check a Motor.
Procedure • 01L 0V Distribution RAP
NOTE: The bin 1 90% full sensor and the bin 1 lower limit switch are mounted on the same
bracket. This bracket can be in either of two positions. It is in the upper position, only when a • Bin 1 elevator motor, PL 12.105 Item 10.
tri-folder module is installed. • HVF PWB, PL 12.140 Item 2.
NOTE: The bin 1 upper level sensor controls the height of the tray during normal use. The sen- Enter the dC330 code, 12-163, bin 1 motor encoder sensor. Turn the encoder wheel. The dis-
sor is in two parts: the receiver at the rear of the tray and the transmitter at the front of the tray. play changes.
Only the LED of the front sensor is used and only the light sensitive transistor of the rear sen- Y N
sor is used. Refer to WD 12.13. Go to WD 12.13. Check the wiring and repair as necessary. Check Q12-163. Refer to:
Figure 1 shows the location of the components. • GP 11 How to Check a Sensor.
NOTE: If required, the following component control codes can be used to move bin 1 tray:
12-059, elevator motor up.
12-060, elevator motor down.
• Bin 1 motor encoder sensor, PL 12.105 Item 3.
12-241, elevator home.
12-242, elevator cycle.
Place a 1 cm (0.4 inch) stack of paper on the bin 1 tray. Switch off the machine, then switch on Enter the dC330 code 12-188, bin 1 upper level sensor. Remove the paper from the tray. Actu-
the machine. The bin 1 tray moves during initialization. ate the sensor by breaking the light beam from the front transmitter to the rear receiver. The
Y N display changes.
If the tray is not at the upper limit, enter the dC330 code 12-190, bin 1 upper limit switch. Y N
Manually actuate the switch, Figure 1. The display changes. Go to WD 12.13 and WD 12.15. Check the wiring and repair as necessary. Check the two
Y N parts of the bin 1 upper level sensor, Q12-188. Refer to:
Go to WD 12.13. Check the wiring and repair as necessary, REP 1.1. Check S12- • GP 11 How to Check a Sensor.
190. Refer to: • 12A-171, HVF Power Distribution RAP.
• GP 13 How to Check a Switch. Install new components as necessary:
• 12A-171, HVF Power Distribution RAP. • Bin 1 upper level sensor (receiver), PL 12.110 Item 16.
• 01L 0V Distribution RAP • Bin 1 upper level sensor (transmitter), PL 12.110 Item 20.
A B C
C
Enter the dC330 code 12-187, bin 1 90% full sensor. Actuate the sensor using a piece of
paper. The display changes.
Y N
Go to WD 12.13. Check the wiring and repair as necessary. Check Q12-187. Refer to:
• 12A-171, HVF Power Distribution RAP. Bin 1 motor encoder
sensor, Q12-163 Bin 1 lift
motor,
Install new components as necessary: Bin 1 rear wall sensor, MOT12-451
Q12-322
• Bin1 90% full sensor, PL 12.105 Item 3.
Lower the bin 1 tray by pressing the PTU switch. Enter the dC330 code 12-322, paper pressing
sensor Q12-322. Actuate the paper pressing sensor using a sheet of paper. The display
changes.
Y N
Go to WD 12.12. Check the wiring and repair as necessary, REP 1.1. Check the paper
pressing sensor, Q12-322. Refer to: Bin 1 upper level sensor
• GP 11 How to Check a Sensor. (transmitter), Q12-188
Install new components as necessary: Bin 1 upper level sensor,
(receiver)
• Paper pressing sensor, PL 12.110 Item 17.
Bin 1 upper limit
If the fault is intermittent, install a new bin 1 elevator assembly, PL 12.105 Item 10. switch, S12-190
Bin 1 90% full

sensor, Q12-187
Bin 1 lower limit

switch, S12-191

A B
12-463-00-171, 12-464-00-171 HVF BM +24V Failure RAP Y N
12-463-00-171 The booklet maker control PWB has failed to detect +24V at the input from the
HVF.
Check the connectors and harness between PJ559 and PJ131. Repair the harness
as necessary, REP 1.1.
12-464-00-171 The booklet maker control PWB has detected an internal +24V failure, such as
over current, short circuit or under voltage.
If a inserter is installed, go to PJ703. +24V is available between PJ703 pin 1 and PJ111
pin 1.
Initial Actions Y N
Go to 12-316-00-171, 12-319-00-171 HVF Inserter Interlock RAP
WARNING Go to WD 12.6. +24V is available at PJ601 between pins 1 and pin 4.

Ensure that the electricity to the machine is switched off while performing tasks that do Y N
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Install a new BM PWB, PL 12.175 Item 10.
Go to WD 12.6. +24V is available at PJ601 between pins 4 and 6.
Y N
WARNING Go to the 12-310-00-171, 12-312-00-171, 12-313-00-171 Docking and Interlocks
RAP.
• Ensure the HVF BM is correctly docked to the machine and all interlocks are closed. The +24V supply is good. Go to SCP 5 Final actions.
• Check the interlock actuator for damage.
The +24V supply is good. Go to SCP 5 Final actions.
Procedure
Refer to Figure 1. Close or cheat all the HVF BM interlocks. The HVF BM performs a
mechanical reset.
Y N
Go to WD 1.1. ACL is available at PJ3AC on the LVPS and base module between
pins 1 and 2.
Y N

Y N
Figure 1. +24V is available at T001 on the HVF power supply between pins 1
and 5.
Y N
Install a new HVF power supply module, PL 12.140 Item 1.
Check the connectors and harness between T001 and PJ111. Repair the harness as
necessary, REP 1.1.
Go to WD 12.6. +24V is available at PJ111 between pins 1 and 4 and between pins 3
and 6.
Y N
Go to the 12-310-00-171, 12-312-00-171, 12-313-00-171 Interlocks RAP.

Y N
+24V is available at PJ131 between pins 1 and 2.
A B
12-465-00-171 to 12-468-00-171 Paddle Unit Position RAP
12-465-00-171 The paddle unit has failed to return to the upper position.
12-466-00-171 The paddle unit has failed to move from the upper position.
12-467-00-171 The paddle unit has failed to return to the lower position.
12-468-00-171 The paddle unit has failed to move from the lower position.
Initial Actions
WARNING
Check for damage or obstructions that would prevent the paddle unit from operating correctly.
Procedure
NOTE: All HVF BM interlocks must be made to supply +24V to the motors.
Enter dC330, code 12-239 to run the paddle unit motor, MOT12-239, Figure 1. The motor
runs.
Y N
Go to WD 12.10. Check the paddle unit motor, MOT12-239.
Refer to:
• Paddle unit motor, PL 12.120 Item 6.
The paddle unit moves.

Tri-folder unit Y N
Check the drive gears on the paddle unit. Install new components as necessary, PL
12.115 Item 2.
Enter dC330, code 12-174 paddle unit upper sensor, Q12-174. Select code 12-240 to run the
HVF power
paddle unit motor. The sensor status changes.
supply module
HVF PWB Y N
BM PWB Go to WD 12.9. Check Q12-174.
Refer to:
Figure 1 Component location • 01L 0V Distribution RAP
A
Xerox® ColorQube® 9203 Family 2-163 12-463-00-171, 12-464-00-171, 12-465-00-171 to 12-
A
Enter dC330, code 12-175 paddle unit lower sensor, Q12-175. Select code 12-239 to run the
paddle unit motor. The sensor status changes.
Y N
Go to WD 12.9. Check Q12-175. Paddle unit lower
Paddle unit upper
Refer to: sensor, Q12-174. sensor, Q12-175.
Paddle unit motor,

MOT12-239

A
12-473-00-171 to 12-478-00-171 Support Finger Position Enter the dC330 code 12-171 pressing and support B sensor, Q12-171. Turn the gear wheel to
extend the support fingers approximately 25 mm (1 inch). The display changes.
RAP Y N
12-473-00-171 The pressing and support motor does not return to initial position within the Go to WD 12.12. Check Q12-171. Refer to:
required time. • GP 11 How to Check a Sensor.
12-474-00-171 The pressing and support motor does not move out to initial position within the • 01L 0V Distribution RAP
required time.
12-475-00-171 The pressing and support motor does not return to home position within the • Rear tamper assembly, PL 12.110 Item 29.
required time. • HVF PWB, PL 12.140 Item 2.
12-476-00-171 The pressing and support motor does not move out of home position within the Enter the dC330 code 12-173, pressing and support C sensor, Q12-173. Turn the gear wheel
required time. to extend the support fingers approximately 105 mm (4.1 inch). The display changes.
Y N
12-477-00-171 The pressing and support motor does not return to out position within the Go to WD 12.12. Check Q12-173. Refer to:
required time. • GP 11 How to Check a Sensor.
12-478-00-171 The pressing and support motor does not move out of out position within the • 01L 0V Distribution RAP
required time.
Procedure • Rear tamper assembly, PL 12.110 Item 29.
WARNING Make several small sets of prints. Check that the support fingers extend between each set.
The support fingers extended.
Y N
Remove the HVF top cover and rear cover, REP 12.1-171. Remove the upper right side
cover REP 12.5-171. Enter the dC330 code 12-093, pressing and support encoder sen-
NOTE: When manually extending the fingers to check the sensors, the pressing and support A sor, Q12-093. Manually turn the support motor encoder disc. The display changes.
sensor operates first, followed by the pressing and support B sensor. The pressing and support Y N
C sensor operates when the fingers are fully extended. All three sensors are spared as part of Go to WD 12.12. Check Q12-093. Refer to:
the rear tamper assembly. • GP 11 How to Check a Sensor.
Figure 2 shows the component locations.
Remove the HVF front door and front cover REP 12.1-171. Cheat the front door interlock. • 01L 0V Distribution RAP
Enter dC330 code 12-249 SU1 Motor Forward, to move staple head to the rear of the HVF. Dis- Install new components as necessary:
connect then reconnect the pressing and support A sensor, Figure 2. • Pressing and support encoder sensor, PL 12.110 Item 15.
Enter dC330 code 12-172, pressing and support A sensor, Q12-172. Note the position of the • HVF PWB, PL 12.140 Item 2.
support fingers at rest. Turn the gear wheel shown in Figure 1, downwards. The support fingers
extend to the right as the gear is turned. Extend the support fingers approximately 6mm (0.25 Go to WD 12.15 and check the wiring and repair as necessary, REP 1.1. Install new com-
inch). The display changes. ponents as necessary:
Y N • Motor encoder assembly, PL 12.110 Item 18.
Go to WD 12.12. Check Q12-172. Refer to:
• 12A-171, HVF Power Distribution RAP. Perform SCP 5 Final Actions.
• Rear tamper assembly, PL 12.110 Item 29.
A
Pressing and
support C sensor,
Q12-173
Gear wheel
Pressing and support

A sensor
Pressing and
support encoder
Pressing and support sensor, Q12-093
B sensor, Pressing and support A
Q12-171 Pressing and support
sensor, Q12-172. motor, MOT12-323

A
12-479-00-171 Inserter Paper Length Fault RAP • 01L 0V Distribution RAP
12-479-00-171 A shorter than expected sheet has been fed from the inserter. Install new components as necessary:
• Inserter paper length sensor 3, PL 12.300 Item 12.
Initial Actions • Inserter PWB, PL 12.310 Item 9.
WARNING Enter the dC330 code 12-084, inserter TE sensor, Q12-084. Actuate the sensor. The display
Ensure that the electricity to the machine is switched off while performing tasks that do changes.
death or injury. Moving parts can cause injury. Go to WD 12.13 and WD 12.21. Check the inserter TE sensor, Q12-084. Refer to:
Check that the inserter paper path is clear of obstructions and the sensors are clean.
Procedure
Figure 1 shows the component locations.
Enter the dC330 code 12-079, inserter paper length sensor 1, Q12-079. Actuate the sensor. • Inserter TE sensor, PL 12.310 Item 11.
The display changes. • Inserter PWB, PL 12.310 Item 9.
Y N • HVF PWB, PL 12.140 Item 2.
Go to WD 12.13, WD 12.21 and WD 12.22. Check the inserter paper length sensor 1,
Q12-079. Refer to: Enter the dC330 code 12-083, inserter LE sensor, Q12-083. Actuate the sensor. The display
• GP 11 How to Check a Sensor. changes.
• 12A-171, HVF Power Distribution RAP. Y N
• 01L 0V Distribution RAP Go to WD 12.13 and WD 12.21. Check the inserter LE sensor, Q12-083. Refer to:
• Inserter paper length sensor 1, PL 12.300 Item 12.
• Inserter LE sensor, PL 12.310 Item 11.
Enter the dC330 code 12-080, inserter paper length sensor 2, Q12-080. Actuate the sensor. • Inserter PWB, PL 12.310 Item 9.
The display changes. • HVF PWB, PL 12.140 Item 2.
Y N
Go to WD 12.13, WD 12.21 and WD 12.22. Check the inserter paper length sensor 2, Enter the dC330 code 12-260, to energize the inserter clutch, CL12-260. The inserter clutch
Q12-080. Refer to: energizes.
• 12A-171, HVF Power Distribution RAP. Go to WD 12.14, WD 12.21 and WD 12.22. Check the inserter clutch, CL12-260. Refer to:
• 01L 0V Distribution RAP • GP 12 How to Check a Solenoid or Clutch.
Install new components as necessary: • 12A-171, HVF Power Distribution RAP.
• Inserter paper length sensor 2, PL 12.300 Item 12. • 01L 0V Distribution RAP
• Inserter PWB, PL 12.310 Item 9. Install new components as necessary:
• HVF PWB, PL 12.140 Item 2. • Inserter clutch, PL 12.310 Item 3.
Enter the dC330 code 12-090, inserter paper length sensor 3, Q12-090. Actuate the sensor. • HVF PWB, PL 12.140 Item 2.
Y N Enter the dC330 code 12-261, to run the inserter motor, MOT12-261. The motor runs.
Go to WD 12.14 and WD 12.22. Check the inserter paper length sensor 3, Q12-090. Y N
Refer to: Go to WD 12.14 and WD 12.22. Check MOT12-261. Refer to:
• GP 11 How to Check a Sensor. • GP 10 How to Check a Motor.
• 12A-171, HVF Power Distribution RAP. • 12A-171, HVF Power Distribution RAP.
A B
B
• 01L 0V Distribution RAP 12-492-00-171 to 12-494-00-171 IME To Finisher Failure
RAP
• Inserter unit motor, PL 12.315 Item 1.
12-492-00-171 CDI Communications failure with the finisher
• HVF PWB, PL 12.140 Item 2. 12-493-00-171 The finisher failed to cycle up.
Perform SCP 5 Final Actions. 12-494-00-171 The finisher failed to return a prep time to the IME within 1 second.
Inserter paper length

sensor 1, Q12-079
Initial Actions
sensor 2, Q12-080
WARNING
sensor 3, Q12-090 Ensure that the electricity to the machine is switched off while performing tasks that do
Inserter TE sensor,
Q12-084 death or injury. Moving parts can cause injury.
• Check the finisher power cord is plugged into the IME.
• Check that the communication harness from the finisher is plugged in to the IME.
• Fault 12-494-00 only. Reload the software, GP 4.
Procedure
Refer to in line connector PJ904 and to WD 8.5. Switch the machine off, GP 14 and disconnect
PJ904 on the back of the image processing module. Reconnect PJ904 and switch the machine
on, GP 14. If the fault is still present check for damaged pins on PJ904 and on the Media Path
Driver PWB.
Inserter clutch,
CL12-260 • Power communications cable, PL 12.140 Item 7.
• Power cord, PL 12.140 Item 4.
Inserter motor, Inserter LE sensor,
MOT12-261 Q12-083

12-762-00-171, 12-764-00-171, 12-765-00-171 IME To 12A-171 HVF Power Distribution RAP
Finisher Communication Failure RAP The HVF has an integral power supply providing +24V and +5V supplies to the HVF PWB and
HVF BM PWB. The AC power for the HVF power supply comes from the LVPS and base mod-
12-762-00-171 Communications failure between the IME and the finisher
ule of the machine. Refer to Figure 3 for component location.
12-764-00-171 The IME cannot detect a finisher plugged in.
Initial Actions
12-765-00-171 The IME has detected an incompatible / unknown finisher.

death or injury. Moving parts can cause injury. WARNING
• Check that the communication harness from the finisher is plugged in to the IME. Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
• Check the finisher power cord is connected correctly.
• Check that the actuator, PL 12.100 Item 17 is attached to the right hand machine frame CAUTION
and is making the docking interlock. Do not connect the HVF power cord directly to the AC wall outlet. The HVF cannot operate
• Go to 12K-171 HVF Initialization Failure RAP to determine when the fault occurs. without the machine. The machine controls the distribution of electricity to the HVF/HVF BM for
• Check the fault history for faults that occurred at the same time as the 12-762-00, 12-764- correct power on and power off sequencing.
00-171, 12-765-00-171 fault. If fault codes are present then go to the appropriate RAP • Ensure the HVF/HVF BM is correctly docked to the machine and all interlocks are closed.
before proceeding with this RAP. • Check the interlock actuator for damage.
• Refer to HVF Control PWB and BM PWB LEDs to identify the status of the PWB’s.
Procedure
Perform the following: Procedure
1. Refer to in line connector PJ904 and to WD 8.5. Switch off the machine, GP 14. Discon- Figure 1 shows the component locations.
nect PJ904 on the back of the image processing module. Reconnect PJ904 then switch Close or cheat all the HVF BM interlocks. The HVF BM performs a mechanical reset.
on the machine, GP 14. If the fault is still present check for damaged pins on PJ904 and Y N
on the Media Path Driver PWB. Go to WD 12.6. +5V is available at PJ113 between pins 1 and 2.
• Media path driver PWB, PL 1.15 Item 5. +5V is available at T001 on the HVF power supply unit between pins 4 and 8.
• Power communications cable, PL 12.140 Item 7. Y N
Go to WD 1.1. ACL is available at PJ3AC on the LVPS and base module
2. Refer to WD 12.6. Check for:
between pins 1 and 2.
• +5V between PJ113 pins 1 and 2. Y N
• +24V between PJ111 pins 1 and 4. Go to the 01A AC Power Distribution RAP then check the AC output volt-
• +24V between PJ111 pins 1 and 6. ages.
If either voltage is not present, go to the 12A-171 HVF Power Distribution RAP.
Switch off the machine, GP 14. Disconnect all PJs on the HVF PWB except
PJ111 and PJ113. Switch on the machine, GP 14. Go to WD 12.6. +5V is
available at T001 on the HVF power supply unit between pins 4 and 8.
Y N
Install a new HVF power supply unit, PL 12.140 Item 1.
A B C D
Xerox® ColorQube® 9203 Family 2-169 12-762-00-171, 12-764-00-171, 12-765-00-171, 12A-
A B C D A E
NOTE: Before each PJ is reconnected, switch off the machine, GP 14. Go to WD 12.6. +5V is available at PJ601 between pins 3 and 4.
Y N
The HVF has a short circuit. Reconnect each PJ one at a time until the source
of the short circuit is found. Repair the harness REP 1.1, or install new compo-
Y N
nents as necessary. Install a new HVF PWB, PL 12.140 Item 2.
Go to WD 12.6. Disconnect PJ113. +5V is available at the harness end of PJ113

between pins 1 and 2. as necessary, REP 1.1.
Y N
Check the connectors and harness between T001 and PJ113. Repair the har-
ness as necessary, REP 1.1. Y N
Y N
Install a new BM PWB, PL 12.175 Item 10.
Y N
+24V is available at T001 between pins 5 and 3. as necessary, REP 1.1.
Y N
Install a new HVF power supply module, PL 12.140 Item 1.
The +24V and +5V supplies are good. Go to SCP 5 Final actions.
Check the in-line fuse, F1 (10A), and as necessary install a new fuse, PL 12.140
Item 5. Check the connectors and harness between T001 and PJ111. Repair the
Y N
harness as necessary, REP 1.1. Go to the 12-310-00-171, 12-312-00-171, 12-313-00-171 Docking and Interlocks RAP.
Go to WD 12.6 and WD 12.8. Close the front door and top cover and ensure the HVF is
The +24V and +5V supplies are good. Go to SCP 5 Final actions.
docked to the machine. +24V is available at PJ111 pin 1 and PJ112 pins 8.
Y N
Go to the 12-310-00-171, 12-312-00-171, 12-313-00-171 Docking and Interlocks
RAP.

Y N
Y N
Install a new HVF PWB, PL 12.140 Item 2
as necessary.

Y N
Y N
as necessary, REP 1.1.
If an inserter is installed, go to PJ703. +24V is available between PJ703 pin 1 and

PJ111 pin 1.
Y N
Go to 12-316-00-171, 12-319-00-171 HVF Inserter Interlock RAP
A E
12A-171 2-170 Xerox® ColorQube® 9203 Family
HVF Control PWB and BM PWB LEDs Figure 2 shows the LEDs on the BM PWB. These are:
Figure 1 shows the LEDs on the HVF PWB. These are:
• LED 1 - red, steady. This indicates a fault or other abnormal status.
• LED 1 - red. Not used. • LED 2 - yellow, flashing at about 1Hz. This indicates that the software is operating in nor-
• LED 2 - red. Not used. mal mode. In other modes, e.g., software downloading, the flashing rate is higher.
• LED 3 - red, flashing. This indicates the functioning of the CPU. When flashing at 2Hz, • LED 3 - orange, steady. This indicates either:
(every 1/2 second), the software is running normally. When flashing at about 1/4Hz, – that the tri-folder front door and top cover interlocks are closed, and +24V is avail-
(every 4 seconds), this indicates that the software is encountering a code problem and a able to the BM module or, if the tri-folder in not installed;
possible software upgrade is needed. If this LED is OFF, the CPU does not function and a – that the interlock cheater is present in PJ553 on the BM control PWB the logic
new HVF control PWB is needed. cheater is present in PL563 on the BM control PWB.
• LED 4 - red. Not used. • LED 4 - orange, steady. This indicates that the +24V supply is within voltage and current
• LED 5 - red. Not used. limits, and that the power limiting circuit has not been active for over a set time limit.
• LED 6 - red. Not used. • LED 5 - blue, steady. this indicates that the +5V supply is present in the BM module.
• LED 7 - red. Not used.
• LED 8 - red, steady. This indicates that the HVF top cover, front door and docking inter-
locks are all closed and +24V is available at the HVF module.
• LED 9 - red, steady. This indicates that the +5V supply is present in the HVF module.
Figure 2 LEDs on the BM control PWB
Figure 1 LEDs on the HVF PWB

Xerox® ColorQube® 9203 Family 2-171 12A-171
12B-171 HVF BM to Machine Communications Interface
and BM Present RAP
A communication fault exists between the HVF BM and the machine.
Procedure
WARNING
WD 12.9 and WD 12.19 show the communications between the booklet maker and the HVF
PWB. For communications between the HVF PWB and the machine go to WD 12.9.
The pulses on the connections between PJ133 and PJ562 cannot be measured, but may be
detected using a meter that can record maximum and minimum voltage levels, or by using an
AC voltage range. Check the wiring and repair as necessary, REP 1.1.

• Booklet maker PWB, PL 12.175 Item 10.
If the machine indicates that the booklet maker is not present, check that PJ133, pin 6 is held
at zero. If necessary, repair the wiring, REP 1.1 or install a new HVF PWB, PL 12.140 Item 2.
Tri-folder unit
In-line fuse,
(F1)
HVF power
supply module
HVF PWB
BM PWB

12A-171, 12B-171 2-172 Xerox® ColorQube® 9203 Family
A
12C-171 HVF BM Bin 2 Failure RAP Install new components as necessary:
Bin 2 fails to remove the finished booklets from the exit area of the booklet maker. • BM conveyor belts drive motor, PL 12.190 Item 4.
• BM PWB, PL 12.175 Item 10.
Initial Actions
sary install new conveyor belts, PL 12.190 Item 1.
WARNING
Check for a jam or any other obstruction that could prevent the conveyor belt mechanism from
moving.
Procedure
Enter dC330 code 12-206. Actuate the BM bin 2 path transport full sensor, Q12-206, Figure 1.
Y N
If a tri-folder is installed, go to WD 12.18. Check the connection at PJ583 on the tri-folder.
The connection are good.
Y N
Check the connectors and harness at the tri-folder. Repair the harness as neces-
sary, REP 1.1.

Refer to:
• 12A-171 HVF Power Distribution RAP. BM bin 2 90% full
• 01L 0V Distribution RAP sensor Q12-206 BM conveyor drive
Install new components as necessary: motor, MOT12-274
• BM PWB, PL 12.175 Item 10.
• BM bin 2 90% full sensor PL 12.190 Item 5.
NOTE: The BM conveyor belts drive motor stops after 10 seconds.

Enter dC330, code 12-274 to run the BM conveyor drive motor, MOT12-274. The motor runs.
Y N
If a tri-folder is installed, go to WD 12.17. Check the connection at PJ583 on the tri-folder.
The connection are good.
Y N
Check the connectors and harness at the tri-folder. Repair the harness as neces-
sary, REP 1.1.

Refer to:
A
Xerox® ColorQube® 9203 Family 2-173 12C-171
12D-171 Booklet Quality RAP Procedure
Use this RAP to identify and correct the causes of poor booklet quality in the HVF BM. Produce three 4 sheet / 16 page booklets, using 80gsm (20lb) paper. Paper size and weight
must conform the specification in GP 20 Paper and Media Size Specification.
The following booklet quality problems are covered in this RAP:
Examine the booklets for defects. Refer to the following:
• The alignment of the top and bottom edges of the booklet are not within specification.
• Top and Bottom Edge Alignment.
• The alignment of the open side edges of the booklet are not within specification.
• Open Side Edge Alignment.
• The booklet staples are badly formed.
• Badly Formed Booklet Staples
• The booklet compiling is not correct (page order is wrong).
• Booklet Compiler is Not Correct
• The booklet crease is skewed greater than the specification.
• Skewed Booklet Crease.
• The booklet crease is off-centre, greater than the specification.
• Booklet Crease is Off Centre.
• The booklet staple position is not within the specification.
• Booklet Staple Position is Not On The Fold.
• The booklet is not sufficiently creased.
• The Booklet is Not Sufficiently Creased.
Initial Actions
Top and Bottom Edge Alignment
Figure 1, open out the booklet at the centre page and press it onto a flat surface. Measure the
WARNING mis-alignment of the top and bottom edges of the booklet.
• Check that the paper loaded in the paper trays matches the paper size displayed on the
UI.
• Ensure that the paper being fed to the BM conforms to the specification, GP 20 Paper and
Media Size Specification.
• Ensure that the booklets being produced do not exceed the maximum contents given in
Table 1.
Table 1 Booklet contents

Maximum Maximum
Maximum number of number of
number of booklet unstapled
Media Paper weight sheets pages sheets
Plain paper 60 to 80gsm (16 to 21lb bond) 15 60 5
Heavyweight 90gsm (24lb bond) 13 52 -
Measure the total scatter
Plain paper 60 to 80 gsm (16 to 21lb bond) 14 including 56 -
with heavy- with 160 gsm (43lb bond) cover 1 cover
Figure 1 Top and bottom alignment
weight cover
Table 2 Top and bottom edge alignment
• Check the machine and HVF BM paper paths for any obstruction that could cause mis-
Paper weight 95% of booklets 99.7% of booklets
alignment of the paper fed to the BM compiling area.
80gsm (20lb) 1mm 2mm
All other BM approved weights in GP 20 2mm 3mm

12D-171 2-174 Xerox® ColorQube® 9203 Family
If the top and bottom edge alignment does not conform to the specification in Table 2, check Table 3 Open side edge alignment
the operation of the BM tampers, refer to the 12-066-00-171, 12-384-00-171, 12-419-00-171,
Paper weight 95% of booklets 99.7% of booklets
12-420-00-171 HVF BM Tamper Failure RAP. If the tampers are operating correctly, go to ADJ
12.5-171 Booklet Tamping and check the tampers are correctly adjusted. 80gsm (20lb) 1mm 2mm
All other BM approved weights in GP 20 2mm 3mm
If the booklet skew does not conform to the specification in Table 4. Perform the following:
If the open side edge alignment does not conform to the specification in Table 3, check the
• Check the operation of the BM stack hold solenoids, refer to 12-065-00-171, 12-383-00- operation of the BM stack hold solenoids, refer to the 12-065-00-171, 12-383-00-171 HVF
171 HVF Booklet Back Stop failure RAP. Booklet Back Stop Failure RAP. If the stack hold solenoids are operating correctly, check care-
• If the stack hold solenoids are operating correctly, check for contamination or debris in the fully for any contamination or debris in the compiling area of the BM, that could cause the mis-
compiling area of the BM that could cause the mis-alignment. alignment.
Open Side Edge Alignment Badly Formed Booklet Staples

Figure 2, open out the booklet at the centre page and press it onto a flat surface. Measure the If the booklet staples are not formed correctly, perform ADJ 12.3-171 Staple Anvil Alignment.
mis-alignment of the open side edges of the booklet.
Booklet Compiler is Not Correct
If the page order of the booklets is not correct, perform ADJ 12.6-171 Booklet Compiling Posi-
tion.
Measure the total scatter
Skewed Booklet Crease
Figure 3, open out the booklet at the centre page and press it onto a flat surface. Measure the
amount of booklet skew.
The amount of skew is the difference

Figure 2 Open side edge alignment between the two measurements
Figure 3 Booklet skew

Table 4 Skew tolerance Booklet Crease is Off Centre
Paper size A4, Paper size A4, Figure 4, open out the booklet at the centre page and press it onto a flat surface. Measure the
8.5x11in, 8.5x11in, position of the booklet crease.
8.5x13in or 8.5x13in or Paper size A3 Paper size A3
Paper weight 8.5x14in 8.5x14in or 11x17in or 11x17in
Measure from the booklet
95% of 99.7% of 95% of 99.7% of edge to the crease
- booklets booklets booklets booklets
80gsm (20lb) Less than Less than 2.5mm Less than Less than
1.0mm 1.4mm 3.1mm
All other booklet Less than Less than 3.0mm Less than Less than
maker approved 1.5mm 2.1mm 3.6mm
weights in GP 20
If the booklet skew does not conform to the specification in Table 4, perform the following:
1. Check the operation of the BM stack hold solenoids, refer to the 12-065-00-171, 12-383-
00-171 HVF BM Back Stop Motor Fault RAP. If the stack hold solenoids are operating cor-
rectly, check for any contamination or debris in the compiling area of the BM, that could
cause the mis-alignment.
2. ADJ 12.9-171 Booklet Maker Skew.
3. Check the BM back stop assembly for damage. If necessary, install a new BM back stop
Figure 4 Booklet crease position
Table 5 Crease position and tolerance

Paper size Edge to crease measurement
A4 148.5 +/- 1.5mm
A3 210 +/- 1.5mm
8.5x11 inch 139.5 +/- 1.5mm
8.5x13 inch 165.1 +/- 1.5mm
8.5x14 inch 178.0 +/- 1.5mm
11x17 inch 216.0 +/- 1.5mm
If the booklet crease position does not conform to the specification in Table 5, perform ADJ
12.7-171 Booklet Crease Position.

12D-171 2-176 Xerox® ColorQube® 9203 Family
Booklet Staple Position is Not On The Fold The Booklet is Not Sufficiently Creased
Figure 5, open out the booklet at the centre page and press it onto a flat surface. Measure the Figure 6, Measure the open dimension of the booklets.
position of the booklet staple from the crease line.
Staple position
must align with the
crease +/-1.5mm
Figure 6 Booklet creasing

Figure 5 Booklet staple position
Table 6 Creasing tolerance
If the booklet staple position does not conform to the specification in Figure 5, perform ADJ
Paper size A4,
12.8-171 Booklet Staple Position.
8.5x11in, Paper size A4,
8.5x13in or 8.5x11in, 8.5x13in Paper size A3 or Paper size A3 or
Paper weight 8.5x14in or 8.5x14in 11x17in 11x17in
- 95% of booklets 99.7% of booklets 95% of booklets 99.7% of booklets

80gsm (20lb) Less than 30mm Less than 35mm Less than 22mm Less than 25mm
If the open dimension of the booklets does not conform to the specification in Table 6, install
new crease nip springs, PL 12.170 Item 12.

12E-171 Copy Damage in the HVF BM RAP 12F-171 Mis-Registration in Stapled and Unstapled Sets
Use this RAP to identify and correct the causes of copy damage in the HVF BM. RAP
Use this RAP to identify and correct the causes of mis-registration in stapled sets, resulting in
Procedure staples missing some sheets in the set, or poorly registered non-stapled sets.
Procedure
WARNING
Check the following: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Check the alignment between the IME and the HVF BM, ADJ 12.1-171. death or injury. Moving parts can cause injury.
• Look for paper fragments in the HVF BM paper path. Paper fragments can move through A probable cause of mis-stapled or mis-compiled sheets is a defective paddle unit or ejector
the IME and HVF BM paper path without causing a problem until they finally wedge them- assembly.
selves at some point. A likely place for a fragment of paper to be wedged is at the hole • If output prints 2 to 100 in the compile area are not fully pulled back against the HVF back-
punch assembly, where the top and bottom guides form the narrowest part of the paper stops inspect the paddles of the paddle unit for physical signs of wear, PL 12.115 Item 25.
path. • If output print 1 in the compile area is not fully pulled back against the HVF backstops
• Ensure that the exit diverter solenoid SOL12-225, PL 12.120 Item 4, energizes correctly inspect the ejector paddle assembly for physical signs of wear, PL 12.110 Item 22.
and has full movement.
A probable cause of mis-registration is the condition of the paper and/or damage such as, curl,
• Ensure that the hole punches park at the fully open position. If they protrude, even wrinkle, creases, dog ears, etc.
slightly, a jam will occur in the narrow paper path of the hole punch. Refer to the 12-044-
• Curl, wrinkle and creases are probably caused in the IME, go to the IQ 1 Image Quality
00-171 to 12-047-00-171 Punch Head Position RAP. Entry RAP.
• Check that all the idler rolls in the HVF BM paper path are free to rotate, particularly those • For other copy / print damage and dog ears, go to the 12E-171 Copy Damage in the HVF
on the jam clearance guides. Refer to ADJ 4.1 Machine Lubrication.
BM RAP.
• Make sure that the jam clearance guides 5a, 5b and 5c close and latch correctly.
• Check that the paper path ribs of the BM paper guide 6e, PL 12.150 Item 7 and the upper
• Check the alignment between the IME and the HVF BM, ADJ 12.1-171.
exit guide PL 12.125 Item 8 are free of scores and nicks. Check also for contamination
• Turn over the paper stack in the tray in use.
and glue from label stock.
• Use a new ream of paper in the tray in use.
• Make sure that the compiler carriage tampers move to the correct paper size.
• Paper type, especially recycled paper, can lead to registration problems. Try changing to
• Check that the paper size reported on the user interface corresponds to the actual paper
size loaded in the trays, refer to the 71B Tray 1 and 2 Wrong Size Paper RAP. a different brand or type of paper.
• Make sure that the BM tampers move to the correct paper size, refer to the 12-066-00- • Ensure that the guides in the paper trays are correctly set and reported on the UI for the
171, 12-384-00-171, 12-419-00-171, 12-420-00-171 HVF BM Tamper Failure RAP. paper size loaded, refer to the 71B Tray 1 and 2 Wrong Size Paper RAP.
• Ensure that the BM paper guide, PL 12.150 Item 7, closes and latches correctly. • Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
the compiler capacity can be exceeded.
• If heavy-weight paper is used, the paper can stop in the vertical transport and cause a
• Check for obstructions in the compiler.
fault. The fault is caused when the vertical transport motor is over loaded. Check the posi-
tion of the jam clearance guides 5a, 5b and 5C. Check the vertical transport rolls and • Ensure the paddle roll mechanism in the eject housing operating correctly, refer to the 12-
bearings for contamination. If necessary remove and clean the drive shaft and the bear- 024-00-171, 12-025-00-171 Paddle Roll Position RAP.
ings. If the problem continues then install a new transport motor,. • Make sure that the compiler carriage tampers move to the correct paper size.
• Make sure that the BM tampers move to the correct paper size, refer to 12-066-00-171,
12-384-00-171, 12-419-00-171, 12-420-00-171 HVF BM Tamper Failure RAP.

12E-171, 12F-171 2-178 Xerox® ColorQube® 9203 Family
12G-171 HVF BM Poor Stacking RAP 12H-171 Pause to Unload (PTU) RAP
Use this RAP to find the cause of poor stacking in the HVF BM. Use this RAP to diagnose Pause to Unload problems.
Procedure Procedure
WARNING WARNING
Check the following; Figure 1 shows the component locations. Go to WD 12.15. Check the wiring and the voltages.
• Look for sets that are not dropping back fully in the bin 1 tray and therefore not being Refer to PJ903. Repair the wiring as necessary, REP 1.1. Install new components as neces-
detected by the kicker fingers and sensors: sary:
– Large paper sizes should not be stacked on top of small paper sizes.
• PTU PWB, PL 12.140 Item 3.
– Ensure that the paper stack in each paper tray has been fanned.
– Turn over the paper stack in each paper tray.
– Ensure that all paper or other copy stock being used is within the size and weight
specifications. Refer to GP 20 Paper and Media Size Specifications.
– Try using a fresh ream of paper.
– Ensure that the edge guides of all paper trays are adjusted correctly for the paper
size and that the trays are fully closed.
• Labels must not be fed to bin1, but to bin 0 only.
• It is recommended that transparencies are fed to bin 0 whenever possible.
• Check that the bin 1 upper limit switch, S12-190 and the bin 1 lower limit switch, S12-191
are working correctly. Refer to the 12-460-00-171 to 12-462-00-171 Bin 1 Position RAP.
• Check that the HVF BM is not positioned near an air conditioning or ventilation output
duct. Air flow across the output bins can cause poor stacking.
PTU PWB
PTU switch, PTU LED

S12-208

Xerox® ColorQube® 9203 Family 2-179 12G-171, 12H-171
12J-171 Inserter Paper Sensing and +5V Supply RAP Y N
Go to WD 12.13, WD 12.21 and WD 12.22 and check the inserter paper width sensor 2.
Use this RAP to find the cause of inserter empty, inserter paper width and +5v supply prob-
Refer to:
lems.
• PJ8 and PJ4 on the Inserter PWB.
Procedure
Ensure that the electricity to the machine is switched off while performing tasks that do • Inserter paper width sensor 2, PL 12.300 Item 13.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Inserter PWB, PL 12.310 Item 9.
Figure 1 and Figure 2 show the component locations.
If a +5V supply problem is suspected, perform the following: Go to WD 12.13 and WD 12.22. Measure the voltage from the inserter acceleration sensor
Go to the 12A-171 HVF Power Distribution RAP. Check the 0V and +5V supply from the HVF (Q12-316), while actuating the sensor with paper. The voltage changes.
PWB to the inserter PWB. Repair the wiring as necessary, REP 1.1. Y N
Install new components as necessary: Check the inserter acceleration sensor (Q12-316). Refer To:
• Inserter PWB, PL 12.310 Item 9. • GP 11 How to check a Sensor.
• HVF PWB, PL 12.140 Item 2. • PJ11 and PJ4 on the Inserter PWB.
To diagnose inserter paper sensing and paper width problems, perform the following: • 12A-171 HVF Power Distribution RAP.
Enter the dC330 code 12-082 inserter unit empty sensor, Q12-082. Actuate the sensor. The • 01L 0V Distribution RAP
display changes. Install new components as necessary:
Y N
• Inserter acceleration sensor, PL 12.300 Item 10.
Go to WD 12.13 and WD 12.21. Check Q12-082. Refer to:
• GP 11 How to Check a Sensor. • Inserter PWB, PL 12.310 Item 9.
• PJ8 and PJ4 on the Inserter PWB. • HVF PWB, PL 12.140 Item 2.
Go to WD 12.14 and WD 12.22. Measure the voltage from the inserter pickup sensor (Q12-
• 01L 0V Distribution RAP 315) while actuating the sensor with paper. The voltage changes.
Install new component as necessary: Y N
• Inserter unit empty sensor, PL 12.300 Item 11. Check the inserter pickup sensor (Q12-315). Refer to:
• Inserter PWB, PL 12.310 Item 9. • GP 11 How to check a Sensor.
• HVF PWB, PL 12.140 Item 2. • PJ7 and PJ4 on the Inserter PWB.
Enter dC330 code 12-081, inserter paper width sensor 1, Q12-081. Actuate the sensor. The • 01L 0V Distribution RAP
display changes. Install new components as necessary:
Y N
• Inserter pickup sensor PL 12.310 Item 10.
Go to WD 12.13 and WD 12.21. Check Q12-081. Refer to:
• GP 11 How to Check a Sensor. • Inserter PWB, PL 12.310 Item 9.
• PJ8 and PJ4 on the Inserter PWB. • HVF PWB, PL 12.140 Item 2.
Perform SCP 5 final actions.
• Inserter paper width sensor 1, PL 12.300 Item 13.
Enter dC330 code 169, inserter paper width sensor 2, Q12-169. Actuate the sensor. The dis-
play changes.

12J-171 2-180 Xerox® ColorQube® 9203 Family
Inserter paper width sensor
Inserter unit empty sensor, 1, (Q12-081)
Q12-082
Inserter paper width

sensor 2, (Q12-169)
Inserter Pickup
sensor (Q12-315) Inserter acceleration
sensor (Q12-316)
Figure 1 Component location Figure 2 Component location

Xerox® ColorQube® 9203 Family 2-181 12J-171
12K-171 HVF Initialization Failure RAP Initial Actions
When an initialization command is received from the machine, the HVF is initialized with the
following actions:
WARNING
1. The stacker tray lower, then raises.
2. The ejector assembly paddle performs two revolutions.
3. The paddle module's center flap raises. death or injury. Moving parts can cause injury.
4. The paddle module moves to the up position. Open the HVF front door. Cheat the front door interlock switch. Fully pull out the BM module
5. The paper pusher moves to the down position.
6. The ejector moves out. Procedure
7. The paddle module's center flap lowers. If the initialization sequence fails completely, go to the 12A-171 HVF Power Distribution RAP. If
8. The stapler unit travels to the inboard position. the initialization sequence fails to place any unit at the home position, go to the appropriate
9. The stapler unit returns to the outboard (home) position. RAPs:
10. The curl suppression solenoid energizes and raises the paddle module's center flap. • Front tamper not at home, refer to 12-392-00-171 to 12-395-00-171 HVF Front tamper
11. The paper pusher moves to the up position. Tray RAP
12. The ejector assembly returns to the home position. • Rear tamper not at home, refer to 12-396-00-171 to 12-399-00-171 HVF Rear Tamper
Tray RAP.
13. The pressing and support motor runs and drives the support fingers to the initialization
position which in turn pushes the pressing fingers down onto bin 1. • Paddle not at home, refer to 12-024-00-171, 12-025-00-171 Paddle Roll Position RAP.
14. The pressing and support motor reverses and drives the support fingers to the home posi- • Bin 1 not at home, refer to 12-460-00-171 to 12-462-00-171 HVF Bin 1 Position RAP.
tion which in turn retracts the pressing fingers. • Punch not at home, refer to 12-044-00-171 to 12-047-00-171 Punch head Position RAP
15. The rear tamper motor runs and moves the rear tamper in the ejector assembly away, • Staple head not at home, refer to 12-369-00-171 to 12-377-00-171 HVF stapler Position
then back to the home position. and Priming RAP.
16. The paddle module moves down. • Ejector not at home, refer to 12-450-00-171, 12-456-00-171 to 12-459-00-171 HVF Ejec-
17. The transport motors run. tor Module RAP.
18. If installed, booklet maker diverter solenoid energizes. • The buffer motor fails to start, refer to 12-141-00-171, 12-142-00-171 HVF Buffer Path
RAP.
19. The exit diverter solenoid energizes.
• Entry feed motor 1 fails to start, refer to 12-125-00-171, 12-126-00-171 HVF Entry Sensor
20. The booklet maker diverter solenoid de-energizes.
RAP.
21. The exit diverter solenoid de-energizes.
• Transport motor 2 fails to start, refer to 12-171-00-171, 12-172-00-171 HVF Top Exit Sen-
22. If installed, the punch unit motor and the punch head motor run momentarily. sor RAP.
23. The transport motors stop. • The booklet maker diverter solenoid fails to energizes, refer to 12-113-00-171, 12-114-00-
NOTE: The HVF initialization procedure can be triggered by opening and closing the HVF front 171, 12-190-00-171, 12-192-00-171 HVF BM Entry RAP.
door, or by raising and lowering the top tray. When this is done the tray will not lower com- • The exit diverter solenoid fails to energies, refer to 12-171-00-171, 12-172-00-171 HVF
pletely, but will adjust its position. Top Exit Sensor RAP.
• Either of the BM staple heads are not at the home position, refer to 12-063-00-171, 12-
The booklet maker is initialized as follows:
411-00-171 HVF BM Stapler Unit 1 Failure RAP or 12-403-00-171, 12-413-00-171, 12-
1. The BM tampers are driven to their home position, unless already home. 414-00-171 HVF BM Stapler Head 2 and Stapler Module RAP.
2. The BM backstop is driven to the home position, unless already home. • The BM tampers are not at the home position, refer to 12-066-00-171, 12-384-00-171, 12-
3. The BM crease roll gate is driven to the home position, unless already home. 419-00-171, 12-420-00-171 HVF BM Tamper Failure RAP.
4. The BM crease blade is driven to the home position, unless already home. • The BM backstop is not at the home position, refer to 12-065-00-171, 12-383-00-171 HVF
5. The BM staple heads are driven to their home position, unless already home. BM Backstop Failure RAP.
• The BM crease roll gate is not at the home position, refer to 12-415-00-171 HVF BM
Crease Roll Gate Home RAP.
• The BM crease blade is not at the home position, refer to 12-061-00-171, 12-416-00-171
HVF BM Creasing RAP.

12K-171 2-182 Xerox® ColorQube® 9203 Family
12L-171 Tri-Folder Not Detected RAP 12M-171 Not Used
Use this RAP when the machine fails to detect the tri-folder module.
NOTE: The machine must be loaded with A4 or 8.5 x 11 inch SEF paper for the tri-folder to
function. Also, booklet mode will only be available if A4, 11, 14 or 17 inch paper is loaded in the
machine.
Initial Actions
WARNING
Check for damage or obstructions that would prevent the tri-folder from operating correctly.
Procedure
Go to WD 12.19. Check the wiring of the tri-folder present link, and repair as necessary, REP
1.1. Check for 0V at PJ563, pin 7. Refer to:

Xerox® ColorQube® 9203 Family 2-183 12L-171, 12M-171
12N-171 Chad Bin Present and Bin Full RAP
Use this RAP when there is a false indication of a missing or full chad bin.
Initial Actions
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Chad bin level sensor,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause (Q12-193)
Check that the chad sensor hole in the side of the bin is clear of obstruction. Check that the bin
is fully inserted and is empty.
Procedure
Enter dC330 code 12-118, chad bin present sensor, Q12-118. Remove the chad bin and actu-
ate the sensor manually. The display changes.
Y N Chad bin present
Go to WD 12.12 and check the wiring. Repair as necessary, REP 1.1. Check the chad bin sensor, (Q12-118)
present sensor,Q12-118. Refer to:
As necessary, install new components:
• Chad bin present sensor, PL 12.125 Item 18.
• HVF PWB, PL 12.140 Item 2. UNDERSIDE VIEW
Enter the dC330 code, 12-193, chad bin level sensor, Q12-193. Remove the chad bin and Figure 1 Component location
actuate the sensor with paper. The display changes.
Y N
Go to WD 12.12 and check the wiring. Repair as necessary, REP 1.1. Check Q12-193.
Refer to:
• Chad bin level sensor, PL 12.125 Item 17.

12N-171 2-184 Xerox® ColorQube® 9203 Family
12P-171 Buffer Path Clamp Problems RAP
Use this RAP when having problems with the buffer path clamp on the HVF. Problems in this
area result in paper jams at the exit and poor compiling.
Initial Actions
WARNING
Check that the solenoid and the clamp can move freely without obstruction.
Procedure
Enter the dC330 code 12-056, set clamp solenoid. The solenoid actuates.
Y N
Go to WD 12.8 and check the wiring. Repair as necessary, REP 1.1. Check SOL12-056.
Refer to:
• Set clamp solenoid, PL 12.120 Item 4.
Set clamp solenoid, SOL12-056 REAR VIEW

Xerox® ColorQube® 9203 Family 2-185 12P-171
12P-171 2-186 Xerox® ColorQube® 9203 Family
16-000-00 to 16-000-26 Cannot Create RPC With ENS RAP 16-001-09 to 16-001-90 Unable to Synchronize Startup RAP
16-000-00 Format services non shutdown ESS faults 16-001-09 Unable to do startup synchronization
16-000-01 ENS service non shutdown ESS faults 16-001-14 Unable to do startup synchronization
16-000-09 Cannot create RPC connection wit h ENS 16-001-19 Unable to do startup synchronization
16-000-14 Cannot create RPC connection with ENS 16-001-26 Unable to Start up and synchronize with SC
16-000-19 Cannot create RPC connection with ENS 16-001-47 Unable to do startup synchronization
16-000-26 Cannot create RPC connection with ENS 16-001-90 Unable to do startup synchronization
Procedure Procedure
WARNING WARNING
1. If a single occurrence, the network controller (ESS) will automatically re-boot. 1. If a single occurrence, take no action.
2. For multiple occurrences, reinstall software, GP 4. 2. For multiple occurrences switch off the machine, then switch on the machine, GP 14.
3. If the fault remains, reinstall software, GP 4.

16-002-09 to 16-002-19 Unable to Register as RPC RAP 16-003-09 to 16-003-90 Too Many IPC Handles RAP
16-002-09 Unable to Register as an RPC server 16-003-09 Too many IPC handles
16-002-14 Unable to Register as an RPC server 16-003-14 Too many IPC handles
16-002-19 Unable to Register as an RPC server 16-003-19 Too many IPC handlers
16-002-26 Unable to Register as an RPC server 16-003-90 Utility insert handler failure
16-002-46 Unable to Register as an RPC server Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1. If a single occurrence, take no action.
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14.
1. If a single occurrence, take no action.

16-002-09 to 16-002-19, 16-003-09 to 16-003-90 2-188 Xerox® ColorQube® 9203 Family
16-004-14 to 16-005-92 RPC Failure to Register RAP 16-006-09, 16-006-19 Cannot Register for Events RAP
16-004-14 RPC call failure to ESS registration service 16-006-09 Cannot register for events
16-004-19 RPC connect failure to ESS registration service 16-006-19 Cannot register for events
16-004-26 RPC connect failure to ESS registration service Procedure

16-004-46 RPC connect failure to ESS registration service (to register with)
WARNING
16-005-14 RPC call failure to ESS registration service
16-005-26 RPC call failure to ESS registration service 1. Switch off the machine, then switch on the machine, GP 14.
16-005-46 RPC call failure to ESS registration service (to register with)
16-005-90 RPC call failure to ESS registration failed
Procedure
WARNING

Xerox® ColorQube® 9203 Family 2-189 16-004-14 to 16-005-92, 16-006-09, 16-006-19
16-007-92 to 16-010-99 Invalid IPC / RPC Data RAP 16-013-14, 16-014-14 Copier Synchronization Error RAP
16-007-92 Invalid RPC data received 16-013-14 Digital copier ENS synchronization error
16-009-09 Invalid IPC data received 16-014-14 Digital copier ENS synchronization error
16-010-14 Unable to send IPC Procedure

16-010-99 IPC open, create, signal queue failed
WARNING
WARNING 1. Switch off the machine, then switch on the machine, GP 14.
Ensure that the electricity to the machine is switched off while performing tasks that do 2. If the fault remains, reinstall software, GP 4.

16-007-92 to 16-010-99, 16-013-14, 16-014-14 2-190 Xerox® ColorQube® 9203 Family
16-015-14, 16-015-19 Data Store Variable Not Set RAP 16-016-14, 16-016-19 Data Store Initialization Failed RAP
16-015-14 SESS data store environmental variable not set 16-016-14 Data store initialization failed
16-015-19 SESS data store environmental variable not set 16-016-19 Data store initialization failed
Procedure Procedure
WARNING WARNING
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. 1. If a single occurrence, the network controller (ESS) will automatically re-boot.
2. For multiple occurrences, reinstall the software, GP 4. 2. For multiple occurrences, reinstall the software, GP 4.

16-017-19 to 16-021-26 Send Event Failure / Could Not Get 16-021-46 Unable to Get Host Name RAP
Host Name RAP 16-021-46 Unable to get Host Name
16-017-19 Send event failure. Unable to send event to ESS ENS
Procedure
16-021-19 ESS PM registration connect error
16-021-26 Service could not get Host name WARNING

Procedure not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14.
WARNING 2. For multiple occurrences, reinstall the software, GP 4.

16-023-09, 16-023-26 RPC Call Failure RAP 16-026-09 to 16-026-92 Memory Allocation Error RAP
16-023-09 RPC call failure to ENS 16-026-09 Memory allocation failure
16-023-26 RPC call failure to ENS 16-026-14 Malloc error
Procedure 16-026-46 Memory allocation failure
16-026-90 Malloc error

WARNING
16-026-92 Memory allocation failure
death or injury. Moving parts can cause injury. Procedure
2. For multiple occurrences switch off the machine, then switch on the machine, GP 14. WARNING
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14

Xerox® ColorQube® 9203 Family 2-193 16-023-09, 16-023-26, 16-026-09 to 16-026-92
16-027-90 Unable to Obtain Queue ID RAP 16-028-09, 16-028-90 Unable to Complete RPC Call / Invalid
16-027-90 Unable to obtain well known queue ID Range RAP
16-028-09 Unable to complete RPC call
Procedure
16-028-90 Invalid range string
WARNING Procedure
1. If a single occurrence, take no action. Ensure that the electricity to the machine is switched off while performing tasks that do
2. For multiple occurrences, reinstall the software, GP 4. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

16-030-19 Unable to Obtain Client RAP 16-031-09 Invalid Event Notification RAP
16-030-19 Unable to obtain client RPC handle to EJS 16-031-09 Invalid event notification received
Procedure Procedure
WARNING WARNING
1. If a single occurrence, take no action. 1. If a single occurrence, take no action.
2. For multiple occurrences switch off the machine, then switch on the machine, GP 14. 2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14.
3. If the fault remains, reinstall software, GP 4. 3. If the fault remains, reinstall software, GP 4.

16-032-19, 16-039-00 NVM Connection Failure / Pthread 16-040-92 Semaphore Fault RAP
Create Error RAP 16-040-92 Semaphore fault
16-032-19 NVM connection failure
Procedure
16-039-00 Pthread create error
Procedure WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 1. If a single occurrence, switch off the machine, then switch on the machine, GP 14.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 2. For multiple occurrences, reinstall software, GP 4.
2. For multiple occurrences, reinstall the software, GP 4.

16-048-09 Unable to Set Binding RAP 16-048-14, 16-048-90 Cannot Set ESS Client Binding RAP
16-048-09 Unable to set binding 16-048-14 Cannot set ESS client binding
Procedure 16-048-90 Cannot set ESS client binding
Procedure
WARNING
1. If a single occurrence, take no action. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
1. Switch off the machine, then switch on the machine, GP 14

16-048-99 Unable to Set Client Binding RAP 16-150-09 Cannot Send Registration Event RAP
16-048-99 Unable to set client binding 16-150-09 Cannot send Registration Event
Procedure Procedure
WARNING WARNING
1. If a single occurrence, take no action. 1. Switch off the machine, then switch on the machine, GP 14.
2. For multiple occurrences switch off the machine, then switch on the machine, GP 14. 2. If the fault remains, reinstall software, GP 4.

16-150-14 Unable to Obtain RPC Transport RAP 16-150-19 Unable to Sync Peer RAP
16-150-14 Unable to obtain RPC transport 16-150-19 Unable to sync peer (within ESS) infrastructure services
Procedure Procedure
WARNING WARNING
1. If a single occurrence, take no action. 1. Switch off the machine, then switch on the machine, GP 14.
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. 2. If the fault remains, reinstall software, GP 4.

16-150-26 Fault Service Failed to Write Log RAP 16-150-90 Invalid IPC Request Destination RAP
16-150-26 Fault Service Failed to write log 16-150-90 Invalid IPC request destination
Procedure Procedure
WARNING WARNING
1. Switch off the machine, then switch on the machine, GP 14. 1. If a single occurrence, take no action.
2. If the fault remains, reinstall software, GP 4. 2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14.

16-150-92 Consumer Interface Fault RAP 16-151-09 to 16-151-19 Invalid IPC Command / SNMP Reg
16-150-92 Consumer interface fault Failure RAP
16-151-09 Invalid IPC command
Procedure
16-151-14 SNMP event registration failed
WARNING 16-151-19 Invalid IPC command

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Procedure
1. Switch off the machine, then switch on the machine, GP 14
2. If the fault remains, reinstall software, GP 4. WARNING

Xerox® ColorQube® 9203 Family 2-201 16-150-92, 16-151-09 to 16-151-19
16-151-26 Fault Service Failed to Get a Log RAP 16-151-90 Environment Variable Failure RAP
16-151-26 Fault service failed to get a log handle 16-151-90 Put environment variable failure
Procedure Procedure
WARNING WARNING
2. If the fault remains, reinstall software, GP 4. 2. For multiple occurrences, reinstall software, GP 4.

16-152-09 Internal IPC Failure RAP 16-152-14 Empty Internal Event Failure RAP
16-152-09 Internal IPC failure 16-152-14 Empty internal event received by ENS
Procedure Procedure
WARNING WARNING
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. 2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14.

16-152-19 Unable to Send Request to SESS RAP 16-152-26 Unable to Send Request to SESS RAP
16-152-19 Unable to send request to SESS 16-152-26 Unable to send request to SESS
Procedure Procedure
WARNING WARNING
1. If a single occurrence, take no action. 1. If a single occurrence, reinstall software, GP 4.
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. 2. For multiple occurrences on machines W/O TAG 006, first check the harness connections
3. If the fault remains, reinstall software, GP 4. then if problem persists install a new HDD network controller assembly, PL 3.10 Item 2.
3. For multiple occurrences on machines W/TAG 006, first check the harness connections
then if problem persists install a new HDD, PL 3.11 Item 2.

16-153-09 Unable to Obtain IPC Queue RAP 16-153-14 Unable to Initialize Event List RAP
16-153-09 Unable to obtain IPC queue 16-153-14 Can not initialize internal event list
Procedure Procedure
WARNING WARNING
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. 2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14.

16-153-19 NVM Save Failure RAP 16-154-09 ESS Registration Configuration Error RAP
16-153-19 NVM save failure 16-154-09 ESS Registration service configuration error
Procedure Procedure
WARNING WARNING
2. For multiple occurrences, reinstall software, GP 4. 2. If problem persists there could be a bad software release. Install new software, GP 4.

16-154-14 Cannot Create Internal Event Queue RAP 16-154-19 NVM Read Failure RAP
16-154-14 Cannot create internal event 16-154-19 NVM read failure
Procedure Procedure
WARNING WARNING

16-155-19 ESS Failed to Boot from Alternate Disk RAP 16-156-19 Service Run Loop Failed RAP
16-155-19 ESS failed to boot from alternate disk partition 16-156-19 Service run loop failed
Procedure Procedure
WARNING WARNING
1. If a single occurrence, take no action. 1. If a single occurrence, switch off the machine, then switch on the machine, GP 14.
2. For multiple occurrences, reinstall software, GP 4. 2. For multiple occurrences, reinstall software, GP 4.

16-160-09 ESS Reg Service Process Death RAP 16-161-09, 16-164-09 Cannot Send Reg Event / List Access
16-160-09 ESS Registration Service Process Death Failure RAP
16-161-09 Cannot send registration event
Procedure
16-164-09 List access failure (create, add, find, delete)
WARNING Procedure
1. If a single occurrence, take no action. Ensure that the electricity to the machine is switched off while performing tasks that do
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
3. If the fault remains, reinstall software, GP 4. death or injury. Moving parts can cause injury.

16-161-09 to 16-164-09 Cannot Send Reg Event / List 16-429-00, 16-431-00 Unable to Write to Data Store / Get
Access and ESS Services Failure RAP System Time RAP
16-161-09 Cannot send registration event 16-429-00 Unable to write to data store
16-162-09 ESS platform manager services process death 16-431-00 Unable to get system time
16-163-09 ESS DM agent services process death Procedure

16-164-09 List access failure (create, add, find, delete)
WARNING

16-432-00 Unknown Scheduler Received RAP 16-433-00 RPC Call Failed RAP
16-432-00 Unknown scheduler received 16-433-00 RPC call failed
Procedure Procedure
WARNING WARNING

16-434-00 Unable to Change Scheduler RAP 16-600-07 to 16-600-67 Cannot Create RPC Connection
16-434-00 Unable to change scheduler received RAP
16-600-07 Cannot create RPC connection to ENS
Procedure
16-600-35 Cannot create RPC connection to ENS
WARNING 16-600-46 Cannot create RPC connection to ENS

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-600-66 Unable to create RPC connection to ENS
1. Switch off the machine, then switch on the machine, GP 14. 16-600-67 Unable to create RPC connection to ENS
Procedure
WARNING
1. If a single occurrence, the network controller (ESS) will automatically re-boot.
2. For multiple occurrences, reinstall the software, GP 4.

16-434-00, 16-600-07 to 16-600-67 2-212 Xerox® ColorQube® 9203 Family
16-601-26 to 16-601-46 Queue Setup / System Control 16-601-47 Diagnostics Service Failed IPC Queue Setup
Failed / Invalid UI Info RAP RAP
16-601-26 Fault Service Failed IPC Queue Setup 16-601-47 Diagnostics service failed IPC queue setup
16-601-35 System control initialization Failed Procedure

16-601-46 Invalid UI information (RPC data) returned
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 2. If the fault remains, reinstall software, GP 4.

Xerox® ColorQube® 9203 Family 2-213 16-601-26 to 16-601-46, 16-601-47
16-601-66, 16-601-67 Unable to Do Start Up Sync RAP 16-601-68 Unable to Start Up and Sync RAP
16-601-66 Unable to do start up synchronization 16-601-68 Unable to start up & synchronize with SC
16-601-67 Unable to do start up synchronization Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1. Switch off the machine, then switch on the machine, GP 14.
1. If a single occurrence switch off the machine, then switch on the machine, GP 14.
2. For multiple occurrences, reinstall software, GP 4.

16-601-105 Unable Synchronize At Start Up RAP 16-602-07 to 16-603-105 RPC Service Registration Failure
16-601-105 Unable to do start up synchronization RAP
16-602-07 RPC service registration failure
Procedure
16-602-09 Unable to unregistered as RPC service during shutdown
WARNING 16-602-11 RPC server register failed

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-602-28 RPC server registration failed
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. 16-602-35 RPC server registration failed
16-602-38 RPC server registration failed
16-602-66 Unable to register as an RPC server
Procedure
WARNING

16-603-11, 16-603-28 Replace Handler Call Failed RAP 16-603-46 to 16-603-67 Too Many IPC Handlers RAP
16-603-11 Replace handler call failed 16-603-46 Too many IPC handlers
16-603-28 Replace handler call failed 16-603-66 Too many IPC handlers
Procedure 16-603-67 Too many IPC handlers
Procedure
WARNING
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
2. For multiple occurrences, reinstall software, GP 4. death or injury. Moving parts can cause injury.

16-603-11, 16-603-28, 16-603-46 to 16-603-67 2-216 Xerox® ColorQube® 9203 Family
16-603-68, 16-604-105 Replace Handler Call Failed / Data 16-603-46, 16-603-105, 16-604-14 RPC Call Failure to ESS
Store Variable Not Set RAP Reg Service RAP
16-603-68 Replace handler call failed 16-603-46 RPC call failure to ESS registration service
16-604-105 SESS data store environmental variable not set 16-603-105 RPC call failure to Network Controller registration service.
Procedure 16-604-14 Unable to unregister as RPC service during shutdown. Registration failed.
Procedure
WARNING
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

Xerox® ColorQube® 9203 Family 2-217 16-603-68, 16-604-105, 16-603-46, 16-603-105, 16-
16-604-38 to 16-605-07 Could Not Register With Reg 16-605-14, 16-605-105 Unable to Unregister As RPC
Service RAP Service / RPC Call Failure RAP
16-604-38 Could not register with registration service 16-605-14 RPC call failure to ESS registration service
16-604-99 Could not register with registration service 16-605-105 Unable to unregister as RPC service during shutdown
16-605-07 Unable to register with registration service Procedure
Procedure
WARNING

16-605-26 Fault Service Timed Out Registering RAP 16-605-35 to 16-605-67 RPC Call Failure to ESS RAP
16-605-26 Fault service timed out registering with registration service 16-605-35 RPC call failure to ESS registration service
Procedure 16-605-47 RPC call failure to ESS registration service (to register with)

WARNING
2. If the fault remains, reinstall software, GP 4. WARNING

16-606-07 Cannot Register For Events RAP 16-606-105 OS Problem RAP
16-606-07 Cannot register for events 16-606-105 OS problem
Procedure Procedure
WARNING WARNING
1. Switch off the machine, then switch on the machine, GP 14. 1. If a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-606-35 to 16-606-99 Cannot Register For Events RAP 16-607-19 to 16-608-14 Invalid RPC Data / Unable to Free
16-606-35 Cannot register for events Resources RAP
16-607-19 Invalid RPC data received
16-606-46 Cannot register for events
16-606-99 Cannot register for events
16-607-47 Invalid RPC disk diagnostic data received
Procedure
WARNING 16-607-105 Service run loop failed

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-608-09 Unable to free IPC resources
1. Switch off the machine, then switch on the machine, GP 14. 16-608-11 IPC unregister failed
16-608-14 Unable to free IPC resources
Procedure
WARNING

16-608-26 Fault Service Failed to Unbind RAP 16-608-28 to 16-608-67 Unable to Free IPC Resources RAP
16-608-26 Fault service failed to unbind with SC 16-608-28 IPC unregister fail
Procedure 16-608-35 Unable to free IPC resources
16-608-38 Unable to unregister as IPC server

WARNING
1. If a single occurrence, reinstall software, GP 4. 16-608-67 Unable to free IPC resources
2. For multiple occurrences on machines W/O TAG 006, first check the harness connections
then if problem persists install a new HDD network controller assembly, PL 3.10 Item 2. Procedure
WARNING

16-608-105 Unable Build UI SVC Obtain Client Failed RAP 16-609-07 Unknown Message Received RAP
16-608-105 Unable build UI SVC obtain client failed 16-609-07 Unknown message received from DM agent
Procedure Procedure
WARNING WARNING
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. 2. For multiple occurrences on machines W/O TAG 006, first check the harness connections
3. If the fault remains, reinstall software, GP 4. then if problem persists install a new HDD network controller assembly, PL 3.10 Item 2.

16-609-19, 16-609-105 Too Many IPC Handlers / Invalid 16-609-26 Fault Service Encountered Error RAP
RPC Data RAP 16-609-26 Fault service encountered error trying to get IPC message
16-609-105 Too many IPC handlers
Procedure
Procedure WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 1. If a single occurrence, reinstall software, GP 4.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 2. For multiple occurrences on machines W/O TAG 006, first check the harness connections
death or injury. Moving parts can cause injury. then if problem persists install a new HDD network controller assembly, PL 3.10 Item 2.
1. If a single occurrence, take no action. 3. For multiple occurrences on machines W/TAG 006, first check the harness connections
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. then if problem persists install a new HDD, PL 3.11 Item 2.

16-609-46 to 16-609-92 Invalid IPC Data Received RAP 16-610-00, 16-610-07 IPC Send Failure RAP
16-609-46 Invalid IPC data received 16-610-00 IPC send failure to ESS triple A service for queue command authorization
16-609-47 Invalid IPC data received. Get SC diagnostics handle failed; 16-610-07 IPC send failure to DM agent
16-609-92 Invalid IPC data received Procedure
Procedure
WARNING
death or injury. Moving parts can cause injury. 2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14.
1. If a single occurrence, take no action. 3. If the fault remains, reinstall software, GP 4.

16-610-09 Cannot Send IPC Message RAP 16-610-11 to 16-610-90 Unable to Send IPC Message RAP
16-610-09 Cannot send IPC message to ESS platform manage 16-610-11 IPC communication failed
Procedure 16-610-19 Unable to send IPC message
16-610-26 Unable to send IPC message

WARNING
16-610-28 IPC communication failed
16-610-35 Unable to send IPC message
1. Switch off the machine, then switch on the machine, GP 14. 16-610-46 Unable to send IPC message
16-610-90 IPC send response error
Procedure
WARNING

16-610-92 Failure to Send Queue Status RAP 16-610-99 Unable to Send IPC Message RAP
16-610-92 Failure to send queue status 16-610-99 Unable to send IPC message
Procedure Procedure
WARNING WARNING

16-611-07, 16-611-38 Client Removal Failed RAP 16-611-19 to 16-611-47 Unable to Remove RPC Connection
16-611-07 Client removal failure RAP
16-611-09 Unable to remove RPC connection
16-611-38 Client removal failure
Procedure
WARNING 16-611-26 Unable to remove RPC connection

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-611-46 Unable to remove RPC connection
1. If a single occurrence, take no action. 16-611-47 Unable to remove RPC connection
Procedure
WARNING

16-611-66 to 16-611-99 Unable to Remove RPC Connection 16-612-09 to 16-612-68 Unable to Do Shutdown Sync RAP
RAP 16-612-09 Unable to do shutdown synchronization
16-612-14 Unable to do shutdown synchronization
Procedure 16-612-47 Downgrade not permitted

WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Procedure
1. If a single occurrence, take no action. WARNING
2. For multiple occurrences, switch off the machine, then switch on the machine, GP 14. Ensure that the electricity to the machine is switched off while performing tasks that do
3. If the fault remains, reinstall software, GP 4. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

16-613-09 to 16-614-19 DC Sync / Comms Error RAP 16-614-47 Invalid Software Upgrade RAP
16-613-09 DC registration synchronization error 16-614-47 Invalid SW upgrade file
16-613-14 DC ENS synchronization error Procedure

16-613-19 DC sys mgr sync error
WARNING
16-614-09 DC registration communications error
16-614-14 Digital copier ENS registration error
16-614-19 DC sys mgr communications error 1. Verify that the correct software file is being used, refer to GP 4.
Procedure
WARNING

16-615-35, 16-615-46 Data Store Variable Not Set RAP 16-615-47 Multiple Software Upgrade File RAP
16-615-35 SESS data store environmental variable not set 16-615-47 Multiple SW upgrade files in directory
16-615-46 SESS data store environmental variable not set Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1. Ensure that there is only one software upgrade file in the directory, refer to GP 4.

16-615-66 Data Store Variable Not Set RAP 16-615-67, 16-615-90, 16-616-38, 16-616-46 SESS Data
16-615-66 SESS data store environmental variable not set Store Environmental Variable RAP
16-615-67 SESS data store environmental variable not set.
Procedure
16-615-90 Corrupt environment variable, configuration script error.
WARNING 16-616-35 SESS Faults 206 or 207. Data store not created. Corrupt environment.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-616-38 Shared memory fault when initializing with the data store.
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. 16-616-46 SESS Faults 206 or 207, data store not created, corrupt environment variable.
Procedure
WARNING
1. For a single occurrence, take no action.
2. For multiple occurrences switch off the machine, then switch on the machine, GP 14.
3. If the fault remains, reinstall the software, GP 4.

16-615-66, 16-615-67, 16-615-90, 16-616-38, 16-616-46 2-232 Xerox® ColorQube® 9203 Family
16-616-47 IPC Message Failure RAP 16-616-67 Submission Of E-mail OR IFax Job Failed RAP
16-616-47 IPC message failure. 16-616-67 Submission of e-mail or IFax job failed.
Procedure Procedure
WARNING WARNING
1. For a single occurrence, take no action. 1. For a single occurrence, take no action.
2. For multiple occurrences switch off the machine, then switch on the machine, GP 14. 2. For multiple occurrences switch off the machine, then switch on the machine, GP 14.
3. If the fault remains, reinstall the software, GP 4. 3. If the fault remains, reinstall the software, GP 4.

16-617-19 RPC Information Corrupt RAP 16-617-47 TAR Extraction Failure RAP
16-617-19 Invalid event information or data. ENS failure, system RPC information corrupt. 16-617-47 TAR extraction failure
Procedure Procedure
WARNING WARNING
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-618-47 DLM SPI Extraction Failure RAP 16-619-14 to 16-619-93 Cannot Unregister From
16-618-47 DLM SPI Extraction failure Registration Service RAP
16-619-14 Registration service failed to respond in time.
Procedure
16-619-19 Registration service failed to respond in time.
WARNING 16-619-26 Could not register with Registration Service. Communication failure, software error.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-619-46 Unable to unregister with Network Controller Registration Service. Registration Ser-
death or injury. Moving parts can cause injury. vice was too slow to respond.
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
16-619-47 DMPR Failure at web.
2. For a multiple occurrence, reinstall software, GP 4.
16-619-68 Unable to unregister with Network Controller Registration Service. Registration Ser-
vice was too slow to respond.
16-619-93 Unable to unregister with Network Controller Registration Service. Registration Ser-
vice was too slow to respond.
Procedure
WARNING

16-620-07 to 16-620-90 Registration Service Failed RAP 16-620-92, 16-620-93, 16-620-99 Unable to Register With
16-620-07 Registration Service failed. Network Controller Registration Service RAP
16-620-92 Unable to unregister with network controller registration service due to registration
16-620-14 Registration Service failed. service failure.
16-620-19 Registration Service failed.

16-620-93 Unable to unregister with network controller registration service due to registration
service failure.

Procedure

WARNING
16-620-47 Upgrade request rejected. Ensure that the electricity to the machine is switched off while performing tasks that do
16-620-90 Registration Service failed. death or injury. Moving parts can cause injury.
Procedure 2. For a multiple occurrence, reinstall software, GP 4.
WARNING

16-620-07 to 16-620-90, 16-620-92, 16-620-93, 16-620- 2-236 Xerox® ColorQube® 9203 Family
16-621-00, 16-621-07, 16-621-11, 16-621-28, 16-621-35, 16- 16-622-07, 16-622-09, 16-622-11, 16-622-14, 16-622-19, 16-
621-38, 16-621-47, 16-621-66, 16-621-67, 16-621-93, 16-621- 622-26, 16-622-28, 16-622-35, 16-622-38, 16-622-46, 16-622-
99 Unable to Obtain Host Name RAP 47 Corrupt RPC Table RAP
16-621-00 Unable to get host name. Configuration error. 16-622-07 Corrupt O/S RPC table.
16-621-07 Unable to get host name. Configuration error. 16-622-09 Corrupt O/S table.
16-621-11 Unable to get host name. Configuration error. 16-622-11 Corruptly O/S table.
16-621-28 Unable to get host name. Configuration error. 16-622-14 Corruptly O/S table.
16-621-35 Failed to get host name using GetHostName call. 16-622-19 Corruptly O/S table.
16-621-66 Unable to get host name. 16-622-35 Corruptly O/S table.
16-621-67 Unable to get host name. 16-622-38 Corruptly O/S table.
16-621-99 Failed to get host name using GetHostName call. 16-622-47 Software upgrade file failure.
Procedure Procedure
WARNING WARNING
1. For single occurrence, switch on the machine, then switch off the machine, GP 14. 1. For single occurrence, switch on the machine, then off the machine, GP 14.
2. For multiple occurrence, reinstall software, GP 4. 2. For multiple occurrence, reinstall software, GP 4.

Xerox® ColorQube® 9203 Family 2-237 16-621-00, 16-621-07, 16-621-11, 16-621-28, 16-621-
16-622-66, 16-622-67, 16-622-68 Unable to Register RPC 16-623-35, 16-623-47, 16-624-46 ENS Service Failed to
Service RAP Respond In Time RAP
16-622-66 Unable to unregister as RPC service during shutdown. 16-623-35 ENS Service failed to respond in time.
16-622-67 Unable to register as RPC service during shutdown. 16-623-47 ENS service failed to respond in time.
16-622-68 Unable to register as RPC service during shutdown. 16-624-46 RPC corrupted o/s failure.
Procedure Procedure
WARNING WARNING
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. 1. For a single occurrences, switch off the machine, then switch on the machine, GP 14.

16-622-66, 16-622-67, 16-622-68, 16-623-35, 16-623-47, 2-238 Xerox® ColorQube® 9203 Family
16-625-35, 16-625-46, 16-625-66, 16-625-67, 16-625-90 16-626-00, 16-626-11, 16-626-38, 16-626-47, 16-626-67
Invalid IPC Type RAP Memory Leak RAP
16-625-35 Unknown message received. Software version mismatch. 16-626-00 Memory leak, software bug memory corrupt. Virtual memory exhausted. Process
size exceeding system limits.
16-625-46 Software version mismatch.
16-626-11 Memory leak, software bug memory corrupt. Virtual memory exhausted. Process
16-625-66 Invalid IPC message type. size exceeding system limits.
16-625-67 Invalid IPC message type. 16-626-38 Memory leak, software bug memory corrupt. Virtual memory exhausted. Process
size exceeding system limits.
16-625-90 Known service sends message that does not make sense.
16-626-47 Memory leak, software bug memory corrupt. Virtual memory exhausted. Process
Procedure size exceeding system limits.
16-626-67 Memory allocation failed.

WARNING
WARNING

16-628-07, 16-628-09, 16-628-35, 16-628-46, 16-628-66, 16- 16-629-11, 16-629-26, 16-629-46, 16-629-67, 16-629-68, 16-
628-67 Range Environment Variable RAP 629-92, 16-629-93 No Acknowledgment For RPC Message
16-628-07 Range environment variable not set. Set to invalid numeric string. RAP
16-629-11 Fault service call to PSW callback failed.
16-628-09 Not defined.
16-629-26 Fault service call to PSW callback failed.
16-628-35 Range environment variable not set. Set to invalid numeric string.
16-629-46 No acknowledgment for RPC message.
16-629-92 No acknowledgment for RPC message. RPC time out calling program received void
Procedure response due to corrupt RPC.
16-629-93 No acknowledgment for RPC message. RPC time out calling program received void
WARNING response due to corrupt RPC.
2. For multiple occurrences, reinstall software, GP 4. WARNING

16-630-09, 16-630-26, 16-630-35, 16-630-38, 16-630-46, 16- 16-631-19, 16-631-46, 16-631-19, 16-633-19, 16-634-46, 16-
630-47, 16-630-66, 16-630-67, 16-630-68, 16-630-99 Corrupt 635-07, 16-635-35, 16-635-46, 16-635-99-16-636-35, 16-636-
RPC RAP 99 XDR Data Error RAP
16-630-09 Corrupt O/S RPC table. 16-631-19 Software error in the ENS service or in the service generating the fault.
16-630-26 Corrupt system configuration. 16-631-46 Software error in the ENS or in the service generating the fault.
16-630-35 Unable to get RPC client handle. Corrupt system configuration. 16-633-19 Invalid system configuration. NVM corrupted.
16-630-38 Null pointer returned when obtain client attempted. 16-634-46 Unable to specify shutdown routine during initialization.
16-630-46 Corrupt system configuration. 16-635-07 Cannot free XDR data.
16-630-47 Corrupt system configuration. 16-635-35 Cannot free XDR data.
16-630-66 Unable to get RPC client handle. 16-635-46 Unable to free XDR data.
16-630-67 Unable to get RPC client handle. 16-635-99 Unable to convert serialized data to internal data structure.
16-630-68 Unable to get RPC client handle. 16-636-35 Unable to convert serialized data to internal data structure. Unable to free XDR
data.
16-630-99 Corrupt system configuration.
16-636-99 Unable to convert serialized data to internal structure. Unable to free XDR data.
Procedure
Procedure
WARNING
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. death or injury. Moving parts can cause injury.
2. For multiple occurrences, reinstall software, GP 4. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-637-11, 16-637-26, 16-637-38, 16-637-47, 16-637-66, 16- 16-638-66, 16-638-67, 16-639-38, 16-639-46, 16-640-28, 16-
637-67, 16-637-93, 16-637-95 File Error RAP 640-35, 16-640-46, 16-641-00, 16-641-26, 16-641-46 O/S
16-637-11 Failed to open system jobs file. Failure RAP
16-638-66 Unable to initialize with queue library.
16-637-26 Failed to open system jobs file.
16-638-67 Unable to initialize with queue library.
16-637-38 Disk write error.
16-639-38 O/S failure memory.
16-637-47 Failed to open a file. Bad disk.
16-639-46 O/S failure memory.
16-637-66 File I/O error.
16-640-28 Calling program received void.
16-640-35 RPC send corrupt.
16-640-46 O/S failure.
16-641-00 Cannot log fault to network controller fault log. Either registration or network control-
Procedure ler fault service is not available.
16-641-26 Unable to log a fault on the network controller.

WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 16-641-46 Cannot log fault to network controller fault service.
WARNING

16-642-46, 16-642-47, 16-643-19, 16-643-26, 16-643-47, 16- 16-644-11, 16-644-26, 16-644-46, 16-644-47, 16-644-66, 16-
644-11 Unable To Close File RAP 644-67, 16-645-11, 16-645-26, 16-645-46, 16-645-47, 16-645-
16-642-46 Software error. 66, 16-645-67 Unable To Read From File RAP
16-644-11 Common logging utility failed to get log size.
16-642-47 Software error.
16-644-26 Common logging utility failed to get log size.
16-643-19 Disk write error.
16-644-47 Failed while trying to get data for next process to be verified.
16-643-26 Failed to close system jobs file.
16-643-47 Failed to close a file.
Procedure
16-645-11 Failed write to system jobs file.
WARNING 16-645-26 Failed write to system jobs file.

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-645-46 Failed to write to a file.
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. 16-645-47 Failed to write to a file.
Procedure
WARNING
2. For multiple occurrences, reinstall software GP 4.

16-646-26, 16-647-19, 16-647-26, 16-649-35, 16-650-35, 16- 16-651-19, 16-651-35, 16-651-99, 16-652-38, 16-652-99, 16-
650-99 Invalid Service Attribute RAP 653-38, 16-654-38, 16-654-99, 16-655-38, 16-656-38 Register
16-646-26 Failed to delete system jobs file. Failure RAP
16-651-19 IPC, OS, SESS or SC operation.
16-647-19 Lynx OS not responding
16-651-35 IPC and OS failure. SESS not responding.
16-647-26 Diagnostic failure, O/S failure.
16-651-99 IPC and OS failure. SESS not responding.
16-652-38 SPI enroll failed. Unable to enroll SPI callbacks.
16-650-35 Service making invalid attribute request.
16-650-99 Service making invalid attribute request.
Procedure
16-653-38 When DM passes completed job logged an invalid job.
WARNING 16-654-38 DM returned from SPI register function because of error.

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-654-99 DM returned from log function because of error.
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. 16-655-38 DM returned to SPI register function because of error.
16-656-38 RPC processing fault.
Procedure
WARNING

16-658-07, 16-659-11, 16-659-28, 16-659-93, 16-659-95, 16- 16-662-11, 16-662-28, 16-662-93, 16-662-95, 16-663-28, 16-
660-95, 16-660-99, 16-661-95 Parser Utility Open Failure 663-93, 16-663-95 Parser Utility Template Failed To Parse
RAP RAP
16-658-07 Unable to get host name. Configuration error. 16-662-11 Parser utility template failed to parse.
16-659-11 Parser utility open failure. 16-662-28 Parser utility template failed to parse.
16-660-95 Cannot read local directory entries. 16-663-28 Parser utility template failed to parse.
16-660-99 Service initialization failed. 16-663-93 Parser utility template failed to parse.
16-661-95 Cannot create spool directory. 16-663-95 Parser utility template failed to parse.
Procedure Procedure
WARNING WARNING

16-664-11, 16-664-28, 16-664-93, 16-664-95, 16-665-95 16-666-11, 16-666-28, 16-666-93, 16-666-95 Parser Utility
Parser Utility Closing Failure RAP Invocation Failed RAP
16-664-11 Parser utility parser closing failed. 16-666-11 Parser utility invocation failed.
16-665-95 Unable to detach from child thread. Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
death or injury. Moving parts can cause injury. 2. For multiple occurrences, reinstall software, GP 4.

16-667-11, 16-667-28, 16-667-95, 16-668-47 Parser Utility 16-668-93, 16-668-95 Unable To Determine Local File
Set Status Failure RAP Statistics RAP
16-667-11 Parser utility set status failed. 16-668-93 Unable to determine local file statistics.
16-667-28 Parser utility set status failed. 16-668-95 Unable to determine local file statistics.
16-667-95 Parser utility set status failed. Procedure

16-668-47 Failed to write NVM.
WARNING
WARNING 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-669-28, 16-669-93, 16-669-95, 16-670-00 Unable To Write 16-670-11, 16-670-28, 16-670-47, 16-670-93, 16-671-00, 16-
Job Template RAP 671-47 Unable To Decode Template File RAP
16-669-28 Unable to write job template to network controller disk. 16-670-11 Unable to decode template file.
16-669-93 Unable to write job template to network controller disk. 16-670-28 Unable to decode template file.
16-669-95 Unable to write job template to network controller disk. 16-670-47 Failed to save NVM.
16-670-00 Unable to lock/unlock data store. 16-670-93 Unable to decode template file.
Procedure 16-671-00 Sort jobs failed.
16-671-47 Failed to initialize NVM.

WARNING
WARNING
2. For multiple occurrences, reinstall software, GP 4. Ensure that the electricity to the machine is switched off while performing tasks that do
1. For a single occurrence, switch off the machine, then switch on the machine GP 14.

16-617-93, 16-671-95, 16-672-09, 16-672-95, 16-673-95, 16- 16-674-09, 16-675-00, 16-700-00, 16-701-00, 16-701-68, 16-
674-00, 16-674-09, 16-675-00, 16-6700-00, 16-700-35 File 701-99, 16-702-00, 16-702-95, 16-707-00, 16-709-00 XSA
Error RAP Database Failure RAP
16-671-93 Unable to encode template file. 16-674-09 RPC server not responding.
16-671-95 Unable to encode template file. 16-675-00 Database server not responding.
16-672-09 Software error. File system corruption. 16-700-00 In a list job request, an unknown attribute was requested.
16-672-95 Software error. File system corruption. 16-700-35 Unknown attribute requested passes into a function.
16-673-95 Software error. File system corruption. 16-701-00 LOA failure. Unable to communicate with XSA database.
16-674-00 RPC server not responding. 16-701-68 Unable to communicate with postgre database.
Procedure 16-701-99 LOA failure. Unable to communicate with XSA database.
16-702-00 LOA failure. Unable to communicate with XSA database.

WARNING
16-702-95 LOA failure. Unable to communicate with XSA database.
16-707-00 Unknown queue request received.
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. 16-709-00 Unknown modify request received.
Procedure
WARNING

16-710-00, 16-710-35, 16-716-00, 16-726-00, 16-728-00, 16- 16-718-00 to 16-16-724-00 Hard Disk Partition Full RAP
730-00, 16-730-28, 16-730-35, 16-730-66, 16-740-19, 16-750- 16-718-00 Data store threshold exceeded.
07, 16-750-09, 16-750-11 Unable To Create Client Handle 16-720-00 Disk partition root threshold exceeded.
RAP
16-710-00 Service being communicated to is dead. System resource corrupted. 16-722-00 Disk partition /var threshold exceeded.
16-710-35 Service trying to communicate to is dead. System resources corrupted. 16-724-00 Disk partition /tmp threshold exceeded.
16-716-00 Data store not created. Corrupt environment variable. Procedure
16-726-00 RPC connections exhausted.

WARNING
16-728-00 Range environment variable set to invalid numeric string. Ensure that the electricity to the machine is switched off while performing tasks that do
16-730-00 Unable to create client handle. death or injury. Moving parts can cause injury.
16-730-28 Unable to create client handle.
16-730-35 Unable to create client handle. 3. If the fault remains, install new components as necessary:
• (W/O TAG 006) HDD copy controller assembly, PL 3.10 Item 2.
16-730-66 Unable to create client handle. • (W/O TAG 006) Copy controller PWB, PL 3.10 Item 17.
• (W/TAG 006) HDD single board controller assembly, PL 3.11 Item 2.
16-740-19 Immediate image overwrite failed on network controller hard disk.
• (W/TAG 006) Single board controller PWB, PL 3.11 Item 13.
16-750-07 Message received from DM not processed correctly.
16-750-09 Service tried to register and service is already registered.
16-750-11 Template cache file is missing.
Procedure
WARNING

16-742-19 Hard Disk ODIO Failure RAP 16-750-14, 16-750-19, 16-750-26, 16-750-35, 16-750-38, 16-
16-742-19 Hard disk ODIO failure 750-46, 16-750-47, 16-750-66, 16-750-67, 16-750-90 Invalid
Request RAP
Procedure
16-750-14 Too many messages sent to SESS system control.
16-750-19 Invalid request data from calling service.

WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 16-750-26 Invalid number of faults requested.
death or injury. Moving parts can cause injury. 16-750-35 Data store failure.
2. For multiple occurrences, reinstall software, GP 4. 16-750-38 Initialization of SPI and job tracking table failed in SVC initialize service.
16-750-46 Client requested an unknown object or invalid object type.
16-750-47 Bad parameter returned.
16-750-66 Failure to set service state.
16-750-67 Failure to set service state.
16-750-90 Unexpected service sends this message.
Procedure
WARNING

16-750-92, 16-750-93, 16-750-95, 16-751-00, 16-751-07, 16- 16-751-28, 16-751-35, 16-751-38, 16-751-46, 16-751-66, 16-
751-09, 16-751-11, 16-751-14, 16-751-19, 16-751-26 751-67, 16-751-92, 16-751-93 Unknown Attribute RAP
Database Error RAP 16-751-28 Templates attributes are invalid, or syntax error.
16-750-92 Unable to open bit map captured to disk. bad or full disk.
16-751-35 Invalid queue ID.
16-750-93 IFS error when requesting memory.
16-751-38 Unknown attribute returned for completed job list.
16-750-95 Local spool area does not exist.
16-751-46 Client requested an unknown object or invalid object type.
16-751-00 Database err known by service registry or registry not available.
16-751-47 Failed to replace the current directory with directory from alt. partition.
16-751-07 Message received from network controller AAA not processed correctly.
16-751-66 Unable to send event to network controller ENS.
16-751-09 Registration receives unrequested ENS notification.
16-751-67 Unable to send event to network controller ENS.
16-751-11 Initialization procedure fails.
16-751-92 Cannot set job to complete.
16-751-14 SC not responding.
16-751-93 Invalid template attribute.
16-751-19 Invalid permission to change date.
Procedure
16-751-26 Unrecognized code. Service raises code that the fault service doesn’t know how to
handle.
WARNING
WARNING 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
Ensure that the electricity to the machine is switched off while performing tasks that do 2. For multiple occurrences, reinstall software, GP 4.

16-752-00, 16-753-00 File Cabinet Application Registration 16-752-07, 16-752-09, 16-752-14, 16-752-19, 16-752-26, 16-
Error RAP 752-28, 16-752-35, 16-752-46, 16-752-47 Invalid File Details
16-752-00 File cabinet application registration error RAP
16-752-07 Data store error.
16-753-00 File cabinet application un-registration error
16-752-09 Configuration control problem.
Procedure
16-752-14 SC not responding. SC IPC queue does not exist.
WARNING 16-752-19 RPC failure.

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 16-752-26 Unrecognized SESS error code.
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. 16-752-28 Template cache file is missing.
16-752-35 Invalid queue ID.
16-752-46 Invalid row of table object.
16-752-47 Invalid test pattern source.
Procedure
WARNING

16-752-66, 16-752-67, 16-752-92, 16-752-93, 16-752-95, 16- 16-753-35, 16-753-46, 16-753-47, 16-753-66, 16-753-67, 16-
753-09, 16-753-14, 16-753-19, 16-753-26, 16-753-28 Scan to 753-90, 16-753-92, 16-753-93, 16-753-95, 16-753-09 Data
FAX Registration Error RAP Store Read Failure RAP
16-752-66 Scan to FAX services registration error. 16-753-35 Unable to change EJS status to offline.
16-752-67 Scan to FAX services registration error. 16-753-46 Invalid table row.
16-752-92 Configuration problem. 16-753-47 Failed to close a directory during verification check. Corrupt disk.
16-752-93 Error accessing jobs in job list. 16-753-66 Data store read failure.
16-752-95 File transfer failure. 16-753-67 Data store read failure.
16-753-09 Software bug. 16-753-90 Software error.
16-753-14 Calling service used an invalid event number. 16-753-92 Configuration problem.
16-753-19 Invalid event information or data. ENS failure. System RPC information corrupt. 16-753-93 Error adding jobs in job list.
16-753-26 PSW failure. O/S failure. CCM failure. 16-753-95 Requested transfer protocol not supported.
16-753-28 Cannot communicate with UI for template list request. 16-754-09 Still registered services after time out.
Procedure Procedure
WARNING WARNING

16-754-14, 16-754-19, 16-754-26, 16-754-28, 16-754-35, 16- 16-754-90, 16-754-92, 16-754-92, 16-754-93, 16-754-95, 16-
754-46, 16-754-47, 16-754-66, 16-754-67, 16-754-68 OS 755-00, 16-755-09, 16-755-14, 16-755-19, 16-755-26, 16-755-
Error RAP 28 Fault Service Error RAP
16-754-14 Receipt is not there. Failure on ENS side. 16-754-90 Software bug.
16-754-19 Shutdown request reason unknown. 16-754-92 Data store failure.
16-754-26 Fault service encountered error reading fault log. File system corrupted. 16-754-93 Error deleting jobs from job list.
16-754-28 Initialization procedure fails. 16-754-95 Unable to remove advisory lock on network server.
16-754-35 OS corrupt. 16-755-00 Service registry cannot initialize database.
16-754-46 Attempted to write a read only object. Software configuration error. 16-755-09 Cannot register new service due to too many entries in SRV table.
16-754-47 Failed to replace a file that was missing with file from alt. partition. 16-755-14 Message buffer full. Full queue.
16-754-66 OS problem. 16-755-19 SESS system control broken or too many IPC messages.
16-754-67 OS problem. 16-755-26 Disk write error. Software error.
16-754-68 Initialize procedure fails. 16-755-28 Cancel request failed.
Procedure Procedure
WARNING WARNING

16-755-35, 16-755-46, 16-755-47, 16-755-67, 16-755-90, 16- 16-756-35, 16-756-46, 16-756-47, 16-756-66, 16-756-67, 16-
755-93, 16-755-99, 16-756-09, 16-756-14 Request Error RAP 756-93, 16-757-09, 16-757-14, 16-757-19, 16-757-26 NVM
16-755-35 OS corrupt. Software corrupt. Data store corrupt. Corrupt RAP
16-756-35 OS corrupt. Software error. NVM error.
16-755-46 Mismatched data type during object write. Software configuration error or request
mishandled configuration index data. 16-756-46 Poll select failed.
16-755-47 Failed to repair the permission of the current file being checked.
16-756-47 Executable missing or corrupt. Invalid test parameters.
16-755-67 Cancel request failed.
16-756-66 Unable to read NVM value.
16-755-90 Software limit reached. 16-756-67 Unable to read NVM value.
16-755-93 Unable to initialize with IFS.

16-756-93 IPA operation failed.
16-755-99 Unable to abort job fault.
16-757-09 System RPC corrupt.
16-756-09 Service not registered. 16-757-14 Programming bug. Attempted to shorten time out.
16-756-14 Client provided wrong binding information. Client not required as RPC server.
16-757-19 System manager died or communications link failed.
16-757-26 Software error. Bad disk.
Procedure Procedure
WARNING WARNING

16-757-35, 16-757-46, 16-757-47, 16-757-66, 16-757-67, 16- 16-758-35, 16-758-46, 16-758-47, 16-758-66, 16-758-67, 16-
757-93, 16-758-09, 16-758-14, 16-758-19, 16-758-26 Unable 758-93, 16-759-09, 16-759-14, 16-759-19, 16-759-26 Service
to Write NVM Value RAP Run Loop Failed RAP
16-757-35 OS corrupt. Software error. NVM corrupt. 16-758-35 Unable to change EJS state to offline.
16-757-46 O/S failure. 16-758-46 Failed setting up monitor routine with registration service.
16-757-47 Failed while trying to replace the file with a file from alt. partition. Configuration error. 16-758-47Error searching for job ID during print job submission. Print submission tool failed.
16-757-66 Unable to write NVM. 16-758-66 Service run loop failed.
16-757-67 Unable to write NVM. 16-758-67 Service loop failed.
16-757-93 Unable to set ICS document state. 16-758-93 Unable to obtain data store object handle.
16-758-09 Invalid service failure reported. 16-759-09 Software error.
16-758-14 RPC communications error to client. 16-759-14 Request for wildcard from non-NC
16-758-19 Unable to unregister registration service. 16-759-19 Network controller failed cold reset 3 times in a row.
16-758-26 Fault service encountered error trying to access its own queue ID. 16-759-26 Service requesting information of fault service. Software error.
Procedure Procedure
WARNING WARNING

16-759-46, 16-759-47, 16-759-66, 16-759-67, 16-759-93, 16- 16-760-47, 16-760-67, 16-760-68, 16-760-93, 16-760-99, 16-
760-09, 16-760-14, 16-760-19, 16-760-26, 16-760-46 Fail to 761-09, 16-761-14, 16-761-19, 16-761-26, 16-761-46 File
Enable Process RAP Error RAP
16-759-46 Process no in correct state, O/S failure. 16-760-47 Found incorrect checksum partition 1 during software verify check. Bad disk and
bad software.
16-759-47 Failed to abort the requested process.
16-760-67 Create list failed.
16-759-66 OA event register failed.
16-760-68 SRS returns to login service. Invalid fields, invalid data or missing data.
16-759-67 OA event register failed.
16-760-93 Job report failure from CCM.
16-759-93 Unable to create.dat file.
16-760-99 RPC failure. CCM not responding.
16-760-09 Software error. Check fault log for more specific reasons.
16-760-14 Software error. Calling service not registered.
16-761-14 Invalid RPC data.
16-760-19 Any network controller start up.
16-761-19 Any network controller shut down.
16-760-26 Software failure.
16-761-26 Unable to become client of UI.
16-761-46 Hardware failure.
Procedure
Procedure
WARNING
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. death or injury. Moving parts can cause injury.
2. For multiple occurrences, reinstall software, GP 4. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-761-47 to 16-769-95 Other Network Faults 1 RAP 16-765-93 Unable to access data store.
16-761-47 Failed to initialize. Files needed for software verify. 16-766-09 Adobe process failure. Check faults log for more specific reasons.
16-761-67 Failed to retrieve public list. 16-766-19 DM admin error.
16-761-68 Login gets no response from SRS. 16-766-46 Software failure.
16-761-93 Image conversion to TIFF failed. 16-766-47 No servers responded.
16-761-95 Unable to read template pool configuration information. 16-766-67 Failed to bind to LDAP server.
16-762-09 Netware process failed. Software error. Check fault log for more specific reasons. 16-766-93 TIFF handle has become null.
16-762-14 Invalid internal table type. 16-766-95 Cannot create image file name.
16-762-19 DC platform mgr communication error. 16-767-09 Software error. Check fault log for more specific reasons.
16-762-26 Unable to become client of SCS diagnostic service. 16-767-19 Request to cancel spooling job error. Job map library unable to cancel job.
16-762-46 Hardware failure. 16-767-46 Software failure.
16-762-47 Missing file found during software verify check. Disk access problem. Configuration 16-767-47 Server name in configuration list is not up.
problem. 16-767-67 Error performing LDAP search.
16-762-67 Invalid index for recipient list. 16-767-93 Get document image count failed.
16-762-68 Service registry bad data corrupted. 16-767-95 Cannot determine filing policy for transfer.
16-762-93 IFS Image done call failed. 16-768-09 Software error. Check fault log for more specific reasons.
16-762-95 Unable to read document repository configuration information. 16-768-19 Job map library unable to hold or release jobs.
16-763-09 Software error. Check fault log for more specific reasons. 16-768-46 Software failure.
16-763-14 Reached internal limit for events. 16-768-47 Network controller not attached to server.
16-763-19 System manager died, its platform crashed or RPC comm corrupt. 16-768-67 Error performing public search.
16-763-26 No acknowledgment to RPC message. RPC time-out. 16-768-93 Increment image count failed.
16-763-46 Hardware failure. 16-768-95 Cannot get network advisory lock file name.
16-763-47 Invalid permission found during software verify check. 16-769-09 Software error. Check fault log for more specific reasons.
16-763-67 Failed to retrieve LDAP list. 16-769-19 Novell network failed to respond to request.
16-763-93 Document image count not found. 16-769-46 Software failure.
16-763-95 Internal destination error. 16-769-47 Network controller not attached to the print queue.
16-764-09 Apple talk process failure. Software error. Check fault log for more specific reasons. 16-769-67 Failed to cancel search request.
16-764-14 Internal logic error. 16-769-93 IFS de-register call failed.
16-764-19 System call to signal failed. 16-769-95 Cannot determine appropriate lock name and address.
16-764-46 Hardware failure. Procedure
16-764-47 Found incorrect checksum during software verify check. Bad disk and bad software.
16-764-67 Create list failed.
WARNING
16-765-19 Set status failed. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
16-765-46 Software failure. death or injury. Moving parts can cause injury.
16-765-47 Novell daemon not running.
16-765-67 Failed to retrieve recipient list.

16-770-09 to 16-779-95 Other Network Faults 2 RAP 16-776-46 TCPIP invalid interface.
16-776-95 Cannot clean up after job completion.
16-770-19 SESS/DM job command not processed. 16-777-09 Software error. Check fault log for more specific reasons.

16-777-19 Software error. Data store corrupt, missing configuration.
16-770-47 Network controller attached to both queue and server.
16-777-46 TCPIP invalid addressing.
16-770-67 Required attribute missing. 16-777-95 Cannot log requested network server.
16-771-19 UI/PSW/RDT/ RPC corrupt.
16-771-46 Software failure. 16-778-46 TCPIP socket failure.
16-771-47 Failed to configure novell network.

16-778-95 Cannot generate confirmation sheet.
16-779-00 System manager power saver complete callback failed. System manager failed or
communications link failed.
16-772-46 TCPIP address already being used.
16-779-19 System manager callback SM power save completed failed.
16-772-47 Failed doing registration or RPC call.
16-779-46 TCPIP interface attach.
16-772-95 Invalid transfer request.
16-779-47 SESS diagnostic failure.
16-779-95 Cannot create the template/job log name.
16-773-46 Failed requesting platform reset.

Procedure
16-774-09 Check fault log for more specific reasons.

WARNING
16-774-19 Client provided wrong binding info. Client not registered as RPC server. System Ensure that the electricity to the machine is switched off while performing tasks that do
RPC info is corrupt. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
16-774-46 BOOTP status file error. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
16-775-19 Data store not configured. Software error.
16-775-46 TCPIP missing configuration data.
16-775-95 Cannot create temporary file name.

16-770-09 to 16-779-95 2-260 Xerox® ColorQube® 9203 Family
16-780-00 to 16-789-47 Other Network Faults 3 RAP 16-785-19 UI does not respond to upgrade prep command.
16-780-00 Power save request time out.
16-785-46 TCPIP resolve file failure.
16-780-09 Software error. Check fault log for more specific reasons. 16-785-47 SESS diagnostic failure.
16-780-19 Power saver request time out.

16-786-09 Software error. Check alt log for more specific reasons.
16-780-46 TCPIP enable interface.
16-786-19 Network controller ntar of upgrade file fails.
16-780-47 SESS diagnostic failure. 16-786-46 TCPIP ELT file failure.
16-780-95 Cannot determine the remote directory.

16-787-09 Software error. Check fault log more specific reasons.
16-781-19 Customer software upgrade file is corrupted on transfer. 16-787-19 Network controller times out. Cannot communicate with IOT.
16-781-46 TCPIP NVRAM failure.

16-787-46 TCPIP IPC failure.
16-782-09 Network controller configuration synchronization process failure. Software error. 16-788-09 Software error. Check fault log for more specific reasons.
check fault log for more specific reasons.
16-788-19 Option load failure software.
16-782-19 Software upgrade manifest file does not match software upgrade files.
16-788-46 Failed performing dynamic DNS update.
16-782-46 TCPIP gateway failure.
16-783-09 Software error. IPC failure. SC not processing IPC.
16-783-19 Network controller does not enter upgrade mode. Network controller does not
respond to upgrade prep command. 16-789-46 Failed performing autonet IP process.
16-783-46 TCPIP host file failure.

Procedure
16-784-09 Software error. Registration service out of date.
16-784-19 Software upgrade aborted, IOT failed to enter upgrade mode. IOT does not respond WARNING
to upgrade prep command. Ensure that the electricity to the machine is switched off while performing tasks that do
16-784-46 TCPIP resolve file failure. death or injury. Moving parts can cause injury.
16-784-47 SESS diagnostic failure. 2. For multiple occurrences, reinstall software, GP 4.
16-785-09 Network controller agent process failure. Software error. Check fault log for more
specific reasons.

16-790-09 to 16-799-47 Other Network Faults 4 RAP 16-798-09 Software error. Check fault log for more specific reasons.
16-798-19 Option already enabled.
16-790-19 Option load failure software. 16-798-47 SESS diagnostic failure.

16-799-19 Option already enabled.
16-791-19 Scan to file DLM is not defined. 16-799-47 SESS diagnostic failure.
16-791-46 DHCP V6 failure

Procedure
16-792-09 Software error. Check fault log for more specific reasons. WARNING
16-792-19 Lan fax DLM is not defined. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
16-792-47 SESS diagnostic failure. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
16-793-19 Job based accounting DLM is not defined.
16-794-09 Cross platform synchronization error.
16-794-19 Install password mismatch.

16-800-09 to 16-809-47 Other Network Faults 5 RAP 16-807-09 Job log service unavailable.
16-800-09 List access failure (create, add, find, delete.)
16-807-19 State change failed.
16-800-19 Option not supported. 16-807-47 SESS diagnostic failure.
16-800-46 Unable to connect to device when setting up IP over Ethernet.

16-808-00 Job tracker death error.
16-808-09 Job tracker service unavailable.
16-801-09 Invalid SESS event/IPC error. 16-808-47 SESS diagnostic failure.
16-801-19 Serial mismatch.

16-809-00 Kerberos death error.
16-801-46 Unable to connect to device when setting up IP over token ring.
16-809-09 Kerberos service unavailable.
16-801-47 SESS diagnostic failure. 16-809-47 SESS diagnostic failure.
16-802-09 Web service edge client process death.

Procedure
16-802-19 Counters do not match.
16-802-46 Error occurred when attempting to get the IP data from the DHCP server. WARNING
16-802-47 SESS diagnostic failure. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
16-803-09 Web service edge client process death. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
16-803-46 Unable to get the IP address from the RARP server.
16-805-19 Accounting install failed.
16-806-00 CPI death error.
16-806-09 CPI service unavailable.
16-806-19 Counters did not increment.
16-807-00 Job log service death error.

16-810-00 to 16-16-819-47 Other Network Faults 6 RAP Procedure
16-810-00 Scan to distribution death error.
16-810-09 Scan service available. WARNING

16-810-19 Failed to remove accounting. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
16-810-47 SESS diagnostic failure. 1. For a single occurrence, switch off the machine, then switch on the machine, GP 14.
16-811-00 SMB death error.
16-811-09 SMB service unavailable.
16-811-19 Failed to initiate operation.
16-812-00 TCP/IP death error.
16-812-09 TCPIP service unavailable.
16-812-19 Failed to change the enable upgrade flag.
16-813-00 WS scan temp death error.
16-813-09 Scan service unavailable
16-814-00 Scan compressor death error.
16-814-09 Scan compressor service unavailable.
16-815-09 Service registry process death.
16-816-09 EIP service not responding.

16-810-00 to 16-16-819-47 2-264 Xerox® ColorQube® 9203 Family
16-820-47 to 16-829-47 Other Network Faults 7 RAP 16-830-47 to 16-839-47 Other Network Faults 8 RAP
16-820-47 SESS diagnostics failure. 16-830-47 Unable to get the default router for the device.
16-821-47 SESS diagnostics failure. 16-831-47 Unable to get the subnet mask for the device.
16-822-47 SESS diagnostics failure. 16-832-47 Failure while getting local IP devices on the network.
16-823-47 SESS diagnostics failure. 16-833-47 Failure while perfuming ARP command.
16-824-47 SESS diagnostics failure. 16-834-47 Failed to get a default file server from the config. utility.
16-825-47 SESS diagnostics failure. 16-835-47 Failed to the novell frame type from the config. utility.
16-826-47 SESS diagnostics failure. 16-836-47 Failed SESS call to initialize netware.
16-827-47 SESS diagnostics failure. 16-837-47 Diagnostic name returned from SESS not found in list.
16-828-47 SESS diagnostics failure. 16-838-47 Failed to setup catching alarm signals for repair time outs.
16-829-47 SESS diagnostics failure. 16-839-47 Failure to repair a file of file length 0. Corrupt disk.
Procedure Procedure
WARNING WARNING

16-840-47 Corrupt OS, software error. 16-850-47 Failed adding stream to stream editor array.
16-841-47 Corrupt file system. 16-851-47 Failed on call to stream editor.
16-842-47 Machine out of configuration. Software error. 16-852-47 Unable to read a fault for the error report.
16-843-47 Corrupt OS machine in bad running state. Software error. 16-853-47 Failed getting the last reset time for the error report.
16-844-47 Corrupt OS machine in bad running state. Software error. 16-854-47 Failed calling fault service for the error report.
16-845-47 Corrupt OS machine in bad running state. Software error. 16-855-47 Failed sending event for diagnostic test.
16-846-47 Corrupt OS machine in bad running state. Software error. 16-856-47 Failed doing a unix c system call.
16-847-47 Corrupt OS machine in bad running state. Software error. 16-857-47 Abort request, unable to find process.
16-848-47 Error reading the fault file from fault service. 16-858-47 Failed to dump the fault logs.
16-849-47 Error creating command array from stream editor. 16-859-47 Software verify test returned error.
Procedure Procedure
WARNING WARNING

16-860-47 No machines responded to an ICMP echo request. 16-870-47 SESS NETBIOS test illegal name number.
16-861-47 Failed setting up monitor routine with registration service. 16-871-47 SESS NETBIOS test cannot find name or no answer.
16-862-47 Command not valid to cancel. 16-872-47 SESS NETBIOS test name in use.
16-863-47 Illegal buffer length. 16-873-47 SESS NETBIOS test name deleted.
16-864-47 Illegal local session number. 16-874-47 SESS NETBIOS test session abnormal end.
16-865-47 SESS NETBIOS test session closed. 16-875-47 SESS NETBIOS test name conflict. Name conflict on network.
16-866-47 SESS NETBIOS test command cancelled. 16-876-47 Software verify setup SIGTERM failed.
16-867-47 SESS NETBIOS test name de-registered. Name de-registered, session active. 16-877-47 SESS PCI test unknown error.
16-868-47 SESS NETBIOS test local session table full. Local session table full. 16-878-47 SESS PCI test failed to open driver.
16-869-47 SESS NETBIOS test no listen in remote computer. 16-879-47 SESS PCI test failed flushing stream buffer.
Procedure Procedure
WARNING WARNING

16-880-47 to 16-890-47 Other Network Faults 13 RAP 16-891-00, 16-892-00 Edge Server Auto Registration Failed
16-880-47 SESS PCI test failed on put message call. RAP
16-891-00 Edge server auto registration failed
16-881-47 SESS PCI test invalid argument.
16-892-00 Edge server communication failed
16-882-47 SESS PCI test failed on put message call.
16-883-47 SESS PCI test failed on ioctl call.

Procedure
16-884-47 SESS PCI test control flag area too small.

WARNING
16-885-47 SESS PCI test driver not initialized. Ensure that the electricity to the machine is switched off while performing tasks that do
16-886-47 SESS PCI test info request failed. death or injury. Moving parts can cause injury.
16-887-47 SESS PCI test driver failed to register. 2. For multiple occurrences, reinstall software, GP 4.
16-888-47 SESS PCI test driver failed to unregister.
16-889-47 Software verify get data failed.
16-890-47 Software verify get next proc failed.
Procedure
WARNING

16-900-19 Failed to open SMC driver. 16-910-19 Failed untar file.
16-901-19 Failed to make ioctl call using SMC driver. 16-911-19 Error changing directory.
16-902-19 Address specified is invalid. 16-912-19 Install script did not execute.
16-903-19 Result from ioctl does not match FD. 16-913-19 Write failure to file.
16-904-19 Invalid ioctl request. 16-914-19 Shared memory was corrupted.
16-905-19 Unknown ioctl failure. 16-915-19 Open failed.
16-906-19 Malloc failed for net upgrade. 16-916-19 CRC failed.
16-908-19 Error opening file. 16-917-19 Failed to close on checksum.
16-909-19 Error transfer data to CCM. 16-918-19 CRC comparison failed.
Procedure 16-919-19 Restart request failed.
Procedure
WARNING
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

16-920-19 ELT daemon start failed. 16-930-19 Failed to remove jobs.
16-922-19 NVM store failed. 16-931-19 Failed to close on SMC driver.
16-923-19 Failed saving persistent data. 16-932-19 NVM write failure.
16-924-19 Failed in restoring persistent data. 16-933-19 Failed to remove file.
16-925-19 Failed saving web config data. 16-934-19 Job based accounting not enough dc memory.
16-926-19 Failed to save data store values. 16-935-19 Auto-upgrade failed. Cannot read/write attributes to machine.
16-927-19 Failed to restore web config data. 16-936-19 Auto-upgrade failed. Cannot connect to remote server.
16-928-19 Failed to install files. 16-937-19 Auto-upgrade failed. Cannot access directory on remote server.
16-929-19 Failed to restore data store values. 16-938-19 Auto-upgrade failed. Cannot access directory remote server.
Procedure 16-939-19 Auto-upgrade failed. Multiple upgrade files found on remote server.
Procedure
WARNING
1. For a single occurrence, switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

16-940-19 Auto-upgrade failed. Machine in diagnostics mode. 16-950-19 Scan to email image processing hardware not available.
16-941-19 Auto-upgrade failed. Network controller cannot communicate with main controller. 16-951-19 Internet fax image processing hardware not available.
16-942-19 Auto-upgrade failed upgrade is invalid. Incompatible with main controller. 16-952-19 Scan to email memory size error.
16-943-19 Auto-upgrade failed. Upgrade file invalid. Installed software is more recent. 16-953-19 Internet fax memory size error.
16-944-19 Auto-upgrade failed. Upgrade file is invalid. File corruption detected. 16-954-19 Set by internet fax service when it gets no response from service registry when try-
ing to register.
16-945-19 Auto-upgrade failed. Upgrade file is invalid. File not appropriate for current machine
software. 16-958-19 Failed to install kerberos.
16-946-19 Failed install scan to email. 16-959-19 Failed to install SMB.
16-947-19 Failed to install internet fax. Procedure

16-948-19 Remove of scan to email option failed.
WARNING
16-949-19 Remove of internet fax option failed.
Procedure death or injury. Moving parts can cause injury.
WARNING 2. For multiple occurrences, reinstall software, GP 4.
2. Verify that the correct software file is being used, refer to GP 4.

16-960-19 Failed to install SMTP. 16-975-19 Failed to install immediate image overwrite.
16-961-19 Failed to remove kerberos. 16-976-19 Failed to install immediate image overwrite.
16-962-19 Failed to remove SMB. 16-977-00 Queue list jobs failure. Request to SESS’s document manager failed for list jobs.
Corrupt data sent to DM communication problem Dm failed.
16-963-19 Failed to remove SMTP.
16-977-19 Network controller PM failed to remove disk overwrite. Option load failure software.
16-964-19 Failed to cancel operation.
16-977-35 Queue list jobs failure. Request to SESS’s document manager failed for list jobs.
16-965-19 Failed to send platform unavailable. Corrupt data sent to DM. Communication problem DM failed.
16-966-19 Failed to install job tracker. 16-978-00 Unable to get copy jobs. Invalid data communication problem.
16-967-19 Failed to remove job tracker. 16-978-19 Network controller PM failed to remove job overwrite. Option load failure software.
16-968-19 Failed to install POP3. 16-978-35 Unable to get copy jobs. Invalid data communication problem.
16-969-19 Failed to remove POP3. 16-979-00 Unknown attribute returned. Invalid data returned data store corrupt
Procedure 16-979-19 Network controller PM failed to remove embedded fax. Option load failure software.
16-979-35 Unknown attribute returned. Invalid data returned data store corrupt.
WARNING
WARNING

16-980-00 DM request handle NULL. Null data received from DM. 16-990-00 Promote response from DM received with errors. Software error.
16-980-19 Network controller PM failed to install G4. Option load failure software. 16-990-35 Promote response from DM received with errors. Software error.
16-980-35 DM request handle NULL. Null data received from DM. 16-991-00 Request to DM to promote job failed. Failure status returned on call to request
library to promote job. Data store problem.
16-981-00 Object handler corrupted. Null handle returned. Data store corrupt.
16-991-35 Request to DM to promote job failed. Failure status returned on call to request
16-981-35 Unable to obtain job handle which is used to fetch data store attributes.
library to promote job. Data store problem.
16-982-00 Unknown finishing value returned. Unable to map attribute or invalid data.
16-992-00 Unable to build SESS job identifier for promote routing that converts the job ID
16-982-19 Failed to remove embedded fax. returned. Null memory allocation error.
16-982-35 Unknown finishing value returned. Unable to map attribute or invalid data. 16-992-35 Unable to build SESS job identifier for promote routine that converts the job ID
returned. Null memory allocation error.
16-983-00 Unknown offset value returned. Unable to map attribute or invalid data.
16-993-00 Unable to get admin name from data store for promote. Request library call failed.
16-983-19 Failed to remove G4.
16-993-35 Unable to get admin name from data store for promote. Request library call failed.
16-983-35 Unknown offset value returned. Unable to map attribute or invalid data.
16-994-00 Cancel response from DM received with errors. Software error.
16-984-00 Unknown job state reason value returned. Unable to map attribute or invalid data.
16-994-35 Cancel response with errors. A job could not be cancelled.
16-984-35 Unknown job state reason value returned. Unable to map attribute or invalid data.
16-995-00 Request to DM to cancel job failed.
16-985-00 Unknown medium type value returned. Unable to map attribute or invalid data.
16-995-35 Request to DM to cancel job failed.
16-985-35 Unknown medium type value returned. Unable to map attribute or invalid data.
16-996-00 Routine that converts the job ID returned. Null memory allocation error.
16-986-00 Unknown collection value returned. Unable to map attribute or invalid data.
16-996-35 Routine that converts the job ID returned. Null memory allocation error.
16-986-35 Unknown collection value returned. Unable to map attribute or invalid data.
16-997-00 Request library call failed.
16-987-00 Unknown tray value returned. Unable to map attribute or invalid data.
16-997-35 Request library call failed.
16-987-35 Unknown tray value returned. Unable to map attribute or invalid data.
16-998-00 Job not found in held table.
16-988-00 Unknown signature value returned. Unable to map attribute or invalid data.
16-998-35 Job not set to released state. Job not found in held table.
16-988-35 Unknown signature value returned. Unable to map attribute or invalid data.
16-999-00 Could not obtain job PIN for authorization.
16-989-00 Unknown plex value returned. Unable to map attribute. Invalid information received 2.
16-999-35 Could not obtain job PIN for authorization.
16-989-35 Unknown plex value returned. Unable to map attribute. Invalid information received 3.
Procedure
Procedure
WARNING
WARNING

16-954-19, 16-955-19 Internet Fax Application Registration 16-956-19, 16-957-19 E-mail Application Registration Error
Error RAP RAP
16-954-19 Internet Fax application registration error 16-956-19 E-mail application registration error
16-955-19 Internet Fax application un-registration error 16-957-19 E-mail application un-registration error
Procedure Procedure
WARNING WARNING
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. 1. If a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-954-19, 16-955-19, 16-956-19, 16-957-19 2-274 Xerox® ColorQube® 9203 Family
16-985-19, 16-986-19 Network Scanning Application 16-987-19, 16-988-19 Server Fax Application Registration
Registration Error RAP Error RAP
16-985-19 Network scanning application registration error 16-987-19 Server Fax application registration error
16-986-19 Network scanning application un-registration error 16-988-19 Server Fax application un-registration error
Procedure Procedure
WARNING WARNING
1. If a single occurrence, switch off the machine, then switch on the machine, GP 14. 1. If a single occurrence, switch off the machine, then switch on the machine, GP 14.

16-989-19 Disk Encryption Operation Failed RAP 16A Network Error Entry RAP
16-989-19 Disk encryption operation failed Use this RAP when the customer reports network failures. e.g. Cannot connect to the scan
server when using the FPT or SMB protocols, or when a folder on the scan server cannot be
Procedure opened.
NOTE: The fault message will be printed on the confirmation report. The report may take sev-
WARNING eral minutes to print after scanning the document.
Ensure that the electricity to the machine is switched off while performing tasks that do Initial Actions
Consult your manager before troubleshooting the customer’s network, as the policy varies
according to region.
Procedure
NOTE: If it is possible to log into the web UI by entering the IP address of the machine, then
the network controller PWB or the single board controller PWB is good.
1. Check that the machines date and time are correctly set, refer to GP 38.
2. Print a configuration report.
3. Check with customer that the printing of the confirmation report is enabled. If necessary,
ask the customer to enable printing of the confirmation report.
4. Ensure that the machine is configured for scan to file:
a. Check the back of the configuration report under the heading Workflow Scanning.
b. If a IP address or name is not listed next to Alt1 Repository Protocol, ask the cus-
tomer to configure the machine before continuing.
5. Go to the relevant procedure:
• 16B FTP or SMB Unable to Connect to Remote Server RAP.
• 16C Remote Directory Lock Failed RAP.

16-989-19, 16A 2-276 Xerox® ColorQube® 9203 Family
A
16B FTP or SMB Unable to Connect to Remote Server RAP Y N
Perform an Altboot, GP 4.
Either the machine cannot connect, find or login to the scan server.
The machine software is up to date.
Procedure Y N
Upgrade the software, GP 4. The fault persists.
NOTE: The FTP/SMB protocol will be followed by a colon and port number, :21 is for FTP and
:139 is for SMB. Y N
Scan the document using the default template and one other template. The fault is present
on both templates. Perform the Customers Settings Check. Changes were made to the customers
Y N settings.
The template that failed is incorrectly configured. Ask the customer or system administra- Y N
tor to verify the settings of the web template that failed, including the login password. Escalate the fault to the system Administrator. If the customer does not have a
System Administrator, they should contact the Customer Support Centre or
Ask the customer to open the machines CWIS page. The machines CWIS page can be request a Xerox analyst troubleshoot their network which will be subject to a
opened. charge.
Y N
Look at the front of the configuration report. Make sure that HTTP is enabled and set to Retry the job. The job was successful.
port 80. The settings are correct. Y N
Y N Escalate the fault to the system Administrator. If the customer does not have a
Enable HTTP, GP 39 and set the port to 80 on the UI. Restart this RAP from the System Administrator, they should contact the Customer Support Centre or
beginning. If this path has been followed previously, escalate the fault to the system request a Xerox analyst troubleshoot their network which will be subject to a
Administrator. If the customer does not have a System Administrator, they should charge.
contact the Customer Support Centre or request a Xerox analyst troubleshoot their
network which will be subject to a charge. Perform SCP 5 Final Actions.
Disconnect the network cable from the machine. Make sure the PWS network adaptor Perform the Customers Settings Check. Changes were made to the customers set-
settings are set to Auto. Use a crossover cable, PL 26.10 Item 2 to connect the PWS to tings.
the machine. Either the two LEDs on the (W/O TAG 006) network controller PWB, Y N
(W/TAG 006) SBC PWB or the PWS are lit, indicating a connection. Escalate the fault to the system Administrator. If the customer does not have a Sys-
Y N tem Administrator, they should contact the Customer Support Centre or request a
Perform the following: Xerox analyst troubleshoot their network which will be subject to a charge.
1. Change the network speed setting of the machine, GP 43.
2. If either the two LEDs on the (W/O TAG 006) network controller PWB, (W/TAG Retry the job. The job was successful.
Y N
006) SBC PWB or the PWS are not lit, repeat the steps in GP 43.
Escalate the fault to the system Administrator. If the customer does not have a Sys-
3. If the LEDs light, use the new network speed setting. Inform the customer that
tem Administrator, they should contact the Customer Support Centre or request a
the network speed has been changed then follow the Yes path from this step. Xerox analyst troubleshoot their network which will be subject to a charge.
4. (W/TAG 006) If the LEDs do not light, install a new single board controller PWB,
PL 3.11 Item 13. Perform SCP 5 Final Actions.
5. (W/O TAG 006) If the LEDs do not light, install a CBC to SBC conversion kit, PL
31.10 Item 17. Ask the customer to ping the scan servers IP address or name.
NOTE: Refer to service bulletin T8260-05-14 - End of life for Single Board Controller NOTE: The scan server is the computer that the job is being sent. The scan servers IP address
Conversion Kit. or name is displayed on the confirmation report.
Correctly configure the IP address of the PWS, GP 42. Make sure the firewall of the PWS The customer can ping the scan server.
is disabled, GP 44. Ping the machine from the PWS, GP 41. Y N
Check the configuration report for default gateway IP address listed under TCP/IPv6 Set-
NOTE: Re-enable the PWS firewall after completion of this procedure.
tings. A default gateway IP address is listed.
The machine responds to the ping request.
A B
B
Y N Customers Settings Check
Perform the Customers Settings Check. Changes were made to the customers
settings. NOTE: Both the configuration and confirmation reports are required to check the customers
Y N settings. Corrections must be made through the machines CWIS page.
Escalate the fault to the system Administrator. If the customer does not have a
Check the following with the customer, ask the customer to correct any errors:
System Administrator, they should contact the Customer Support Centre or
1. That the scan server is switched on and online.
request a Xerox analyst troubleshoot their network which will be subject to a
charge. NOTE: The scan server is the computer that the job is being sent.
Retry the job. The job was successful. 2. That the scan servers IP address or name is correct.
Y N 3. That the path and user name are correct.
Escalate the fault to the system Administrator. If the customer does not have a 4. (SMB protocol only) That the Share name is correct, referred too as the Volume on the
System Administrator, they should contact the Customer Support Centre or configuration report.
request a Xerox analyst troubleshoot their network which will be subject to a
5. Check with System Administrator that the correct password has been entered on the
charge.
machines CWIS page.
Perform SCP 5 Final Actions. NOTE: The password is not printed on the configuration or confirmation reports.
The customer can ping the default gateway IP address.

Y N
Xerox analyst troubleshoot their network which will be subject to a charge.
Perform the Customers Settings Check. Changes were made to the customers set-
tings.
Y N
Retry the job. The job was successful.

Y N
Perform the Customers Settings Check. Changes were made to the customers settings.
Y N
Escalate the fault to the system Administrator. If the customer does not have a System
Administrator, they should contact the Customer Support Centre or request a Xerox ana-
lyst troubleshoot their network which will be subject to a charge.
Retry the job. The job was successful.

Y N
Escalate the fault to the system Administrator. If the customer does not have a System
Administrator, they should contact the Customer Support Centre or request a Xerox ana-
lyst troubleshoot their network which will be subject to a charge.

16B 2-278 Xerox® ColorQube® 9203 Family
16C Remote Directory Lock Failed RAP
Use this RAP when the customer reports that the machine has logged onto the scan server,
but cannot create a folder inside of the scan directory. The creation of the scan folder is neces-
sary for the machine to successfully complete the can to file job.
NOTE: The scan server is the computer that the job is being sent.
Procedure
The machines login name that it is using to log onto the scan server, for this file repository,
does not have sufficient rights. Ask the customer to verify the rights for this user at the scan
server, or escalate the problem to their System Administrator. If the customer does not have a
System Administrator, they should contact the Customer Support Centre or request a Xerox
analyst troubleshoot their network which will be subject to a charge.

Xerox® ColorQube® 9203 Family 2-279 16C
16C 2-280 Xerox® ColorQube® 9203 Family
19-300-00 to 19-310-00 Image Disk (HDD 1) Failure RAP For machines W/O TAG 006, install new components as necessary:
• Hard disk drive 1, PL 3.10 Item 2.
19-300-00 Unable to read or write data from the image disk.
19-301-00 Unable to write data to the image disk. For machines W/TAG 006, install new components as necessary:
• Hard disk drive, PL 3.11 Item 2.
19-302-00 Bad data received from the disk (i.e. disk returns data other than a read or write • Single board controller PWB, PL 3.11 Item 13.
operation in response to a read or write request from).
19-303-00 Unable to format the image disk.
19-310-00 Disk system does not return capacity information during power up.
Procedure
WARNING
On machines W/O TAG 006, check that the SATA cable from PJ5 on the Copy Controller PWB
to PJ210 on hard disk drive 1 is correctly connected and not damaged. If necessary, install a
new cable, PL 3.10 Item 3.
On machines W/TAG 006, check that the SATA cable from PJ222 on the single board control-
ler PWB to PJ210 on the hard disk drive is correctly connected and not damaged. If necessary,
install a new cable, PL 3.11 Item 3.
For machines W/O TAG 006, check the power harness from PJDC4 / PJ215 on the power sup-
ply unit to PJ211 on hard disk drive 1.
For machines W/TAG 006, check the power harness from PJDC4 / PJ215 on the power supply
unit to PJ211 on the hard disk drive. The wiring is good.
Y N
For machines W/O TAG 006, repair the harness, REP 1.1 or install a new harness, PL
3.10 Item 16, as necessary.
For machines W/TAG 006, repair the harness, REP 1.1 or install a new harness, PL 3.11
Item 12, as necessary.
For machines W/O TAG 006, refer to WD 1.7 and WD 3.3. Measure +5V between pins 4 and 3
on PJ13 on the Power Distribution PWB.
For machines W/TAG 006, refer to WD 1.7 and WD 3.6. Measure +5V between pins 4 and 3 on
PJ13 on the Power Distribution PWB. +5V was measured.
Y N
Go to 01D +5V Distribution RAP.
For machines W/O TAG 006, measure +12V between pins 1 and 2 on PJ13 on the Power Dis-
tribution PWB.
For machines W/TAG 006, measure +12V between pins 1 and 2 on PJ13 on the Power Distri-
bution PWB. +12V was measured.
Y N
Go to 01E +12V Distribution RAP.
If necessary, perform a software upgrade, GP 4.

19-401-00, 19-402-00 Stress Out of Memory RAP 19-403-00 EPC Out of Memory RAP
19-401-00 Out of memory caused by a stress document. 19-403-00 Out of memory with greater than one job in EPC.
19-402-00 Out of memory caused by a stress job. Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause No service action is required. Re-scan the job.
If this fault remains for more than five minutes, switch off the machine, then switch on the
machine, GP 14. The fault has cleared.
Y N
Perform a software upgrade, GP 4.
Go to SCP 5 Final Actions.

19-409-00 Job Integrity Failure RAP 19-410-00 to 19-410-13 Image Structure Failure RAP
19-409-00 Video determines that it cannot guarantee the integrity of the job being processed. 19-410-00 The system has detected a mark output time-out.
19-410-01 The system has detected a mark output time-out.
Procedure
19-410-02 The system has detected a compress image time-out.
19-410-03 The system has detected a decompress image time-out.
WARNING
19-410-04 The system has detected a merge image time-out.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 19-410-05 The system has detected a rotate image time-out.
19-410-06 The system has detected a network Input failure.
19-410-07 The system has detected an e-fax send/receive failure.
1. Switch the off machine, then switch on the machine, GP 14.
2. Re-run all the uncompleted jobs. 19-410-08 The system has detected a scan input failure.
19-410-09 The system has detected a byte counter error.
19-410-10 The system has detected the image set up was too late.
19-410-11 The system has detected a DMA master abort.
19-410-12 The system has detected a Huffman error, (image encoding error).
19-410-13 The system has detected an EOR error.
Procedure
WARNING
If this fault remains for more than five minutes, switch off the machine, then switch on the
machine, GP 14. Re-run the job. The fault has cleared.
Y N
• Check the in-line connectors PJ 15 and PJ 19 from the scanner and the UI.
• W/O TAG 006 machines.
– Ensure the machine is at software level 060.050.009.30823 or higher.
– If the machine is at soft ware level 060.050.009.30823 perform the T7481 ser-
vice bulletin procedure.
• W/TAG 006 machines.
– Perform a software re-load, GP 4.
– Reseat all connections on the scanner PWB
– If necessary install a new scanner PWB, PL 62.16 Item 8 W/O TAG 007, PL
62.17 Item 1 W/ TAG 007.
– If the problem is intermittent and the Identify Deleted Jobs message is dis-
played on the UI, install a new SBC PWB.

19-750-00 EPC Memory Change Detected RAP 19-752-00 Image Rotation Detected RAP
19-750-00 The system detects that the EPC memory size configuration has changed during 19-752-00 The system detects that the image rotation configuration has changed during the
the power on sequence. Power On sequence.
Procedure Procedure
WARNING WARNING
No service action required. Re-run the job. Switch off the machine, then switch on the machine, GP 14. Re-run the job.

19-754-00 Image Disk Change RAP
19-754-00 The system detects that the Image disk configuration (present vs. not present) has
changed during the power on sequence.
Procedure
WARNING
Switch off the machine, then switch on the machine, GP 14. Re-run the job. The fault has
cleared.
Y N
Go to 19-300-00 to 19-310-00 Image Disk (HDD 1) Failure RAP.

20-302-00, 20-303-00 Fax Reset Failure RAP 20-305-00 Fax System Low Memory Unrecoverable RAP
The embedded fax PWB will automatically reset itself. The embedded fax PWB will automatically reset itself.
20-302-00 Unexpected reset on the embedded fax PWB due to hardware or software error. 20-305-00 Unrecoverable fax system low memory due to hardware or software error
20-303-00 Unrecoverable embedded fax PWB failed due to hardware or software error. Initial Actions
Initial Actions
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Make a backup of the phone book and the customer settings, refer to dC361 Save and
death or injury. Moving parts can cause injury. Restore.
Make a backup of the phone book and the customer settings, refer to dC361 Save and
Restore. Procedure
Switch off the machine, then switch on the machine, GP 14. The fault still occurs.
Procedure Y N
Switch off the machine, then switch on the machine, GP 14. The fault still occurs. Go to SCP 5 and complete the final actions.
Y N
Go to SCP 5 and complete the final actions. Clear the images from the embedded Fax PWB. Go to dC301 NVM Initialization. Select Fax
NVM Initialization. Perform the routine, All Data. The fault is cleared.
Clear the fax card NVM. Go to dC301, select Fax NVM initialization and perform the routine, All Y N
Data. The fault is cleared. Reload the software, GP 4.
Y N
Reload the software, GP 4. The fault is cleared. Go to SCP 5 and complete the final actions.
Y N
Go to RAP 20G Embedded Fax Checkout.
Go to SCP 5 and complete the final actions.

20-320-00 Fax Fault Not Cleared by Reset RAP 20-322-00 Non-Volatile Device not Installed RAP
20-320-00 After five instances of an unrecoverable fax fault and has not been cleared by a 20-322-00 The non-volatile device has not been installed on the embedded fax PWB.
card reset.
Initial Actions
Initial Actions
WARNING
death or injury. Moving parts can cause injury. Make a backup of the phone book and the customer settings, refer to dC361 Save and
Make a backup of the phone book and the customer settings, refer to dC361 Save and Restore.
Restore.
Procedure
Procedure Switch off the machine, then switch on the machine, GP 14. The fault still occurs.
Switch off the machine, then switch on the machine, GP 14. The fault still occurs. Y N
Y N Go to SCP 5 and complete the final actions.
(W/O TAG X-001) Check if the compact flash has been installed and plugged in correctly.
Clear the fax card NVM. Go to dC301 NVM Initialization. Select Fax NVM initialization. Perform Y N
the routine, All data. The fault is cleared. Remove and install the compact flash memory, PL 20.05 Item 3.
Y N If necessary install a new compact flash memory, PL 20.05 Item 3
Reload the software, GP 4.
Clear the fax card NVM. Go to dC301 NVM Initialization. Select Fax NVM initialization. Perform
Go to SCP 5 and complete the final actions. the routine, All data. The fault still occurs.
Y N
Install new parts in the following order:

• (W/O TAG X-001) Compact flash memory, PL 20.05 Item 3.
• Embedded fax PWB, PL 20.05 Item 4.

20-323-00, 20-324-00 Fax System Memory Low RAP 20-327-00 Extended Fax PWB Failure RAP
20-323-00 The fax system memory is low, less than 6Mb. 20-327-00 The registers cannot be accessed on the extended fax PWB.
20-324-00 There is not enough memory to use the fax service. Initial Actions
Initial Actions
WARNING
Restore. Procedure
Procedure • Switch off the machine, then switch on the machine, GP 14.
• Check if the extended fax PWB is installed, PL 20.05 Item 2.
Y N
Go to SCP 5 and complete the final actions. • Check that the embedded fax PWB is connected correctly into the riser PWB.
• If an extended fax PWB has just been installed and the Fax continues to reset with an
Clear the fax card NVM. Go to dC301 NVM Initialization. Select Fax NVM initialization. Perform error message. Perform the following:
the routine, All data. The fault is cleared. – Remove the extended Fax PWB from the embedded fax PWB, PL 20.05 Item 4 and
Y N install the embedded fax PWB back into the machine.
Install new components as necessary: – Remove the embedded fax PWB and install the extended fax PWB onto it.
• (W/O TAG X-001) Install a new compact flash memory, PL 20.05 Item 3.
– Install the embedded fax PWB and extended fax PWB and complete the install pro-
• Embedded fax PWB, PL 20.05 Item 4. cedure.
• Install a new extended fax PWB, PL 20.05 Item 2. If the fault remains, install a new
Go to SCP 5 and complete the final actions. embedded fax PWB, PL 20.05 Item 4.

A
20-331-00, 20-338-00, 20-339-00, 20-341-00 Fax Network For machines W/O TAG 006, install new parts in the following order:
• Telephone cable, PL 20.05 Item 8.
Line 1 Fault RAP
20-331-00 No communication via the PSTN 1 port.
• Riser PWB, PL 3.10 Item 11.
20-338-00 Fax Communication Error at power up or reboot. • Copy controller PWB, PL 3.10 Item 17.
For machines W/TAG 006, install new parts in the following order:
20-339-00 Fault at fax port 1 on the basic fax card. • Telephone cable, PL 20.05 Item 8.
20-341-00 Miscellaneous faults on the embedded fax PWB.
Initial Actions • Single board controller PWB, PL 3.11 Item 13.
WARNING
WARNING
Do not touch the test pads on the embedded fax PWB while the fax cable is connected
Restore.
Procedure
Y N
Check the connection between the embedded fax PWB, PL 20.05 Item 4 and the riser PWB,
PL 3.10 Item 11. The connections are good.
Y N
For machines W/O TAG 006, install new parts as necessary:
For machines W/TAG 006, install new parts as necessary:
Check that the customer line is operational, plug a phone into the line and check for a dial tone.
If a phone is not available then use a line test tool, PL 26.11 Item 16. The phone line connec-
tion is good.
Y N
The telephone line has a fault, inform the customer to have the line checked by the tele-
phone company.
A
20-332-00, 20-340-00 Fax Network Line 2 Fault RAP 20-342-00 Fax File Integrity Fault RAP
20-332-00 No communication via the PSTN 2 port. 20-342-00 An error has occur when accessing the file on a non-volatile device.
20-340-00 Extended card port 2 fault. Initial Actions
Initial Actions
WARNING
Restore. Procedure
Procedure Y N
Y N Clear the fax card NVM. Go to dC301 NVM Initialization. Select Embedded Fax NVM initialisa-
Go to SCP 5 and complete the final actions. tion. Perform the routine, All data. The fault is cleared.
Y N
Check the connection pins on the extended fax PWB. The pins are good. Reload the software, GP 4.
Y N
Install a new extended fax PWB, PL 20.05 Item 2. Go to SCP 5 and complete the final actions.
Check that the customer line is operational, plug a phone into the line and check for a dial tone.
If a phone is not available then use a line test tool, PL 26.11 Item 16. The phone line connec-
tion is good.
Y N
The telephone line has a fault, advise the customer to have the line checked by the tele-
phone company.
Install new parts in the following order:


20-701-00 Fax Phone Book Download Failed RAP 20-701-00A Fax Phone Book Download Failed RAP (W/O
20-701-00 The fax phone book download failed. TAG X-001)
Procedure
Initial Actions
WARNING
WARNING
• Check that the embedded fax PWB is correctly grounded. Ensure that the grounding strip,
PL 20.05 Item 7 is securely attached to the bracket of the embedded fax PWB. Y N
• Make a backup of the phone book and the customer settings, refer to dC361 Save and Go to SCP 5 and complete the final actions.
Restore.
Retry to download the fax phone book. The phone book downloads.
Procedure Y N
Go to the relevant procedure: Check the connection between the embedded fax PWB PL 20.05 Item 4 and the riser
PWB PL 3.10 Item 11. The connections are good.
• 20-701-00A Fax Phone Book Download Failed RAP (W/O TAG X-001)
Y N
• 20-701-00B Fax Phone Book Download Failed RAP (W/TAG X-001) Install new parts as necessary:
The fault still occurs.

Y N
Install a new compact flash memory, PL 20.05 Item 3. The fault still occurs.
Y N
Reload the software, GP 4.

20-701-00, 20-701-00A 2-292 Xerox® ColorQube® 9203 Family
20-701-00B Fax Phone Book Download Failed RAP (W/TAG 20-710-00, 20-711-00 Image Overwrite Error RAP
X-001) 20-710 Immediate image overwrite error has occurred on the fax card when overwriting the
job.
Procedure
20-711 On demand image overwrite error has occurred on the fax card when overwriting the
compact flash memory.
WARNING
1. Reload the machine software, GP 4. WARNING
2. For machines (W/O TAG 006). Install a new copy controller PWB, PL 3.10 Item 17. Ensure that the electricity to the machine is switched off while performing tasks that do
For machines (W/TAG 006). Install a new single board controller, PL 3.11 Item 13. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Restore.
Procedure
Go to the relevant procedure
• 20-710-00, 20-711-00A Image Overwrite Error RAP (W/O TAG X-001)
• 20-710-00, 20-711-00B Image Overwrite Error RAP (W/TAG X-001)

Xerox® ColorQube® 9203 Family 2-293 20-701-00B, 20-710-00, 20-711-00
20-710-00, 20-711-00A Image Overwrite Error RAP (W/O 20-710-00, 20-711-00B Image Overwrite Error RAP (W/TAG
TAG X-001) X-001)
Procedure Procedure
WARNING WARNING
Switch off the machine, then switch on the machine, GP 14. The fault still occurs. Switch off the machine, then switch on the machine, GP 14. The fault still occurs.
Y N Y N
Go to SCP 5 Final Actions. Go to SCP 5 Final Actions.
Clear the fax card NVM. Go to dC301 NVM Initialization. Select Fax NVM initialization. Perform Clear the fax card NVM. Go to dC301 NVM Initialization. Select Fax NVM initialization. Perform
the routine, All data. The fault is cleared. the routine, All data. The fault is cleared.
Y N Y N
Install new components as necessary: Perform an Altboot, GP 4. The fault is cleared.
• Compact flash memory, PL 20.05 Item 3. Y N
Go to SCP 5 Final Actions. • For machines (W/O TAG 006). Install a new copy controller PWB, PL 3.10 Item
17.
For machines (W/TAG 006). Install a new single board controller, PL 3.11 Item
13.

20-710-00, 20-711-00A, 20-710-00, 20-711-00B 2-294 Xerox® ColorQube® 9203 Family
20A Fax Entry RAP Y N
Go to 20E Fax Will Not Print RAP.
Use this RAP to isolate components which contribute to Fax communications failure.
The fault is cleared.
Initial Actions Y N
Go to 20G Embedded Fax Checkout RAP.
WARNING The Fax is working correctly. Send a three page test Fax to a known good Fax machine. Print a
Ensure that the electricity to the machine is switched off while performing tasks that do Protocol Report and check for errors.
• Check that the telephone line cables are properly connected. Fax Line 1 from the tele-
phone line outlet connects to line 1 socket on the machine. Fax line 2 (if installed) from Line 1 socket
the telephone line outlet connects to line 2 socket on the machine, Figure 1.
• Use a hand set to dial remote number and listen to dial type, (tone / pulse)
• Perform 20H Embedded Fax PWB Voltage Checkout (W/O TAG X-001).
• Check the ground connection on the embedded fax PWB, PL 20.05 Item 4.
• Check the Fault History. If the fault codes are 20-331-00, 20-338-00, 20-339-00, 20-341-
00 or 20-332-00, 20-340-00, then go to the appropriate RAP.
Line 2 socket
• Check the Fax setup for any active feature that would inhibit the sending of a Fax, such W/O TAG X-001 only
as: Delayed start time, Local name and ID are set, Dialing type or junk Fax prevention.
Enter Admin / Tools / Service Settings / Embedded Fax Setting and check the following:
– Fax Country setting
– Line Setup
– Options
– Dial type setting, tone / pulse.
• Enter Admin / Tools / Service Settings / Embedded Fax Settings / Print Fax Reports. Print
a Activity Report and check for error codes.
Figure 1 Line 1 and line 2 sockets
Procedure
The Fax tab is available
Y N
Go to 20F Fax Tab Not Available RAP.
The machine will send a Fax to all machines.

Y N
The machine will send a fax to some machines.
Y N
Go to 20B Unable To Send A Fax RAP.
Go to 20C Unable To Send A Fax To Some Machines RAP.
The machine will receive a fax from the remote machine.

Y N
Go to 20D Unable To Receive A Fax RAP.
The Fax prints out.

A B
20B Unable To Send A Fax RAP The dial tone - dialling answer tones are present.
Y N
Use this RAP to isolate components which contribute to a send failure.
The exchange is receiving the digits too quickly or is not processing the digits cor-
rectly. Ask the customer if the exchange is DTMF (Dual Tone Multiple Frequency) or
Initial Actions pulse dialing.
• Ensure that the machine is set for the correct dialing tone.
WARNING
Enter dC131 NVM Read / Write. Reset the values at NVM ID 200-201
Ensure that the electricity to the machine is switched off while performing tasks that do FaxLine1DialTypeDef and at NVM ID 200-202 FaxLine2DialTypeDef set to 0 =
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Tone or 1 = Pulse.
• Insert a pause ( , ) between the first and second digit of the dial string. In the
Dialling Options select Dialling Characters / Pause / Add Character / Save.
WARNING The Fax only dials once and hangs up or the busy tone has unusual timing, frequency or
Do not touch the test pads on the embedded fax PWB while the fax cable is connected level. The busy tones are recognized.
to the machine. Dangerous voltages may be present that could cause death or injury. Y N
Refer to the 20A Fax Entry RAP and complete all of the initial actions. Check the number for a voice or tone answer.
Check that the values at NVM ID 200-461 to 200-466 are set to the correct defaults
Procedure to match the appropriate country setting.
Verify with the customer that PSTN / PABX (Public Switched Telephone Network / Private The Fax is working correctly. Send a three page test Fax to a known good Fax machine.
Automatic Branch Exchange) line is operational. Connect a telephone handset into line outlet Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax Reports. Print a
and listen for a dial tone. Use a known good telephone handset. The dial tone is present. Protocol Report and check for errors. Re-enter the details from the fax options
Y N
Use the line test tool, PL 26.11 Item 16 to check the telephone line. The green normal Check that the customer is dialing the correct number. The number is correct.
indicator light is on. Y N
Y N Ask the customer to dial the number using the appropriate access codes.
Ask the customer to request a line check by the telephone company.
Enable audio line monitor (Enter Admin / Tools / Service Settings / Embedded Fax Setting /
Use a telephone handset to dial a known good number. The ring back is heard. Transmission Defaults / Audio Line Monitor) and set to Enable. Select High volume and max
Y N time.
Ask the customer to request a line check by the telephone company. Dial the Fax number and listen for a dial tone or dialing and answer tones. A Fax tone is
present.
Enable audio line monitor (Enter Admin / Tools / Service Settings / Embedded Fax Setting Y N
/ Transmission Defaults / Audio Line Monitor) and set to Enable and High volume. Enter dC131 NVM Read / Write. Reset the value at the following location:
Dial the Fax number and listen for a dial tone or dialing and answer tones. A Fax tone is NVM ID 200-415 Line1CurrentDetect = 0
present. NVM ID 200-416 Line2CurrentDetect = 0 A Fax tone is present.
Y N Y N
(W/O TAG X-001). Enter dC131 NVM Read / Write. Reset the value at the following Go to the 20G Embedded Fax Checkout.
location: Install new components as necessary:
NVM ID 200-415 Line1CurrentDetect = 0
NVM ID 200-416 Line2CurrentDetect = 0 A Fax tone is present.
Y N • Telephone cable, PL 20.05 Item 8.
Go to the 20G Embedded Fax Checkout.
Install new components as necessary: The Fax is working correctly. Send a three page test Fax to a known good Fax machine.
Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax Reports. Print a
Protocol Report and check for errors.
The dial tone - dialling answer tones are present.
The Fax is working correctly. Send a three page test Fax to a known good Fax
machine. Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax
Reports. Print a Protocol Report and check for errors.
A B
Y N 20C Unable To Send A Fax To Some Machines RAP
The exchange is receiving the digits too quickly or is not processing the digits correctly.
Use this RAP to isolate components which contribute to a failure to send a Fax to some
Ask the customer if the exchange is DTMF (Dual Tone Multiple Frequency) or pulse dial-
machines.
ing.
• Ensure that the machine is set for the correct dialing tone.
Initial Actions
Enter dC131 NVM Read / Write. Reset the values at NVM ID 200-201
FaxLine1DialTypeDef and at NVM ID 200-202 FaxLine2DialTypeDef set to 0 = Tone
WARNING
or 1 = Pulse.
• Insert a pause ( , ) between the first and second digit of the dial string. In the Dialling
Options select Dialling Characters / Pause / Add Character / Save.
• Enter dC131 NVM Read / Write. Set NVM ID 200-397 FaxTimeBeforeDial to 13.
Refer to the 20A Fax Entry RAP and complete all of the initial actions.
The Fax only dials once and hangs up or the busy tone has unusual timing, frequency or level.
Are the busy tones recognized. Procedure
Y N The correct number is being dialled to make the connection. The connection is made.
• Check the number for a voice or tone answer. Y N
• Check that the values at NVM ID 200-237 to 200-242 are set to the correct defaults The exchange is not processing the digits correctly, the machine needs longer pause
to match the appropriate country setting. between digits.
• Insert a pause ( , ) between the first and second digit of the dial string. In the Dialling
The fax is working correctly. Send a three page test Fax to a known good Fax machine. Options select Dialling Characters / Pause / Add Character / Save.
Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax Reports. Print a Pro- • Enter dC131 NVM Read / Write. Change setting at NVM ID 200-411 FaxDTMFInter-
tocol Report and check for errors. Re-enter the details from the fax options digitTime to 100.
Call the fax number from a known good telephone and listen for the answer fax tone. The Fax
tone is heard.
Y N
Fax on remote end is not picking up or no Fax is connected. Advise customer to check the
machine at the remote end.
Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax Reports. Print a Pro-
tocol Report. The Protocol Report shows RNR (Receive Not Ready) is received from the
remote Fax repeatedly until time out and DCN (Disconnect). Check communication failure after
V34-PH2 / V34-PH3 or DCS / TCF. The remote Fax receives and prints the Fax.
Y N
Compatibility problem with remote Fax.
• Print a Protocol Report and check for communication errors.
• Line quality too poor for Super G3 to function correctly. Possible mains interference
on line.
• Disable V34 (Super G3). Enter dC131 NVM Read / Write. Reset the value at the fol-
lowing locations:
– NVM ID 200-087 T30MaxSpeedL1Tx = 11 (14400).
– NVM ID 200-088 T30MaxSpeed2Tx = 11 (14400).
If mains noise, try installing and using line 2 instead of line 1.
• When sending to a PC fax or fax server that has an ISDN card, there is a need to
customize the CEQ values. Enter dC131 NVM Read / Write. Set the value at NVM ID
CEQTX 203-031 and CEQRX 203-032 to 0.

Xerox® ColorQube® 9203 Family 2-297 20B, 20C
A
The Protocol Report shows MCF (Message Confirmation) is not sent by the remote Fax (last 20D Unable To Receive A Fax RAP
page), only DCN (Disconnect). The failure report printed out, but the remote fax prints
Use this RAP to isolate components which contribute to the fax not received from the machine.
multiple copies of the job or failed page.
Y N
The Fax is working correctly. Send a three page test Fax to a known good Fax machine. Initial Actions
Print a Protocol Report and check for errors.
The machine will resend up to 10 times before printing the failure report. WARNING
Enter Admin / Tools / Service Settings/ Embedded Fax Setting / Transmission Defaults / Auto- Ensure that the electricity to the machine is switched off while performing tasks that do
matic Resend. Set number of resend to 1 or 2. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
WARNING
Refer to the 20A Fax Entry RAP and complete all of the initial actions.
Procedure
Verify with the customer that PSTN / PABX (public switched telephone network / private auto-
matic branch exchange) line is operational. Use a known good telephone handset or use the
line test tool, PL 26.11 Item 16 to check the telephone line. The dial tone is present.
Y N
Ensure Fax service is enabled and supported on that line by a PBX administrator.
Call the handset from another telephone. The phone rings.

Y N
Ensure Fax service is enabled and supported on that line by a PBX administrator.
Enable audio line monitor (Enter Admin / Tools / Service Setting / Embedded Fax Setting /
Transmission Defaults / Audio Line Monitor) and set to Enable and High volume.
Dial the Fax number and listen for a dial tone or dialing and answer tones. A Fax tone is
present.
Y N
(W/O TAG X-001). Enter dC131 NVM Read / Write. Reset the value at the following loca-
tion:
NVM ID 200-077 Line1CurrentDetect = 0
NVM ID 200-078 Line2CurrentDetect = 0 A Fax tone is present.
Y N
Go to 20G Embedded Fax Checkout
The fax is working correctly. Send a three page test fax to a known good fax machine.
Reconnect the fax and call the fax number from a independent telephone line and listen for a
Fax tone. The machine answers and a fax tone is heard.

20C, 20D 2-298 Xerox® ColorQube® 9203 Family
Y N 20E Fax Will Not Print RAP
Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax Reports. Print
Use this RAP to solve fax printing problems.
Activity Report. Check for receive calls on the Activity Report. Machine probably does not
bleep to indicate incoming call.
Check that the NVM values at NVM ID 200-203 and at NVM ID 200-423 to 200-427 are Initial Actions
set to the correct defaults to match the appropriate country setting. The machine
answers and a Fax tone is heard.
Y N WARNING
Go to 20G Embedded Fax Checkout Ensure that the electricity to the machine is switched off while performing tasks that do
Install new components as necessary: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Embedded fax PWB, PL 20.05 Item 4. death or injury. Moving parts can cause injury.
• Compact flash memory, PL 20.05 Item 3. • Check the condition of the paper in all trays.
• Check that the paper trays are loaded with the appropriate paper sizes for printing the
The Fax is working correctly. Send a three page test Fax to a known good Fax machine. Fax. Refer to GP 20.
Print a Protocol Report and check for errors.
Procedure
Receive a three page test Fax from the original Fax machine. Print a Protocol Report and
check for errors. The Protocol Report shows communication failure after CSI / DIS • If the received fax has mixed size documents (example, the first prints are 8.5 x 11 and
(Called Subscriber Identified / Digital Identification Signal) or DCS / TCF (Digital Com- then followed by 8.5 x 14 prints). Check in the ‘All Incomplete Jobs’ queue, the job will
mand Signal / Training Check) or (W/O TAG X-001) after V34-PH2 / V34-PH3 or EQM (Eye print 8.5 x 11 pages without printing 8.5 x 14 pages and then the job will be deleted.
Quality Monitor) value greater than 5000. Perform the following:
Y N In Tools menu, go to Fax setup and select:
The problem may be intermittent, inform the operator of the remote machine, they should – Receive Defaults.
report the problem to the telephone company.
– Receive Printing mode and change to Manual.
Perform the following: – In paper sizes, select correct page for each size to match the paper in the tray.
• Confirm line is standard PSTN / PBX analogue line – Save and then change back to Auto. Save and Exit.
• Line quality too poor for Super G3 or G3 to function correctly. Possible mains interference • If the User Interface is asking for a size paper that is not loaded in trays.
on line. Possible DSL line, not properly filtered. Perform the following:
• Ask customer to request Fax capable service from telephone company. In Tools menu, go to Fax setup and select:
• If mains noise, install a (W/O TAG X-001) embedded fax PWB, PL 20.05 Item 4 and an – Receive Defaults.
extended fax PWB, PL 20.05 Item 2. Use line 1. – Receive Printing mode.
• Enter dC131 NVM Read / Write. Set the value at the following locations: – Select manual, change small paper setting to None and Save.
– NVM ID 200-085 T30 Maximum resolution Line 1 Rx = 7
NOTE: For small, long and large paper sizes select NONE if the corresponding
– NVM ID 200-086 T30 Maximum resolution Line 2 Rx = 7 paper is not loaded in the paper trays.
This sets the receive resolution capabilities for line 1 and line 2 to 400x400 max, this will
shorten the DIS. – Change setting to Auto and Save.
• The DIS field is too long to enable successful communication.
Enter dC131 NVM Read / Write. Change NVM ID 200-141 USSTOCKSUPPORTRAX to 0
(disable).
• Disable V34 (Super G3). Enter dC131 NVM Read / Write and reset the value at the follow-
ing locations:
– NVM ID 200-089 T30MaxSpeedL1Rx = 11 (14400)
If the problem still exists try a lower line receive (Rx) speed: 12 = 12000, 13 = 9600, 14 =
7200, 15 = 4800, 16 = 2400
• Send a three page test Fax from a known good fax machine.

Xerox® ColorQube® 9203 Family 2-299 20D, 20E
20F Fax Tab Not Available RAP Y N
The fax is installed correctly. Send a three page test fax to a known good fax machine.
Use this RAP to isolate the problem when the Fax tab is not available or greyed out.
Enter Admin / Tools / Service Settings / Embedded Fax Setting / Print Fax Reports. Print a
Protocol Report and check for errors.
Initial Actions
Perform an AltBoot, GP 4.
WARNING NOTE: Software should only be loaded on a working machine. Loading or reloading software
onto a machine (or fax card) that has a fault will not work.
• Check for the correct installation of the embedded fax option. Refer to the system admin-
istration guide CD1, for the install instruction. Follow the screen prompts.
Procedure
The Fax tab is displayed on the user interface screen.
Y N
The fax installation was not completed.
Go to Admin / Tools / Service Setting / Embedded Fax Setting / Fax Setup. Select Enable
and Save. Switch off the machine and switch on the machine, GP 14. This will initiate the
‘Fax Install Wizard’ and follow the prompts on the screen to complete the install of the
Fax.
The Fax tab is displayed after installation.

Y N
Check that the embedded fax PWB and the (W/O TAG X-001) compact flash memory are
installed correctly, PL 20.05.
1. Switch off the machine, GP 14.
2. (W/O TAG X-001). Remove and install the compact flash card, PL 20.05 Item 3.
3. For machines W/O TAG 006, check the connection between the embedded fax PWB
and the riser PWB. Check the connection between the copy controller PWB, PL 3.10
Item 17 and the riser PWB, PL 3.10 Item 11. Switch on the machine, GP 14.
4. For machines W/TAG 006, check the connection between the embedded fax PWB
and the riser PWB. Check the connection between the single board controller PWB,
PL 3.11 Item 13 and the riser PWB, PL 3.11 Item 9.
5. Switch on the machine, GP 14.
The super fine tab is displayed.

Y N
The Server Fax may be enabled.
Go to Admin / Tools / Service Setting / Embedded Fax Setting / Fax Setup and press Dis-
able and Save. This will disable the Server Fax.
After installing Embedded Fax. The Fax selection tab is greyed out and requesting a
pass code to enable the Embedded Fax (Scan to E-mail installed).

20F 2-300 Xerox® ColorQube® 9203 Family
20G Embedded Fax Checkout For machines W/O TAG 006, reconnect the following:
• The Riser PWB to the Copy Controller PWB.
Use this RAP to check for problems with the embedded Fax PWB.
• The Embedded fax PWB to the Riser PWB.
Initial Actions For machines W/TAG 006, reconnect the following:
• The Riser PWB to the Single Board Controller PWB.
• The Embedded fax PWB to the Riser PWB.
WARNING Switch on the machine, GP 14. The fault is cleared.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Return to the original fault code RAP and perform the remaining actions in the procedure.
Go to SCP 5 and perform the final actions.
WARNING
• Check that the embedded fax PWB, PL 20.05 Item 4 is located correctly.
• Check that the embedded fax PWB is correctly grounded. Ensure that the grounding strip,
PL 20.05 Item 7 is securely attached to the bracket of the embedded fax PWB.
• If an extended fax PWB, PL 20.05 Item 2 has just been installed and the fax continues to
reset with an error message. Refer to 20-327-00 Extended Fax PWB failure RAP
• For copy quality defects, go to IQ 27 Unacceptable Received Facsimile Image Quality
RAP.
Procedure
Go to WD 1.4. Check the +3.3V, +5V and +12V voltages. The voltages are good.
Y N
Refer to the following:
For machines W/O TAG 006, if necessary install a new Riser PWB, PL 3.10 Item 11.
For machines W/TAG 006, if necessary install a new Riser PWB, PL 3.11 Item 9.
For machines W/O TAG 006, switch off the machine GP 14. Disconnect the following:
• The Embedded Fax PWB from the Riser PWB.
• The Riser PWB from the Copy Controller PWB.
For machines W/TAG 006, switch off the machine GP 14. Disconnect the following:
• The Embedded Fax PWB from the Riser PWB.
• The Riser PWB from the Single Board Controller PWB.
For machines W/O TAG 006, check that the connectors are clean and not damaged. If the con-
nectors are damaged then install new components as necessary:
• Copy Controller PWB, PL 3.10 Item 17.
For machines W/TAG 006, check that the connectors are clean and not damaged. If the con-
nectors are damaged then install new components as necessary:
• Single Board Controller PWB, PL 3.11 Item 13.

Xerox® ColorQube® 9203 Family 2-301 20G
20H Embedded Fax PWB Voltage Checkout (W/O TAG X-
001)
Use this procedure when there is communication or image quality defects with the fax. The Line 1 test pads 1, 2 and 3
image quality defects are caused by electrical noise on the line.
Procedure
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Line 2 test pads 4, 5 and 6
WARNING
NOTE: The voltages on the embedded fax PWB test pads can be between 50V to 100V AC if
the machine has a ground problem or is in receipt of a fax.
Figure 1 Line 1 and line 2 test pads
2. Disconnect all telephone line cables.
3. Remove the embedded fax PWB, PL 20.05 Item 4.
4. Remove the safety cover, PL 20.05 Item 1 and the lower cover, PL 20.05 Item 5.
5. Remove the extended fax PWB, PL 20.05 Item 2.
6. Install the Embedded Fax PWB, PL 20.05 Item 4.
7. Connect all telephone line cables.
9. On the multimeter, select the AC volts and auto range.
Check that the voltage is between 0 and less than 1V on the test pads.
• For line 1. Measure between test pad 1 and test pad 2 and between test pad 2 and
test pad 3, Figure 1.
• For line 2. Measure between test pad 4 and test pad 5 and between test pad 5 and
test pad 6, Figure 1.
If the voltage is more than 1V, this indicates a possible ground connection problem. Refer
to 01L 0V Distribution RAP.
If the machine ground connections are good, request that the customer has the power
outlet socket checked.

20J Fax Problems on Digital Networks RAP
Use this RAP to isolate the problem when using digital networks.
The Fax option was designed as an analogue Group 3 device. This will have the best perfor-
mance when connected to a dedicated analog phone PSTN (Public Switched Telephone Net-
work) line or POTS (Plain Old Telephone system).
• The Fax option will function on the following technologies:

– ADSL - Asymmetric Digital Subscriber Line
– DSL - Digital Subscriber Line
– VOIP - Voice Over Internet Protocol
– T1 Trunk / E1 Trunk (Europe).
NOTE: Due to the compression used on the technologies. The level of performance
will be lower than on a PSTN or POTS.
• The Fax option will not function on the following technologies:
– ISDN - Integrated Services Digital Network
– FOIP - Fax Over Internet Protocol, (T.38 protocol).
Initial Actions
WARNING
• Check with the customer or IT person on what network the Fax service is being used and
what is the quality of service.
• Check that an analogue adapter or a connection for analogue terminals are available.
• Ask the customer to check with service provider that an analogue port for Fax service has
been provided and enabled.
Procedure
• Go to 20A Fax Entry RAP.
• Request the latest SPAR release.
• Disable V34.
Enter dC131 NVM Read / Write and reset the value at the following locations:
– NVM ID 200-087 T30MaxSpeedL1Tx = 11 (14400)
– NVM ID 200-088 T30MaxSpeedL2Tx = 11 (14400)
• If problems are still not resolved after these actions, then escalate the problem using the
normal escalation process

Xerox® ColorQube® 9203 Family 2-303 20J
20J 2-304 Xerox® ColorQube® 9203 Family
22-300-05 Image complete not received from video. 22-310-04 Pages received from extended job service out of sequence.
22-300-10 Failed to transfer image due to decoding error. 22-314-04 Module registration error.
22-300-16 When machine determines that it needs to do a reset in order to avoid an impending 22-316-04 Job requires paper tray that does not exist.
real time clock overflow.
22-317-04 Job requires finishing capability that does not exist.
22-301-05 Scan resources not available.
22-318-04 Job requires an IOT capability that does not exist.
22-309-04 Consecutive no accepts received from a module exceeds threshold value (currently
20). Five consecutive 22-309-04 will cause 22-319-04. Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform the following:
death or injury. Moving parts can cause injury. • Switch off the machine, then switch on the machine, GP 14.

22-315-04 One or More Modules Did Not Respond RAP 22-319-04 IOT Integrity Problem While Printing a Job RAP
22-315-04 One or more modules did not respond with completion message. 22-319-04 Integrity problem while printing a job. The IOT cycles down and up 10 times without
printing a page within the same job causing the fault. The system automatically executes a
Procedure reset.
Procedure
WARNING
Perform the following: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Delete the original job and rerun the job.

22-321-00 SM Failed to Remove Scan to File RAP 22-321-04 Proposal Response Time Out Error RAP
22-321-00 SM failed to remove the scan to file. 22-321-04 Proposal res[ponse time out error - RS422 configuration mismatch.
Procedure Procedure
WARNING WARNING
Perform the following: Perform the following:
• Check machine configuration.

22-325-01 Cleaning Unit Extended Life Mode Entered RAP 22-328-00 Incomplete System Information RAP
22-325-01 Cleaning unit extended life mode entered (CU snooze mode). 22-328-00 Incomplete system information. The accounting service data has been corrupted.
Procedure Procedure
WARNING WARNING

22-330-00 Page Pack PIN Entry Locked RAP 22-330-01 List Jobs Request Timed Out Between UI and
22-330-00 Page pack PIN entry locked due to repeated incorrect PIN entry attempts. Copy Controller RAP
22-330-01 List jobs request timed out between UI and copy controller.
Procedure
Procedure
WARNING
Perform the following: death or injury. Moving parts can cause injury.
• An incorrect page pack PIN has been entered more than 3 times and entry is now locked
for 24 hours. Only one retry is now possible every 24 hours.
• Obtain a new PIN and try again.

22-330-02 List Jobs Request Timed Out Between Copy 22-330-03 List Jobs Request Timed Out Between Copy
Controller and ESS Print Service RAP Controller and Scan to File Service RAP
22-330-02 List jobs request timed out between copy controller and ESS print service. 22-330-03 List jobs request timed out between copy controller and scan to file service.
Procedure Procedure
WARNING WARNING

22-330-04 List Jobs Request Timed Out Between Copy 22-330-05 List Jobs Request Timed Out Between Queue
Controller and Scan to Fax Service RAP Utility and DC Job Service RAP
22-330-04 List jobs request timed out between copy controller and scan to Fax service. 22-330-05 List jobs request timed out between queue utility and DC job service.
Procedure Procedure
WARNING WARNING

22-330-06 ESS Scan to Distribution Service not 22-350-01, 22-350-02 Software Detects Non-valid Xerox
Responding to List Jobs RPC Call RAP SOK RAP
22-330-06 ESS scan to distribution service not responding to list RPC call. 22-350-01 Software detected non-valid Xerox SOK 1.
Procedure 22-350-02 Software detected non-valid Xerox SOK 2 or 3.
Procedure
WARNING
Perform the following: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Switch off the machine, then switch on the machine, GP 14. death or injury. Moving parts can cause injury.
2. Ignore all requested options from the software option key (SOK).

22-351-01 to 22-351-03 SOK Write Failure RAP 22-352-00 Serial Number Missing RAP
22-351-01 SOK 1 write failure. 22-352-00 Serial number has been lost.
22-351-02 SOK 2 write failure. Initial Actions

22-351-03 SOK 3 write failure.
WARNING
WARNING • Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for 03-xxx fault codes. Go to the appropriate RAP.
Procedure
1. Check that the machine serial number is correct on the UI or the option to install the cor-
rect value is available, refer to dC132.
2. Ignore all requested options from the software option key (SOK).
2. Check that the SIM card is present in the SIM slot in the image processing module, PL
3.10 Item 29 or PL 3.11 Item 22.
4. Enter dC131. Select CCS NVM ID 616-003 Product Configuration.
• Check that the values are set to 112 = 9201, 113 = 9202 or 114 = 9203 as appropri-
ate to what speed the machine should be. No further action should be required as
the machine has recovered its configuration from the SIM card.
• If the value is 0 the machine has never been installed. A blank SIM card of the
appropriate speed, billing plan and service plan can be installed. This should have
been supplied with the machine so a replacement would need to be obtained
through normal process to complete a missing part not delivered at install.
• If the value is 49, this is the default at manufacture. If the value is 48, this means the
machine has lost its serial number which is stored on the software module. Any other
number is likely caused by a memory corruption. For all these instances a pre-serial-
ized SIM card / SW module will be required. Escalate the request through normal
channels to obtain one.

Xerox® ColorQube® 9203 Family 2-313 22-351-01 to 22-351-03, 22-352-00
22-371-00, 22-372-00 Fax Application Registration Error 22-701-04 Module Completion Message Received RAP
RAP 22-701-04 Module completion message received after IOT returned to standby.
22-371-00 Set by Fax Service when it gets no response from Service Registry when trying to
Register. Procedure
22-372-00 Set by Fax Service when it gets no response from Service Registry when trying to
Un-Register. WARNING
Procedure not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
WARNING • Switch off the machine, then switch on the machine, GP 14.
2. Check the Fax connections.
3. Reload the software, GP 4.

22-720-00 Service Registry Bad Data/Corrupted RAP 22-721-00 No Response From The Service Registry RAP
22-720-00 Service bad data/corrupted. 22-721-00 Triple A gets no response from the service registry service.
Procedure Procedure
WARNING WARNING

22-750-04 to 22-755-17 Other Network Faults 25 RAP
22-750-04 Output device configuration mismatch.
22-750-17 When the system detects that the accessory card configuration mismatch has
changed during the power on sequence.
22-751-04 Paper tray configuration mismatch.
22-754-17 When the system detects the UI configuration has changed during the power on
sequence.
22-755-17 After the 2nd user confirmation of configuration mismatch if the system detects that
the RDT configuration has changed during the power on sequence.
Procedure
WARNING

42-500-00 Marking Unit Air Solenoid Over Current RAP 42-504-00 Enclosure Fan Over Current RAP
42-500-00 The low pressure assist solenoid valve current demand is inconsistent with 42-504-00 The enclosure fan current demand is inconsistent with expected value.
expected value.
Initial Actions
Initial Actions
WARNING
death or injury. Moving parts can cause injury. • Check the harness leading to the fan.
• Check the harness leading to the solenoid. • Check for damage or debris that restricts movement of the fan.
• Check for damage or debris that restricts movement of the solenoid.
Procedure
Procedure Go to WD 9.4. Check the wiring between the enclosure fan and PJ901 on the Drum Driver
Enter dC330 code 91-045 to energize the low pressure assist value solenoid, SOL91-045, PL PWB. The wiring is good.
93.10 Item 15. The value solenoid energizes. Y N
Y N Repair the wiring as necessary, REP 1.1.
Check the air lines for kinks or blockages. The air lines are good.
Y N Enter dC330 code 42-063 to run the enclosure fan, MOT42-063, PL 1.15 Item 6. The fan
Route the air lines correctly. runs.
Y N
Refer to WD 9.14. Check the low pressure assist value solenoid, SOL91-045. Refer to: Check for +12V at PJ901 pin 12 on the Drum Driver PWB. +12V is present.
• GP 12 How to Check a Solenoid or Clutch. Y N
• PJ130, Solenoid Patch PWB. Check for +12V at PJ602 pin 10 on the Drum Driver PWB. If +12V is present, install
a new drum driver PWB, PL 1.15 Item 4.
• 01E +12V Distribution RAP.
Install a new enclosure fan, PL 1.15 Item 6.
Check the ink loader wiring harness, repair as necessary, REP 1.1. If necessary, install a
new ink reservoir, PL 93.10 Item 10. Check for obstructions or debris blocking fan rotation. The fan is clean.
Y N
The fault may be intermittent. Check the ink loader wiring harness, repair as necessary, REP Clean ducts and filters as necessary, GP 27.
1.1. If necessary, install a new reservoir, PL 93.10 Item 10.
The fault may be intermittent, check for damaged wiring or loose connectors. Repair the wiring
as necessary, REP 1.1. If necessary, install a new enclosure fan, PL 1.15 Item 6.

42-505-00 Abatement Fan Over Current RAP
42-505-00 The abatement fan current demand is inconsistent with expected value.
Initial Actions
WARNING
• Check the harness leading to the fan.
• Check for damage or debris that restricts movement of the fan.
Procedure
Go to WD 9.4. Check the wiring between the abatement fan and the drum driver PWB. The
wiring is good.
Y N
Repair the wiring as necessary, REP 1.1.
Enter dC330 code 42-062 abatement fan, MOT42-062, PL 94.20 Item 11. The fan runs.
Y N
Check for +12V at PJ901 pin 9 of the drum driver PWB. +12V is present.
Y N
Check for +12V at PJ602 pin 10. If +12V is present, install a new drum driver PWB
PL 1.15 Item 4.
Install a new abatement fan assembly, PL 94.20 Item 11.
Check for obstructions or debris blocking fan rotation. The fan is clean.
Y N
Clean ducts and filters as necessary, GP 27.
as necessary, REP 1.1. If necessary, install a new abatement fan assembly, PL 94.20 Item 11.

62-277-00 Scanner to DADH Communication Fail Entry 62-277-00A Scanner to DADH Communication Fail RAP
RAP Initial Actions
62-277-00 A communication failure between scanner PWB and DADH PWB has been
detected.
WARNING
Go to the relevant procedure: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• For machines W/O TAG 007 and W/O TAG 006, go to the 62-277-00A Scanner to DADH
Communication Fail RAP. • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-
277-00 Scanner to DADH Communication Fail Entry RAP.
• For machines W/TAG 007 and W/TAG 006, go to the 62-277-00B Scanner to DADH Com-
munication Fail RAP. • Switch off, then switch on the machine, GP 14.
• For machines W/TAG 007 and W/O TAG 006, go to 62-277-00C Scanner to DADH Com-
munication Fail RAP. Procedure
Remove the DADH rear cover, PL 5.10 Item 1. Remove the scanner PWB cover, refer to REP
62.12. Refer to WD 5.2 and WD 6.1. Check the wiring between PJ188 on the DADH PWB and
PJ921 on the scanner PWB. The wiring is good.
Y N
Re-seat loose connectors or install new components as necessary:
• DADH Communication / power cable, PL 5.10 Item 6.

Xerox® ColorQube® 9203 Family 2-319 62-277-00, 62-277-00A
62-277-00B Scanner to DADH Communication Fail RAP 62-277-00C Scanner to DADH Communication Fail RAP
WARNING WARNING
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62- • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-
277-00 Scanner to DADH Communication Fail Entry RAP. 277-00 Scanner to DADH Communication Fail Entry RAP.
• Switch off, then switch on the machine, GP 14. • Switch off, then switch on the machine, GP 14.
Procedure Procedure
Remove the DADH rear cover, PL 5.10 Item 1. Remove the scanner PWB cover, refer to REP Remove the DADH rear cover, PL 5.10 Item 1. Remove the scanner PWB cover, refer to REP
62.21. Refer to WD 5.2 and WD 6.4. Check the wiring between PJ188 on the DADH PWB and 62.21. Refer to WD 5.2 and WD 6.4. Check the wiring between PJ188 on the DADH PWB and
PJ921 on the scanner PWB. The wiring is good. PJ921 on the scanner PWB. The wiring is good.
Y N Y N
Re-seat loose connectors or install new components as necessary: Re-seat loose connectors or install new components as necessary:
• DADH / Communication / power cable, PL 5.10 Item 6. • DADH / Communication / power cable, PL 5.10 Item 6.
• DADH PWB, PL 5.10 Item 5. • DADH PWB, PL 5.10 Item 5.
• Scanner PWB, PL 62.17 Item 1. • Scanner PWB, PL 62.17 Item 1.
Perform SCP 5 Final Actions. Perform SCP 5 Final Actions.

62-277-00B, 62-277-00C 2-320 Xerox® ColorQube® 9203 Family
62-310-00 Scanner to Copy Controller/Single Board 62-310-00A Scanner to Copy Controller Communication
Controller Communication Fail Entry RAP Fail RAP
62-310-00 (W/O TAG 007) A communication failure between the scanner PWB and the copy Initial Actions
controller PWB has been detected.
62-310-00 (W/TAG 007) A communication failure between the scanner PWB and the single WARNING
board controller PWB has been detected.
Procedure death or injury. Moving parts can cause injury.
Go to the relevant procedure: • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-
• For machines W/O TAG 007 and W/O TAG 006, go to the 62-310-00A Scanner to Copy 310-00 Scanner to Copy Controller/Single Board Controller Communication Fail Entry
Controller Communication Fail RAP. RAP.
• For machines W/TAG 007 and W/TAG 006, go to the 62-310-00B Scanner to Single • Switch off, then switch on the machine, GP 14.
Board Controller Communication Fail RAP.
• For machines W/TAG 007 and W/O TAG 006, go to the 62-310-00C Scanner to Copy Procedure
Controller Communication Fail RAP.
Remove the scanner PWB cover, refer to REP 62.12. Refer to WD 6.1 and WD 3.1. Check the
• For machines W/O TAG 007 and W/TAG 006, go to the 62-310-00D Scanner to Single wiring between PJ922 on the scanner PWB and PJ15 on the copy controller PWB. The wir-
Board Controller Communication Fail RAP. ing is good.
Y N
• Scanner / copy controller module harness, PL 62.16 Item 7.
Refer to WD 6.1. Check the wiring between PJ920 on the scanner PWB and PJ852 on the rear
of the scanner. The wiring is good.
Y N
• DADH / IIT power comms harness, PL 62.16 Item 13.
Refer to WD 6.1 and WD 1.8. Check the wiring between PJ852 on the rear of the scanner and
PJ8 on the power distribution PWB. The wiring is good.
Y N
• Power distribution PWB, PL 3.10 Item 1.
• DADH / IIT power / communication harness, PL 62.10 Item 12.
Refer to WD 1.8 and WD 3.3. Check the wiring between PJ9 on the power distribution PWB
and PJ18 on the copy controller PWB. The wiring is good.
Y N
• Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14.

A
Refer to WD 1.5 and WD 1.6. Check the wiring between PJ1 on the power distribution PWB 62-310-00B Scanner to Single Board Controller
and PJDC4 on the power supply unit. Check for the correct voltages from the power supply at
PJDC4 and at PJ1 on the power distribution PWB. Wiring and voltages are good. Communication Fail RAP
Y N Initial Actions
• Power distribution PWB, PL 3.10 Item 1. WARNING
• Copy controller PWB, PL 3.10 Item 17. Ensure that the electricity to the machine is switched off while performing tasks that do
Perform SCP 5 Final Actions. death or injury. Moving parts can cause injury.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-310-
00 Scanner to Copy Controller/Single Board Controller Communication Fail Entry RAP.
Procedure
wiring between PJ922 on the scanner PWB and PJ15 on the single board controller PWB.
The wiring is good.
Y N
• DADH / IIT power and comms harness, PL 62.17 Item 15.
Refer to WD 6.4 and WD 1.9. Check the wiring between PJ920 on the scanner PWB and PJ8
on the power distribution PWB. The wiring is good.
Y N
and PJ18 on the single board controller PWB. The wiring is good.
Y N
• Power distribution PWB to single board PWB harness, PL 3.11 Item 11.
PJDC4 and at PJ1 on the power distribution PWB. Wiring and voltages are good.
Y N

62-310-00A, 62-310-00B 2-322 Xerox® ColorQube® 9203 Family
62-310-00C Scanner to Copy Controller Communication 62-310-00D Scanner to Single Board Controller
Fail RAP Communication Fail RAP
WARNING WARNING
310-00 Scanner to Copy Controller/Single Board Controller Communication Fail Entry RAP. 310-00 Scanner to Copy Controller/Single Board Controller Communication Fail Entry
• Switch off, then switch on the machine, GP 14. RAP.
Procedure
wiring between PJ922 on the scanner PWB and PJ15 on the copy controller PWB. The wir-
Procedure
ing is good. Remove the scanner PWB cover, refer to REP 62.12. Refer to WD 6.1 and WD 3.4. Check the
Y N wiring between PJ922 on the scanner PWB and PJ15 on the single board controller PWB.
Re-seat loose connectors or install new components as necessary: The wiring is good.
Y N
Refer to WD 6.4 and WD 1.8. Check the wiring between PJ920 on the scanner PWB and PJ8 • Single board controller PWB, PL 3.11 Item 13.
on the power distribution PWB. The wiring is good.
Y N Refer to WD 6.1 Check the wiring between PJ920 on the scanner PWB and PJ852 on the rear
Re-seat loose connectors or install new components as necessary: of the scanner. The wiring is good.
• Power distribution PWB, PL 3.10 Item 1. Y N
Refer to WD 1.8 and WD 3.6. Check the wiring between PJ9 on the power distribution PWB • Scanner PWB, PL 62.16 Item 8.
and PJ18 on the copy controller PWB. The wiring is good.
Y N Refer to WD 6.1 and WD 1.9. Check the wiring between PJ852 on the rear of the scanner and
Re-seat loose connectors or install new components as necessary: PJ8 on the power distribution PWB. The wiring is good.
Y N
• Power distribution PWB to single board PWB harness, PL 3.11 Item 11.
and PJ18 on the single board controller PWB. The wiring is good.
Y N Y N
• Harness PDB to SBC, PL 3.11 Item 11.

A

Xerox® ColorQube® 9203 Family 2-323 62-310-00C, 62-310-00D
A
Refer to WD 1.5 and WD 1.6. Check the wiring between PJ1 on the power distribution PWB 62-450-00 to 62-472-00 Calibration Failure Entry RAP
62-450-00 Calibration dark range not clear.
Y N 62-451-00 Calibration dark range not done.
62-452-00 Calibration Pixel offset not clear.
• Power distribution PWB, PL 3.11 Item 1. 62-453-00 Calibration Pixel offset not done.
• Single board controller PWB, PL 3.11 Item 13. 62-454-00 Calibration gain range not clear.
62-455-00 Calibration gain range not done.
62-456-00 Calibration Pixel gain not clear.
62-457-00 Calibration Pixel gain not done.
62-458-00 Calibration dark range errors.
62-459-00 Calibration pixel offset hi errors.
62-460-00 Calibration pixel offset lo errors.
62-461-00 Calibration gain range errors.
62-462-00 Calibration pixel gain hi errors.
62-463-00 Calibration pixel gain lo errors.
62-464-00 Scan controller busy error.
62-465-00 Dark loop settle error.
62-466-00 Dark range rail error.
62-467-00 Gain range rail error.
62-468-00 Colour state error.
62-469-00 FPGA Comms error.
62-470-00 FPGA Read error.
62-471-00 FPGA write wrap error.
62-472-00 FPGA Bus time out error.
Procedure
• For machines W/O TAG 007 and W/O TAG 006, go to the 62-450-00A to 62-472-00A Cal-
ibration Failure RAP.
• For machines W/TAG 007 and W/TAG 006, go to the 62-450-00B to 62-472-00B Calibra-
tion Failure RAP.
• For machines W/TAG 007 and W/O TAG 006, go to the 62-450-00C to 62-472-00C Cali-
bration Failure RAP.

62-310-00D, 62-450-00 to 62-472-00 2-324 Xerox® ColorQube® 9203 Family
62-450-00A to 62-472-00A Calibration Failure RAP 62-450-00B to 62-472-00B Calibration Failure RAP
WARNING WARNING
450-00 to 62-472-00 Calibration Failure Entry RAP. 450-00 to 62-472-00 Calibration Failure Entry RAP.
Procedure Procedure
Enter dC330 code 62-002 to activate the exposure lamps. Exposure lamps illuminate. Enter dC330 code 62-002 to activate the exposure lamp. Exposure lamp illuminate.
Y N Y N
Go to 62B Exposure Lamp Failure RAP. Go to 62D Exposure Lamp Failure RAP.
Remove the scanner PWB cover, refer to REP 62.12. Refer to WD 6.3. Check the wiring Remove the scanner PWB cover, refer to REP 62.21. Refer to WD 6.6. Check the ribbon har-
between PJ928 on the scanner PWB and the scan carriage assembly. The wiring is good. ness between PJ931 and PJ932 on the scanner PWB and PJ1 and PJ2 on the CCD PWB.
Y N The ribbon harness is good.
Re-seat loose connectors or install new components as necessary: Y N
• Scanner PWB, PL 62.16 Item 8. Re-seat loose connectors or install new components as necessary:
• Scan carriage ribbon cable, PL 62.15 Item 4. • CCD PWB assembly, PL 62.17 Item 11.
Refer to WD 6.1, WD 1.8, WD 3.1 and WD 3.3. Check the wiring between:
• PJ9 on the power distribution PWB and PJ18 on the copy controller PWB. Refer to WD 6.4, WD 1.9, WD 3.4 and WD 3.6. Check the wiring between:
• PJ850 on the power distribution PWB and PJ852 on the scanner PWB. • PJ9 on the power distribution PWB and PJ18 on the single board controller PWB.
• PJ15 on the copy controller PWB and PJ922 on the scanner PWB. • PJ8 on the power distribution PWB and PJ920 on the scanner PWB.
The wiring is good. • PJ15 on the single board controller PWB and PJ922 on the scanner PWB.
Y N The wiring is good.
Re-seat loose connectors or install new components as necessary: Y N
• DADH / IIT power comms harness, PL 62.16 Item 13. Re-seat loose connectors or install new components as necessary:
• Scanner / copy controller module harness, PL 62.16 Item 7. • DADH / IIT power and comms harness, PL 62.17 Item 15.
• Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14. • Harness PDB to SBC (PJ18), PL 3.11 Item 11.
• Power distribution PWB, PL 3.10 Item 1. • Power distribution PWB, PL 3.11 Item 1.
• Copy controller PWB, PL 3.10 Item 17. • Single board controller PWB, PL 3.11 Item 13.
Go to IQ 29 and refer to CVT and Document Glass Checkout. Check the white calibration strip Go to IQ 29 and refer to CVT and Document Glass Checkout. Check the white calibration strip
on the front undersides of the document and CVT glass. Calibration strip is clean. on the front undersides of the document and CVT glass. Calibration strip is clean.
Y N Y N
Clean with film remover, PL 26.11 Item 14. Clean with film remover, PL 26.11 Item 14.
If the fault persists install new components as necessary: If the fault persists install new components as necessary:
• Scan carriage assembly, PL 62.15 Item 1. • Scan carriage assembly, PL 62.18 Item 11.
• Scanner module, PL 62.10 Item 1. • Scanner module, PL 62.10 Item 1.

Xerox® ColorQube® 9203 Family 2-325 62-450-00A to 62-472-00A, 62-450-00B to 62-472-
62-450-00C to 62-472-00C Calibration Failure RAP 62-473-00 UART RX Wrap Error Entry RAP
Initial Actions 62-473-00 UART RX wrap error.
Procedure
WARNING Go to the relevant procedure:
Ensure that the electricity to the machine is switched off while performing tasks that do • For machines W/O TAG 007 and W/O TAG 006, go to the 62-473-00A UART RX Wrap
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Error RAP.
death or injury. Moving parts can cause injury. • For machines W/TAG 007 and W/TAG 006, go to the 62-473-00B UART RX Wrap Error
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62- RAP.
450-00 to 62-472-00 Calibration Failure Entry RAP. • For machines W/TAG 007 and W/O TAG 006, go to the 62-473-00C UART RX Wrap Error
• Switch off, then switch on the machine, GP 14. RAP.
Procedure
Enter dC330 code 62-002 to activate the exposure lamp. Exposure lamp illuminate.
Y N
Go to 62D Exposure Lamp Failure RAP.
Remove the scanner PWB cover, refer to REP 62.21. Refer to WD 6.6. Check the ribbon har-
ness between PJ931 and PJ932 on the scanner PWB and PJ1 and PJ2 on the CCD PWB.
The ribbon harness is good.
Y N
• CCD PWB assembly, PL 62.17 Item 11.
• PJ9 on the power distribution PWB and PJ18 on the copy controller PWB.
• PJ8 on the power distribution PWB and PJ920 on the scanner PWB.
• PJ15 on the copy controller PWB and PJ922 on the scanner PWB.
The wiring is good.
Y N
Go to IQ 29 and refer to CVT and Document Glass Checkout. Check the white calibration strip
on the front undersides of the document and CVT glass. Calibration strip is clean.
Y N
Clean with film remover, PL 26.11 Item 14.
If the fault persists install new components as necessary:
• Scan carriage assembly, PL 62.15 Item 1.
• Scanner module, PL 62.10 Item 1.

62-450-00C to 62-472-00C, 62-473-00 2-326 Xerox® ColorQube® 9203 Family
62-473-00A UART RX Wrap Error RAP 62-473-00B UART RX Wrap Error RAP
WARNING WARNING
473-00 UART RX Wrap Error Entry RAP. 473-00 UART RX Wrap Error Entry RAP.
Procedure Procedure
Refer to WD 6.1, WD 1.8, WD 3.1 and WD 3.3. Check the wiring between: Refer to WD 6.4, WD 1.9, WD 3.4. and WD 3.6. Check the wiring between:
• PJ9 on the power distribution PWB and PJ18 on the copy controller PWB. • PJ9 on the power distribution PWB and PJ18 on the single board controller PWB.
• PJ850 on the power distribution PWB and PJ852 on the scanner PWB. • PJ8 on the power distribution PWB and PJ920 on the scanner PWB.
• PJ15 on the copy controller PWB and PJ922 on the scanner PWB. • PJ15 on the single board controller PWB and PJ922 on the scanner PWB.
The wiring is good. The wiring is good.
Y N Y N
• DADH / IIT power comms harness, PL 62.16 Item 13. • DADH / IIT power and comms harness, PL 62.17 Item 15.
• Scanner / copy controller module harness, PL 62.16 Item 7. • IIT video / SBC PWB harness, PL 62.17 Item 3.
• Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14. • Harness PDB to SBC (PJ18), PL 3.11 Item 11.
• Copy Controller PWB, PL 3.10 Item 17. • Single board controller PWB, PL 3.11 Item 13.

Xerox® ColorQube® 9203 Family 2-327 62-473-00A, 62-473-00B
62-473-00C UART RX Wrap Error RAP 62-474-00, 62-475-00 Stepper Speed/Reset Error RAP
Initial Actions 62-474-00 Stepper speed error.
62-475-00 Move before reset error.

WARNING
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-
WARNING
473-00 UART RX Wrap Error Entry RAP. Ensure that the electricity to the machine is switched off while performing tasks that do
• Switch off, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Go to 62-473-00 UART RX Wrap Error Entry RAP.
Procedure
The wiring is good.
Y N

62-473-00C, 62-474-00, 62-475-00 2-328 Xerox® ColorQube® 9203 Family
62-476-00 Scan Carriage Home Sensor Entry RAP 62-476-00A Scan Carriage Home Sensor RAP
62-476-00 Carriage home sensor is not cleared or made in time. 62-476-00 Carriage home sensor is not cleared or made in time.

• For machines W/O TAG 007 and W/O TAG 006, go to the 62-476-00A Scan Carriage
Home Sensor RAP. WARNING
• For machines W/TAG 007 and W/TAG 006, go to the 62-476-00B Scan Carriage Home Ensure that the electricity to the machine is switched off while performing tasks that do
Sensor RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• For machines W/TAG 007 and W/O TAG 006, go to the 62-476-00C Scan Carriage Home
Sensor RAP. • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-
476-00 Scan Carriage Home Sensor Entry RAP.
Procedure
Visually check the scanner carriage alignment through the document glass. Carriage align-
ment is good.
Y N
Perform ADJ 62.2 Scan Carriage Assembly.
The wiring is good.
Y N
Enter dC330 code 62-023 carriage motor, MOT62-063. Scan carriage returns to the home
position.
Y N
Check the condition and adjustment of the scan drive belt, PL 62.16 Item 12.
Refer to:
• ADJ 62.3 Carriage Motor and Scanner Drive Belt.
Refer to WD 6.2. Check MOT62-023. Refer to:
• PJ929 Scanner PWB.
A

A
Install new components as necessary: 62-476-00B Scan Carriage Home Sensor RAP
• Scan drive belt, PL 62.16 Item 12.
Initial Actions
• Carriage motor and bracket assembly PL 62.16 Item 15.
WARNING
Enter dC330 code 62-018 carriage home sensor, Q62-018. Stack codes 62-023 and 62-024 to
move the carriage home, then away from home. The display changes.
Y N
Refer to WD 6.2. Check Q62-018:
476-00 Scan Carriage Home Sensor Entry RAP.
Procedure
Visually check that the scan cables are correctly positioned through the document glass. Refer
Install new components as necessary: to REP 62.23. The scan cable position is correct.
• Carriage home sensor PL 62.15 Item 7. Y N
• Scanner PWB, PL 62.16 Item 8. Perform REP 62.23 Scan Cables.
Perform SCP 5 Final Actions. Refer to WD 6.4, WD 1.9, WD 3.4 and WD 3.6. Check the wiring between:
• PJ9 on the power distribution PWB and PJ18 on the single board controller PWB.
• PJ15 on the single board controller PWB and PJ922 on the scanner PWB.
The wiring is good.
Y N
• IIT video / SBC PWB harness, PL 62.17 Item 3.
• Harness PDB to SBC (PJ18), PL 3.11 Item 11.
position.
Y N
• PJ929 scanner PWB.
• Carriage motor, PL 62.17 Item 5.
A
A
Enter dC330 code 62-018 carriage home sensor, Q62-018. Stack codes 62-023 and 62-024 to 62-476-00C Scan Carriage Home Sensor RAP
Y N Initial Actions
Refer to WD 6.5 Check Q62-018:
WARNING
• 01C +3.3V Distribution RAP. death or injury. Moving parts can cause injury.
• 01L 0V Distribution RAP. • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62-
Install new components as necessary: 476-00 Scan Carriage Home Sensor Entry RAP.
• Carriage home sensor PL 62.17 Item 7. • Switch off, then switch on the machine, GP 14.
Procedure
Visually check that the scan cables are correctly positioned through the document glass. Refer
to REP 62.23. The scan cable position is correct.
Y N
Perform REP 62.23 Scan Cables.
The wiring is good.
Y N
• IIT video / CCB PWB harness (PJ922), PL 62.16 Item 6.
position.
Y N
• Carriage motor, PL 62.17 Item 5.

Xerox® ColorQube® 9203 Family 2-331 62-476-00B, 62-476-00C
A
Enter dC330 code 62-018 carriage home sensor, Q62-018. Stack codes 62-023 and 62-024 to 62-477-00 to 62-481-00 Timing Errors RAP
62-477-00 Stepper busy error.
Y N
Refer to WD 6.5 Check Q62-018:
62-478-00 Real time error.
• PJ923 scanner PWB. 62-479-00 Page synchronization error.
• 01C +3.3V Distribution RAP. 62-480-00 Initialize time error.
62-481-00 DADH client time out.
• Carriage home sensor PL 62.17 Item 7. Procedure
Perform SCP 5 Final Actions. WARNING


62-476-00C, 62-477-00 to 62-481-00 2-332 Xerox® ColorQube® 9203 Family
62-484-00 Apps Code Not Present RAP 62-485-00 +12V Supply Error Entry RAP
62-484-00 Apps code not present. 62-485-00 +12V supply error.
Procedure Procedure
• For machines W/O TAG 007 and W/O TAG 006, go to the 62-485-00A +12V Supply Error
WARNING RAP.
Ensure that the electricity to the machine is switched off while performing tasks that do • For machines W/TAG 007 and W/TAG 006, go to the 62-485-00B +12V Supply Error RAP.
• For machines W/TAG 007 and W/O TAG 006, go to the 62-485-00C +12V Supply Error
RAP.

62-485-00A +12V Supply Error RAP 62-485-00B +12V Supply Error RAP
WARNING WARNING
485-00 +12V Supply Error Entry RAP. 485-00 +12V Supply Error Entry RAP.
Procedure Procedure
Enter dC330 code 62-021 12V Detect. 12V supply is detected. Enter dC330 code 62-021 12V Detect. 12V supply is detected.
Y N Y N
Check the +12V supply, refer to: Check the +12V supply, refer to:
• 01E +12V distribution RAP. • 01E +12V distribution RAP.
• 01L 0V distribution RAP. • 01L 0V distribution RAP.
Refer to WD 6.1, WD 1.8, WD 3.1 and WD 3.3. Check the wiring between: Refer to WD 6.4, WD 1.9, WD 3.4. and WD 3.6. Check the wiring between:
• PJ9 on the power distribution PWB and PJ18 on the copy controller PWB. • PJ9 on the power distribution PWB and PJ18 on the single board controller PWB.
• PJ15 on the copy controller PWB and PJ922 on the scanner PWB. • PJ15 on the single board controller PWB and PJ922 on the scanner PWB.
Y N Y N
• DADH / IIT power comms harness, PL 62.16 Item 13. • DADH / IIT power comms harness, PL 62.17 Item 15.
• Scanner / copy controller module harness, PL 62.16 Item 7. • Harness PDB to SBC (PJ18), PL 3.11 Item 11.
• Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14. • IIT video / SBC PWB harness, PL 62.17 Item 3.
• Copy Controller PWB, PL 3.10 Item 17. • Single board controller PWB, PL 3.11 Item 13.

62-485-00C +12V Supply Error RAP 62-486-00 +24V Supply Error Entry RAP
Initial Actions 62-486-00 +24V supply error.
Procedure
WARNING Go to the relevant procedure:
Ensure that the electricity to the machine is switched off while performing tasks that do • For machines W/O TAG 007 and W/O TAG 006, go to the 62-486-00A +24V Supply Error
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause RAP.
death or injury. Moving parts can cause injury. • For machines W/TAG 007 and W/TAG 006, go to the 62-486-00B +24V Supply Error RAP.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 62- • For machines W/TAG 007 and W/O TAG 006, go to the 62-486-00C +24V Supply Error
485-00 +12V Supply Error Entry RAP. RAP.
Procedure
Enter dC330 code 62-021 12V Detect. 12V supply is detected.
Y N
Check the +12V supply, refer to:
• 01E +12V distribution RAP.
• 01L 0V distribution RAP.
The wiring is good.
Y N
• IIT video / CCB PWB harness (PJ922), PL 62.16 Item 6.

Xerox® ColorQube® 9203 Family 2-335 62-485-00C, 62-486-00
A
62-486-00A +24V Supply Error RAP • Power distribution PWB, PL 3.10 Item 1.
Initial Actions
WARNING
486-00 +24V Supply Error Entry RAP.
• Remove the document glass, REP 62.3. Check the LED lamp ribbon harness, PL 62.15
Item 5 for damage caused by contact with scanner PWB cover which can cause a +24V
short. If necessary, install a new LED lamp ribbon harness, PL 62.15 Item 5.
Procedure
Enter dC330 code 62-020 24V Detect. +24V supply is detected.
Y N
Check the +24V power supply, refer to:
• 01H +24V distribution RAP.
• 01L 0V distribution RAP.
Check for +24V on both sides of fuse F1, adjacent to PJ920 on the scanner PWB. +24V is
present.
Y N
Install new scanner PWB, PL 62.16 Item 8.
The wiring is good.
Y N
and PJDC4 on the power supply unit. The wiring is good.
Y N
A
62-486-00A 2-336 Xerox® ColorQube® 9203 Family
62-486-00B +24V Supply Error RAP 62-486-00C +24V Supply Error RAP
WARNING WARNING
486-00 +24V Supply Error Entry RAP. 486-00 +24V Supply Error Entry RAP.
Procedure Procedure
Enter dC330 code 62-020 24V Detect. +24V supply is detected. Enter dC330 code 62-020 24V Detect. +24V supply is detected.
Y N Y N
Check the +24V power supply, refer to: Check the +24V power supply, refer to:
• 01H +24V distribution RAP. • 01H +24V distribution RAP.
• 01L 0V distribution RAP. • 01L 0V distribution RAP.
Refer to WD 6.4, WD 1.9, WD 3.4 and WD 3.6. Check the wiring between: Refer to WD 6.4, WD 1.8, WD 3.1 and WD 3.3. Check the wiring between:
• PJ9 on the power distribution PWB and PJ18 on the single board controller PWB. • PJ9 on the power distribution PWB and PJ18 on the copy controller PWB.
• PJ15 on the single board controller PWB and PJ922 on the scanner PWB. • PJ15 on the copy controller PWB and PJ922 on the scanner PWB.
Y N Y N
• DADH / IIT power comms harness, PL 62.17 Item 15. • DADH / IIT power comms harness, PL 62.17 Item 15.
• IIT video / SBC PWB harness, PL 62.17 Item 3. • IIT video / CCB PWB harness (PJ922), PL 62.16 Item 6.
• Harness PDB to SBC (PJ18), PL 3.11 Item 11. • Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14.
• Single board controller PWB, PL 3.11 Item 13. • Copy controller PWB, PL 3.10 Item 17.
Refer to WD 1.5 and WD 1.6. Check the wiring between PJ1 on the power distribution PWB Refer to WD 1.5 and WD 1.6. Check the wiring between PJ1 on the power distribution PWB
and PJDC4 on the power supply unit. The wiring is good. and PJDC4 on the power supply unit. The wiring is good.
Y N Y N
• Power supply unit, PL 1.15 Item 2. • Power supply unit, PL 1.15 Item 2.
• Single board controller PWB, PL 3.11 Item 13. • Copy controller PWB, PL 3.10 Item 17.

Xerox® ColorQube® 9203 Family 2-337 62-486-00B, 62-486-00C
62-487-00 System Phase Lock Loop (PLL) Error RAP 62A Scanning Document Size RAP (W/O TAG 007)
62-487-00 System phase lock loop (PLL) error. The scanner has encountered a document that is larger than expected.
Procedure The scanner has encountered a document of unknown size. The document size sensors have
incorrectly determined the size of the original.
WARNING Initial Actions

Go to 62-473-00 UART RX Wrap Error Entry RAP. Ensure that the electricity to the machine is switched off while performing tasks that do
For machines W/TAG 007, go to the 62C Scanning Document Size RAP (W/TAG 007).
Procedure
NOTE: If necessary, temporarily install the document glass when checking the document size
sensors to ensure that the document is the correct distance from the sensor.
Check that the input module angle sensor actuator is not damaged. If necessary install a new
input module angle sensor actuator PL 62.15 Item 10. Enter dC330 code 62-301 angle sensor.
Actuate the input module angle sensor actuator. The display changes.
Y N
Refer to WD 6.2. Check the angle sensor, PL 62.15 Item 7.
• Angle sensor, PL 62.15 Item 7.
Raise the DADH. Enter dC330 code 62-251 document size sensor 1. Actuate Q62-251 docu-
ment size sensor 1 by placing a piece of paper on the document glass above the sensor.
Repeat the test for Q62-252 document size sensor 2. The display changes.
Y N
Refer to WD 6.2. Check Q62-251 and Q62-252.
• Document size sensor 1 or 2, PL 62.16 Item 10.
A
62-487-00, 62A 2-338 Xerox® ColorQube® 9203 Family
A
Refer to WD 6.1, WD 1.8, WD 3.1 and WD 3.3. Check the wiring between: 62B LED Exposure Lamp Failure RAP (W/O TAG 007)
• PJ9 on the power distribution PWB and PJ18 on the copy controller PWB. The LED lamp(s) do not illuminate.
• PJ15 on the copy controller PWB and PJ922 on the scanner PWB. Initial Actions
The wiring is good.
Y N
Re-seat loose connectors or install new components as necessary: WARNING
• DADH / IIT power comms harness, PL 62.16 Item 13. Ensure that the electricity to the machine is switched off while performing tasks that do
• Scanner / copy controller module harness, PL 62.16 Item 7. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14. death or injury. Moving parts can cause injury.
• Scanner PWB, PL 62.16 Item 8. For machines W/TAG 007, go to the 62D Exposure Lamp Failure RAP (W/TAG 007).
• Copy Controller PWB, PL 3.10 Item 17. Procedure
Enter dC330, input code 62-002 to activate the exposure lamps. Exposure lamps illuminate.
Perform SCP 5 Final Actions. Y N
Remove the scanner PWB cover, refer to REP 62.12. Refer to WD 6.1, WD 1.8, WD 3.1
and WD 3.3. Check the wiring between:
The wiring is good.
Y N
Refer to WD 6.2. Check the wiring between PJ926 on the scanner PWB and the LED
Exposure lamps, PL 62.15 Item 2. The wiring is good.
Y N
• LED exposure lamps, PL 62.15 Item 2.
Refer to WD 6.2. Check the in line ribbon harness PL 62.15 Item 3 between CN1 and
CN2. Harness is good.
Y N
• LED exposure lamps, PL 62.15 Item 2.
• In line ribbon harness, PL 62.15 Item 3.

Xerox® ColorQube® 9203 Family 2-339 62A, 62B
A
62C Scanning Document Size RAP (W/TAG 007) For machines W/TAG 006, refer to WD 6.4, WD 1.9, WD 3.4 and WD 3.6. Check the wiring
between:
The scanner has encountered a document that is larger than expected.
The scanner has encountered a document of unknown size. The document size sensors have • PJ8 on the power distribution PWB and PJ920 on the scanner PWB.
incorrectly determined the size of the original. • PJ15 on the single board controller PWB and PJ922 on the scanner PWB.
For machines W/O TAG 006, refer to WD 6.4, WD 1.8, WD 3.1 and WD 3.3. Check the wiring
Initial Actions between:
WARNING
The wiring is good.
Y N
For machines W/TAG 006. Re-seat loose connectors or install new components as nec-
For machines W/O TAG 007, go to the 62A LED Exposure Lamp Failure RAP (W/O TAG 007). essary:
Procedure • Harness PDB to SBC (PJ18), PL 3.11 Item 11.
NOTE: If necessary, temporarily install the document glass when checking the document size • Scanner PWB, PL 62.17 Item 1.
sensors to ensure that the document is the correct distance from the sensor. • Power distribution PWB, PL 3.11 Item 1.
Check that the input module angle sensor actuator is not damaged. If necessary install a new • Single board controller PWB, PL 3.11 Item 13.
input module angle sensor actuator PL 62.17 Item 10. Enter dC330 code 62-301 angle sensor. For machines W/O TAG 006. Re-seat loose connectors or install new components as
Actuate the input module angle sensor actuator. The display changes. necessary:
Y N • DADH / IIT power comms harness, PL 62.17 Item 15.
Refer to WD 6.5 Check the angle sensor, PL 62.15 Item 7. • Harness PDB to CCB (PJ9, PJ18), PL 3.10 Item 14.
• GP 11, How to Check a Sensor. • Scanner PWB, PL 62.17 Item 1.
• PJ923 scanner PWB. • Power distribution PWB, PL 3.10 Item 1.
• 01D +5V Distribution RAP. • Copy controller PWB, PL 3.10 Item 17.
• 01L 0V Distribution RAP. Perform SCP 5 Final Actions.
• Angle sensor, PL 62.17 Item 7.
Raise the DADH. Enter dC330 code 62-251 document size sensor 1. Actuate Q62-251 docu-
ment size sensor 1 by placing a piece of paper on the document glass above the sensor.
Repeat the test for Q62-252 document size sensor 2. The display changes.
Y N
Refer to WD 6.5. Check Q62-251 and Q62-252.
• Document size sensor 1 or 2, PL 62.17 Item 14.
A
62C 2-340 Xerox® ColorQube® 9203 Family
A
62D Exposure Lamp Failure RAP (W/TAG 007) Y N
The exposure lamp does not illuminate.
Initial Actions • Exposure lamp inverter PWB, PL 62.18 Item 6.
• Scan lamp ribbon cable, PL 62.17 Item 6.
WARNING Refer to WD 6.5. Check the lamp harness. Harness is good.

Y N
death or injury. Moving parts can cause injury. • Exposure lamp, PL 62.18 Item 1.
For machines W/O TAG 007, go to the 62B LED Exposure Lamp Failure RAP (W/O TAG 007).
Procedure Perform SCP 5 Final Actions.

Enter dC330, input code 62-002 to activate the exposure lamps. Exposure lamps illumi-
nate.
Y N
Remove the scanner PWB cover, refer to REP 62.21.
For machines W/TAG 006. Refer to WD 6.4, WD 1.9, WD 3.4 and WD 3.6. Check the wir-
ing between:
• PJ15 on the single board controller PWB and PJ922 on the scanner PWB.
For machines W/O TAG 006, refer to WD 6.4, WD 1.8, WD 3.1 and WD 3.3. Check the
wiring between:
The wiring is good.
Y N
For machines W/TAG 006. Re-seat loose connectors or install new components as
necessary:
• Harness PDB to SBC (PJ18), PL 3.11 Item 11.
For machines W/O TAG 006. Re-seat loose connectors or install new components
as necessary:
Refer to WD 6.5. Check the ribbon cable between PJ926 on the scanner PWB and the
exposure lamp inverter PWB, PL 62.18 Item 6. The ribbon cable is good.
A

Xerox® ColorQube® 9203 Family 2-341 62D
70-312-00 Tray 1 to Tray 3 Communication Failure RAP 70-325-00 Lower Left Door Open in Run RAP
70-312-00 IME to tray 1, tray 2 and tray 3 communications failure. 70-325-00 Lower left door assembly open during run.

• Ensure the lower left hand door assembly, PL 70.25 Item 5 is closed.
• Check the door hinge and latch for damage, PL 70.25.
WARNING
Procedure
Refer to Wiring Diagram WD 7.3 and WD 8.2. Perform the following: WARNING
1. Switch off the machine, then switch on the machine, GP 14. Ensure that the electricity to the machine is switched off while performing tasks that do
2. Check the harness between PJ950 on the 3 Tray Module PWB and PJ 401 on the Media
Path Driver PWB.
Enter dC330 code 01-302 lower door interlock, Q01-301, PL 70.10 Item 18. Press Start. Manu-
3. Check the PJ connections and wiring. Repair the wiring as necessary, REP 1.1.
ally actuate the sensor. The display changes.
If necessary, install new components: Y N
• 3 Tray Module PWB, PL 73.16 Item 4. Go to WD 7.4. Check the lower door interlock. Refer to:
• Media Path Driver PWB, PL 1.15 Item 5. • GP 11 How to Check a Sensor.
• Media Path Driver PWB to 3 Tray Module PWB Harness (PJ 950 to PJ401), PL 1.15 Item • PJ953, 3 Tray Module PWB.
21. • 01D +5V Distribution RAP.
• Lower door interlock, PL 70.10 Item 18.
• 3 tray module PWB, PL 73.16 Item 4.
• Media Path Driver PWB, PL 1.15 Item 5.

• Check that the sensor is correctly located.
• Check that the actuator on the lower left door assembly is not damaged or missing.
• If necessary, install a new lower left hand door assembly, PL 70.25 Item 5.

A
71-101-00, 71-106-00 Tray 1 Mis-Feed Jam RAP Check that the nudger spring is installed correctly, PL 81.25 Item 10. Check that the spring is
not damaged. The spring is good.
71-101-00 The feed sensor 1 did not actuate at the correct time after paper feed from tray 1.
Y N
71-106-00 LE late to takeaway roll 1 sensor when feeding from tray 1. Install a new spring, PL 81.25 Item 10.
Initial Actions Enter dC330 code 70-025 3 tray transport motor, MOT70-025, PL 73.16 Item 3. Press Start.
The motor runs.
Y N
WARNING Go to WD 7.5. Check MOT70-025. Refer to:
Ensure that the electricity to the machine is switched off while performing tasks that do • GP 10 How to Check a Motor.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • PJ956, 3 tray module PWB.
death or injury. Moving parts can cause injury. • 01H +24V Distribution RAP.
• Check the condition of the paper in tray 1. Refer to IQ 1 and GP 20. • 01L 0V Distribution RAP.
• Check that the paper guides are set correctly. Install new components as necessary:
• Check that the lower left hand door, PL 70.25 Item 5 is latched correctly. • 3 tray transport motor, PL 73.16 Item 3
• Check the condition of the tray 1 feed, nudger and retard rolls. Use a cloth dampened with • 3 Tray Module PWB, PL 73.16 Item 4.
water to clean the rolls, GP 27. If necessary, install a new tray 1 feed roll kit, PL 81.25
Item 28.
• Go to dC135 CRU/HFSI Status. Check the count of the tray 1 feed roll set. If the count is Observe the transport rolls, PL 73.16. The transport rolls rotate.
near end of life, install a new tray 1 feed roll kit, PL 81.25 Item 28. Y N
Check the drive belt and gears, PL 73.16 Item 7.
Procedure
Enter dC330 code 71-101 tray 1 feed sensor, Q71-101, PL 81.25 Item 19. Press Start. Remove
CAUTION
tray 1 and tray 2. Manually actuate the sensor. The display changes.
Y N To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 71-
Go to WD 7.3. Check tray 1 feed sensor, Q71-101. Refer to: 002 is run in diagnostics.
• GP 11 How to Check a Sensor. Enter dC330 code 71-002 tray 1 feed / elevate motor, MOT71-002, PL 81.25 Item 22. Press
start The feed rolls rotate.
• PJ951, 3 tray module PWB.
Y N
• 01D +5V Distribution RAP. Remove the tray feed assembly, REP 81.1. Manually rotate the feed roll shaft The drive
• 01L 0V Distribution RAP. gears rotate.
• Tray 1 feed sensor, PL 81.25 Item 19. Check the gears for damage. If necessary, install new components, PL 81.35.
Install the tray 1 feed assembly.
• Media Path Driver PWB, PL 1.15 Item 5. Go to WD 7.3. Check MOT71-002. Refer to:
Enter dC330 code 71-395 TAR 1 Sensor, Q71-395, PL 73.16 Item 11. Press Start. Open the
left hand door and manually actuate the sensor. The display changes. • PJ951, 3 tray module PWB.
Y N • 01H +24V Distribution RAP.
Go to WD 7.4. Check takeaway roll sensor 1, Q71-395. Refer to: • 01L 0V Distribution RAP.
• GP 11 How to Check a Sensor. Instal new Components as necessary:
• PJ955, 3 tray module PWB. • Tray 1 feed / elevate motor, PL 81.25 Item 22.
• 01D +5V Distribution RAP. • 3 tray module PWB, PL 73.16 Item 4.
• 01L 0V Distribution RAP. • Media Path Driver PWB, PL 1.15 Item 5.
The nudger roll rotates.
• TAR 1 Sensor, PL 73.16 Item 11.
Y N
• 3 tray module PWB, PL 73.16 Item 4. Check the nudger roll drive belt and drive coupling for damage. If necessary, install new
• Media Path Driver PWB, PL 1.15 Item 5. components, PL 81.25.
A B
B
With the paper tray removed. Manually move the retard nip split mechanism The retard roll 71-215-00 Tray 1 Elevate Up Failure RAP
moves against the feed roll.
71-215-00 Tray 1 stack height sensor did not actuate within the correct time after the feed / ele-
Y N
vator motor turned on.
Check the retard roll drive coupling and mechanism for damage.
If necessary, install new components, PL 81.25.
Initial Actions
• Check the feed roll assembly, PL 81.25 Item 11.
WARNING
• Check the feed assembly, PL 81.25 Item 1.
• Check for paper or obstructions behind the tray.
• Check that the tray 1 stack height sensor, PL 81.25 Item 17 is clean and located correctly.
• Ensure that the tray is pushed fully home.
• Check the stack height mechanism actuator in the feeder, PL 81.25.
• Check the drive gears and coupling on the tray, PL 70.10.
• Check the elevator drive coupling on the feeder assembly, PL 81.25.
• Check for the lift plate is not bowed under the elevate plate assembly.
Procedure
Enter dC330 code 71-336 tray 1 stack height sensor, Q71-336, PL 81.25 Item 17. Press Start.
Pull out tray 1. Manually actuate the sensor. The display changes
Y N
Go to WD 7.3. Check tray 1 stack height sensor, Q71-336. Refer to:
• Tray 1 stack height sensor, PL 81.25 Item 17.
CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
out before MOT71-002 is run in diagnostics.
Enter dC330 code 71-002 tray 1 feed / elevator motor, MOT71-002, PL 81.25 Item 22. Pull out
tray 1. Press Start. The motor runs
Y N
Go to WD 7.3. Check tray 1 feed / elevator motor, MOT71-002. Refer to:
A

A
Install new components as necessary: 71-320-00 Tray 1 Open In Run RAP
• Tray 1 feed / elevator motor, PL 81.25 Item 22. 71-320-00 Tray 1 was opened during run when the paper is fed from tray 1.
• 3 Tray Module PWB, PL 73.16 Item 4.
• Media Path Driver PWB, PL 1.15 Item 5. Initial Actions
• Check the feeder / elevator motor drive gears, PL 81.25. WARNING
• Check the tray 1 stack height mechanism on the feeder assembly, Ensure that the electricity to the machine is switched off while performing tasks that do
If the fault still occurs, go to 71A Tray 1 Empty RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Check for obstructions behind the tray.
• Ensure the tray is pushed fully home.
• Check the tray 1 location catch for damage, PL 70.10 Item 17.
Procedure
Tray 1 and tray 2 do not have a dedicated home sensor. The 5 size sensing switches on the 3
tray module PWB, PL 73.16 Item 4, are used. When at least one switch is actuated the tray is
closed. When no switches are actuated, the tray is open.
Enter dC330 codes 71-311, 71-312, 71-313, 71-314 and 71-315. Press Start. Remove the tray
and manually actuate each switch. The display changes for each switch.
Y N
Go to WD 7.5. Check tray 1 size switches. Refer to:
• 3 Tray module PWB, PL 73.16 Item 4.

• Check the length and width sensing bracket on the paper tray, PL 70.10 Item 12, PL 70.10
Item 13
• If the problem persists, install new components as necessary:
– 3 tray module PWB, PL 73.16 Item 4.
– Media Path Driver PWB, PL 1.15 Item 5.

71A Tray 1 Empty RAP 71B Tray 1 Wrong Size Paper RAP
Use this RAP when the copier display instructs the operator to add paper to the tray that is not Use this RAP when the paper fed from the tray does not match the paper size indicated by the
empty. tray paper size switch. Tray 1 and tray 2 feed mechanisms are identical.
WARNING WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Ensure that the electricity to the machine is switched off while performing tasks that do
from the customer supply while performing tasks that do not need electricity. Electricity not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
can cause death or injury. Moving parts can cause injury. death or injury. Moving parts can cause injury.
Enter dC330 code 71-201. Press Start. Manually actuate the tray empty sensor Q71-201, PL • Check that the tray paper guides are set up to the edges of the paper.
81.25 Item 19. The display changes. • Check for paper down the back of the tray.
Y N
• Make sure the guides are located in the tray base slots if a standard paper size is used.
Go to WD 7.3. Check tray 1 empty sensor, Q71-201.
Refer to: • Check the length and width bracket on the rear of the tray, PL 70.10 Item 12 and PL 70.10
Item 13.
• PJ951, 3 tray module PWB
Procedure
Go to Table 1. Compare the paper size in the tray to the size switches actuated.
Enter dC330 and relevant component control code as shown in the table. Press Start. Manually
Install new components as necessary. actuate the paper size switch on the 3 tray module PWB, PL 73.16 Item 4. The display
• Tray 1 empty sensor, PL 81.25 Item 19. changes.
• 3 tray module PWB, PL 73.16 Item 4. Y N
• Media Path Driver PWB, PL 1.15 Item 5. Go to WD 7.5. Check the tray 1 size switch 1, 2, 3, 4 and 5 at the switch on the 3 tray
module PWB. Check the voltage on the centre pin of the relevant switch on the rear of the
PWB. Refer to:
• Check that the sensor is free of paper dust and is located correctly.
• 01B +3.3V ESTAR Distribution RAP
• Check the paper feed mechanism and feedhead, PL 81.25 Item 1.
Set the paper tray paper guides to a standard size of paper. Push in the tray. Refer to Table 1 to
identify the switches that should be actuated.
Enter dC330 and relevant component control code to operate the size switch as shown in the
table. Press Start. Open and close the tray and observe the change of state of the size switch.
Set the paper guides to various other paper sizes, to actuate all 5 size switches The size
switches change to the correct state for the paper size selected.
Y N
Check the length and width sensing bracket on the paper tray, PL 70.10 Item 12, PL 70.10
Item 13. Install new parts as required.
If the problem is random, check the paper tray for worn or damaged parts. If necessary install a
new tray assembly, PL 70.10 Item 1.

72-101-00, 72-106-00, 72-110-00 Tray 2 Mis-Feed Jam RAP
72-101-00 The feed sensor 2 did not actuate in the correct time after paper feed from tray 2.
Table 1 Tray 1 paper size table
Size Size Size Size Size 72-106-00 LE late to takeaway roll 2 sensor when feeding from tray 2.
switch 1 switch 2 switch 3 switch 4 switch 5
Paper (S71-311) (S71-312) (S71-313) (S71-314) (S71-315) 72-110-00 LE late to takeaway roll 1 sensor when feeding from tray 2.
A5 SEF 0V +3.3V 0V 0V +3.3V
5.5 x 8.5 inch SEF Initial Actions
A4 LEF +3.3V 0V 0V 0V +3.3V
A4 SEF 0V +3.3V +3.3V 0V 0V WARNING

A3 SEF +3.3V 0V +3.3V +3.3V +3.3V not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
A5 SEF 0V +3.3V 0V +3.3V +3.3V • Check the condition of the paper in tray 2. Refer to IQ 1 and GP 20.
B5 SEF and JIS B5 • Check that the paper guides are set correctly.
5.5 x 8.5 inch SEF • Check that the left hand door is latched correctly.
EXEC 184 x 267 mm 0V +3.3V 0V +3.3V 0V • Check the condition of the tray 2 feed, nudger and retard rolls. Use a cloth dampened with
B5 SEF and JIS B5 water to clean the rolls, GP 27. If necessary, install a new tray 2 feed roll kit, PL 81.26
8.5 x 11 LEF (Letter) 0V 0V 0V +3.3V +3.3V Item 28.
• Go to dC135 CRU/HFSI Status. Check the count of the tray 2 feed roll set. If the count is
8.5 x 11 SEF (Letter) 0V +3.3V +3.3V +3.3V 0V near end of life, install a new tray 2 feed roll kit, PL 81.26 Item 28.
8.5 x 13 SEF (Folio) 0V +3.3V +3.3V 0V +3.3V Procedure

216 x 330 mm Enter dC330 code 72-102 tray 2 feed sensor, Q72-102, PL 81.26 Item 19. Press Start. Remove
tray 1 and tray 2 then manually actuate the sensor. The display changes.
8.5 x 14 SEF (Legal) 0V +3.3V +3.3V +3.3V +3.3V Y N
B4 SEF and JIS B4 Go to WD 7.3.Check tray 2 feed sensor, Q72-102. Refer to:
11 x 17 SEF (Tabloid) 0V 0V +3.3V +3.3V +3.3V • PJ952, 3 tray module PWB.
Enter dC330 code 72-396 TAR 2 Sensor, Q72-396, PL 73.16 Item 11. Press Start. Open the
left hand door and manually actuate the sensor. The display changes.
Y N
Go to WD 7.4. Check TAR 2 Sensor, Q72-396. Refer to:
A
71B, 72-101-00, 72-106-00, 72-110-00 2-348 Xerox® ColorQube® 9203 Family
A
• TAR sensor 2, PL 73.16 Item 11. Go to WD 7.3. Check tray 2 feed/elevator motor, MOT72-001. Refer to:
• 3 Tray Module PWB, PL 73.16 Item 4. • GP 10 How to Check a Motor.
• Media Path Driver PWB, PL 1.15 Item 5. • PJ952, 3 tray module PWB.
Check that the nudger spring is installed correctly, PL 81.26 Item 10. Check that the spring is • 01L 0V Distribution RAP.
not damaged. The spring is good. Install new components as necessary:
Y N
• Tray 2 feed/elevator motor, PL 81.26 Item 22.
Install a new spring, PL 81.26 Item 10.
Enter dC330 code 71-395 TAR 1 Sensor, Q71-395, PL 73.16 Item 11. Press Start. Open the • Media Path Driver PWB, PL 1.15 Item 5.
left hand door and manually actuate the sensor. The display changes.
Y N The nudger roll rotates.
Go to WD 7.4. Check TAR 1 Sensor, Q71-395. Refer to: Y N
• GP 11 How to Check a Sensor. Check the nudger roll drive belt and drive coupling for damage. If necessary, install a new
• PJ955, 3 tray module PWB. components, PL 81.26 Item 12.

With the paper tray removed. Manually move the retard nip split mechanism, PL 81.26. The
• 01L 0V Distribution RAP. retard roll moves against the feed roll.
• TAR 1 Sensor, PL 73.16 Item 11. Check the retard roll drive coupling and mechanism for damage.
• 3 Tray module PWB, PL 73.16 Item 4. If necessary, install new components, PL 81.26.

Enter dC330 code 70-025 3 tray module transport motor, MOT70-025, PL 73.16 Item 3. Press
Start. The motor runs. • Check the feed assembly, PL 81.26 Item 1.
Y N
Go to WD 7.5. Check 3 tray module transport motor, MOT81-025. Refer to:
• PJ956 on 3 tray module PWB.
• 3 tray module transport motor, PL 73.16 Item 3.
The transport rolls rotate.

Y N
Check the drive belt and gears, PL 73.16 Item 7.
CAUTION
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 72-
001 is run in diagnostics.
Enter dC330 code 72-001 tray 2 feed/elevator motor, MOT72-001, PL 81.26 Item 22. Press
Start. The motor runs.

A
72-215-00 Tray 2 Elevate Up Failure RAP Install new components as necessary:
72-215-00 Tray 2 stack height sensor did not actuate within the correct time after the feed / ele- • Tray 2 feed / elevator motor, PL 81.26 Item 22.
vator motor turned on. • 3 tray module PWB, PL 73.16 Item 4.
Initial Actions
• Check the feeder / elevator motor drive gears, PL 81.26.
WARNING • Check the tray 2 stack height mechanism on the feeder assembly,
Ensure that the electricity to the machine is switched off while performing tasks that do If the fault still occurs then go to 72A Tray 2 Empty RAP.
• Check that the tray 2 stack height sensor, PL 81.26 Item 17 is clean and located correctly.
• Check for obstructions behind the tray.
• Ensure that the tray is pushed fully home.
• Check the stack height mechanism actuator on the back of the tray, PL 81.26.
• Check the drive gears and coupling on the tray, PL 70.10.
• Check the elevator drive coupling on the feeder assembly, PL 81.26.
• Check for the lift plate is not bowed under the elevate plate assembly.
Procedure
Pull out tray 1. Manually actuate the sensor. The display changes
Y N
CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
out before MOT72-001 is run in diagnostics.
Enter dC330 code 72-001 tray 2 feed / elevate motor, MOT72-001, PL 81.26 Item 22. Pull out
tray 2. Press Start. The motor runs
Y N
Go to WD 7.3. Check tray 2 feed / elevate motor, MOT72-001. Refer to:
A
72-320-00 Tray 2 Open in Run RAP 72A Tray 2 Empty RAP
72-320-00 Tray 2 was opened during run when the paper is fed from tray 2. Use this RAP when the copier display instructs the operator to add paper to the tray that is not
empty.
Initial Actions
Procedure
WARNING
• Check for obstructions behind the tray. death or injury. Moving parts can cause injury.
• Ensure that the tray is pushed fully home. Tray 2 empty sensor, Q72-201. Enter dC330 code 72-201, PL 81.26 Item 19. Press Start.
Manually actuate the tray empty sensor. The display changes.
• Check the tray 2 location catch for damage, PL 70.10 Item 17.
Y N
Go to WD 7.3. Check tray 2 empty sensor, Q72-201.
Procedure Refer to:
Tray 1 and tray 2 do not have a dedicated home sensor. The 5 size switches on the 3 tray mod- • GP 11 How to Check a Sensor.
ule PWB, PL 73.16 Item 4, are used. When at least one switch is actuated, the tray is closed. • PJ952, 3 tray module PWB.
When all switches are not actuated, the tray is open.
Enter dC330 and enter code 72-321, 72-322, 72-323, 72-324 and 72-325 one at a time. Press
Start. Remove the tray and manually actuate each switch. The display changes for each • 01L 0V Distribution RAP.
switch. Install new components as necessary.
Y N • Tray 2 empty sensor, PL 81.26 Item 19.
Go to WD 7.5. Check tray 2 size switches. Refer to: • 3 tray module PWB, PL 73.16 Item 4.
• GP 13 How to Check a Switch. • Media Path Driver PWB, PL 1.15 Item 5.
• 01L 0V Distribution RAP. Perform the following:
Install new components as necessary: • Check that the sensor is free of paper dust.
• 3 tray module PWB, PL 73.16 Item 4. • Check the paper feed mechanism, PL 81.26 Item 1.

• Check the size switches on the 3 tray module PWB, PL 73.16 Item 4.
• Check the length and width sensing bracket on the paper tray, PL 70.10 Item 12, PL 70.10
Item 13
• If the problem persists, install new components as necessary:
– 3 tray module PWB, PL 73.16 Item 4.
– Media Path Driver PWB, PL 1.15 Item 5.

Xerox® ColorQube® 9203 Family 2-351 72-320-00, 72A
72B Tray 2 Wrong Size Paper RAP NOTE: Standard sizes will be offered as indicated, as well a custom sizes limited to the range
supported.
Use this RAP when the paper fed from the tray does not match the paper size indicated by the
tray paper size switch. Tray 1 and tray 2 feed mechanisms are identical.
Table 1 Tray 2 paper size table
Initial Actions Size Size Size Size Size

switch 1 switch 2 switch 3 switch 4 switch 5
Paper (S72-321) (S72-322) (S72-323) (S72-324) (S72-325)
WARNING A5 SEF 0V +3.3V 0V 0V +3.3V
Ensure that the electricity to the machine is switched off while performing tasks that do 5.5 x 8.5 inch SEF
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause A4 LEF +3.3V 0V 0V 0V +3.3V
• Check that the tray paper guides are set up to the edges of the paper. A4 SEF 0V +3.3V +3.3V 0V 0V
• Check for paper down the back of the tray.
• Make sure the guides are located in the tray base slots if a standard paper size is used. A3 SEF +3.3V 0V +3.3V +3.3V +3.3V
• Check the length sensing bracket, PL 70.10 Item 12 and width sensing bracket, PL 70.10
Item 13 on the rear of the tray. A5 SEF 0V +3.3V 0V +3.3V +3.3V
B5 SEF and JIS B5
5.5 x 8.5 inch SEF
Procedure
EXEC 184 x 267 mm 0V +3.3V 0V +3.3V 0V
Go to Table 1. Compare the paper size in the tray to the size switches actuated. B5 SEF and JIS B5
Enter dC330 and relevant component control code as shown in the table. Press Start. Manually
8.5 x 11 LEF (Letter) 0V 0V 0V +3.3V +3.3V
actuate the paper size switch on the 3 tray module PWB, PL 73.16 Item 4. The display
changes.
Y N 8.5 x 11 SEF (Letter) 0V +3.3V +3.3V +3.3V 0V
Go to WD 7.5. Check tray 2 size switch 1, 2, 3, 4 and 5 at the switch on the 3 tray module
PWB. Check the voltage on the centre pin of the relevant switch on the rear of the PWB. 8.5 x 13 SEF (Folio) 0V +3.3V +3.3V 0V +3.3V
Refer to: 216 x 330 mm
• 01B +3.3V ESTAR Distribution RAP. 8.5 x 14 SEF (Legal) 0V +3.3V +3.3V +3.3V +3.3V
B4 SEF and JIS B4
11 x 17 SEF (Tabloid) 0V 0V +3.3V +3.3V +3.3V
Set the paper tray paper guides to a standard size of paper. Push in the tray. Refer to Table 1 to
identify the switches that should be actuated.
Enter dC330 and relevant component control code to operate the size switch as shown in the
table. Press Start. Open and close the tray and observe the change of state of the size switch.
Set the paper guides to other paper sizes, to actuate all 5 size switches The size switches
change to the correct state for the paper size selected.
Y N
Check the length and width sensing bracket on the paper tray, PL 70.10 Item 12, PL 70.10
Item 13. Install new parts as required.
If the problem is random, check the paper tray for worn or damaged parts. If necessary install a
new tray assembly, PL 70.10 Item 1.

73-101-00, 73-106-00, 73-110-00 Tray 3 Mis-Feed Jam RAP Y N
73-101-00 The feed sensor 3 did not actuate in the correct time after paper feed from Tray 3.
73-106-00 The lead edge of the paper is late to takeaway roll 3 sensor. • PJ954, 3 tray module PWB.
73-110-00 The lead edge of the paper is late to horizontal transport sensor. • 01L 0V Distribution RAP.
Initial Actions • TAR 3 sensor, PL 81.35 Item 18.
WARNING • Media Path Driver PWB, PL 1.15 Item 5.
Remove the right side cover, PL 70.25 Item 4. Check that the nudger spring is installed cor-
rectly, PL 81.30 Item 10. Check that the spring is not damaged. The spring is good.
Y N
NOTE: dC640 can be used to isolate a defective EPC memory PWB. In the case of a defective Install a new spring, PL 81.30 Item 10.
EPC PWB the procedure will stop at 99% of completion then the system will hang. With a good
EPC memory PWB the dC640 procedure will complete within 20 seconds. Enter dC330 code 70-398 tray 3 transport sensor (2), Q70-398, PL 81.35 Item 18. Press Start.
Pull out the horizontal transport assembly, PL 81.35 Item 1. Manually actuate the sensor by
• Check the condition of the paper in tray 3. Refer to GP 20. placing a piece of paper over the sensor but not in the nip rolls. Push in the horizontal trans-
• Ensure that the tray is pushed fully home. port. The display changes.
• Ensure that the tray 3 paper tray guides are set correctly, ADJ 73.1. Y N
• Check that the EPC memory PWB is installed and seated correctly, PL 3.10 Item 28. Go to WD 7.4. Check tray 3 transport sensor (2), Q70-398. Refer to:
• Check the condition of the tray 3 feed, nudger and retard rolls. Use a cloth dampened with • GP 11 How to Check a Sensor.
water to clean the rolls, GP 27. If necessary, install a new tray 3 feed roll kit, PL 81.30 • PJ954, 3 tray module PWB.
Item 26. • 01D +5V Distribution RAP.
• Go to dC135 CRU/HFSI Status. Check the count of the tray 3 feed roll set. If the count is • 01L 0V Distribution RAP.
near end of life, install a new tray 3 feed roll kit, PL 81.30 Item 26. Install new components as necessary:
• Tray 3 transport sensor (2), PL 81.35 Item 18.
Procedure • 3 Tray Module PWB, PL 73.16 Item 4.
Enter dC330 code 73-103 tray 3 feed sensor, Q73-103, PL 81.30 Item 19. Open tray 3. Press • Media Path Driver PWB, PL 1.15 Item 5.
Start. Manually actuate the sensor. The display changes.
Y N Enter dC330 code 70-025 3 tray transport motor, MOT70-025, PL 73.16 Item 3. Press Start.
Go to WD 7.4. Check tray 3 feed sensor, Q73-103. Refer to: The motor runs.
• PJ953, 3 tray module PWB. Go to WD 7.5. Check 3 tray transport motor, MOT70-025. Refer to:
• 01D +5V Distribution RAP. • GP 10 How to Check a Motor.
• 01L 0V Distribution RAP. • PJ953, 3 tray module PWB
Install new components as necessary: • 01H +24V Distribution RAP
• Tray 3 feed sensor, PL 81.30 Item 19. • 01L 0V Distribution RAP
• 3 tray module PWB, PL 73.16 Item 4. Install new components as necessary:
• Media Path Driver PWB, PL 1.15 Item 5. • 3 tray module transport motor, PL 73.16 Item 3.
Enter dC330 code 73-397 TAR 3 Sensor, Q73-397, PL 81.35 Item 18. Press Start. Pull out the • Media Path Driver PWB, PL 1.15 Item 5.
horizontal transport assembly, PL 81.35 Item 1. Manually actuate the sensor by placing a piece
of paper over the sensor but not in the nip rolls. Push in the horizontal transport. The display The transport rolls rotate.
changes. Y N
Check the gears and drive belt, PL 73.16.
A

A
73-212-00 Tray 3 Elevate Encoder Failure RAP
CAUTION 73-212-00 Tray 3 encoder failed to operate when the tray was moving up.
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 73-
001 is run in diagnostics. Initial Actions
Enter dC330 code 73-001 tray 3 feed motor, MOT73-001, PL 81.30 Item 22. Press Start. The
motor runs.
Y N WARNING
Go to WD 7.4. Check tray 3 feed motor, MOT73-001. Refer to: Ensure that the electricity to the machine is switched off while performing tasks that do
• GP 10 How to Check a Motor. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• PJ953, 3 tray module PWB. death or injury. Moving parts can cause injury.
• 01H +24V Distribution RAP. • Check the encoder wheel for damage and that it is located on the motor correctly. If nec-
• 01L 0V Distribution RAP. essary install new components, PL 73.16.
Install new components as necessary: • Check that the encoder sensor and wheel are clean
• Tray 3 feed motor, PL 81.30 Item 22.
Procedure
• Media Path Driver PWB, PL 1.15 Item 5. Pull out the relevant tray and allow it to move fully down. Close the tray. The tray moves up.
Y N
Perform the following: Go to 73-215-00 Tray 3 Hoist Failure RAP.
Enter dC140 Analog Monitor select code 073-003 3TM elevator encoder. Perform the routine
• Check the tray 3 feed assembly, PL 81.30 Item 1. Refer to REP 81.2 and check the feed for the encoder. The encoder routine is good.
head housing location. Y N
• Check the tray is level. Perform the following: Go to WD 7.5. Check the 3TM elevator encoder sensor, Q73-003. Refer to:
1. Remove the tray front cover. • GP 11 How to Check a Sensor.
2. Elevate the tray to the stack height position.
NOTE: In this check place a piece of paper in the sensor. The check is difficult due
3. Hold the elevator drive gear and pull out the tray. Check that the tray is level. to the problem in moving the timing disc.
4. If the tray is not level then install new elevator cables, PL 73.15 Item 18.
• If the fault still occurs, check the following:
– The takeaway roll, PL 81.35 Item 16.
– The transport roll 2, PL 81.35 Item 15.
– The transport roll 1, PL 81.35 Item 14.
• Tray 3 elevator motor, PL 73.16 Item 2.
Go to WD 7.5. Check that the tray 3 limit switch, PL 81.30 Item 25, is not actuated. While not
actuated, check for +24V at both contacts on the switch. Refer to:
• Tray 3 feedhead module, PL 81.30 Item 1.

A
73-215-00 Tray 3 Hoist Failure RAP Enter dC330 code 73-002 tray 3 elevator motor, MOT73-002, PL 73.16 Item 2. Pull out tray 3.
Press Start. The motor runs
73-215-00 Tray 3 stack height sensor did not actuate within the correct time after the elevator
Y N
motor turned on.
Go to WD 7.5. Check that the tray 3 limit switch, PL 81.30 Item 25, is not actuated. While
not actuated, check for +24V at both contacts on the switch. Refer to:
Initial Actions • GP 13 How to Check a Switch.
WARNING • 01H +24V Distribution RAP.
Ensure that the electricity to the machine is switched off while performing tasks that do • 01L 0V Distribution RAP.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Install new components as necessary:
death or injury. Moving parts can cause injury. • Tray 3 limit switch, PL 81.30 Item 25.
• Check for obstructions behind the tray. • 3 tray module PWB, PL 73.16 Item 4.
• Ensure that the tray is pushed fully home. • Media Path Driver PWB, PL 1.15 Item 5.
• Check that the tray elevator cables and mechanisms are located correctly. Refer to REP Go to WD 7.5. Check tray 3 elevator motor, MOT73-002. Refer to:
73.3. • GP 10 How to Check a Motor.
• If the tray only elevates up by 25mm (1 inch) and stops. Go to 73A RAP and check the • PJ957, 3 tray module PWB.
tray empty actuator.
Procedure
Enter dC330 code 73-303 tray 3 home sensor, Q73-303, PL 73.16 Item 8. Press Start. Pull out
• Tray 3 elevator motor, PL 73.16 Item 2.
the tray. The display changes.
Y N • 3 tray module PWB, PL 73.16 Item 4.
Go to WD 7.4. Check tray 3 home sensor, Q73-303. Refer to: • Media Path Driver PWB, PL 1.15 Item 5.
• Check elevator cables, PL 73.15.
• Check elevator motor drive coupling, PL 73.16 Item 2.
• Check tray elevator drive gears and drive coupling, PL 73.15 Item 11.
If the fault still occurs, then go to 73A Tray 3 Out of Paper RAP.
• Tray 3 home sensor, PL 73.16 Item 8.
Pull out tray 3. Manually actuate the stack height sensor. The display changes
Y N

73-320-00 Tray 3 Open in Run RAP 73-325-00 Feeder HT Drawer Open in Run RAP
73-320-00 Tray 3 open during run when the paper is fed from tray 3. 73-325-00 Tray 3 horizontal transport drawer open in run.
WARNING WARNING
• Check for obstructions behind the tray. • Check for obstructions behind the transport.
• Ensure that the tray is pushed fully home. • Ensure that the transport is pushed fully home.
• Check the tray 3 home sensor, PL 73.16 Item 8 actuator on the tray. • Check the switch actuator on the back of the drawer, part of the horizontal transport, PL
• Check the tray 3 latch parts (on the tray and on the machine base), PL 73.16 Item 1. 73.16 Item 18.
• Check the latch on the rear of the horizontal transport, PL 81.35 above the connector for
Procedure damage
Enter dC330 code 73-303 tray 3 home sensor, Q73-303, PL 73.16 Item 8. Press Start. Open
and fully close the tray. The display changes. Procedure
Y N Enter dC330 code 70-100 horizontal transport home switch, Q70-100, on the 3 tray module
Go to WD 7.4. Check tray 3 home sensor, Q73-303. Refer to: PWB, PL 73.16 Item 4. Press Start. Open and fully close the horizontal transport. The dis-
• GP 11 How to Check a Sensor. play changes.
Y N
Go to WD 7.5. Check horizontal transport home switch, Q70-100. The home switch is
located on the 3 tray module PWB. Check the voltage on the centre pin of the switch on
• 01L 0V Distribution RAP. the rear of the PWB. Refer to:
Install new components as necessary: • GP 13 How to Check a Switch.
• Tray 3 home sensor, PL 73.16 Item 8. • 01B +3.3V ESTAR Distribution RAP
• 3 tray module control PWB, PL 73.16 Item 4. • 01L 0V Distribution RAP.
• Media Path Driver PWB, PL 1.15 Item 5. Install new components as necessary:
Check the tray 3 home sensor is secure and correctly positioned.
If the problem continues, install new components as necessary:
• Tray 3 home sensor, PL 73.16 Item 8.
Check the alignment of the actuator to the sensor on the horizontal transport., PL 81.35 Item 1.
• 3 tray module PWB, PL 73.16 Item 4. If the problem continues, install new components as necessary:
• Media Path Driver PWB, PL 1.15 Item 5. • HT and main harness latch, PL 73.16 Item 18.
• Horizontal transport assembly, PL 81.35 Item 1.

73A Tray 3 Out of Paper RAP 74-101-00 Bypass Tray Mis-Feed RAP
Use this RAP when the copier display instructs the operator to add paper to tray 3 when the 74-101-00 The feed sensor did not actuate in the correct time after paper feed from the bypass
tray is not empty. tray
WARNING WARNING
• Check the position of the tray empty sensor, PL 81.30 Item 19. • Check the condition of the paper in tray. Refer to GP 20.
• Clean the tray empty sensor. • Check the paper guides are set correctly.
• Check the condition of the bypass tray feed, nudger and retard rolls. Use a cloth damp-
Procedure ened with water to clean the rolls, GP 27. If necessary, install a new feed roll kit, PL 31.11
Item 26.
Enter dC330 code 73-201 Tray 3 empty sensor, PL 81.30 Item 19. Press Start.
Use a piece of paper to manually actuate the tray empty sensor. with a piece of paper The • Go to dC135 CRU/HFSI Status. Check the count of the bypass feed roll set. If the count is
display changes. near end of life, install a new feed roll kit, PL 31.11 Item 26.
Y N
Go to WD 7.4. Check tray 3 empty sensor, Q73-201. Refer to: Procedure
Enter dC330 code 74-406 bypass feed sensor, Q74-406, PL 74.10 Item 19. Press Start. Manu-
• PJ953, 3 tray module PWB. ally actuate the bypass feed sensor. The display changes.
• 01D +5V Distribution RAP. Y N
• 01L 0V Distribution RAP. Go to WD 8.3. Check bypass feed sensor, Q74-406. Refer to:
Install new components as necessary: • GP 11 How to Check a Sensor.
• Tray 3 empty sensor, PL 81.30 Item 19. • PJ405, Media path driver PWB.
• 3 tray module PWB, PL 73.16 Item 4. • 01C +3.3V Distribution RAP.
• Media Path Driver PWB, PL 1.15 Item 5. • 01L 0V Distribution RAP.
Enter dC330 code 73-383 tray 3 stack height sensor, Q73-383, PL 81.30 Item 17. Press Start. • Bypass feed sensor, PL 74.10 Item 19.
Pull out tray 3. Manually actuate the stack height sensor. The display changes
Y N
Go to WD 7.4. Check tray 3 stack height sensor, Q73-383. Refer to: Enter dC330 code 74-420 Bypass feed motor (M7), MOT74-420, PL 74.10 Item 2. Support the
• GP 11 How to Check a Sensor. nudger assembly. Press Start. The motor runs.
• PJ953, 3 tray module PWB. Y N
• 01D +5V Distribution RAP. Go to WD 8.3. Check Bypass feed motor (M7), MOT74-420. Refer to:
• 01L 0V Distribution RAP. • GP 10 How to Check a Motor.
Install new components as necessary: • PJ405, Media path driver PWB.
• Tray 3 stack height sensor, PL 81.30 Item 17. • 01H +24V Distribution RAP.
• 3 tray module PWB, PL 73.16 Item 4. • 01L 0V Distribution RAP.
• Media Path Driver PWB, PL 1.15 Item 5. Install new components as necessary:
• Bypass module, PL 74.10 Item 1.
The fault may be intermittent. Perform the following: • Media path driver PWB, PL 1.15 Item 5.
• Check that the base plate in tray 3 is located correctly.
• Check that PJ958 harness is connected correctly and not damaged. Refer to REP 81.2 Perform the following, install new components as necessary:
Tray 3 Paper Feed Assembly. Repair the wiring as necessary, REP 1.1. • Check the takeaway nip rolls, PL 70.30 Item 12.

Xerox® ColorQube® 9203 Family 2-357 73A, 74-101-00
• Check the feed roll assembly, PL 74.10 Item 14 and nudger roll assembly, PL 74.10 Item 74-120-00 Bypass Tray Guides Move in Run RAP
13. When the motor is running both the feed and nudger rolls should rotate. Should one of
74-120-00 The Bypass tray paper guides moved during run.
the rolls lock or slip remove the clutch assembly, PL 74.10 Item 15 and nudger roll drive
clutch, PL 74.10 Item 23, refer to REP 81.6. Clean the one way bearings of the clutches
with film remover, PL 26.11 Item 14 and lubricate with traction oil PL 26.11 Item 18. Procedure
WARNING
1. Check that the paper guides are in the correct position.

2. Check the paper guides for damage.
3. Check the operation of the paper guides and the function of the width sensor, Q74-415.
Refer to dC140 Analog Monitor and check the voltage on the potentiometer refer to WD
8.3.

74-214-00 Bypass Tray Nudger Failure RAP 74A Bypass Tray Size Sensing Problems RAP
74-214-00 The Bypass tray nudger failed to operate. Use this RAP to troubleshoot problems when the bypass tray fails to indicate the correct paper
size.
Initial Actions
Initial Actions
WARNING
• Check the feeder assembly, PL 74.10 for damage. death or injury. Moving parts can cause injury.
• Check that the nudger home sensor, PL 74.10 Item 18 is positioned correctly. • Check the condition of the media used in the bypass tray. Refer to IQ 1 and GP 20.
• Check that the width sensor guide is up to the edge of the paper.
Procedure • If there is a width sensing problem, then check that the bypass tray width sensing potenti-
ometer, PL 74.11 Item 10 is not damaged.
Enter dC330 code 74-413 bypass nudger home sensor, Q74-413, PL 74.10 Item 18. Press
Start. Manually actuate the sensor. The display changes.
Y N Procedure
Go to WD 8.3. Check Q74-413. Refer to: Enter dC330 code 74-335 bypass empty sensor, Q74-335, PL 74.10 Item 18. Press Start. Man-
• GP 11 How to Check a Sensor. ually actuate the sensor. The display changes.
• PJ405, Media path driver PWB. Y N
Go to WD 8.3. Check the bypass empty sensor, Q74-335. Refer to:
• Bypass nudger home sensor, PL 74.10 Item 18.
Enter dC330 code 74-420 Bypass feed motor, MOT74-420, PL 74.10 Item 2. Press Start. The • Bypass empty sensor, PL 74.10 Item 18.
motor runs. • Media path driver PWB, PL 1.15 Item 5.
Y N
Go to WD 8.3. Check Bypass feed motor, MOT74-420. Refer to: Enter dC330 code 74-350 bypass width sensor Q74-350, PL 74.11 Item 6. Press Start. Move
• GP 10 How to Check a Motor. the width guides to actuate the sensor. The display changes.
Go to WD 8.3.Check Bypass width sensor, Q74-350. Refer to:
Check the cam mechanism for the nudger home sensor. Manually rotate the cam and check for • Bypass width sensor, PL 74.11 Item 6.
damage. Install new parts as required, PL 74.10. • Media path driver PWB, PL 1.15 Item 5.
If necessary install a new Bypass module, PL 74.10 Item 1.
Enter dC140 code 74-415 Bypass width potentiometer, Q74-415, PL 74.11 Item 10. Press
Start. Move the width guides to actuate the sensor. The display changes.

Y N 75-101-00 Tray 5 Mis-Feed RAP
NOTE: The width sensor is a potentiometer. The arm on the potentiometer is attached to 75-101-00 Tray 5 feed sensor did not actuate in the correct time after paper feed from Tray 5.
the bypass tray side guide. This gives a variable voltage to indicate the paper width set-
ting. Initial Actions
Go to WD 8.3. Check Bypass width potentiometer, Q74-415. Refer to:
WARNING
Install new components as necessary. death or injury. Moving parts can cause injury.
• Bypass module, PL 74.10 Item 1. • Check the condition of the paper in tray 5. Refer to GP 20.
• Media path driver PWB, PL 1.15 Item 5. • Check that the middle left side door, PL 70.30 Item 16 is correctly latched.
• Check that the paper tray is set to the correct paper size.
• Check the condition of the tray 5 feed, nudger and retard rolls. Use a cloth dampened with
• Ensure that the customer is not filling the tray above the max fill line.
water to clean the rolls, GP 27. If necessary, install a new tray 5 feed roll kit, PL 81.45
• Clean the feed, retard and nudger roll with a cloth dampened with water, GP 27. Item 20.
• If necessary, install new components as required, PL 74.10. • Go to dC135 CRU/HFSI Status. Check the count of the tray 5 feed roll set. If the count is
near end of life, install a new tray 5 feed roll kit, PL 81.45 Item 20.
Procedure
Enter dC330 code 75-105 tray 5 feed sensor, Q75-105 PL 81.45 Item 6. Press Start. Manually
actuate the sensor. The display changes.
Y N
Go to WD 7.1. Check tray 5 feed sensor, Q75-105. Refer to:
• PJ504, Tray 5 control PWB.
• Tray 5 control PWB, PL 75.68 Item 8.
Enter dC330 code 75-117 tray 5 feed motor, MOT75-117, PL 81.40 Item 3. Open the door.
Press Start. The motor runs.
Y N
Go to WD 7.2. Check tray 5 feed motor, MOT75-117. Refer to:
• GP 10 How to Check a motor.
• Tray 5 feed motor, PL 81.40 Item 3.
The feed shaft rotates.

74A, 75-101-00 2-360 Xerox® ColorQube® 9203 Family
A
Y N • One way pulley clutch, PL 81.46 Item 4.
Check the drive gears between the motor and the feed shaft. Install new components as • Take away roller, PL 81.46 Item 5.
necessary:
• Motor drive gear, PL 81.40 Item 5. Enter dC330 code 82-125 confirm sensor (16), Q82-125, PL 82.10 Item 7. Press Start.
• Gear 30T bearing, PL 81.40 Item 18. Open the left hand door and manually actuate the sensor. The display changes.
• Gear 29T, PL 81.45 Item 11. Y N
Go to WD 8.1. Check confirm sensor (16), Q82-125. Refer to:
The feed roll rotates • GP 11 How to Check a Sensor.
Y N • PJ104, Media path driver PWB.
Check the one way coupling between the feed roller and the clutch. Install new compo-
nents as necessary:
• One way coupling, PL 81.45 Item 4.
• Clutch, PL 81.45 Item 10. NOTE: Ambient light can effect the operation of the confirm sensor (16), Q82-125. There-
• Feed roller, PL 81.45 Item 2. fore, ensure all machine covers are replaced after the installation of a new sensor, before
checking for the reoccurrence of a fault.
The nudger roll rotates
Y N
Check the nudger pulley and nudger roller. Check the roller belt between the feed roller • Confirm sensor (16), PL 82.10 Item 7.
and the nudger roller. Install new components as necessary: • Media path control PWB, PL 1.15 Item 5.
• Nudger pulley, PL 81.45 Item 3.
• Roller belt, PL 81.45 Item 15.
• Nudger roller, PL 81.45 Item 8.
The retard roll rotates

Y N
Check the coupling between the retard roller, retard clutch and clutch. Install new compo-
nents as necessary:
• Retard clutch, PL 81.46 Item 3.
• Clutch, PL 81.46 Item 7.
• Retard roller, PL 81.46 Item 2.
Enter dC330 code 75-018 tray 5 transport motor, MOT75-018 PL 81.40 Item 2. Press Start.
The motor runs.
Y N
Go to WD 7.1. Check tray 5 transport motor, MOT75-018. Refer to:
• Tray 5 transport motor, PL 81.40 Item 2.
The take away roller rotates.

Y N
Check the drive belt and the one way pulley clutch for damage, GP 7. Check the belt ten-
sioner. Install new components as necessary:
• Drive belt, PL 81.40 Item 7.

75-212-00, 75-215-00 Tray 5 Elevate Up Failure RAP Y N
Go to WD 7.1. Check tray 5 upper limit switch, S75-412. Refer to:
75-212-00 A signal was not detected by the encoder when the elevator motor was driving up.
75-215-00 The tray 5 stack height sensor did not actuate in expected time during hoist. • PJ504, Tray 5 control PWB.
• Tray 5 stack upper limit switch, PL 75.68 Item 12.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Enter dC140 code 75-015 tray 5 elevator encoder sensor, Q75-015, PL 75.68 Item 5. Press
death or injury. Moving parts can cause injury. Start. Manually lift the motor to actuate the sensor. The display changes
• Check for obstructions in the tray. Y N
• Check that the door latches correctly. Go to WD 7.2. Check tray 5 elevator encoder, Q75-015. Refer to:
• Open and close the tray 5 door. If the tray moves up check for intermittent failures. Refer • GP 11 How to Check a Sensor.
to WD 7.1 and WD 7.2. • PJ506, Tray 5 control PWB.
Procedure • 01L 0V Distribution RAP.
Enter dC330 code 75-010 tray 5 door switch, S75-010, PL 75.60 Item 6. Press Start. Manually Install new components as necessary:
toggle the door interlock switch. The display changes. • Elevator encoder sensor, PL 75.68 Item 5.
Y N
Check the wiring to the switch, REP 1.1.
Go to WD 7.2. Check tray 5 switch, S75-010. Refer to:
Enter dC330 code 75-019 tray 5 elevator motor (up), MOT75-019, PL 75.68 Item 4. Press
• GP 13 How to Check a Switch. Start. The motor runs
• PJ507, Tray 5 control PWB. Y N
• 01D +5V Distribution RAP. Go to WD 7.1. Check tray 5 elevator motor, MOT75-019. Refer to:
• 01L 0V Distribution RAP. • GP 10 How to Check a Motor.
Install new components as necessary: • PJ504, Tray 5 control PWB.
• Tray 5 door interlock switch, PL 75.60 Item 6. • 01H +24V Distribution RAP.
• Tray 5 control PWB, PL 75.68 Item 8 • 01L 0V Distribution RAP.
Enter dC330 code 75-011 tray 5 stack height sensor, Q75-011, PL 81.45 Item 7. Press Start. • Tray 5 elevator motor, PL 75.68 Item 4.
Manually actuate the stack height sensor on the paper feed assembly. The display changes
Y N
Go to WD 7.2. Check tray 5 stack height sensor, Q75-402. Refer to: • Media path driver PWB, PL 1.15 Item 5.
The tray 5 elevator motor is operating correctly. Perform SCP 5 Final Actions.
Go to PJ504 pin 4 on the Tray 5 control PWB. Manually actuate the tray upper limit switch
(S75-412), PL 75.68 Item 12, on the paper feed assembly. The voltage changes.

75-213-00, 75-216-00 Tray 5 Elevate Down Failure RAP Y N
Go to WD 7.1. Check tray 5 down limit switch, S75-415. Refer to:
75-213-00 A signal was not detected by the encoder when the elevator motor was driving
down. NOTE: Tray down limit switch S75-415 is located in the paper tray. Press the plate under
the paper tray to actuate the switch.
75-216-00 The tray 5 stack down sensor did not actuate in expected time during lower.
Initial Actions • PJ504, Tray 5 control PWB.
Ensure that the electricity to the machine is switched off while performing tasks that do • Tray 5 down limit switch, PL 75.70 Item 2.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Tray 5 control PWB, PL 75.68 Item 8.
• Check for obstructions in the tray. Enter dC140 code 75-015 tray 5 elevator motor encoder sensor, Q75-015, PL 75.68 Item 5.
• Check that the door latches correctly. Press Start. Manually lift the motor to actuate the sensor. The display changes
• Open and close the tray 5 door. If the tray moves down, check for intermittent failures. Y N
Refer to WD 7.1 and WD 7.2. Go to WD 7.2. Check tray 5 elevator motor encoder, Q75-015. Refer to:
Procedure • PJ506, Tray 5 control PWB.
Enter dC330 code 75-010 tray 5 door switch, S75-010, PL 75.60 Item 6. Press Start. Manually • 01D +5V Distribution RAP.
toggle the door interlock switch. The display changes. • 01L 0V Distribution RAP.
Go to WD 7.2. Check tray 5 door interlock switch, S75-010. Refer to: • Elevator motor encoder sensor, PL 75.68 Item 5.
• GP 13 How to Check a Switch. • Tray 5 control PWB, PL 75.68 Item 8.
• 01D +5V Distribution RAP. Enter dC330 code 75-373 tray 5 elevator motor (down), MOT75-019, PL 75.68 Item 4. Press
• 01L 0V Distribution RAP. Start. The motor runs
Y N
Go to WD 7.1. Check tray 5 elevator motor (down), MOT75-019. Refer to:
• Tray 5 door interlock switch, PL 75.60 Item 6.
Enter dC330 code 75-012 tray 5 down sensor, Q75-012, PL 75.68 Item 9. Press Start. Manu- • 01H +24V Distribution RAP.
ally actuate the stack down sensor actuator. The display changes • 01L 0V Distribution RAP.
Go to WD 7.2. Check tray 5 down sensor, Q75-012. Refer to: • Tray 5 elevator motor, PL 75.68 Item 4.
• GP 11 How to Check a Sensor. • Tray 5 control PWB, PL 75.68 Item 8.
• PJ505, Tray 5 control PWB. • Media path driver PWB, PL 1.15 Item 5.
• 01L 0V Distribution RAP. The tray 5 elevator motor is operating correctly. Perform SCP 5 Final Actions.
• Tray 5 down sensor, PL 75.68 Item 9.
Go to PJ504 pin 6 on the Tray 5 control PWB, WD 7.1. Manually actuate the tray 5 down limit
switch (S75-415), PL 75.70 Item 2, on the paper tray. The voltage changes.

75-312-00 IME to Tray 5 Communication Failure RAP 75-320-00 Tray 5 Opened In Run RAP
75-312-00 Image Marking Engine to tray 5 communications failure. 75-320-00 Tray 5 was opened during run when the paper is fed from tray 5.
WARNING WARNING
Refer to Wiring Diagram WD 7.1 and WD 8.4. Perform the following: • Ensure that the door is pushed fully home.
• Check the switch actuator on the door.
2. Check the communications link between the Tray 5 control PWB and PJ704 on the Media Procedure
Path Driver PWB.
Enter dC330 code 75-010 tray 5 door switch, S75-010, PL 75.60 Item 6. Press Start. Open and
fully close the door The display changes.
• Communication harness, PL 75.68 Item 26. Y N
• Tray 5 Control PWB, PL 75.68 Item 8. Go to WD 7.2. Check tray 5 door switch, S75-010. Refer to:
• Media Path Driver PWB, PL 1.15 Item 5. • GP 13 How to Check a Switch.
• Tray 5 door switch, PL 75.60 Item 6.
Check that the door opens and closes and latches correctly. If necessary install new front door

75-325-00 Tray 5 Undocked In Run RAP 75A Tray 5 Door Open During Run RAP
75-325-00 Tray 5 was undocked during run when the paper is fed from tray 5. Use this RAP when Tray 5 door open during run when the paper is fed from tray 5.
WARNING WARNING
• Ensure the tray base is located correctly. • Ensure that the door is pushed fully home.
• Check for obstructions between the tray 5 module and the machine. • Check the switch actuator on the door.
Procedure Procedure
Enter dC330 code 75-017 tray 5 docking switch, S75-017, PL 75.64 Item 1. Press Start. Enter dC330 code 75-010 tray 5 door switch, S75-010, PL 75.60 Item 6. Press Start. Open and
Undock and dock tray 5, refer to REP 75.7. The display changes. fully close the door The display changes.
Y N Y N
Go to WD 7.2. Check tray 5 docking switch, S75-017. Refer to: Go to WD 7.2. Check tray 5 door switch, S75-010. Refer to:
• GP 13 How to Check a Switch. • GP 13 How to Check a Switch.
• PJ507, Tray 5 control PWB. • PJ507, Tray 5 control PWB.
• 01D +5V Distribution RAP. • 01D +5V Distribution RAP.
• Tray 5 docking switch, PL 75.64 Item 1. • Tray 5 door switch, PL 75.60 Item 6.
• Tray 5 control PWB, PL 75.68 Item 8. • Tray 5 control PWB, PL 75.68 Item 8.
Perform the following: If the problem continues, install new components as necessary:
• Check the docking latch, PL 75.62 Item 6 on tray 5 is latched onto the machine. • Tray 5 door switch, PL 75.60 Item 6.
• Check the slide assembly, PL 75.62 Item 12. • Tray 5 control PWB, PL 75.68 Item 8.

75B Tray 5 Empty RAP
Use this RAP to solve problems associated with the tray 5 empty sensor.
Initial Actions
WARNING
• Check that the hole in the tray, directly under the sensor is clear and not obstructed.
• Check the sensor for contamination.
Procedure
Enter dC330 code 75-016 tray 5 empty sensor, Q75-016, PL 81.45 Item 6. Press Start.
Manually actuate the tray empty sensor. The display changes.
Y N
Go to WD 7.1. Check tray 5 empty sensor, Q75-016. Refer to:
• Tray 5 empty sensor, PL 81.45 Item 6.
The fault may be intermittent. Perform the steps that follow:

• Check the wiring harness for damaged wire. If necessary repair the harness, REP 1.1.
• Check that Tray 5 empty sensor is located correctly.

82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82-159-00, Procedure
82-164-00 to 82-166-00 Media Path Sensor (5) RAP Enter dC330 code 82-110 vertical transport sensor (5), Q82-110. Press Start. Open the mid left
door then manually actuate the sensor. The display changes.
82-110-00 The sheet has arrived at the media path sensor (5) too early. Y N
Go to WD 8.1. Check the vertical transport sensor (5), Q82-110. Refer to:
82-111-00 The media path sensor (5) has detected a sheet mismatch, the sheet was too long.
82-112-00 The media path sensor (5) has detected a sheet mismatch, the sheet was too short. • PJ104, Media Path Driver PWB.
82-113-00 Media path sensor (5) lead edge timeout. • 01L 0V Distribution RAP.
82-114-00 Media path sensor (5) trail edge timeout.
• Vertical transport sensor (5), PL 82.10 Item 7.
82-152-00 The sheet has arrived at the media path sensor (5) too early. • Media path driver PWB, PL 1.15 Item 5.
82-157-00 The media path sensor (5) has detected the sheet was too long. The machine will Enter dC330 code 82-001 vertical transport motor (M2), MOT82-001. Press Start. The motor
auto purge the media path. runs.
Y N
82-158-00 The media path sensor (5) has detected the sheet was too short. The machine will Go to WD 8.1. Check the vertical transport motor (M2), MOT82-001. Refer to:
auto purge the media path. • GP 10 How to Check a Motor.
82-159-00 A sheet is jammed at media path sensor (5). • 01D +5V Distribution RAP.
82-164-00 The media path sensor (5) has detected the sheet was too long. The machine will
not auto purge the media path.
82-165-00 The media path sensor (5) has detected the sheet was too short. The machine will • Vertical transport motor (M2), PL 82.10 Item 12.
not auto purge the media path. • Media path driver PWB, PL 1.15 Item 5.
82-166-00 TTM horizontal transport bridge sheet in zone 1A. The vertical transport rolls, PL 82.10 rotate.
Y N
Initial Actions Check the drive belt and gears on the vertical transport, PL 82.10.
• Transport rolls, PL 82.10.
WARNING • Drive belts, PL 82.10.
Ensure that the electricity to the machine is switched off while performing tasks that do • Drive gears, PL 82.10. 82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82-159-00,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 82-164-00 to 82-166-00 TEST RAP
• Check the paper stack in the tray. Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start.
Manually rotate the drive gears forward and backward. The display changes.
• Check that the tray guides are against the edges of the paper.
Y N
• Check for paper down the back of the tray. Go to WD 8.1. Check the vertical transport motor (M2), MOT82-001. Refer to:
• Check that the tray is pushed fully home. • GP 10 How to Check a Motor.
• Check for obstructions in the paper path. • PJ104, Media path driver PWB.
• Check that the upper and mid left side doors are latched. • 01D +5V Distribution RAP.
• Check for multifeeds. If there are multifeeds, refer to the OF 8 Multi-feed RAP. • 01J +50V Distribution RAP.
• If glossy media is used then instruct the customer to feed the media from the bypass tray • 01L 0V Distribution RAP.
and select glossy for the media type. Install new components as necessary:
• Vertical transport motor (M2), PL 82.10 Item 12.
A

Xerox® ColorQube® 9203 Family 2-367 82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82-
A
Fault code 82-166 Only. Cheat the front door interlock. Enter dC330 code 10-018 to run the 82-125-00 to 82-133-00, 82-153-00, 82-155-00, 82-160-00,
post transfix motor (M4), PL 10.10 Item 5. The motor runs.
Y N 82-162-00, 82-163-00 Confirm Sensor (16) RAP
Refer to WD 8.2. Check the post transfix motor (M4). Refer to: 82-125-00 The sheet has arrived at the confirm sensor (16) too early.
• GP 10 How to Check a Motor. 82-126-00 The confirm sensor (16) has detected the sheet was too long. The machine will auto
• PJ303, Media Path Driver PWB. purge the media path.
• 01J +50V Distribution RAP. 82-127-00 The confirm sensor (16) has detected the sheet was too short. The machine will
• 01L 0V Distribution RAP. auto purge the media path.
82-128-00 The confirm sensor (16) has detected a sheet mismatch, the sheet was too long.
• Post transfix motor (M4), PL 10.10 Item 5.
82-129-00 The confirm sensor (16) has detected a sheet mismatch, the sheet was too short.
82-130-00 Lead edge late to the confirm sensor (16) from the three tray module.
Check the following, install new components as necessary:
82-131-00 Trail edge late at the confirm sensor (16).
• The bearing, shaft and rolls on the transport roll assembly, PL 82.10.
• The idler rolls in the middle left door assembly, PL 70.30 Item 16. 82-132-00 Lead edge timed out, sheet late at the media path sensor 16 in duplex mode.
• The transport rolls for wear, PL 82.10. 82-133-00 Confirm sensor (16) lead edge timeout from MSI.
• If the jam is occurring in area 4a in duplex mode only, install a new exit paper path assem-
82-153-00 The sheet has arrived at the confirm sensor (16) too early.
bly, PL 10.15 Item 19.
82-155-00 Lead edge too early at the media path sensor 16 in duplex mode.
CAUTION 82-160-00 A sheet is jammed at media path sensor (16).

Incorrect routing of the vertical paper path harness can cause the harness to be pinched when 82-162-00 The confirm sensor (16) has detected the sheet was too long. The machine will not
the marking unit is push to the home position. auto purge the media path.
• Ensure the routing of the vertical paper path harness is correct and secure, Figure 1. 82-163-00 The confirm sensor (16) has detected the sheet was too short. The machine will not
auto purge the media path.
Ensure that the vertical paper

Initial Actions
path harness is secured in the
cable clamp behind the vertical
paper path. WARNING
• Check the paper stack in the tray.
• Check that the tray guides are against the edges of the paper.
• Check that the tray is pushed fully home.
• Check for obstructions in the paper path.
• Check that the upper and mid left doors are fully latched.
• If a 82-130-00 fault occurs when feeding from the bypass tray. Check the bypass feed roll
Vertical paper path harness Procedure
Enter dC330 code 82-125 confirm sensor (16), Q82-125. Press Start. Open the upper left door
then manually actuate the sensor. The display changes.
Y N
Figure 1 Harness routing Go to WD 8.1. Check the confirm sensor (16), Q82-125. Refer to:
A
82-110-00 to 82-114-00, 82-152-00, 82-157-00 to 82- 2-368 Xerox® ColorQube® 9203 Family
A
• 01D +5V Distribution RAP. 82-132-00, 82-155-00 Media Path Sensor 16 Duplex Mode
RAP
NOTE: Ambient light can effect the operation of the confirm sensor (16), Q82-125.
NOTE: Throughout this RAP and the related parts list the media path sensor 16 is referred to
Therefore, ensure all machine covers are replaced after the installation of a new
as the confirm sensor 16.
sensor, before checking for the reoccurrence of a fault.
Install new components as necessary: 82-132-00 Lead edge timed out, sheet late at the media path sensor 16 in duplex mode.
• Confirm sensor (16), PL 82.10 Item 7.
82-155-00 Lead edge too early at the media path sensor 16 in duplex mode.
Enter dC330 code 82-001 vertical transport motor (M2), MOT82-001. Press Start. The motor Initial Actions
runs.
Y N
Go to WD 8.1. Check the vertical transport motor (M2), MOT82-001. Refer to:
WARNING
• 01D +5V Distribution RAP. death or injury. Moving parts can cause injury.
• Check the vertical and horizontal transport rolls for contamination or wear.
• Check that the upper and middle left side doors are fully latched.
Procedure
The vertical transport rolls rotate. Enter dC330 code 82-125 confirm sensor (16), Q82-125. Press Start. Open the left hand door
Y N and manually actuate the sensor. The display changes.
Check the drive belt and drive gears on the vertical transport, PL 82.10. Y N
If necessary, install new components: Go to WD 8.1. Check confirm sensor (16), Q82-125. Refer to:
• Transport rolls, PL 82.10. • GP 11 How to Check a Sensor.
• Drive belts, PL 82.10. • PJ104, Media path driver PWB.
• Drive gears, PL 82.10. • 01D +5V Distribution RAP.
Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start. • 01L 0V Distribution RAP.
Y N NOTE: Ambient light can effect the operation of the confirm sensor (16), Q82-125. There-
Go to WD 8.1. Check the vertical transport motor (M2), MOT82-001. Refer to: fore, ensure all machine covers are replaced after the installation of a new sensor, before
• PJ104, Media path driver PWB. Install new components as necessary:
• 01D +5V Distribution RAP. • Confirm sensor 16, PL 82.10 Item 7.
• 01J +50V Distribution RAP. • Media path driver PWB, PL 1.15 Item 5.
Enter dC330 code 82-002 vertical transport motor (M2) (reverse), MOT82-001. Press Start.
The motor runs.
• Vertical transport motor (M2), PL 82.10 Item 12. Y N
• Media path driver PWB, PL 1.15 Item 5. Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to:
• The bearing, shaft and rolls on the transport roll assembly, PL 82.10,
• The idler rolls in the upper left side door, PL 70.30 Item 4.
• The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2.
A

Xerox® ColorQube® 9203 Family 2-369 82-125-00 to 82-133-00, 82-153-00, 82-155-00, 82-
A B
Install new components as necessary: Enter dC140 Analog Monitor. Select 82-102 horizontal trans motor encoder (M6). Press Start.
• Vertical Transport motor 2, PL 82.10 Item 12. Manually rotate the drive gears forward and backward. The display changes.
Y N
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to:
The vertical transport rolls rotate. • GP 10 How to Check a Motor.
Check the drive belt and drive gears on the vertical transport, PL 82.10. • 01D +5V Distribution RAP.
• Drive belts, PL 82.10.
• Drive gears, PL 82.10.
• Horizontal transport motor (M6), PL 82.15 Item 9.
Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start. • Media path driver PWB, PL 1.15 Item 5.
Y N
Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to: • The bearing, shaft and rolls on the horizontal and vertical transport assembly.
• GP 10 How to Check a Motor. • The idler rolls in the upper left side door, PL 70.30 Item 4.
• PJ104, Media path driver PWB. • The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2.
• 01D +5V Distribution RAP. Install new components as necessary.
• 01J +50V Distribution RAP. NOTE: Calibration of the registration/preheat assembly, dC625, is only required when:
• 01L 0V Distribution RAP. • The registration/preheat assembly is removed or replaced.
Install new components as necessary: • The horizontal transport assembly is removed or replaced.
• Vertical transport motor (M2), PL 82.10 Item 12. Calibration of the registration/preheat assembly is NOT required when:
• Media path driver PWB, PL 1.15 Item 5. • A printhead is replaced.
• The IOD assembly is removed or replaced.
Enter dC330 code 82-004 Horizontal transport motor (M6) (reverse), MOT82-003. Press Start.
The motor runs.
Y N
The horizontal transport rolls rotate.

Y N
Check the drive belt and drive gears on the horizontal transport, PL 82.10 / PL 82.15.
B
A
82-133-00 Media Path Sensor 16 Time out from Tray 5 RAP Install new components as necessary:
NOTE: Throughout this RAP and the related parts list the media path sensor 16 is referred to
as the confirm sensor 16.
82-133-00 Lead edge late to the media path sensor 16 when feeding from tray 5. The vertical transport rolls rotate.
Y N
Initial Actions Check the drive belt and drive gears on the vertical transport, PL 82.10.
WARNING • Drive belts, PL 82.10.
Ensure that the electricity to the machine is switched off while performing tasks that do • Drive gears, PL 82.10.
death or injury. Moving parts can cause injury. Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start.
• Check the paper in tray 5. Manually rotate the drive gears forward and backward. The display changes.
Y N
• Check that the paper guides are set the correct paper size.
Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to:
• Check tray 5 feed assembly, PL 81.45 Item 2.
• Check that the upper and middle left side doors are fully latched, PL 70.30 Item 14, PL
70.30 Item 16.
Procedure
Enter dC330 code 82-125 confirm sensor (16), Q82-125. Press Start. Open the left hand door
and manually actuate the sensor. The display changes. • Vertical transport motor (M2), PL 82.10 Item 12.
Y N • Media path driver PWB, PL 1.15 Item 5.
Go to WD 8.1. Check confirm sensor (16), Q82-125. Refer to:
• GP 11 How to Check a Sensor. Check the following:
• The idler rolls in the upper left side door, PL 70.30 Item 4.
• 01D, +5V Distribution RAP.
• The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2.
• Check tray 5 feed assembly, PL 81.45 Item 2.
NOTE: Ambient light can effect the operation of the confirm sensor (16), Q82-125. There- Install new components as necessary.
fore, ensure all machine covers are replaced after the installation of a new sensor, before

Enter dC330 code 82-001 vertical transport motor (M2), MOT82-001. Press Start. The motor
runs.
Y N

82-134-00 Media Path Sensor 16 Time-out from Tray 4 RAP Y N
Check the drive belt and drive gears on the vertical transport, PL 82.10.
NOTE: Throughout this RAP and the related parts list the media path sensor 16 is referred to If necessary, install new components:
as the confirm sensor 16. • Transport rolls, PL 82.10.
82-134-00 Lead edge late to the media path sensor 16 when feeding from the bypass tray 4. • Drive belts, PL 82.10.
Initial Actions
Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start.
WARNING Y N
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • GP 10 How to Check a Motor.
death or injury. Moving parts can cause injury. • PJ104, Media path driver PWB.
• Check the paper in the bypass tray 4. • 01D +5V Distribution RAP.
• Check that the bypass tray 4 guides are against the edges of the paper • 01J +50V Distribution RAP.
• Check bypass tray 4 feed assembly for contamination or wear. • 01L 0V Distribution RAP.
• Check for obstructions in the paper path. Install new components as necessary:
• Check that the upper and middle left side doors are fully latched. • Vertical transport motor (M2), PL 82.10 Item 12.
Procedure
Enter dC330 code 82-125 confirm sensor (16), Q82-125. Press Start. Open the left hand door
and manually actuate the sensor. The display changes.
Y N • The idler rolls in the upper left side door, PL 70.30 Item 4.
Go to WD 8.1. Check confirm sensor (16), Q82-125. Refer to: • The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2.
• GP 11 How to Check a Sensor. • Check Bypass tray feed assembly, PL 74.10 Item 14.
• PJ104, Media path driver PWB. Install new components as necessary.
• 01D, +5V Distribution RAP.
runs.
Y N
• Vertical transport motor 2, PL 82.10 Item 12.
The vertical transport rolls rotate.

82-140-00, 82-142-00 Media Path Sheet Too Wide or Narrow 82-141-00, 82-147-00, 82-148-00, 82-154-00 Media Path
RAP Sensor 14 RAP
82-140-00 Media path sheet too wide. 82-141-00 or 82-154-00 The sheet has arrived too early at media path sensor 14.
82-142-00 Media path sheet too narrow. 82-147-00 Lead edge time out, sheet late at the media path sensor 14 at pre-registration.
Initial Actions 82-148-00 Trail edge time out, sheet late clearing at the media path sensor 14 at pre-registra-
tion.
WARNING Initial Actions

• Check the paper guides are set correctly in the paper tray. Ensure that the electricity to the machine is switched off while performing tasks that do
• Check for the correct size of paper in the tray.
• The paper size shown on the UI screen indicates the same paper size that is in the paper
tray. If different, then reset the paper guides in the tray so that the two match. • Check for obstructions in the paper path.
• Check the vertical and horizontal transport rolls for contamination or wear.
Procedure • Check that the upper left side door is latched correctly.
This dimension is measured by the registration scan bar (10) Q89-005 on the registration pre-
heat assembly. Procedure
Enter dC330 code 83-125 duplex end sensor (14), Q83-125, PL 82.15 Item 3. Press Start.
1. Refer to WD 8.6. Check the connection of the ribbon cable between the registration scan Open the front door and manually actuate the sensor. The display changes.
bar and PJ1 on the registration preheat interface PWB. Y N
2. Remove the registration preheat assembly, REP 89.1. Go to WD 8.5. Check duplex end sensor (14), Q83-125. Refer to:
Perform the following: • GP 11 How to Check a Sensor.
• Check and clean the registration scan bar sensor, PL 88.10 Item 2. • PJ905, Media path driver PWB.
• Remove and clean the scan bar baffle and the scan bar with lint free cloth, PL 26.10 • 01D +5V Distribution RAP.
Item 6. • 01J +50V Distribution RAP.
If the fault is still present then install new components as necessary: • 01L 0V Distribution RAP.
a. Registration preheat assembly, PL 88.10 Item 1. Install new components as necessary:
b. Media Path Driver PWB, PL 1.15 Item 5. • Duplex end sensor (14), PL 82.15 Item 3.
3. If a jam is occurring in area 4a, when in duplex mode only, install a new exit paper path • Media path driver PWB, PL 1.15 Item 5.
runs.
Y N
Go to WD 8.1. Check vertical transport motor, MOT82-001. Refer to:
• Vertical Transport motor (M2), PL 82.10 Item 12.
A

A
The vertical transport rolls rotate. Y N
Y N Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to:
Check the drive belt and drive gears on the vertical transport, PL 82.10 • GP 10 How to Check a Motor.
If necessary, install new components: • PJ905, Media path driver PWB.
• Transport rolls, PL 82.10. • 01D +5V Distribution RAP.
• Drive belts, PL 82.10. • 01J +50V Distribution RAP.
• Drive gears, PL 82.10. • 01L 0V Distribution RAP.
Manually rotate the drive gears forward and backward. The display changes. • Horizontal transport motor (M6), PL 82.15 Item 9.
• GP 10 How to Check a Motor. Enter dC330 code 89-007 registration motor A1 (M3), MOT89-007. Press Start. The motor
runs.
Y N
Go to WD 8.1. Check registration motor A1 (M3), MOT89-007. Refer to:
Enter dC330 code 82-003 Horizontal transport motor (M6) (forward), MOT82-003. Press Start. • Registration / Preheat assembly, PL 88.10 Item 1
The motor runs. • Media path driver PWB, PL 1.15 Item 5
Y N
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: Enter dC330 code 89-008 registration motor A2 (M3), MOT89-008. Press Start. The motor
• GP 10 How to Check a Motor. runs.
Y N
• Registration / Preheat IF PWB, PL 88.10 Item 10
• Registration / Preheat assembly, PL 88.10 Item 1
Y N • Media path driver PWB, PL 1.15 Item 5
Check the drive belt and drive gears on the horizontal transport, PL 82.15.
If necessary, install new components: Enter dC330 code 89-016 Registration / Preheat hatch open. Press Start. The hatch opens.
Y N
• Transport rolls, PL 82.15 Item 10.
Check the hatch lift mechanism for damage.
• Drive belts, PL 82.15 Item 7. Install new components as necessary:
• Drive gears, PL 82.15. • Registration / Preheat assembly, PL 88.10 Item 1
• Media path driver PWB, PL 1.15 Item 5
NOTE: Under powered stepper motors can still operate in component control. Check dC123
PEST fault history and check for under powered motors.
Enter dC330 code 82-007 Nip C release solenoid, SOL82-007. Press Start. The solenoid
Enter dC140 Analog Monitor. Select 82-102 horizontal trans motor encoder (M6). Press Start. energizes and releases the nip.

Y N 82-145-00, 82-146-00, 82-150-00, 82-151-00, 82-156-00
Go to WD 8.1. Check SOL82-007. Refer to:
Media Path Sensor 14 Time Out in Duplex Mode RAP
• PJ303, Media path driver PWB. 82-145-00 The sheet was too long to clear sensor 14 in duplex mode.
82-146-00 The sheet was too short to clear the media path sensor 14 in duplex mode.
Install new components as necessary: 82-150-00 Lead edge late too the media path sensor 14 in duplex mode.
• Media path driver PWB, PL 1.15 Item 5. 82-151-00 Trail edge late too clear the media path sensor 14 in duplex mode.
• Horizontal paper path assembly, PL 82.15 Item 9.
Enter dC330 code 82-008 Nip D release solenoid, SOL82-008, PL 70.30 Item 13. Press Start. 82-156-00 Lead edge of sheet too early at the media path sensor 14 in duplex mode.
SOL82-008 energizes.
Y N Initial Actions
• PJ405, Media path driver PWB. WARNING
• 01J +50V Distribution RAP. Ensure that the electricity to the machine is switched off while performing tasks that do
• 01L 0V Distribution RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Install new components as necessary: death or injury. Moving parts can cause injury.
• Nip D release solenoid, PL 70.30 Item 13. • Check for obstructions in the paper path.
• Media path driver PWB, PL 1.15 Item 5. • Check the vertical and horizontal transport rolls for contamination or wear.
Enter dC330 code 83-004 HPP diverter solenoid, SOL83-004. Press Start. Check that the
diverter gate moves correctly when activating the solenoid The solenoid energizes. Procedure
Y N
Enter dC330 code 83-125 duplex end sensor (14), Q83-125. Press Start. Open the front door
• PJ303, Media path driver PWB. Go to WD 8.5. Check duplex end sensor (14), Q83-125. Refer to:
• 01J +50V Distribution RAP. • GP 11 How to Check a Sensor.
• 01L 0V Distribution RAP. • PJ905, Media path driver PWB.
Install new components as necessary: • 01D +5V Distribution RAP.
• HPP diverter solenoid, PL 82.15 Item 5. • 01L 0V Distribution RAP.
• Media path driver PWB, PL 1.15 Item 5. Install new components as necessary:
• Duplex end sensor 14, PL 82.15 Item 3.
• The bearing, shaft and rolls on the horizontal and vertical transport assembly, PL 82.10 /
PL 82.15.
• The idler rolls in the upper left side door, PL 74.10 Item 4. runs.
• The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2. Y N
• Check the grounding of the horizontal paper path, GP 7. Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to:
Install new components as necessary. • GP 10 How to Check a Motor.
NOTE: Calibration of the registration/preheat assembly, dC625, is only required when:
• The registration/preheat assembly is removed or replaced.
• The horizontal transport assembly is removed or replaced.
Calibration of the registration/preheat assembly is NOT required when:
• A printhead is replaced.
A

A B
• Media path driver PWB, PL 1.15 Item 5. Enter dC330 code 83-004 HPP diverter solenoid, SOL83-004. Press Start. Check that the
diverter gate moves correctly when activating the solenoid The solenoid energizes.
The vertical transport rolls rotate. Y N
Y N Go to WD 8.1. Check SOL83-004. Refer to:
Check the drive belt and drive gears on the vertical transport, PL 82.10. • GP 12 How to Check a Solenoid or Clutch.
• Transport rolls, PL 82.10 Item 1, PL 82.10 Item 2.
Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start. • HPP diverter solenoid, PL 82.15 Item 5.
Manually rotate the drive gears forward and backward. The display changes. • Media path driver PWB, PL 1.15 Item 5.
Y N
Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to: Enter dC330 code 82-003 Horizontal transport motor (M6), MOT82-003. Press Start. The
• GP 10 How to Check a Motor. motor runs.
Y N
Enter dC330 code 82-008 nip D release solenoid, SOL82-008. Press Start. The solenoid
energize. • Media path driver PWB, PL 1.15 Item 5.
Y N
Go to WD 8.3. Check nip D release solenoid, SOL82-008. Refer to: The horizontal transport rolls rotate.
Y N
Check the drive belt and drive gears on the horizontal transport, PL 82.15.
• PJ405, Media path driver PWB. If necessary, install new components:
• 01J +50V Distribution RAP. • Transport rolls, PL 82.15 Item 10.
• 01L 0V Distribution RAP. • Drive belts, PL 82.15 Item 7.
Install new components as necessary: • Drive gears, PL 82.15
• Media path driver PWB, PL 1.15 Item 5. Enter dC140 Analog Monitor. Select 82-102 horizontal trans motor encoder (M6). Press Start.
Enter dC330 code 82-007 Nip C release solenoid, SOL82-007. Press Start. The solenoid Y N
energizes. Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to:
Y N • GP 10 How to Check a Motor.
B C
C
Enter dC330 code 89-007 registration motor A1 (M3), MOT89-007. Press Start. The motor 82-149-00 Media Path Sensor 14 TE Time Out RAP
runs.
82-149-00 Trail edge timed out, sheet late clearing the media path sensor 14, when the sheet
Y N
was inverted.
Initial Actions
• 01L 0V Distribution RAP. WARNING
Install new components as necessary: Ensure that the electricity to the machine is switched off while performing tasks that do
• Registration / Preheat assembly, PL 88.10 Item 1 not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Media path driver PWB, PL 1.15 Item 5 death or injury. Moving parts can cause injury.
Enter dC330 code 89-008 registration motor A2 (M3), MOT89-008. Press Start. The motor • Check the vertical and horizontal transport rolls for contamination or wear.
runs.
Y N
Procedure
Enter dC330 code 83-125 duplex end sensor (14), Q83-125. Press Start. Open the front door
• 01J +50V Distribution RAP. Go to WD 8.5. Check duplex end sensor (14), Q83-125. Refer to:
• 01L 0V Distribution RAP. • GP 11 How to Check a Sensor.
Install new components as necessary: • PJ905, Media path driver PWB.
• Registration / Preheat IF PWB, PL 88.10 Item 10 • 01D +5V Distribution RAP.
• Registration / Preheat assembly, PL 88.10 Item 1 • 01L 0V Distribution RAP.
• Media path driver PWB, PL 1.15 Item 5 Install new components as necessary:
• Duplex end sensor 14, PL 82.15 Item 3.
• The bearing, shaft and rolls on the horizontal and vertical transport assembly,
• The idler rolls in the upper left side door, PL 70.30 Item 4. Enter dC330 code 82-001 vertical transport motor (M2), MOT82-001. Press Start. The motor
• The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2. runs.
• Check the grounding of the horizontal paper path, GP 7. Y N
Install new components as necessary. Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to:
The vertical transport rolls rotate.

Y N
Check the drive belt and drive gears on the vertical transport, PL 82.10.
• Transport rolls, PL 82.10 Item 1, PL 82.10 Item 2.
A

A B
Enter dC140 Analog Monitor. Select 82-100 vertical trans motor encoder (M2). Press Start. Enter dC330 code 82-007 Nip C release solenoid, SOL82-007. Press Start. The solenoid
Manually rotate the drive gears forward and backward. The display changes. energizes.
Y N Y N
Go to WD 8.1. Check vertical transport motor (M2), MOT82-001. Refer to: Go to WD 8.1. Check SOL82-007. Refer to:
• GP 10 How to Check a Motor. • GP 12 How to Check a Solenoid or Clutch.
• PJ104, Media path driver PWB. • PJ303, Media path driver PWB.
• 01D +5V Distribution RAP. • 01J +50V Distribution RAP.
• 01J +50V Distribution RAP. • 01L 0V Distribution RAP.
• 01L 0V Distribution RAP. Install new components as necessary:
Install new components as necessary: • Nip C release solenoid, PL 82.15 Item 4.
• Vertical transport motor (M2), PL 82.10 Item 12. • Media path driver PWB, PL 1.15 Item 5.
Enter dC330 code 82-008 nip D release solenoid, SOL82-008. Press Start. The solenoid
Enter dC330 code 82-003 Horizontal transport motor (M6), MOT82-003. Press Start. The energize.
motor runs. Y N
Y N Go to WD 8.3. Check nip D release solenoid, SOL82-008. Refer to:
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: • GP 12 How to Check a Solenoid or Clutch.
• GP 10 How to Check a Motor.3 • PJ405, Media path driver PWB.
• PJ905, Media path driver PWB. • 01J +50V Distribution RAP.
• 01D +5V Distribution RAP. • 01L 0V Distribution RAP.
• 01J +50V Distribution RAP. Install new components as necessary:
• 01L 0V Distribution RAP. • Nip D release solenoid, PL 70.30 Item 13.
Install new components as necessary: • Media path driver PWB, PL 1.15 Item 5.
Enter dC330 code 83-004 HPP diverter solenoid, SOL83-004. Press Start. Check that the
diverter gate moves correctly when activating the solenoid The solenoid energizes.
The horizontal transport rolls rotate. Y N
Y N
Check the drive belt and drive gears on the horizontal transport, PL 82.15. • GP 12 How to Check a Solenoid or Clutch.
If necessary, install new components: • PJ303, Media path driver PWB.
• Transport rolls, PL 82.15 Item 10. • 01J +50V Distribution RAP.
• Drive belts, PL 82.15 Item 7. • 01L 0V Distribution RAP.
• Drive gears, PL 82.15 Install new components as necessary:
• HPP diverter solenoid, PL 82.15 Item 5.
Enter dC140 Analog Monitor. Select 82-102 horizontal trans motor encoder (M6). Press Start. • Media path driver PWB, PL 1.15 Item 5.
Y N
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: • The bearing, shaft and rolls on the horizontal and vertical transport assembly,
• GP 10 How to Check a Motor. • The idler rolls in the upper left side door, PL 70.30 Item 4.
• PJ905, Media path driver PWB. • The transport rolls for wear, PL 82.10 Item 1, PL 82.10 Item 2.
• 01D +5V Distribution RAP. • Check the grounding of the horizontal paper path, GP 7.
• 01J +50V Distribution RAP. Install new components as necessary.
B
A
82-161-00 Early Confirm Timeout RAP • 3 Tray Module PWB, PL 73.16 Item 4.
82-161-00 Early confirm timeout.

Enter dC330 code 70-025 3 tray transport motor, MOT70-025. Press Start. The motor runs.
Y N
Initial Actions Go to WD 7.5. Check 3 tray transport motor, MOT70-025. Refer to:
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 01L 0V Distribution RAP.
• Check for obstructions in the tray 3 horizontal transport paper path. • 3 tray module transport motor, PL 73.16 Item 3.
• Check the tray 3 horizontal transport rolls. • 3 tray module PWB, PL 73.16 Item 4.
The transport rolls rotate.

Procedure
Y N
Enter dC330 code 73-397 TAR 3 Sensor, Q73-397, PL 81.35 Item 18. Press Start. Pull out the Check the gears and drive belt, PL 73.16.
horizontal transport. Manually actuate the sensor by placing a piece of paper over the sensor
but not in the nip rolls. Push in the horizontal transport. Perform the following:
NOTE: Sensors Q73-397 and Q70-398 in the horizontal transport, have the same item num- • If the fault still occurs, check the grounding of the following, GP 7:
ber. Ensure you check the correct sensor. – The takeaway roll assembly, PL 81.35 Item 16.
The display changes. – The transport roll 2 assembly, PL 81.35 Item 15.
Y N – The transport roll 1 assembly, PL 81.35 Item 14.
• PJ954, 3 tray module PWB
• TAR 3 sensor, PL 81.35 Item 18.
Enter dC330 code 70-398 tray 3 transport sensor, Q70-398, PL 81.35 Item 18. Press Start. Pull
out the horizontal transport. Manually actuate the sensor by placing a piece of paper over the
sensor but not in the nip rolls. Push in the horizontal transport.
NOTE: Sensors Q73-397 and Q70-398 in the horizontal transport, have the same item num-
ber. Ensure you check the correct sensor.

Y N
Go to WD 7.4. Check tray 3 transport sensor, Q70-398. Refer to:
• Tray 3 transport sensor, PL 81.35 Item 18.

82-500-00, 82-501-00 Vertical Transport Motor M2 Failure • Check that the rolls of the transport roller assemblies, PL 82.10 Item 1 and PL 82.10 Item
2, are not rubbing and binding on the inner frame assembly, PL 82.10 Item 18.
RAP If necessary, install new components:
82-500-00 Transport motor M2 over current fault. • Transport rolls, PL 82.10 Item 1, PL 82.10 Item 2.
82-501-00 Transport motor M2 stalled.
Initial Actions • Vertical paper path, PL 82.10 Item 15.
WARNING
• Check the vertical transport rolls, gears and drive belts for contamination or wear.
Procedure
runs.
Y N
Y N

• Check the wiring for damage.
• Check the drive belt and drive gears on the vertical transport, PL 82.10.

A
82-502-00, 82-503-00 Horizontal Transport Motor M6 Install new components as necessary:
Failure RAP
82-502-00 Transport motor M6 over current fault.
Enter dC140 Analog Monitor. Select 82-102 horizontal trans motor encoder (M6). Press Start.
82-503-00 Transport motor M6 stalled.
Manually rotate the drive gears forward and backward The display changes.
Y N
Initial Actions Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to:
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • 01J +50V Distribution RAP.
death or injury. Moving parts can cause injury. • 01L 0V Distribution RAP.
• Check for obstructions in the horizontal paper path. Install new components as necessary:
• Check the nip rolls on the horizontal paper path, PL 82.15 Item 10. • Horizontal transport motor (M6), PL 82.15 Item 9.
Procedure
Clean the pre transfix sensor 20, PL 88.10 Item 12 and the apertures in the beaming path of
• Check the wiring for damage, REP 1.1.
the sensor. Refer to GP 27. The fault remains.
Y N • The bearing, shaft and rolls on the horizontal paper path, PL 82.15 Item 14.
Perform SCP 5 Final Actions. • Check the drive belt and drive gears on the horizontal paper path, PL 82.15.
Enter dC330 code 89-006 pre transfix sensor (20), Q89-006. Press Start. Manually actuate the • Transport rolls, PL 82.15 Item 10.
sensor. The display changes.
• Transport drive belts, PL 82.15 Item 7.
Y N
Go to WD 8.6. Check pre transfix sensor 20, Q89-006. Refer to: • Drive belt, PL 82.15 Item 8.
• REP 89.1 Registration Preheat/Assembly and Lower Platelet Assembly • Drive gears, PL 82.15.
• PJ5, Registration / Preheat IF PWB.
• Pre transfix sensor (20), PL 88.10 Item 12.
• Registration / pre-heat IF PWB, PL 88.10 Item 10.
• Media path PWB, PL 1.15 Item 5.
Enter dC330 code 82-003 horizontal transport motor (M6), MOT82-003. Press Start. The
motor runs.
Y N

82-507-00, 82-508-00 Nip C and Nip D Release Solenoid 82-510-00 Trailer Slowdown Calculation Fail RAP
Over Current RAP 82-510-00 System timing error.
82-507-00 An over current condition was detected with nip C release solenoid.
Procedure
82-508-00 An over current condition was detected with nip D release solenoid.
Procedure WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Refer to Wiring Diagram WD 8.1, WD 8.2, WD 8.3, WD 8.4 and WD 8.5. Perform the following:
death or injury. Moving parts can cause injury. • Switch off the machine, then switch on the machine, GP 14.
Refer to Wiring Diagram WD 8.1 and WD 8.3. Perform the following: • Check the PJ connections on the media path driver PWB.
• Check the wiring for damage. • Media path driver PWB, PL 1.15 Item 5.
• Check the nip C release solenoid mechanism, PL 82.15 Item 4.
• Check the nip D release solenoid mechanism, PL 70.30 Item 13.
• Check the nip C release solenoid, refer to WD 8.1, and GP 12 How to Check a Solenoid
or Clutch.
• Check the nip D release solenoid, refer to WD 8.3, and GP 12 How to Check a Solenoid
or Clutch.
• Go to WD 1.5 and WD 8.5. Check the harness and voltages between PJ 803 on the
media path driver PWB and PJDC3 on the power supply unit. Install new components or
repair harness as necessary, REP 1.1.
• Power Supply Unit, PL 1.15 Item 2.

A
83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 Media Install new components as necessary:
Path Sensor 13 Duplex Mode RAP
83-110-00 The sheet too long over media path sensor 13 at duplex start.
The diverter gate moves freely.
83-111-00 The sheet too short over media path sensor 13 at duplex start.
Y N
Check the operation and condition of the diverter gate. If necessary install a new exit
83-113-00 The leading edge was late to media path sensor 13 at duplex start.
paper path assembly, PL 10.15 Item 19.
83-114-00 The trailing edge was late over media path sensor 13 at duplex start. Enter dC330 code 83-001 exit motor (M5), MOT83-001. Press Start. The motor runs.
Y N
83-118-00 Sheet arrived too early at the media path sensor 13.
Go to WD 8.2. Check exit motor (M5), MOT83-001. Refer to:
Initial Actions
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Exit motor (M5), PL 10.15 Item 11.
death or injury. Moving parts can cause injury. • Media path driver PWB, PL 1.15 Item 5.
• Check the exit paper path and transport rolls for contamination or wear, PL 10.15. The exit paper path rolls rotate.
• If the fault was caused while running glossy media. Instruct the customer to feed the Y N
media from the bypass tray and select glossy for the media type on the UI. Check the drive belt and drive gears on the exit paper path, PL 10.15.
• N and P nip rolls, PL 10.15 Item 1.
Procedure
• Drive belts, PL 10.15 Item 9.
Enter dC330 code 83-110 duplex start sensor (13), Q83-110. Press Start. Open the front door
and manually actuate the sensor. The display changes. • Drive gears, PL 10.15.
Y N
Go to WD 8.5. Check duplex start sensor (13), Q83-110. Refer to: Enter dC330 code 82-003 Horizontal transport motor (M6) (forward), MOT82-003. Press Start.
The motor runs.
Y N
• PJ905, Media path driver PWB. Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to:
• 01D +5V Distribution RAP. • GP 10 How to Check a Motor.
• 01L 0V Distribution RAP. • PJ905, Media path driver PWB.
Install new components as necessary: • 01D +5V Distribution RAP.
• Duplex start sensor (13), PL 10.15 Item 3. • 01J +50V Distribution RAP.
• Media path driver PWB, PL 1.15 Item 5. • 01L 0V Distribution RAP.
Enter dC330 code 83-006 exit duplex diverter solenoid, SOL83-006. Press Start. The sole-
noid energize. • Horizontal transport motor (M6), PL 82.15 Item 9.
Go to WD 8.1. Check exit duplex diverter, SOL83-006. Refer to:
• GP 12 How to Check a Solenoid or Clutch. The horizontal paper path rolls rotate.
Y N
Check the drive belt and drive gears on the exit paper path, PL 82.15.
• 01J +50V Distribution RAP. If necessary, install new components:
• 01L 0V Distribution RAP. • Nip and takeaway rolls, PL 82.15 Item 10.
• Drive belts, PL 82.15 Item 7.
A B

B C
• Drive gears, PL 82.15. • 01L 0V DIstribution RAP.
• HPP diverter solenoid, PL 82.15 Item 5
Y N • Horizontal paper path assembly, PL 82.15 Item 1.
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: • Media path driver PWB, PL 1.15 Item 5.
Check the bearings, drive shaft’s and nip rolls on the exit paper path, PL 10.15.
Enter dC330 code 82-007 nip C release solenoid, SOL 82-007, press start. The solenoid
energizes.
Y N
Go to WD 8.1, check SOL 82-007, refer to:
• PJ405 Media Path Driver PWB.
• 01L 0V DIstribution RAP.
Enter dC330 code 82-008 nip D release solenoid, SOL 82-008, press start. The solenoid
energizes.
Y N
• 01L 0V DIstribution RAP.
Enter dC330 code 83-004 HPP diverter solenoid, SOL 83-004, press start. Ensure that the
HPP diverter gate moves fully when the solenoid is energized and returns fully when the sole-
noid is generalized. The solenoid energizes and the diverter gate moves correctly.
Y N
Go to WD 8.1, check SOL 83004. Refer to:
C
A
83-112-00, 83-115-00, 83-116-00, 83-117-00, 83-119-00 Media • 01L 0V Distribution RAP.
Path Sensor 13 Invert Mode RAP
83-112-00 The sheet too long over media path sensor 13 at invert.
83-115-00 The trailing edge times out over media path sensor 13 at invert
The diverter gate moves freely.
83-116-00 The leading edge was late too media path sensor 13at invert Y N
Check the operation and condition of the diverter gate. If necessary install a new diverter
gate, PL 10.15 Item 17.
83-117-00 The trailing edge was late over media path sensor 13 at invert.
Enter dC330 code 83-001 exit motor (M5), MOT83-001. Press Start. The motor runs.
83-119-00 Lead edge of sheet arrive too early at media path sensor 13 when inverting to out-
Y N
put
Go to WD 8.2. Check exit motor (M5), MOT83-001. Refer to:
Initial Actions • GP 10 How to Check a Motor.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Exit motor (M5), PL 10.15 Item 11.
• Check the exit paper path rolls. The Exit paper path rolls rotate.
• If tabbed sheets are used, inform the customer to ensure that the sheets are fed with tab Y N
trailing. Check the drive belt and drive gears on the exit paper path, PL 10.15.
• If pre-drilled paper is used, check that the pre-drilled pages are fed with the holes trailing. If necessary, install new components:
• N and P nip rolls, PL 10.15.
Procedure • Drive belts, PL 10.15.
Enter dC330 code 83-110 duplex start sensor (13), Q83-110. Press Start. Open the front door • Drive gears, PL 10.15.
Y N Enter dC330 code 82-003 Horizontal transport motor (M6) (forward), MOT82-003. Press Start.
Go to WD 8.5. Check duplex start sensor (13), Q83-110. Refer to: The motor runs.
Y N
• Duplex start sensor (13), PL 10.15 Item 3.
Enter dC330 code 83-006 exit / duplex diverter solenoid, SOL83-006. Press Start. The sole- • Horizontal transport motor (M6), PL 82.15 Item 9.
noid energize. • Media path driver PWB, PL 1.15 Item 5.
Y N
Go to WD 8.1. Check exit / duplex diverter solenoid, SOL83-006. Refer to: The horizontal paper path rolls rotate.
Check the drive belt and drive gears on the exit paper path, PL 82.15.
• Nip and takeaway rolls, PL 82.15 Item 10.
A B

B C
• Drive belts, PL 82.15 Item 7. • 01J +50V Distribution RAP.
• Drive gears, PL 82.15. • 01L 0V Distribution RAP.
Y N • Horizontal paper path assembly, PL 82.15 Item 1.
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: • Media path driver PWB, PL 1.15 Item 5.
Check the bearings, drive shaft’s and nip rolls on the exit paper path, PL 10.15.
energizes.
Y N
Enter dC330 code 82-008 nip D release solenoid, SOL 82-008, press start. The solenoid
energizes.
Y N
• PJ405 Media Path Driver PWB
Enter dC330 code 83-004 HPP diverter solenoid, SOL 83-004, press start. Ensure that the
Y N
Go to WD 8.1, check SOL 83004. Refer to:
C
A
83-120-00 to 83-125-00 Media Path Sensor 17 RAP • 01D +5V Distribution RAP.
83-120-00 Detected a sheet length too long over media path sensor 17. • 01J +50V Distribution RAP.
83-121-00 Detected a sheet length too short over media path sensor 17. Install new components as necessary:
83-122-00 Lead edge of sheet to late at media path sensor 17.
83-123-00 The trailing edge was late to clear media path sensor 17.
Y N
83-124-00 Trail edge of sheet failed to clear media path sensor 17 in time when inverting to Check the drive belts and drive gears on the horizontal transport, PL 82.15.
output
• Transport rolls, PL 82.15 Item 10.
83-125-00 Lead edge of sheet arrives too early at media path sensor 17.
• Drive belts, PL 82.15 Item 7 and PL 82.15 Item 8.
Initial Actions • Drive gears, PL 82.15 Item 6, PL 82.15 Item 13 and PL 82.15 Item 16.
WARNING Manually rotate the drive gears forward and backward. The display changes.
Y N
death or injury. Moving parts can cause injury. • GP 10 How to Check a Motor.
• Check for obstructions in the paper path. • PJ905, Media path driver PWB.
• Check the vertical and horizontal transport rolls. • 01D +5V Distribution RAP.
• If tabbed sheets are used, inform the customer to ensure that the sheets are fed with tab • 01J +50V Distribution RAP.
trailing. • 01L 0V Distribution RAP.
• If pre-drilled paper is used, check that the pre-drilled pages are fed with the holes trailing. Install new components as necessary:
Procedure • Media path driver PWB, PL 1.15 Item 5.
Enter dC330 code 83-010 duplex sensor (17), Q83-010. Press Start. Open the front door and
manually actuate the sensor. The display changes. Check the items that follow, if necessary install new components:
Y N • The bearing, shaft and rolls on the horizontal transport assembly, PL 82.15.
Go to WD 8.5. Check duplex sensor (17), Q83-010. Refer to: • The idler rolls in the middle left door assembly, PL 70.30 Item 16.
• GP 11 How to Check a Sensor. • The transport rolls for wear, PL 82.10 Item 1 and PL 82.10 Item 2.
• PJ905, Media path driver PWB. Enter dC140 code 82-102 horizontal transport motor encoder. Press start, then manually rotate
• 01D +5V Distribution RAP. the drive gears forward and backward. The display changes.
Y N
Go to WD 8.5. Check Horizontal transport motor (M6), MOT82-003. Refer to:
• Duplex sensor 17, PL 82.15 Item 3.
Enter dC330 code 82-003 Horizontal transport motor (M6), MOT82-003. Press Start. Then • 01J +50V Distribution RAP.
enter the code 82-004 to run the motor in reverse. The motor runs in both forward and • 01L 0V Distribution RAP.
reverse directions. Install new components as necessary:
Y N • Horizontal transport motor (M6), PL 82.15 Item 9.
Go to WD 8.5. Check Horizontal transport motor (M6), MOT82-003. Refer to:
A B

B
Enter dC330 code 83-004 HPP diverter solenoid, SOL 83-004, press start. Ensure that the 83-500-00 Output Transport Motor M5 Failure RAP
83-500-00 Transport motor M5 over current fault.
Y N
Go to WD 8.1, check SOL 83004. Refer to: Initial Actions
WARNING
• 01L 0V Distribution RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Install new components as necessary: death or injury. Moving parts can cause injury.
• HPP diverter solenoid, PL 82.15 Item 5. • Check for obstructions in the exit paper path.
• Horizontal paper path assembly, PL 82.15 Item 1.
• Media path driver PWB, PL 1.15 Item 5. Procedure
Enter dC330 code 83-001 exit motor (M5), MOT83-001. Press Start. The motor runs.
Enter dC330 code 82-008 nip D release solenoid, SOL 82-008, press start. The solenoid Y N
energizes. Go to WD 8.2. Check exit motor (M5), MOT82-003. Refer to:
Y N
• Exit motor (M5), PL 10.15 Item 11.
• Media path driver PWB, PL 1.15 Item 5. Check the following:
• The bearing, shaft and nip rolls on the nip roller ‘N’, PL 10.15 Item 1.
• Check the drive belt and drive gears on the exit paper path, PL 10.15.
energizes.
Y N • Check the wiring for damage.
Go to WD 8.1, check SOL 82-007, refer to: If necessary, install new components:
• GP 12 How to Check a Solenoid or Clutch • Nip rolls, PL 10.15 Item 1 and PL 10.15 Item 6.
• PJ405 Media Path Driver PWB • Drive belts, PL 10.15 Item 8 and PL 10.15 Item 9.
• 01J +50V Distribution RAP. • Drive gears, PL 10.15 Item 12.
The components are all working correctly, check the paper path for any foreign object that
would hinder paper transport.

83-504-00 HPP Diverter Solenoid Failure RAP 83-506-00 Nip D Release Solenoid Failure RAP
83-504-00 HPP diverter solenoid over current fault. 83-506-00 Nip D release solenoid over current fault.
WARNING WARNING
• Check for obstructions in the paper path. • Check for obstructions in the paper path.
Procedure Procedure
Enter dC330 code 83-004 HPP diverter solenoid, SOL83-004. Press Start. The solenoid Enter dC330 code 82-008 Nip D release solenoid, SOL82-008, PL 70.30 Item 13. Press Start.
energizes. SOL82-008 energizes.
Y N Y N
Go to WD 8.1. Check SOL83-004. Refer to: Go to WD 8.3. Check SOL82-008. Refer to:
• GP 12 How to Check a Solenoid or Clutch. • GP 12 How to Check a Solenoid or Clutch.
• PJ303, Media path driver PWB. • PJ405, Media path driver PWB.
• 01J +50V Distribution RAP. • 01J +50V Distribution RAP.
• HPP diverter solenoid, PL 82.15 Item 5. • Nip D release solenoid, PL 70.30 Item 13.
• Media path driver PWB, PL 1.15 Item 5. • Media path driver PWB, PL 1.15 Item 5.
Check the operation and condition of the diverter gate. Ensure that the energized solenoid Check the operation of the nip release link arm, PL 70.30 Item 10. If necessary, install a new
moves the diverter gate fully. If necessary install a new horizontal paper path assembly, PL upper left door, PL 70.30 Item 18.
82.15 Item 1.

88-500-00 to 88-502-00 Preheat Thermal Error RAP The resistance of both pre-heaters is within specification.
Y N
88-500-00 The registration/preheat assembly is too hot.
Check the wiring between PJ5AC, WD 1.2 on the power supply unit and PJ140 on the
Registration / preheat assembly. Repair damaged wiring or install a new registration / pre-
88-501-00 The registration/preheat assembly is too slow to warm up. heat assembly PL 88.10 Item 1.
88-502-00 The registration/preheat assembly thermistor has failed.

Install a new power supply, PL 1.15 Item 2.
Initial Actions
Registration / Pre-heat
WARNING interface PWB
• Check the 2 wiring harnesses leading to the registration/preheat assembly interface
PWB, Figure 1.
• Check the 2 wiring harnesses leading to the chassis bulkhead from the registration / pre-
heat assembly.
Procedure
Enter dC335 and test the registration / preheat thermistor. Select RaLPH in the component list.
NOTE: The registration / preheat thermistor is mounted on the underside of the heater plate.
The temperature read out changes as the RaLPH warms up, cools down and is approxi-
mately correct.
Y N
Install a new registration / preheat assembly, PL 88.10 Item 1. Calibrate the new assem- Thermal cut out on the
bly, dC625. heater located under
the lower plate.
Thermal cut out on the
Check the resistance at media path driver PWB, WD 8.1 from PJ104 pin 16 to 17. Resistance heater located under
should measure approximately 240K ohms cold or 42K ohms hot. The resistance is within the upper plate.
specification.
Y N
Check connections at media path driver PWB, WD 8.1 PJ104 pin 16 to registration / pre-
heat interface PWB, WD 8.6 PJ4 pin 3 and media path driver PWB, WD 8.1 from PJ104
pin 17 to registration / preheat interface PWB, WD 8.6 PJ4 pin 2. Repair or install new
components as necessary.
NOTE: Calibration of the registration / preheat assembly, dC625 is only required when:
Refer to WD 1.2. Disconnect PJ5AC from the power supply unit. Check the electrical resis- • The registration / preheat assembly is removed or replaced,
tance of the registration/pre-heaters by measuring the resistance across the pins of the PJ5AC • The horizontal transport assembly is removed or replaced.
harness as follows: Calibration of the registration / preheat assembly is NOT required when:
• Registration pre-heater 1, pin 3 to pin 9. Expect a cold resistance of approximately 50-60 • A printhead is replaced.
ohms.
• Registration pre-heater 2, pin 2 to pin 8. Expect a cold resistance of approximately 50-60
ohms.

88-508-00 Registration / Preheat Air Pump Incorrect
Current RAP
88-508-00 The registration/preheat air pumps are drawing incorrect current.
Procedure
Registration/preheat
WARNING air pumps
NOTE: Air pump motors vibrate slightly when running, feeling the motor as it starts, stops and
runs is the best way to determine if the motor is operating. Use dc330 to test.
Enter dC330 and test the registration / preheat air pumps MOT88-008, Figure 1. Refer to GP
10, How to Check a Motor. The pumps run.
Y N
Refer to WD 8.6. Check connections at PJ5 of the registration / preheat interface PWB
and at each pump. The connections are secure.
Y N
Reseat all connections to the pump motors and registration / preheater interface
PWB.
Refer to WD 8.1. Check for +12V at PJ104 pin 21 on the media path driver PWB. +12V
is present.
Y N
Check the +12V distribution, go to the 01E +12V Distribution RAP. If necessary,
install a new media driver path PWB, PL 1.15 Item 5.
Refer to WD 8.1. Check the wiring between PJ104 on the media path driver PWB and PJ4
on the registration / pre-heat interface PWB. If the wiring is good, install new air pumps PL NOTE: Calibration of the registration / preheat assembly, dC625 is only required when:
88.10 Item 3, PL 88.10 Item 5. If the error persists, install a new registration/preheat • The registration / preheat assembly is removed or replaced,
assembly PL 88.10 Item 1.
The fault may be intermittent, if the error persists, install new air pumps PL 88.10 Item 3, PL Calibration of the registration / preheat assembly is NOT required when:
88.10 Item 5. • A printhead is replaced.

89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Y N
Failure RAP • GP 10 How to Check a Motor.
89-110-00 The sheet is too long at registration. • PJ202, Media path driver PWB.
89-111-00 The sheet is too short over media path sensor 10 at registration.
89-112-00 The leading edge was late to the media path sensor 10 at registration. Install new components as necessary:
• Registration / Preheat assembly, PL 88.10 Item 1.
89-113-00 The trailing edge was late over media path sensor 10 at registration. • Media path driver PWB, PL 1.15 Item 5.
89-129-00 The sheet arrives late at nip rolls A.

Enter dC330 code 82-007 Nip C release solenoid, SOL82-007. Press Start. The solenoid
energizes.
Initial Actions Y N
WARNING
death or injury. Moving parts can cause injury • 01L 0V Distribution RAP.
If the registration / pre-heat assembly was recently removed and reinstalled or installed a new Install new components as necessary:
prior to this fault occurring. Check that the ribbon cable to the registration / pre-heat interface • Nip C release solenoid, PL 82.15 Item 4.
PWB is seated correctly. Go to REP 89.1 and refer to figure 2 location of ribbon cable. • Media path driver PWB, PL 1.15 Item 5.
Procedure Enter dC330 code 82-008 Nip D release solenoid, SOL82-008. Press Start. The solenoid
energizes.
Open the registration/preheat assembly cover assembly and heat shield. Refer to REP 10.7 to
Y N
release the cover assembly. Insert a sheet of paper into the registration/preheat assembly and
cover the registration scan bar, PL 88.10 Item 2, Q89-005. Close the front door assembly. The
UI reports a paper jam in area 3a. • GP 12 How to Check a Solenoid or Clutch.
Check the connection of the ribbon cable at the scan bar (sensor 10) and at the registra- • 01J +50V Distribution RAP.
tion / preheat interface PWB, WD 8.6. • 01L 0V Distribution RAP.
Reseat all connections to the registration / preheater interface PWB.
Install a new registration/preheat assembly, PL 88.10 Item 1.
Enter dC330 code 89-007 registration motor A1 (M3), MOT89-007. Press Start. The motor • Media path driver PWB, PL 1.15 Item 5.
runs.
Y N Enter dC330 code 83-004 HPP diverter solenoid, SOL83-004. Press Start. Check that the
Go to WD 8.1. Check registration motor A1 (M3), MOT89-007. Refer to: diverter gate moves correctly when activating the solenoid. The solenoid energizes.
• GP 10 How to Check a Motor. Y N
Enter dC330 code 89-008 registration motor A2 (M3), MOT89-008. Press Start. The motor • Media path driver PWB, PL 1.15 Item 5.
runs.
A
A
Enter dC330 code 82-003 Horizontal transport motor (M6) (forward), MOT82-003. Press Start. 89-125-00 to 89-128-00, 89-130-00 Media Path Sensor 20
The motor runs.
Y N Failure RAP
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: 89-125-00 The sheet is too long over media path sensor 20 at pre-transfix.
89-126-00 The sheet is too short over media path sensor 20 at pre-transfix.
• 01D +5V Distribution RAP. 89-127-00 The leading edge was late at media path sensor 20 at pre-transfix.
• 01L 0V Distribution RAP. 89-128-00 The trailing edge was late at media path sensor 20 at pre-transfix.
89-130-00 The lead edge of the sheet was too early at media path sensor 20.
Initial Actions
Y N
Check the drive belt and drive gears on the horizontal transport, PL 82.10 / PL 82.15. WARNING
If necessary, install new components: Ensure that the electricity to the machine is switched off while performing tasks that do
• Transport rolls, PL 82.15. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
death or injury. Moving parts can cause injury
• Check the registration/pre-heat assembly for contamination or paper debris, PL 88.10
Item 1.
Enter dC140 Analog Monitor. Select 82-102 horizontal trans motor encoder (M6). Press Start. • Check for shingled or multi-feed sheets. Go to OF 8 Multi-feed RAP and check the appro-
Manually rotate the drive gears forward and backward. The display changes. priate tray.
Y N
Go to WD 8.5. Check horizontal transport motor (M6), MOT82-003. Refer to: Procedure
• GP 10 How to Check a Motor. Clean the pre transfix sensor 20, PL 88.10 Item 12 and refer to GP 27. The fault remains.
• 01D +5V Distribution RAP. Perform SCP 5 Final Actions.
Enter dC330 code 89-006 pre transfix sensor (20), Q89-006. Press Start. Manually actuate the
• 01L 0V Distribution RAP sensor. The display changes.
• Horizontal transport motor (M6), PL 82.15 Item 9. Go to WD 8.6. Check pre transfix sensor 20, Q89-006. Refer to:
• Media path driver PWB, PL 1.15 Item 5. • REP 89.1 Registration/Preheat Assembly and Lower Platelet Assembly
Check the horizontal transport rolls and nip rolls. PL 82.15 Item 10. • PJ5, Registration / Preheat IF PWB.
NOTE: Calibration of the registration/preheat assembly, dC625, is only required when: • 01D +5V Distribution RAP.
• The registration/preheat assembly is removed or replaced. • 01L 0V Distribution RAP.
• The horizontal transport assembly is removed or replaced. Install new components as necessary:
Calibration of the registration/preheat assembly is NOT required when: • Pre transfix sensor (20), PL 88.10 Item 12.
• A printhead is replaced. • Registration / pre-heat IF PWB, PL 88.10 Item 10.
• The IOD assembly is removed or replaced. • Media path PWB, PL 1.15 Item 5.
Enter dC330 code 88-008 registration/preheat air pumps, MOT88-008. Press Start. The air
pumps run.

Xerox® ColorQube® 9203 Family 2-393 89-110-00 to 89-113-00, 89-129-00, 89-125-00 to 89-
Y N 89-500-00, 89-502-00 Registration Motor Over Current RAP
Go to WD 8.6. Check registration/ preheat air pumps, MOT88-008. Refer to:
89-500-00 Motor M3_A1 current demand is inconsistent with expected value.
• PJ5, Registration / Preheat IF PWB. 89-502-00 Motor M3_A2 current demand is inconsistent with expected value.
• 01L 0V Distribution RAP. Procedure
• Registration/preheat air pumps, PL 88.10 Item 5.
WARNING
• Registration / pre-heat IF PWB, PL 88.10 Item 10.
Check the nip A rollers and registration motors A1 & A2, refer to 89-500-00, 89-502-00 Regis- not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
tration Motor Over Current RAP. death or injury. Moving parts can cause injury
Refer to Figure 1. Enter dC330 and test the registration motors (MOT89-007 and MOT89-008).
Refer to GP 10 How to check a motor. The motors run.
Y N
Refer to WD 8.1. Check connections at PJ202 on the media path driver PWB. The con-
nections are good.
Y N
Reseat connections to the registration motors and registration / preheat interface
PWB. Check the bulkhead connector. Reseat pigtail connectors to chassis bulkhead.
Check operation of the nip A rollers when the motors are run. The rollers rotate.
Y N
Check the drive belts, gears and pulleys for damage or debris.
• Nip 'A' replacement kit, PL 88.11 Item 1.
• Registration/Pre-heat assembly, PL 88.10 Item 1.
Check and clear the media path.
The fault may be intermittent, if the error persists, install a new registration/pre-heat assembly
PL 88.10 Item 1.

89-125-00 to 89-128-00, 89-130-00, 89-500-00, 89-502- 2-394 Xerox® ColorQube® 9203 Family
89-504-00 Registration Sensor Over Current RAP
89-504-00 The registration sensor 10 current demand is inconsistent with expected value.
Procedure
Registration motor A1
(M3), MOT89-007 WARNING
Perform dC969 Clean Ink Smears. The pages exit the registration.
Y N
Open the registration/preheat assembly cover assembly and heat shield. Refer to REP
10.7 to release the cover assembly. Insert a sheet of paper into the registration/preheat
assembly and cover the registration scan bar, Q89-005, Figure 1. Close the front door
assembly. The UI reports a paper jam in area 3a.
Y N
Nip A rollers
• PJ 1, Registration/preheat Interface PWB.
• 01C +3.3V Power Distribution RAP.
Registration motor A2 Install new components as necessary:
(M3), MOT89-008 • Registration/preheat assembly, PL 88.10 Item 1.
The fault may be intermittent, if the error persists, install a new registration/preheat
assembly PL 88.10 Item 1.
The fault may be intermittent, if the error persists, install a new registration/preheat assembly
Figure 1 Component location PL 88.10 Item 1.
• The registration / preheat assembly is removed or replaced,
Calibration of the registration / preheat assembly is NOT required when:

89-512-00 to 89-514-00 Registration Scan Error RAP
89-512-00 Registration Scanner S3 RAM Error.
89-513-00 Registration Scanner CIS Dot Clock Error.
Registration 89-514-00 Registration Scanner DMA Race Error.

scan bar,
Q89-005 Initial Actions
WARNING
• Check connections between the registration/preheat interface PWB, drum driver PWB to
the IME controller PWB.
Procedure
Check connections between the registration / preheat interface PWB, drum driver PWB to the
IME controller PWB. Refer to WD 8.6, WD 9.2 and WD 9.6. The connections are secure.
Y N
Reseat connections along the data path to the IME controller PWB.
Cover assembly If the error persists, install a new IME controller PWB PL 92.10 Item 1.

Figure 1 Registration/preheat assembly. • The horizontal transport assembly is removed or replaced.

A
89-520-00 Home Sensor Timeout RAP • Registration / Preheat assembly, PL 88.10 Item 1.
89-520-00 The home sensor, mounted on the registration / preheat interface PWB, reports a • Media path driver PWB, PL 1.15 Item 5.
value inconsistent with expected value.
Perform the following actions:
Procedure • Check for wiring damage or obstructions preventing jam clearance hatch movement.
Refer to REP 89.1.
• If the error persists, install a new registration/preheat assembly PL 88.10 Item 1.
WARNING
Enter dC330 code 89-004 to check the registration / preheat home sensor Q89-004, Figure 1.
Manually rotate the drive shaft to actuate the sensor, Figure 2. The display changes.
Y N
Check that the flag on the drive gear for damage, Figure 1.
Go to WD 8.6. Check the registration / preheat home sensor, Q89-004.
Refer to:
• PJ4, Registration / preheat interface PWB.
• 01D +5V Power Distribution RAP.
Install new components as necessary: Sensor flag on
• Registration / preheat assembly, PL 88.10 Item 1. Reg /preheat home sensor Q89-004 the drive gear
(mounted on the PWB)
Enter dC330 code 89-007 registration motor A1 (M3), MOT89-007. Press Start. The motor
runs.
Y N
Enter dC330 code 89-008 registration motor A2 (M3), MOT89-008. Press Start. The motor
runs.
Y N
• Registration / Preheat IF PWB, PL 88.10 Item 10.

89-531-00 to 89-534-00 Registration Process Error RAP
89-531-00 The registration sensor (10) failed to detect the lateral edge.
89-532-00 The registration sensor (10) timed out or failed to complete normally.
89-533-00 The registration sensor (10) generated a floating point exception.
89-534-00 The registration sensor (10) scan failed.
Initial Actions
WARNING
• Check for damage or debris that restricts movement of the assembly.
• Check for dust or media debris around the registration scan bar.
Procedure
Enter dC715 Active registration control and disable registration control. Enter dC969 Clean Ink
Smears and run the routine. The pages exit the registration / preheat assembly.
Y N
Go to the 89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Failure RAP.
Rotate the drive shaft
Install a new Registration / preheat assembly, PL 88.10 Item 1

Figure 2 Component location • The registration/preheat assembly is removed or replaced.

89-540-00 to 89-545-00 Registration Process Error RAP 89-550-00, 89-551-00 Media Registration Error RAP
89-540-00 Sensor 10 post registration processing failure. 89-550-00 The registration sensor detected excessive skew on the incoming media.
89-541-00 Sensor 10 post processing leading edge not detected. 89-551-00 The registration sensor detected excessive offset on the incoming media.
89-542-00 Sensor 10 post processing lateral edge not detected. Initial Actions
• Ensure that the tray 3 paper tray guides are set correctly, ADJ 73.1.
89-543-00 Sensor 10 post processing leading edge error.
• Check and clean the vertical and horizontal transport nip rolls up to the registration / pre-
heat assembly.
89-544-00 Sensor 10 post processing lateral edge error.
• Perform dC625 Registration / Preheat Calibration routine.
89-545-00 Sensor 10 post processing leading edge crossing too small.
Procedure
Initial Actions Run the job from a different tray. The fault still occurs.
Y N
Check the tray from which the fault occurs and install new components as necessary.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Enter dC330 code 82-007 Nip C release solenoid, SOL83-007. Press Start. The solenoid
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause energizes.
death or injury. Moving parts can cause injury Y N
• Check for damage or debris that restricts movement of the assembly. Go to WD 8.1. Check SOL83-007. Refer to:
• Check for dust or media debris around the registration scan bar. • GP 12 How to Check a Solenoid or Clutch.
Procedure • 01J +50V Distribution RAP.
Enter dC715 Active registration control and disable registration control. Enter dC969 Clean Ink • 01L 0V Distribution RAP.
Smears and run the routine. The pages exit the registration / preheat assembly. Install new components as necessary:
Y N • Nip C release solenoid, PL 82.15 Item 4.
Go to the 89-110-00 to 89-113-00, 89-129-00 Media Path Sensor 10 Failure RAP. • Media path driver PWB, PL 1.15 Item 5.
Install a new Registration / preheat assembly, PL 88.10 Item 1 Enter dC330 code 82-008 Nip D release solenoid, SOL83-008. Press Start. The solenoid
NOTE: Calibration of the registration/preheat assembly, dC625, is only required when: energizes.
Y N

• Check the vertical and horizontal transport rolls and drive belts.Install new parts as neces-
sary. Refer to PL 82.10 for the vertical transport and PL 82.15 for the horizontal transport.
• If the jam is occurring in area 4a in duplex mode only, install a new exit paper path assem-
bly, PL 10.15 Item 19.
• If the error persists, install a new registration / preheat assembly PL 88.10 Item 1.

NOTE: Calibration of the registration / preheat assembly, dC625 is only required when: 89-555-00, 89-556-00 Media Registration Out of Range RAP
• The registration / preheat assembly is removed or replaced, 89-555-00 The stored registration correction values are out of range.
Calibration of the registration / preheat assembly is NOT required when: 89-556-00 The registration NVM parameters are out of range.
• The IOD assembly is removed or replaced. Initial Actions
WARNING
• Calibrate the assembly using dC625 registration calibration routine.
• If the fault 89-555-00 occurs and the media has severe skew or offset, go to 89-550-00,
89-551-00 Media Registration Error RAP.
Procedure
Switch off, then switch on the machine, GP 14. Perform dC969 to print chase sheets to deter-
mine if NVM is restored. Chase sheets print without error.
Y N
Open the registration/preheat assembly cover assembly and heat shield. Refer to REP
10.7 to release the cover assembly. Insert a sheet of paper into the registration/preheat
assembly and cover the registration scan bar, PL 88.10 Item 2, Q89-005. Close the front
door assembly. The UI reports a paper jam in area 3a.
Y N
• PJ 1, Registration/preheat Interface PWB.
• 01C +3.3V Power Distribution RAP.
• Registration/preheat assembly, PL 88.10 Item 1
Check for ESD failures, 92-527-00, 92-528-00 fault codes in the fault history. If ESD
events are indicated. Check system grounding, go to GP 7. The system grounding is
good.
Y N
Correct any system grounding issues, then retest.
Check and clear the registration/preheat assembly.
If the error persists, install a new registration/preheat assembly PL 88.10 Item 1.


89-561-00 Media Registration Parameters Reset RAP 89-562-00 Incorrect Media RAP
89-561-00 Registration/preheat assembly calibration failed. 89-562-00 No media of the specified size is available.
WARNING WARNING
death or injury. Moving parts can cause injury death or injury. Moving parts can cause injury
• Check for debris or obstructions in the media path. • Check that the machines settings match the media loaded in all trays.
• Check the fault history, dC122. If any other fault occurred at the same time perform the • If the fault occurs when dC625 Registration / Preheat Calibration is run. Then ensure that
relevant RAP. there is a minimum of 30 sheets loaded in the tray of A4 or 8.5 x 11inch media in long
edge feed orientation.
Procedure
Enter dC625 and run the registration calibration routine. Calibration is successful. Procedure
Y N Check that the correct media in the appropriate paper tray. If necessary load the correct media
Go to WD 8.6. Check all connections. and / or adjust the paper guides.
Refer to: If the correct media is loaded, trouble shoot the relevant tray:
• PJ 1 Registration/preheat interface PWB. • 71B Tray 1 Wrong Size Paper RAP.
• PJ 2 to PJ 701 on the Drum driver PWB. • 72B Tray 2 Wrong Size Paper RAP.
• PJ 4 to PJ 104 on the Media path driver PWB. • 74A Bypass Tray Size Sensing Problems RAP.
Reseat any loose connections. For tray 3, check the settings in the UI match what is loaded.
Tray 5 is fixed so this fault will not be seen.
Check for ESD failures, 92-527-00, 92-528-00 fault codes in the fault history. If ESD events are
indicated. Check system grounding, go to GP 7. The system grounding is good.
Y N
Correct any system grounding issues, then retest.
• Registration/preheat assembly PL 88.10 Item 1.
Install a new registration/preheat assembly PL 88.10 Item 1.


89-563-00 IOD Alignment Error RAP 89-564-00 Calibration Image Error RAP
89-563-00 IOD alignment or Y run out calibration is needed before registration calibration. 89-564-00 The machine failed to create a calibration image or sheet.
Procedure Procedure
WARNING WARNING
death or injury. Moving parts can cause injury death or injury. Moving parts can cause injury
Perform the following: This fault is caused by a hardware memory failure within the IME.
1. 91-637-00 Drum Runout Calibration Needed RAP. Remove and reseat the NVRAM, PL 92.10 Item 11 on the IME Controller PWB, PL 92.10 Item
1. The fault is cleared.
2. dC971 Head to Head Alignment Adjustment.
Y N
3. dC625 Registration / Preheat Calibration.
Install a new RAM from a new IME Controller PWB, PL 92.10 Item 1. The fault is
4. If fault persists, perform dC977 Drum Runout Calibration. cleared.
Y N
Install a new IME Controller PWB, PL 92.10 Item 1.

89-565-00, 89-566-00 Scan Measurement Was Out Of 89-567-00 Calibration Scan Detected Floating Point
Range RAP Exception RAP
89-565-00 The intermediate registration value is not valid. 89-567-00 Calibration scan detected floating point exception. This occurs because the scan
did not detect the registration calibration image correctly.
89-566-00 The computed calibration parameter is out of range.
Initial Actions
Initial Actions
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause death or injury. Moving parts can cause injury
death or injury. Moving parts can cause injury • Calibrate the assembly using dC625 registration calibration routine.
• Calibrate the assembly using dC625 registration calibration routine. • If the media has severe skew or offset, go to 89-550-00, 89-551-00 Media Registration
• If the media has severe skew or offset, go to 89-550-00, 89-551-00 Media Registration Error RAP.
Error RAP. • Check for a Service code to indicate the machine is running in degraded mode, refer to
• Check for a Service code to indicate the machine is running in degraded mode, refer to OF 17 Service Code RAP.
OF 17 Service Code RAP.
Procedure
Procedure
An error with either IOD alignment or Y runout needs to be resolved before running the dC625
Registration / Preheat Calibration. Refer to 91-637-00 Drum Runout Calibration Needed RAP. WARNING
Check connections between the registration / preheat interface PWB at PJ2 and drum driver
PWB at PJ701. Refer to WD 8.6 and WD 9.2. Repair harness as necessary, REP 1.1.
If the fault continues install new components in order:

1. Drum driver PWB, PL 1.15 Item 5.
2. Registration / preheat assembly, PL 88.10 Item 1.


91-500-00, 91-600-00 Initial Position Error RAP 91-501-00 to 91-502-00 Image Timing Error RAP
91-500-00 The staggered full width array (SFWA) was not left at the correct position to start the 91-501-00 Printhead image timing error.
imaging process.
91-502-00 Marking sequence timing error.
91-600-00 The staggered full width array (SFWA) stitch or roll motor un-initialized failure.
Initial Actions
Procedure
WARNING
The SWFA was not in the correct position to start the imaging process. The mechanisms were
CAUTION
or may have been moved manually instead of under the software control. This fault will not
occur under normal operation. Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir
Perform the following: located at the back of the drawer if opened with too much force. Ink cross-color contamination
could also occur.
2. Manually move the upper and lower carriages to the parked position, refer to GP 6.
3. Switch on the machine, GP 14. CAUTION
4. If the fault is still present then re-load the software, GP 4. Do not touch the exposed face of the printheads. Surface contamination or minor damage can
destroy the printhead. Printheads must only be cleaned by a purge cycle.
NOTE: The LED on upper (master) printhead circuit board indicates the presence of 3.3 VDC.
• Retry the affected job. Print samples may help to identify the cause of the fault.
• Check the error history for similar or related events.
• Check the service loop for abrasions, PL 92.10 Item 9.
Procedure
Check for ESD failures, 92-527-00, 92-528-00 fault codes in the fault history. Check system
grounding, refer to GP 7. The system grounding is good.
Y N
Correct system grounds, refer to GP 7. Pay particular attention to the exit, transfix roller,
and drum ground connections.
Make a copy from the DADH. The fault remains.

Y N
Install a new IME controller PWB, PL 92.10 Item 1.

91-503-00 Print Image Data Did Not Arrive From the 91-504-00, 91-505-00 Printhead Stitch Motor Over Current
Controller in Time RAP RAP
91-503-00 The image did not reach the IME controller PWB. 91-504-00 Printhead stitch adjust motor 1 current demand exceeds expected value.
Procedure 91-505-00 Printhead stitch adjust motor 2 current demand exceeds expected value.
Initial Actions
WARNING
Go to 92-581-00 Image Transfer Error RAP. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
CAUTION
Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir
located at the back of the drawer if opened with too much force. Ink cross-color contamination
could also occur.
CAUTION
Do not touch the exposed face of the printheads. Surface contamination or minor damage can
NOTE: Override the front door interlock to provide voltage to the motor under test.
• Ensure that the harnesses leading to the motors and surrounding components are routed
correctly and secured by the harness clamps, refer to GP 28. Focus on areas above and
behind the umbilicals.
• Check for damage or debris that restricts printhead movement.
Procedure
Open the marking unit drawer, GP 6 to observe the motors, Figure 1. Enter dC330 code 91-
029 or 91-030 to run the relevant printhead stitch adjust motor, MOT91-029 (1) or MOT91-030
(2).
NOTE: Movement of the motors is small. If necessary, mark the lead screw of the motor to see
the movement.
The motor runs.

Y N
Go to WD 9.9 and WD 9.10. Check MOT91-029 or MOT91-030.
Refer to:
NOTE: The motor will not turn freely due to the gear reduction.
• PJ303 (motor 2) or PJ102 (motor 1), Marking Unit Driver PWB.

• 01H +24V Power Distribution RAP.
A
A
Install new components as necessary 91-506-00 to 91-509-00 Roll Motor Over Current RAP
• Printhead stitch adjust motor 1, PL 91.25 Item 4.
91-506-00 Printhead roll adjust motor 1 current demand exceeds expected value.
• Marking unit driver PWB, PL 92.10 Item 4 91-507-00 Printhead roll adjust motor 2 current demand exceeds expected value.
Perform dC971 Head to Head Alignment Adjustment, then check the image quality, refer
to IQ 1. 91-508-00 Printhead roll adjust motor 3 current demand exceeds expected value.
Check for obstructions or debris blocking motor or printhead movement. The printhead area 91-509-00 Printhead roll adjust motor 4 current demand exceeds expected value.
is free of obstructions.
Y N Initial Actions
Clean the area and retest.
Check the following: WARNING

• Check the black plastic couplers on the lead screws of the printhead roll adjust motors Ensure that the electricity to the machine is switched off while performing tasks that do
and printhead stitch adjust motors. Refer to T7869-01-12 and ETI 1056514. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Check the wire routing along the carriage for abrasions. Install a new wire harness or death or injury. Moving parts can cause injury.
repair the harness, REP 1.1 as necessary. If the error persists, install a new printhead
stitch adjust motor, PL 91.20 Item 4.
Perform dC971 Head to Head Alignment Adjustment, then check the image quality, refer to IQ CAUTION
1. Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir
could also occur.
CAUTION
• Ensure that the harnesses leading to the printhead and surrounding component are
routed correctly and secured by the harness clamps, refer to GP 28. Focus on areas
above and behind the umbilicals.
• Check for damage or debris that restricts printhead movement.
Procedure
Open the marking unit drawer, GP 6 to observe the motors. Enter dC330 code to run the rele-
vant printhead roll adjust motor, MOT91-024 (1), MOT91-026 (2), MOT91-027 (3), MOT91-028
(4), Figure 1.
NOTE: Movement of the motors is small. If necessary, mark the lead screw of the motor to see
the movement.
Printhead stitch Printhead stitch
adjust motor 1, The motor runs.
adjust motor 2,
MOT91-029 MOT91-030 Y N
Go to WD 9.9 or WD 9.10. Check the relevant motor.
Refer to:
NOTE: The motor will not turn freely due to the gear reduction.
• PJ303 (motor 1 and 3) PJ102 (motor 2 and 4), Marking Unit Driver PWB.
A

A
• 01H +24V Power Distribution RAP. 91-510-00, 91-511-00 X Axis Motor Over Current RAP
• 01L 0V Distribution RAP 91-510-00 Upper X axis motor current demands exceed expected value.
• Printhead roll adjust motor, PL 91.20 Item 4 or PL 91.25 Item 4. 91-511-00 Lower X axis motor current demands exceed expected value.
• Marking unit driver PWB, PL 92.10 Item 4.
Perform dC971 Head to Head Alignment Adjustment, then check the image quality, refer Initial Actions
to IQ 1.
Check for obstructions or debris blocking motor or printhead movement. The printhead is WARNING
free of obstructions. Ensure that the electricity to the machine is switched off while performing tasks that do
Y N not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Clean the area and retest. death or injury. Moving parts can cause injury.

• Check the black plastic couplers on the lead screws of the printhead roll adjust motors CAUTION
and printhead stitch adjust motors. Refer to T7869-01-12 and ETI 1056514. Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir
• Check the wire routing along the carriage for abrasions. Install a new wire harness or located at the back of the drawer if opened with too much force. Ink cross-color contamination
repair the harness, REP 1.1 as necessary. If the error persists, install a new printhead could also occur.
stitch adjust motor, PL 91.20 Item 4.
Perform dC971 Head to Head Alignment Adjustment, then check the image quality, refer to IQ 1. CAUTION
• Check the harness leading to the carriage and surrounding components, refer to GP 28.
Focus on areas above and behind the umbilicals.
• Check for damage to the harness and possible shorts.
Procedure
Open the marking unit drawer, GP 6 to observe the motors. Enter dC330 codes 91-033 and 91-
034 to run the upper X axis drive motor, MOT91-033 and the lower X axis drive motor, MOT91-
034, Figure 1. MOT91-033 and MOT91-034 run.
Y N
Go to WD 9.9 and WD 9.11. Check MOT91-033 or MOT91-034.
Refer to:
• PJ303 (lower) PJ102 (upper), Marking Unit Driver PWB.
Printhead roll • 01H +24V Power Distribution RAP.
Printhead roll
adjust motor 4, • 01L 0V Distribution RAP
adjust motor 2,
MOT91-028 Install new components as necessary:
MOT91-026
• Upper axis drive motor, PL 91.20 Item 5.
Printhead roll Printhead roll • Lower axis drive motor, PL 91.25 Item 5.
adjust motor 1, adjust motor 3, • Marking unit driver PWB, PL 92.10 Item 4.
MOT91-024 MOT91-027
Check for obstructions or debris blocking motor or printhead movement. The printhead is
free of obstructions.

Y N 91-512-00, 91-605-00 Marking Unit Motor Short RAP
Clean the area and retest.
91-512-00 Carriage drive motor current demand exceeds expected value.
Check the wire routing along the carriage for abrasions. Install a new wire harness or repair the 91-605-00 One of several marking unit motors, driven by the marking unit driver PWB, is draw-
harness, REP 1.1 as necessary. If the error persists, install a new components as necessary: ing more current than expected.
upper X axis or lower X axis drive motor, PL 91.20 Item 5 or PL 91.25 Item 5.
• Upper axis drive motor, PL 91.20 Item 5.
Initial Actions
• Lower axis drive motor, PL 91.25 Item 5.
• Marking unit driver PWB, PL 92.10 Item 4. WARNING
CAUTION
could also occur.
CAUTION
• Ensure that the harnesses leading to the marking unit motors are secured by the harness
clamps, refer to GP 28.
• Check for damage or debris restricting motor movement.
X axis drive motor lower, X axis drive motor upper,
MOT91-034 MOT91-033 Procedure
Enter dC330. Run the following motors:
Figure 1 Component location • Code 91-021 Carriage drive select motor, MOT91-021, part of the carriage drive train, PL
91.10 Item 1. Refer to WD 9.11.
• Code 91-023 HM vertical motion motor, MOT91-023, PL 91.15 Item 12. Refer to WD 9.11.
• Code 91-024 Printhead roll adjust motor 1, MOT91-024, PL 91.25 Item 4. Refer to WD 9.10.
• Code 91-025 HM horizontal motion motor, MOT91-025, part of the HM horizontal drive gear-
box, PL 91.15 Item 15. Refer to WD 9.11.
• Code 91-029 Printhead stitch adjust motor 1, MOT91-029, PL 91.25 Item 4. Refer to
WD 9.10.
• Code 91-030 Printhead stitch adjust motor 2, MOT91-030, PL 91.20 Item 4. Refer to WD 9.9.
• Code 91-031 Carriage drive motor, MOT91-031, PL 91.10 Item 16. Refer to WD 9.11.
• Code 91-033 X axis drive motor upper, MOT91-033, PL 91.20 Item 5. Refer to WD 9.9.
• Code 91-034 X axis drive motor lower, MOT91-034, PL 91.25 Item 5. Refer to WD 9.11.
• Code 91-035 Upper carriage ship restraint motor, MOT91-035, PL 91.20 Item 7. Refer to
WD 9.9.
• Code 91-036 Lower carriage ship restraint motor, MOT91-036, PL 91.25 Item 7. Refer to
WD 9.10.

The motors run. 91-513-00, 91-514-00, 91-581-00, 91-583-00 IOD Drive Error
Y N
Go to the relevant wiring diagram. Check the relevant motor. RAP
Refer to: 91-513-00 IOD shuttle motor current inconsistent with expected value.
91-514-00 IOD drive stall.
• PJ102, PJ303, PJ304, PJ401, PJ605, PJ607, Marking Unit Driver PWB.
• 01H +24V Power Distribution RAP. 91-581-00 IOD Home time-out.
• 01J +50V Power Distribution RAP. 91-583-00 IOD stall recovery failed.
• 01L 0V Distribution RAP Initial Actions
• Marking unit driver PWB, PL 92.10 Item 4
WARNING
Check the wiring harnesses connecting motors to the marking unit driver PWB. Pay particular
attention to wiring routed near the carriages. The wiring is good.
Y N
Install new wiring or repair as necessary, REP 1.1.

WARNING
CAUTION
Do not disconnect and reconnect the flex cables at the IOD PWB. the flex cables are easily
damaged. The cable must only be handled in the area of the blue backer.
CAUTION
print quality defects.
• Check the IOD to drum driver PWB cable, PL 94.15 Item 5.

• Check for damage or debris that restricts IOD movement.
Procedure
NOTE: If the machine has SMP2 or later software, the stitch and roll motors are disabled and
will not operate in dC914. Use the dC330 component control chain 91 to run these compo-
nents.
Go to dC914 Head to Head Alignment Test. Select test option 1 Move IOD Scan Bar. Follow
instructions on the screen and observe the IOD movement. Select Position and run in the
order:
1. Select Home (moves slowly to the front until a stall is encountered) and return to park
position.
2. Select Rear (moves to the rear) and return to park position.
If the initial fault was 91-581-00 and a ticking noise is heard during the test then install a new
IOD assembly, PL 94.15 Item 1.

NOTE: Always end in the Park position (centre) to protect the IOD sensor from debris. 91-515-00 Vertical Wiper Motor Over Current RAP
The IOD sensor runs to all positions without unusual noises. 91-515-00 The HM vertical motion motor current demand exceeds expected value.
Y N
Perform the following: Initial Actions
1. Check for obstructions or debris blocking motor movement.
2. Go to WD 9.22. Check the IOD shuttle motor, MOT91-043, Figure 1.
Refer to: WARNING
• GP 10 How to Check a Motor. Ensure that the electricity to the machine is switched off while performing tasks that do
• PJ660, IOD pre amplifier PWB.
• 01H +24V Power Distribution RAP
• 01L 0V Distribution RAP NOTE: Override the front door interlock to provide voltage to the device under test.
If necessary, install a new IOD assembly, PL 94.15 Item 1. • Check belts, gears, pulleys and wiper alignment, PL 91.15.
• Check for damage or debris that restricts wiper movement.
Enter diagnostics select Diagnostic Routines and select dC914 Head to Head Alignment Test.
• Check the harness leading to the motor and surrounding components. Refer to GP 28.
Select test option 10 to dC971 Head to Head Alignment Adjustment then follow Measure Head
Alignment. Follow the instructions on the screen. The procedure ran without declaring a
fault. Procedure
Y N Enter dC330 code 91-023 to run the HM vertical motion motor, MOT91-023, PL 91.15 Item 12.
Refer to the appropriate RAP for the new fault code. MOT91-023 runs.
Y N
If the fault is intermittent. Check the wire routing to the IOD for abrasions. Repair the harness, Go to WD 9.11. Check MOT91-023.
REP 1.1 as necessary. If the error persists, install a new Drum Driver PWB, PL 1.15 Item 4. Refer to:
NOTE: Calibration of the registration / preheat assembly is only required when:
• PJ401, Marking Unit Driver PWB.
• HM vertical motion motor, PL 91.15 Item 12.
Check for obstructions or debris blocking motor, gearbox, or belt movement. The wiper
moves up and down smoothly.
Y N
Clean the wiper drive components and retest.
Check the wiring harness. Repair the harness, REP 1.1 as necessary. If the error persists,
install a new HM vertical motion motor, PL 91.15 Item 12.
IOD shuttle motor,

MOT91-043

91-516-00 Low Pressure Assist Over Current RAP 91-517-00 Marking Unit Air Pump Over Current RAP
91-516-00 Low pressure assist solenoid valve current demand exceeds expected value. 91-517-00 Marking unit ink load air pump current demand exceeds expected value.
WARNING WARNING
• Check the harnesses leading to the ink reservoir and sensing components. • Check the harness leading to the pump and surrounding components.
Procedure Procedure
1. Go to WD 9.14. Check the low pressure assist (LPA) valve solenoid, SOL91-045, PL 1. Go to WD 9.14. Check the reservoir pump, MOT93-050, PL 93.10 Item 11.
93.10 Item 15. Refer to:
Refer to: • GP 11 How to Check a Motor.
• GP 12 How to Check a Solenoid valve or Clutch. • PJ130, Solenoid Patch PWB.
• PJ130, Solenoid Valve PWB. • 01E +12V Power Distribution RAP
• 01E +12V Power Distribution RAP • 01D +5V Distribution RAP
• 01D +5V Distribution RAP • 01L 0V Distribution RAP
• 01L 0V Distribution RAP 2. Check the reservoir pump harness. Repair the harness, REP 1.1 as necessary.
2. Check the solenoid valve harness. Repair the harness, REP 1.1 as necessary. If the error persists, install a new components as necessary:
If the error persists, install new components as necessary: • Ink reservoir, PL 93.10 Item 10.
• Ink reservoir, PL 93.10 Item 10. • Marking unit driver PWB, PL 92.10 Item 4.

91-519-00 to 91-522-00, 91-655-00 to 91-690-00, 91-807 to Procedure
91-811-00 Printhead NVM Read or Write Error RAP
91-519-00 Printhead 1 NVM error detected. HCD read failure. WARNING
91-520-00 Printhead 2 NVM error detected. HCD read failure.
91-521-00 Printhead 3 NVM error detected. HCD read failure.
91-522-00 Printhead 4 NVM error detected. HCD read failure. CAUTION

91-655-00 Printhead 1 field corrections corrupt. HFC read or write failure.
could also occur.
91-656-00 Printhead 2 field corrections corrupt. HFC read or write failure.
91-657-00 Printhead 3 field corrections corrupt. HFC read or write failure. CAUTION
91-658-00 Printhead 4 field corrections corrupt. HFC read or write failure. destroy the printhead. Printheads must only be cleaned by a purge cycle.
Check that the ribbon cables connecting the relevant printhead to the IME controller PWB are
91-683-00 Printhead 1 TRC read failed.
correctly and securely connected, and not damaged. Re-seat the ribbon cable as necessary.
The wiring is good.
Y N
Install new ribbon cables as necessary, PL 92.10.
Check for ESD failures, 92-527-00, 92-528-00 fault codes in the fault history. If ESD events are
indicated. Go to GP 7 to check system ground. The system grounding is good.
Y N
91-687-00 Printhead 1 TRC write failed.
Repair any ground issues found, GP 7.
Switch off, then switch on the machine, GP 14. The fault is still present.
Y N
The fault is a NVM write error generated when dC972 is performed. Re-try the relevant
routine:
• Faults 91-655-00 to 91-658-00, dC972 option 3 Head to Head Uniformity.
91-807-00 Attempt to read or write printhead 1 NVM HAY or HAU sections failed. • Faults 91-687-00 to 91-690-00, dC972 option 4 TRC Generation.
• Faults 91-807-00 to 91-810-00, dC972 option 3, Head to Head Uniformity, then
91-808-00 Attempt to read or write printhead 2 NVM HAY or HAU sections failed. option 5, Y Dot Position Correction.
The fault is still present.
91-809-00 Attempt to read or write printhead 3 NVM HAY or HAU sections failed. Y N
Complete the remaining routines in dC972, up to and including option 5.
91-810-00 Attempt to read or write printhead 4 NVM HAY or HAU sections failed.
Perform Final Actions.
91-811-00 Machine has timed out waiting for the adjustment load task to complete reading
printhead NVM. The fault is a NVM read error generated during machine initialization. The fault is generated
by a newly installed printhead.
Y N
Switch off, then switch on the machine, GP 14. The fault is still present.
Y N
A B

A B
Perform Final Actions. 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
Perform dC972 option 1. Select manual and all 4 printheads. Switch off, then switch on the to 91-804-00 Printhead Thermal Error RAP
machine, GP 14. The fault remains. 91-523-00 Printhead 1 Left Jet Heater is Too Hot
Y N
91-524-00 Printhead 2 Left Jet Heater is Too Hot
Perform Final Actions.
Final Actions
Go to WD 9.5, WD 9.6, WD 9.7, WD 9.20 and WD 9.21. Check all connections: 91-527-00 Printhead 1 Left Jet Heater is Too Slow
• PJ101, Printhead PWB. 91-528-00 Printhead 2 Left Jet Heater is Too Slow
• PJ902, PJ904, PJ201, PJ301, IME Controller PWB. 91-529-00 Printhead 3 Left Jet Heater is Too Slow
91-530-00 Printhead 4 Left Jet Heater is Too Slow
• Printhead, PL 91.20 Item 2 or PL 91.25 Item 2.
• IME controller PWB, PL 92.10 Item 1 91-531-00 Printhead 1 Left Jet Thermistor value inconsistent with expected value.
91-532-00 Printhead 2 Left Jet Thermistor value inconsistent with expected value.
• The registration / preheat assembly is removed or replaced, 91-533-00 Printhead 3 Left Jet Thermistor value inconsistent with expected value.
• The horizontal transport assembly is removed or replaced. 91-534-00 Printhead 4 Left Jet Thermistor value inconsistent with expected value.
91-535-00 Printhead 1 Right Jet Heater is Too Hot
91-539-00 Printhead 1 Right Jet Heater is Too Slow
91-543-00 Printhead 1 Right Jet Thermistor value inconsistent with expected value.
91-547-00 Printhead 1 Reservoir Heater Too Hot
91-551-00 Printhead 1 Reservoir Heater Too Slow
91-555-00 Printhead 1 Reservoir Thermistor value inconsistent with expected value.

91-519-00 to 91-522-00, 91-655-00 to 91-690-00, 91-807 2-414 Xerox® ColorQube® 9203 Family
91-556-00 Printhead 2 Reservoir Thermistor value inconsistent with expected value. Procedure
91-557-00 Printhead 3 Reservoir Thermistor value inconsistent with expected value. Check for damage to the cables connecting each printhead. The wiring is good.
Y N
91-558-00 Printhead 4 Reservoir Thermistor value inconsistent with expected value. Install new cables as necessary, PL 92.10.
91-664-00 Printhead 1 thermal failure.
Perform the printhead thermal tests, dC335. The tests complete successfully.
91-665-00 Printhead 2 thermal failure. Y N
91-666-00 Printhead 3 thermal failure. Check the PEST fault history, dC123 for marking unit heater faults (umbilicals, printheads
and ink melt reservoir). All marking unit heaters have failed.
91-667-00 Printhead 4 thermal failure. Y N
91-800-00 Head 1 thermal glitch. Go to WD 9.8, WD 9.13 and WD 9.21. Check the connections and wiring:
• PJ101 and PJ301, Printhead PWB.
91-801-00 Head 2 thermal glitch.
• Disconnect the 8 pin AC printhead connector. Inspect the pins at both ends for
91-802-00 Head 3 thermal glitch. damage.
91-803-00 Head 4 thermal glitch. • PJ401, PJ701, Marking Unit Heater PWB.
91-804-00 Head thermal failure.
• Marking unit heater PWB, PL 92.10 Item 5.
Initial Actions • Printhead, PL 91.20 Item 2.
WARNING Refer to WD 1.1 and WD 9.8, check the wiring between PJ4AC on the Power Supply Unit
Ensure that the electricity to the machine is switched off while performing tasks that do and PJ101 on the Marking Unit Heater PWB. The wiring is good.
death or injury. Moving parts can cause injury. Repair the wiring, REP 1.1.
Check the +3.3V ESTAR distribution to the marking unit heater PWB, refer to the 01B
CAUTION +3.3V ESTAR Distribution RAP. If the fault is still present, install new components as nec-
Do not touch the exposed face of the printheads. Surface contamination or minor damage can essary:
destroy the printhead. Printheads must only be cleaned by a purge cycle. • Marking unit heater PWB cable, PL 92.10 Item 12.
CAUTION • Marking unit driver PWB, PL 92.10 Item 4.
Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir • Power supply unit, PL 1.15 Item 2.
could also occur. The error is intermittent. Refer to GP 7 and check system grounding. Repair any ground issues
found.
CAUTION
Printhead ribbon cables are interchangeable. Damage to the IME controller PWB is likely if the
cables are installed incorrectly. • The horizontal transport assembly is removed or replaced.
• Check all 3 wiring harness leading to the indicated printhead. Focus on areas above and Calibration of the registration / preheat assembly is NOT required when:
behind the umbilicals. Ensure each harness is securely and correctly seated, refer to GP 28. • The a printhead are replaced.

91-559-00 Marking Unit Components Out of Position RAP Y N
Go to WD 9.9 and WD 9.11. Check MOT91-023, MOT91-033 and MOT91-034.
The home position sensors are monitored as wiper or carriage motion is performed. This fault
Refer to:
occurs when carriage or wiper motion is requested and the sensors are not in the expected
state.
• PJ303 (lower), PJ102 (upper) and PJ401, Marking Unit Driver PWB.
91-559-00 Carriage or wiper components out of position for requested action. • 01J +50V Distribution RAP
• HM vertical motion motor, PL 91.15 Item 12.
WARNING • X axis drive motor upper, PL 91.20 Item 5.
Ensure that the electricity to the machine is switched off while performing tasks that do • X axis drive motor lower, PL 91.25 Item 5.
• Carriage drive train, PL 91.10 Item 1.
CAUTION Enter dC330 codes 91-011 and 91-012 to check the lower carriage home sensor, Q91-011 and
Do not handle or attempt to clean the wiper blade. Wiper blade contamination can damage the the upper carriage home sensor, Q91-012, Figure 1. Actuate each sensor. The display
printheads. changes.
Y N
Go to WD 9.11. Check Q91-011 and Q91-012.
CAUTION Refer to:
Do not touch the exposed face of the printheads. Surface contamination or minor damage can • GP 11 How to Check a Sensor.
destroy the printhead. Printheads must only be cleaned by a purge cycle. • PJ304, Marking Unit Driver PWB.
• 01B +3.3V ESTAR Power Distribution RAP.
CAUTION • 01L 0V Distribution RAP
Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir Install new components as necessary
located at the back of the drawer if opened with too much force. Ink cross-color contamination • Lower carriage home sensor, PL 91.10 Item 8.
could also occur. • Upper carriage home sensor, PL 91.10 Item 8.
• Check for damage or debris that restricts movement of the wiper. • Marking unit driver PWB, PL 92.10 Item 4.
• Check the harness leading to the vertical and horizontal wiper drives and home sensor.
Refer to GP 28. Check the condition of the wiper assembly including wiper motors, gearbox, and belts:
• Ensure that the wiper, PL 91.15 Item 13 is aligned horizontally.
Procedure • Check the HM belt, PL 91.15 Item 2 and the horizontal drive cable, PL 91.15 Item 16.
Check that they are positioned and tensioned correctly. Install new components as neces-
Check the position of the carriages. The carriages are docked to the drum. sary, PL 91.15.
Y N
Enter dC965. Run the head maintenance routine. Observe the wiper assembly motion. Check
Perform dC967 Head to Drum Spacing Check. dC967 runs successfully.
that the wiper moves up and down smoothly. Check also that the paddle correctly positions the
Y N
wiper. The wiper operation is good.
Perform ADJ 91.1 Printhead Attachment Check.
Y N
Clean the wiper drive components and retest. Check the wiring harness. Repair the har-
ness, REP 1.1 as necessary. Install new components as necessary:
• Vertical belts, PL 91.15 Item 2.
Enter dC330. Run the following motors:
• Horizontal drive cable, PL 91.15 Item 16.
• Code 91-023 HM vertical motion motor, MOT91-023, PL 91.15 Item 12.
• Code 91-033 X axis drive motor upper, MOT91-033, PL 91.20 Item 5. Check the area surrounding the carriage, wiper assembly, and umbilicals for wiring damage or
• Code 91-034 X axis drive motor lower, MOT91-034, PL 91.25 Item 5. obstructions that prevent carriage or wiper movement. The wiring is good.
• Code 91-031 carriage drive motor, MOT91-031, PL 91.10 Item 16. Y N
The motors run. Go to WD 9.11. Install new wiring or repair as necessary, REP 1.1.
A
A
Go to WD 9.9 and WD 9.11. Check all connections: 91-560-00 Carriage Selection Time Out RAP
• PJ303 (lower), PJ102 (upper) and PJ401, Marking Unit Driver PWB.
91-560-00 The carriage drive select motor timed out moving to stop.
Initial Actions
WARNING
Upper carriage
home sensor, Ensure that the electricity to the machine is switched off while performing tasks that do
Q91-012 not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Lower carriage home CAUTION

sensor, Q91-011 Do not touch the exposed face of the printheads. Surface contamination or minor damage can
CAUTION
could also occur.
NOTE: Override the front door interlock to provide voltage to the device under test.
• Check the wire harness leading to the carriage drive select motor and carriage home sen-
Figure 1 Component location sors, Figure 1.
• Check the carriage select gears in the carriage drive train on the for damage or debris,
Figure 1.
Procedure
Observe the motor and gearbox operation, the selector moves up and down. Enter dC330
code 91-021 carriage drive select motor, MOT91-021, Figure 1. MOT91-021 runs.
Y N
Refer to:
• Carriage drive train, PL 91.10 Item 1.
• Upper or lower carriage drive gear, PL 91.10 Item 9 and PL 91.10 Item 10.
Check for obstructions or damage inside carriage drive train. The drives are good.
Y N
Install a new carriage drives train, PL 91.10 Item 1.

A
If the error persists, install a new carriage drives train, PL 91.10 Item 1. 91-562-00, 91-563-00 Upper Carriage Error RAP
91-562-00 The upper printhead carriage no edge found.
91-563-00 The upper printhead carriage encountered an unexpected event.
Initial Actions
Upper carriage home
sensor, Q91-012
WARNING
Lower carriage home death or injury. Moving parts can cause injury.
sensor, Q91-011
CAUTION
Carriage drive select destroy the printhead. Printheads must only be cleaned by a purge cycle.
motor, MOT91-021
Carriage drive train
CAUTION
Figure 1 Component location located at the back of the drawer if opened with too much force. Ink cross-color contamination
could also occur.
• Check for obstructions, damage or debris that restricts carriage movement.
• Check the harness leading to the carriage drive and their related sensors. Refer to GP 28.
Procedure
Move the marking unit into the service position, GP 6.
Check the area surrounding the carriage and umbilicals for wiring damage or obstructions that
prevent carriage movement. The wiring is good.
Y N
Enter dC330 code 91-031 to run the carriage drive motor, MOT91-031, Figure 1. MOT91-031
runs.
Y N
Refer to:
• Carriage drive motor, PL 91.10 Item 16.
A
A
Observe the motor and gearbox operation, the selector moves up and down. Enter dC330 Y N
code 91-021 carriage drive select motor, MOT91-021, Figure 1. MOT91-021 runs. Perform ADJ 91.1 Printhead Attachment Check.
Y N
Go to WD 9.11. Check MOT91-021. Perform the following:
Refer to: • Go to WD 9.9 and WD 9.11. Check all connections PJ605, PJ 606, PJ304, Marking Unit
• GP 10 How to Check a Motor. Driver PWB.
• PJ607, Marking Unit Driver PWB. • If the fault remains, install a new service loop, PL 92.10 Item 1.
• Carriage drive select motor, PL 91.10 Item 1.
Upper carriage
• Upper or lower carriage drive gear, PL 91.10 Item 9 and PL 91.10 Item 10. home sensor,
• Marking unit driver PWB, PL 92.10 Item 4. Q91-012
Enter dC330 code 91-012 to test the upper carriage home sensor, Q91-012. Actuate Q91-012.
The display changes. Lower carriage home
Y N sensor, Q91-011
Refer to:
• PJ304, Marking Unit Driver PWB. Upper carriage
restraint
Install new components as necessary Upper carriage dock-
• Upper carriage home sensor, PL 91.10 Item 8. ing motor, MOT91-031
• Marking unit driver PWB, PL 92.10 Item 4. Figure 1 Component location
Enter dC330 code 91-011 to test the lower carriage home sensor, Q91-011. Actuate Q91-011.
Y N
Refer to:
• Lower carriage home sensor, PL 91.10 Item 8.
Y N

91-565-00, 91-566-00 Upper Printhead Restraint Error RAP 91-567-00 to 91-568-00 Lower Carriage Error RAP
91-565-00 Upper printhead carriage time-out moving restraint 91-567-00 The lower carriage was not detected while in motion.
91-566-00 Upper printhead carriage restraint stalled. 91-568-00 The lower carriage encountered an unexpected event while in motion.

These fault codes are for future use.
WARNING
CAUTION
CAUTION
could also occur.
• Check the harness leading to carriage drive and related sensors. Refer to GP 28.
• Check for damage or debris that restricts carriage movement.
Procedure
Move the marking unit into the service position, GP 6.
Check the area surrounding the carriage and umbilicals for wiring damage or obstructions that
prevent carriage movement. The wiring is good and correctly secured in the cable
clamps.
Y N
Correctly secure the wiring. Install new wiring or repair as necessary, REP 1.1.
Enter dC330 code 91-032 to run the carriage docking motor, MOT91-031, Figure 1. MOT91-
031 runs.
Y N
Refer to:
• GP 10 How to Check a Motor
• PJ605, Marking Unit Driver PWB
A
A B
Observe the motor and gearbox operation, the selector moves up and down. Enter dC330 Perform dC967 Head to Drum Spacing Check. dC967 runs successfully.
code 91-021 carriage drive select motor, MOT91-021, Figure 1. MOT91-021 runs. Y N
Y N Perform ADJ 91.1 Printhead Attachment Check.
Refer to: Perform the following:
• GP 10 How to Check a Motor. • Go to WD 9.11. Check the connections PJ607, PJ304, Marking Unit Driver PWB.
• PJ607, Marking Unit Driver PWB. • If the fault remains, install a new service loop, PL 92.10 Item 9.
• Carriage drive select motor, PL 91.10 Item 1.
• Upper or lower carriage drive gear, PL 91.10 Item 9 and PL 91.10 Item 10.
NOTE: The lower carriage home sensor and upper carriage home sensor are identical and can Lower carriage home
be interchanged for troubleshooting purposes. sensor, Q91-011
Enter dC330 code 91-011 to test the lower carriage home sensor, Q91-011. Actuate Q91-011.
Y N Lower carriage
Go to WD 9.11. Check Q91-011. restraint
Refer to:
Carriage drive motor,
• 01B +3.3V ESTAR Power Distribution RAP. MOT91-031
• Lower carriage home sensor, PL 91.10 Item 8. Figure 1 Component location
Enter dC330 code 91-012 to test the upper carriage home sensor, Q91-012. Actuate Q91-012.
Y N
Refer to:
• Upper carriage home sensor, PL 91.10 Item 11.
Y N
B

91-570-00, 91-571-00 Lower Printhead Restraint Error RAP 91-572-00, 91-573-00, 91-575-00 Wiper Vertical Error RAP
91-570-00 Lower printhead carriage timeout moving restraint. 91-572-00 Printhead wiper vertical motion edge not found.
91-571-00 Lower printhead carriage restraint stalled. 91-573-00 The wiper encountered an unexpected event while in vertical motion.
Procedure 91-575-00 The vertical wiper could not complete the requested motion.
NOTE: Invalid move errors are typically the result of mechanisms being moved manually
instead of under machine control.
Initial Actions
WARNING
CAUTION
Do not handle or attempt to clean the wiper blade. Wiper blade contamination can damage the
printheads.
CAUTION
CAUTION
could also occur.
• Check the HM tension spring is connected, Figure 1. If necessary install a new spring, PL
91.15 Item 14.
• Check that the wiper blade is level. Refer to the Replacement procedure in REP 91.3.
• Check HM wiper, PL 91.15 Item 13 for full travel.
• Check for damage or debris that restricts wiper movement.
Procedure
Cheat the front door interlock. Open the marking unit drawer, GP 6 to observe wiper motion.
Enter dC330 code 91-023 to run the HM vertical motion motor, MOT91-023, Figure 1. Press
Start.
NOTE: The HM vertical motion motor will run a complete cycle.
MOT91-023 runs.
Y N
Refer to:
A
A
• HM vertical motion motor, PL 91.15 Item 12. HM vertical motion
• Marking unit driver PWB, PL 92.10 Item 4. motor, MOT91-023
Enter dC330 code 91-014 to test the HM position sensor, Q91-014. Actuate Q91-014. The
display changes.
Y N
Refer to:
• 01L 0V Distribution RAP HM position sensor,
Install new components as necessary Q91-014
• HM position sensor, PL 91.15 Item 17.
Check the area surrounding the carriage, wiper assembly, and umbilicals for wiring damage or
obstructions that prevent carriage or wiper movement. The wiring is good.
Y N Check the springs are connected and
Install new wiring or repair, REP 1.1 as necessary. the belts are tensioned.(Front and
rear.)
Go to WD 9.11. Check all connections:
• PJ401, PJ304, Marking Unit Driver PWB.
If necessary, install a new marking unit driver PWB, PL 92.10 Item 4. Figure 1 Component location

A
91-574-00, 91-576-00, 91-598-00 Wiper Horizontal Error Install new components as necessary
• HM horizontal motion gearbox, PL 91.15 Item 15.
RAP • Horizontal drive cable, PL 91.15 Item 16.
91-574-00 The HM wiper did not reach position on time. • Marking unit driver PWB, PL 92.10 Item 4.
91-576-00 The HM wiper was not in the expected vertical position.

Check the alignment of the HM wiper blade PL 91.15 Item 13. Refer to REP 91.3. Wiper
blade alignment is good
91-598-00 The HM horizontal motion motor stalled.
Y N
Install a new HM wiper blade PL 91.15 Item 13.
NOTE: Invalid move errors are typically the result of mechanisms being moved manually
instead of under machine control.
Check the position and tension of the horizontal drive cable, PL 91.15 Item 16 and HM belt, PL
Initial Actions 91.15 Item 2. Position and tension are good.
Y N
WARNING • Horizontal drive cable, PL 91.15 Item 16
Ensure that the electricity to the machine is switched off while performing tasks that do • HM belt, PL 91.15 Item 2
death or injury. Moving parts can cause injury. Check the HM drive pulley, PL 91.15 Item 18 and HM idler pulley, PL 91.15 Item 19. Drive
and idler pulleys are in good condition and spin freely.
Y N
CAUTION Install new components as necessary:
Do not handle or attempt to clean the wiper blade. Wiper blade contamination can damage the • HM drive pulley, PL 91.15 Item 18
printheads. • HM idler pulley, PL 91.15 Item 19
Check the horizontal drive paddle, PL 91.15 Item 5, for proper travel. Paddle travel is good.
CAUTION
Y N
Do not touch the exposed face of the printheads. Surface contamination or minor damage can Install new horizontal drive paddle, PL 91.15 Item 5.
Enter dC965. Test horizontal motion. Observe HM Wiper motion. The HM Wiper moves
smoothly.
CAUTION
Y N
Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir Clean the wiper drive components and retest.
located at the back of the drawer if opened with too much force. Ink cross-color contamination Install new components as necessary:
could also occur. • HM wiper, PL 91.15 Item 13.
• Check the harness leading to the horizontal wiper motor. • HM horizontal motion gearbox, PL 91.15 Item 15.
• Check for damage or debris that restricts horizontal motion. • Horizontal drive cable, PL 91.15 Item 16.
• Switch off, then switch on the machine.
Check the area surrounding the wiper assembly and umbilicals for wiring damage or obstruc-
Procedure tions that prevent HM Wiper movement. The wiring is good.
Y N
Cheat the front door interlock. Move the marking unit into the maintenance position, GP 6 to
observe wiper motion. Enter dC330 code 91-025 to run the HM horizontal motion motor,
MOT91-025, Figure 1. MOT91-025 runs.
Go to WD 9.11. Check all connections:
Y N
Go to WD 9.11. Check MOT91-025. • PJ304, Marking Unit Driver PWB.
Refer to: If necessary, install a new marking unit driver PWB, PL 92.10 Item 4.
A
91-586-00 Quad Wave Amplifier Short RAP
91-586-00 Quad wave amplifier current demand inconsistent with expected value.
Initial Actions
Check the machine is producing a cleaning page for printheads 1 & 2 and printheads 3 & 4.
The lack of a cleaning page for a particular carriage can be a sign of a defective printhead
drawing to much current and is a known cause of this fault. Swapping a suspect defective print-
head one at a time on the upper or lower carriage can fix this fault.
Procedure
WARNING
CAUTION
HM horizontal motion Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir
motor, MOT91-025 located at the back of the drawer if opened with too much force. Ink cross-color contamination
could also occur.
CAUTION
Check the ribbon cables connecting the quad waveamp PWB and printheads for abrasions or
Figure 1 Component location possible electrical arc points, PL 92.10. The cables and connectors are good.
Y N
Check that the marking unit cooling fan, PL 1.15 Item 23 runs. The fan runs.
Y N
Go to WD 9.4. Check the marking unit cooling fan.
Refer to:
• PJ901, Drum Driver PWB.
• 01E +12V Power Distribution RAP.
• Marking unit cooling fan, PL 1.15 Item 23.
• Quad waveamp PWB, PL 92.10 Item 3.
Install a new quad waveamp PWB, PL 92.10 Item 3.

91-587-00, 91-588-00 Quad Wave Amplifier Thermal Error 91-607-00, 91-608-00 Printhead to Drum Error RAP
RAP 91-607-00 Following printhead replacement, thermal data indicates the printhead is in contact
with the drum. System should reboot into diagnostics mode when this fault is detected.
91-587-00 The quad waveamp PWB is too hot.
91-588-00 The quad waveamp PWB thermistor reading is invalid. 91-608-00 The printhead to drum gap, as detected by the printhead, is outside tolerance (the
gap was too small or too large). This fault is currently informational only.
Initial Actions
NOTE: The machine runs a proximity check when a new printhead is detected.
WARNING Procedure
CAUTION not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
could also occur. CAUTION
CAUTION located at the back of the drawer if opened with too much force. Ink cross-color contamination
Do not touch the exposed face of the printheads. Surface contamination or minor damage can could also occur.
NOTE: The eight thermistors are located on the quad wave amp PWB, one for each amplifier. CAUTION
If any one amplifier overheats, this fault is generated. Do not touch the exposed face of the printheads. Surface contamination or minor damage can
• Check the wiring harness leading to the marking unit fan and the quad waveamp PWB.
Check installation of the printhead. Check the following:
Procedure • The AC wiring to the printhead.
Check that the marking unit cooling fan, PL 1.15 Item 23 runs. The fan runs. • The interface ribbon harness to the printhead, refer to REP 91.21.
Y N • The two securing screws for the printhead are tight and seated correctly, refer to REP
Go to WD 9.4. Check the marking unit cooling fan. 91.21.
Refer to: The printhead is installed correctly.
• GP 10 How to Check a Motor. Y N
• PJ901, Drum Driver PWB. Remove the printhead. Check for debris or damage that would prevent the correct print-
• 01E +12V Power Distribution RAP. head installation.
• 01L 0V Distribution RAP Check the following:
Install new components as necessary • The umbilical is seated in the ball plate, refer to REP 91.31.
• Marking unit cooling fan, PL 1.15 Item 23. • The nozzles on the umbilicals are clean.
• Drum driver PWB, PL 1.15 Item 4. • Ink or debris on the ball plate, refer to REP 91.31.
Go to WD 9.13. Check the ribbon cable connecting PJ590 on the quad waveamp PWB to • Ink or debris on the back of the printhead.
PJ101 on the IME controller PWB. Check the ribbon cable for damage and is connected cor- • The cables are correctly routed on the umbilical, refer to REP 91.31.
rectly. Check for continuity through the ribbon cable. The cable and connector are good. Re-install the printhead. Starting with the left screw, alternately tighten each screw 2 or 3
Y N turns until each screw is completely tight. Do not overtighten. Switch on the machine
Correctly connect the ribbon cable. If necessary, install a new Quad waveamp PWB directly into service mode, GP 1. Run dC967.
cable, PL 92.10 Item 13.

• Quad waveamp PWB, PL 92.10 Item 3.
• IME controller PWB, PL 92.10 Item 1.
A
A
NOTE: When a printhead is re-installed into the same location from where it was 91-610-00 to 91-613-00 Printhead Wave amp Calibration
removed, the head to drum spacing check will not run automatically.
Error RAP
Check all connections leading to the printhead. If the error persists, install a new printhead PL
91-610-00 Printhead 1 wave amp calibration error.
91.20 Item 2.
NOTE: Calibration of the registration / preheat assembly, dC625 is only required when: 91-611-00 Printhead 2 wave amp calibration error.
91-612-00 Printhead 3 wave amp calibration error.
Calibration of the registration / preheat assembly is NOT required when: 91-613-00 Printhead 4 wave amp calibration error.
• The IOD assembly is removed or replaced. Procedure
WARNING
CAUTION
CAUTION
could also occur.
CAUTION
The video cable (striped and labeled A, PL 92.10 Item 7) and the wave amp cable (white and
labeled B, PL 92.10 Item 8) should not be interchanged at the printhead connectors. Damage
to the printhead and IME controller PWB will occur if the cables are installed incorrectly.
All 4 fault codes are recorded in the fault history, dC122.
Y N
Swap the faulty printhead with a good printhead. The fault has moved with the print-
head.
Y N
Go to WD 9.13, WD 9.20 and WD 9.21. Check for damage to the video cable
(striped and labeled A) and the wave amp cable (white and labeled B) connecting
each printhead to the quad wave amp PWB. Reseat the video cable and the wave
amp cable on the printhead connectors PJ101 and PJ301. The wiring is good.
Y N
• Video cable, PL 92.10 Item 7.
• Wave amp cable, PL 92.10 Item 8.
Go to WD 9.13, WD 9.20 and WD 9.21.Check and reseat all connections on the IME
controller PWB and quad wave amp PWB
A B

A B
• PJ201 and PJ301, PJ902 and PJ904, IME Controller PWB.
• PJ110, PJ150, PJ930 and PJ970, Quad Waveamp PWB.
The cables are good.
Y N
• Video cable, PL 92.10 Item 7.
• Wave amp cable, PL 92.10 Item 8.
Disconnect the video cable and the wave amp cable from the suspect printhead.
Refer to Figure 1, perform the following check:
• The resistance between GND and VPP should be 5K ohms or greater.
• Perform the same check between GND and VSS.
• If the resistance is 4 ohms or less, then the printhead is shorted.
The printhead resistances are good.
Y N
Install a new printhead, PL 91.20 Item 2 or PL 91.25 Item 2.
Check the cable between the IME controller PWB and quad wave amp PWB for
damage. Install a new cable as necessary, PL 92.10 Item 13.
• Quad wave amp PWB, PL 92.10 Item 3.

• Quad wave amp PWB, PL 92.10 Item 3. Figure 1 Printhead PWB

A B
91-614-00 to 91-617-00 Printhead Data Error RAP Check the ribbon cables from the IME controller PWB for abrasions. Install a new ribbon
cable, PL 92.10 as necessary. If the error persists, install a new printhead, PL 91.20 Item
91-614-00 Printhead 1 field data corrupt.
2.
91-615-00 Printhead 2 field data corrupt. NOTE: Calibration of the registration / preheat assembly, dC625 is only required when:
91-616-00 Printhead 3 field data corrupt.
91-617-00 Printhead 4 field data corrupt. Calibration of the registration / preheat assembly is NOT required when:
Initial Actions • The IOD assembly is removed or replaced.
WARNING
CAUTION
could also occur.
CAUTION
• Check the harness leading to the indicated printhead.
• Check for damage to surrounding harnesses.
Procedure
All 4 fault codes are recorded in the fault history, dC122.
Y N
Enter dC972 and run the Printhead Uniformity test. The test completes successfully.
Y N
Go to WD 9.5, WD 9.6, WD 9.7, WD 9.20 and WD 9.21. Check all connections:
• PJ101, Printhead PWB.
• PJ201, PJ301, PJ902, PJ904, IME Controller PWB.
• Printhead, PL 91.20 Item 2.
Check for ESD failures, 92-527-00, 92-528-00 fault codes in the fault history. If ESD
events are indicated. Check system grounding, refer to GP 7. The system grounding is
good.
Y N
Correct any system grounding issues, GP 7, then retest.
A B

91-630-00 IOD Scan Process Failure RAP 91-631-00 IOD Dark Adjust Failure RAP
91-630-00 The IOD scan process failed. 91-631-00 The IOD dark adjust failed.
The IOD scans a target on the drum to optimize print quality and to check for missing jets. Dur- Initial Actions
ing this scanning process, the drum with the target on it moves over the stationary scan bar of
the IOD. The image is scanned multiple times. Each scan is initiated by a signal from the drum
encoder. If a lower than expected number of scans is encountered, this fault is raised. WARNING
Initial Actions not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Take care during this procedure. The drum will become hot during normal operation.
CAUTION
WARNING Do not connect the harness to the IOD PWB with the machine powered on. Damage to the IOD
Take care during this procedure. The drum will become hot during normal operation. sensor may result.
• Check the harness and the plug connections to the drum drive motor and the drum posi- • Check for damage or debris that restricts IOD movement.
tion encoder.
Procedure
Procedure
Go to dC122 Fault History and dC123 PEST Fault History. Check for drum drive faults occur-
CAUTION
ring at the same time as the current 91-630 fault. A drum drive related fault was declared.
Y N Do not disconnect and reconnect the flex cables at the IOD PWB. the flex cables are easily
Refer to WD 1.1 and WD 9.1. Check the drum drive motor and the drum position encoder.
Install the following components in the listed order. After the installation of each compo-
nent perform the dC971 routine, then check for the 91-630-00 fault. Continue with compo- CAUTION
nent installation until the 91-630-00 fault is cleared, then perform SCP 5 Final Actions.
1. Install a new drum position encoder assembly, PL 94.20 Item 8.
2. Install a new drum belt, PL 94.20 Item 2. Clean the drum drive pulley with IPA.
Perform dC971 Head to Head Alignment Adjustment. Go to dC122 Fault History. Check for
3. Install a new drum driver PWB, PL 1.15 Item 4. another occurrence of fault 91-631. The fault reoccurred.
4. Install a new drum drive motor, PL 94.20 Item 6. Y N
If the fault is still present, install a new IME controller PWB, PL 92.10 Item 1. The fault may be intermittent, check for damaged wiring or loose connectors. Repair the
The fault may be intermittent, check for damaged wiring or loose connectors. Repair the wiring as necessary, REP 1.1. Install new components as necessary:
wiring as necessary, REP 1.1. When all faults are cleared, perform SCP 5 Final Actions. • IOD assembly, PL 94.15 Item 1.
Refer to the appropriate RAP and follow the procedure to rectify any other fault. After complet-
ing the RAP perform dC971 Head to Head Alignment adjust. Follow the on screen instructions Go to WD 9.1 and WD 9.22. Check the cable between PJ101 on the Drum Driver PWB and
and run the routine. If a 91-630-00 fault occurs then return to the start of this procedure. If the PJ1 on the IOD Pre Amplifier PWB. The connections and cable are good.
fault is cleared, perform SCP 5 Final actions. Y N
Correct the cable connections. Install new components as necessary:
• IOD to drum driver cable, PL 94.15 Item 5.
• IOD assembly, PL 94.15 Item 1.
A
A
Remove the IOD assembly, PL 94.15 Item 1. Check that the 12 pin flex cable is connected at 91-636-00 IOD in Degraded Mode RAP
the sensor, Figure 1. Handle the flex cable only in the area of the blue backer and hold the fold
91-636-00 The machines print quality maintenance software periodically runs corrective proce-
closed. If the connections are good then install a new IOD assembly, PL 94.15 Item 1. The
dures to maintain output quality. This error indicates that these procedures are suspended due
fault is cleared.
Y N to unrecoverable errors.
This procedure describes how to return a machine to normal operation from fault tolerant
Perform SCP 5 Final actions mode, also known as IOD degraded mode. Fault tolerant mode is indicated by the fault code
91-636-00 or by the service code displayed on the UI, refer to the OF 17 Service Code RAP.
Initial Actions
NOTE: dC640 can be used to isolate a defective EPC memory PWB. In the case of a defective
EPC PWB the procedure will stop at 99% of completion then the system will hang. With a good
EPC memory PWB the dC640 procedure will complete within 20 seconds.
Check the:
• PEST error log (dC123) for component failures.
• Service code displayed on the machine information UI, refer to OF 17.
• Fault history (dC122) to verify fault tolerant mode.
• EPC memory PWB is installed and seated correctly, PL 3.10 Item 28.
• Lead screws PL 91.20 Item 21, of the printhead roll adjust motors 2 and 4 and printhead
stitch adjust motor 2 for cracks on the black plastic couplers. Refer to T7869-01-12 and
ETI 1056514. for instructions on how to check the couplers.
• Lead screws PL 91.25 Item 21, of the printhead roll adjust motors 1 and 3, and printhead
stitch adjust motor 1 for cracks on the black plastic couplers. Refer to T7869-01-12 and
ETI 1056514. for instructions on how to check the couplers.
12 pin flex cable.
Procedure
WARNING
If the IOD sensor detects an imaging problem, one or more attempts are made to correct the
error. If the machine is unable to self-correct specific imaging errors, it suspends operation of
one or more of these normal print-quality adjustment routines. Refer to Table 1.
1. Enter dC131 NVM Read/Write and check the status of each routine by entering the NVM
chain-link listed in Table 1.
2. Check if the routine is in degraded state by checking the status value in dC131 NVM
Read/Write with the value in Table 2.
3. If the routine is found to be in degraded mode. Refer to Table 2 and perform the actions
as required.
4. Check and clear all related faults listed in dC122 by using the appropriate RAP to return
the status to optimal.
NOTE: The optimal value for all settings is 0.

5. When the routine is returned to optimal, recheck the current status values of the other 6. Repeat this procedure (1 through to 5) until all the routines report a NVM status value of 0.
routines.
Table 1 Print Quality Management Status Check

NVM NVM NVM Manual
Adjustment Routine Chain Link Settings Procedure Comment
Head to Head Alignment 490 019 0-4 dC971 Manual and Automatic
Adjustment Refer to dC131 for NVM settings
Drum Runout Calibration 492 069 0 or 1 dC977 Refer to dC131 for NVM settings
Printhead Uniformity 490 008 0-4 dC972 Manual and Automatic
Option 3 Refer to dC131 for NVM settings
TRC Generation 490 011 0-4 dC972 Refer to dC131 for NVM settings
Option 4
Y-dot position 490 005 0-4 dC972 Manual and Automatic
Option 5 Refer to dC131 for NVM settings

Table 2 Routine Status Value and Description
NVM
Status IOD Do not manually write status
Adjustment Routines Value NVM Description Degraded Actions value to NVM
dC971 Head to Head Align- 0 Optimal No No Do not write
ment
NOTE: If the dC971 routine Head to Head Alignment Adjustment fails to com-
plete refer to service bulletin T7869-01-12 and ETI 1056514.
1 Non-Optimal no Run the routine Do not write
2 Auto Disabled Yes Run the routine Do not write
3 Manually Disabled Yes Set status to 4 to Manually Enabled and run the routine
4 Manually Enabled No Run the routine
dC977 Drum Runout 0 Optimal No No Do not write
1 Non-Optimal Yes Run the routine Do not write
dC972 Printhead Uniformity 0 Optimal No No Do not write
1 Non-Optimal No No Do not write
2 Auto Disabled Yes Run the dC972 in automatic mode to calibrate the printer uniformity. Fix Do not write
issues that prevent successful completion. If the print quality is unacceptable,
then run the following:
1. Run option 3 in Manual
3. Run option 5 for high quality calibration.
3 Manually Disabled Yes Set status to 4 to Manually Enabled
Run the dC972 in automatic mode to calibrate the printer uniformity. Fix
3. Run option 5 for high quality calibration.
4 Manually Enabled Yes Run the dC972 in automatic mode to calibrate the printer uniformity. Fix
3. Run option 5 for high quality calibrate.
TRC Generation 0 Optimal No No Do not write
1 Non-Optimal Yes Run dC972 option 4. Do not write
2 Auto Disabled Yes Run dC972 option 4. Do not write
3 Manually Disabled Yes Set status to 4 to Manually Enable and run dC972 option 4.
4 Manually Enabled Yes Run dC972 option 4.
Y-dot Position Correction 0 Optmal No No Do not write
1 Non-Optimal Yes Run dC972 option 5. Do not write
2 Auto Disabled Yes Run dC972 option 5. Do not write
3 Manually Disabled Yes Set status to 4 to Manually Enabled and run dC972 option 5.
4 Manually Enabled Yes Run dC972 option 5.

The NVM descriptions are explained below. 91-637-00 Drum Runout Calibration Needed RAP
• Optimal means that the calibration firmware has successfully optimized the Print Quality 91-637-00 The drum runout table in NVM (DC301) was reset. This fault clears when the drum
related to the routine executed.
runout (aka Y runout) diagnostic routine is manually run, and the values are properly set in
• Non-Optimal state indicates that the calibration firmware has not yet had a chance to exe- NVM. This fault can be caused by corruption of the NVM, a calibration error during the drum
cute the related Print Quality routine. Non-Optimal state also indicates that the routine runout routine or encoder problems.
could have run with failures, but not reached Auto disabled state. Execute the routine
manually and check dC122 for associated fault reports. Initial Actions
• Auto Disabled state refers to when the routine was executed and failed more than a spec-
• Check the fault history and service codes (refer to OF 17) for fault codes 94-534-00, 94-
ified number of retries. See Table 3 for maximum number of retries for each routine before
547-00 and 94-555-00. If the fault codes are present then go to the appropriate RAP
it is automatically disabled. before proceeding with this RAP.
• If manually disabled, both automatic and manual executions are blocked. To clear manu- • Check the lead screws PL 91.20 Item 21, of the printhead roll adjust motors 2 and 4 and
ally disabled, set the manually enabled flag by using the NVM value of 4 (use the speci-
printhead stitch adjust motor 2 for cracks on the black plastic couplers. Refer to T7869-
fied tool’s NVM chain and link). When manually enabled, the tool will transition to non-
01-12 and ETI 1056514. for instructions on how to check the couplers.
optimal state and the memories of all failure counters associated with the tool are cleared.
• Check the lead screws PL 91.25 Item 21, of the printhead roll adjust motors 1 and 3, and
Only Manually Enabled and Manually Disabled NVM Status values (3 and 4) are to be printhead stitch adjust motor 1 for cracks on the black plastic couplers. Refer to T7869-
written to NVM. DO NOT write any other Status value (0, 1 or 2) to NVM.
01-12 and ETI 1056514. for instructions on how to check the couplers.
Table 3 Consecutive Failures

Procedure
Maximum number
NVM NVM of retries before WARNING
Adjustment Routine Chain Link disabling Comment
Head to Head Align- - - 2 Maximum of 2 retries before not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
ment Adjust disable. death or injury. Moving parts can cause injury.
Not in NVM. Reset at reboot
Drum Runout - - 0 Not in the NVM. Routine can
only be executed manually. CAUTION
Head to Head Unifor- 490 004 3 Maximum number of 3 retries Use care when working near the drum. The drum can be damaged easily, which will cause
mity before disable. print quality defects.
TRC Generation 0 Routine can only be executed Run dC971 to perform a complete alignment of all the printheads.
manually. Using dC612, make the stitch prints. Examine the horizontal lines print, also used to evaluate Y
stitch, to determine if runout correction is incorrect. Drum runout calibration is needed.
Y-dot position Correc- 490 010 3 Maximum of 3 retries before
Y N
tion disable.
Perform SCP 5 Final actions.
Enter dC977 to recalibrate the drum runout values. The drum runout completes without
error.
Y N
1. Perform the RAP associated with the error code received during the drum runout
calibration.
2. Go to WD 9.1 and WD 9.22. Check the IOD sensor, part of the IOD assembly, PL
94.15 Item 1. Refer to:
• PJ1, IOD Pre Amplifier PWB.
• 01D +5V Power Distribution RAP
Enter dC612 and make Y runout prints and examine. The prints are good (no runout).

Y N 91-638-00 IOD Detects Chronic Jet Error RAP
91-638-00 The IOD has detected chronic jets.
• Drum position encoder assembly, PL 94.20 Item 8.
• IOD assembly, PL 94.15 Item 1. Also use this RAP to recover weak, sputtering or missing jets not detected by the IOD.
Remove the cleaning unit, PL 94.10 Item 21 and the abatement plenum, PL 94.20 Item 12. Initial Actions
Enter dC330 code 91-043 IOD shuttle motor. Observe the IOD sensor. The IOD sensor runs
to all positions without unusual noise.
Y N
WARNING
CAUTION death or injury. Moving parts can cause injury.
Do not connect the harness to the IOD PWB J1 with the machine powered on. Damage to • Enter the customer administration tools, GP 5. On the Tools tab select Troubleshooting
the IOD Sensor may result. then Automatic Light Lines Fix. Set Quick Fix to On. Set Full Fix to Eco Fix.
NOTE: Ensure that the customer’s Automatic Light Lines and Full Fix settings are
CAUTION restored to the original settings when the fault has been corrected.
Do not disconnect and reconnect the flex cables at the IOD PWB. The flex cables are
NOTE: By setting Quick Fix to On, except for service jet test pages (executed via dC968)
easily damaged. The cable must only be handled in the area of the blue backer.
all images will use jet substitution.
Perform the actions that follow:
• Switch off the machine, GP 14. Select the Machine
• Inspect the harness connection PJ101 on the drum driver PWB. Verify it is correctly • 9203 Machine.
connected and there are no broken wires. Repair the wiring as necessary, REP 1.1. • 9201 or 9202 Machine.
9203 Machine
• Inspect the harness connection to IOD Pre Amplifier PWB. Verify it is correctly con-
nected and there are no broken wires. Repair the wiring as necessary, REP 1.1. Follow the Procedure below:
• Go to WD 9.22. Check MOT91-043, refer to: Procedure
– GP 10 How to Check A Motor NOTE: Before printing TP 20 or TP 21, ensure that A4 or 8.5 x 11 inch plain paper is loaded
– 01H +24V Power Distribution RAP long edge feed into tray 4. Use the best quality media available. Do not use hole punched
– 01L 0V Distribution RAP paper.
• Remove the IOD assembly, REP 91.22. Inspect the IOD for debris. Remove any Fault code 91-638 is displayed in the fault history, dC122.
debris that may be in the gear train, then re-install the IOD assembly. If no obvious Y N
problems are found by inspection, install a new IOD assembly, PL 94.15 Item 1. Print five copies of TP 11 colour bands and dithers test pages. The missing jet is visible
Switch on the machine, GP 14. The fault still exists. on both solids and dithers.
Y N Y N
Perform SCP 5 Final actions. Go to IQ 9 Line Deletions in the Process Direction RAP. Perform the Missing Jet
Checkout.
Empty the waste tray. Perform dC968 Head Purge and dC971 Head to Head Alignment
Perform SCP 5 Final actions. Adjustment on the faulty heads up to three times. After each purge/alignment cycle, print
five copies of TP 11 colour bands and dithers test pages. The test pages are good.
Y N
Remove the waste tray and check that ink is present. An empty waste tray can indi-
cate a problem with the purge system. Refer to 93-549-00 to 93-552-00 and 93-557-
00 to 93-560-00 Printheads 1 and 3 Printhead Reservoir Fill Error RAP or 93-553-00
to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead Reservoir
Fill Error RAP. Print five copies of TP 11 colour bands and dithers test pages. The
test pages are good.
A B

A B C
Y N The customer uses media with a feed width greater than 297 mm (11.7 inches).
Perform dC959 cleaning unit exerciser self test. The self test was success- Y N
ful. The chronic jets do not impact the customer. Mask the chronic jets, GP 30 How to Mask
Y N Jets / Jet Substitution.
Install new cleaning unit PL 94.10 Item 21.
Perform dC972 Printhead Uniformity, option 6 Reset Head Uniformity Data. Select the faulty
Print TP 20 oil bar chase test page. Evaluate the oil bar chase page only. Test printheads. Print the service jet test pages, TP 21. The test pages are good.
page is good. Y N
Y N Install a new printhead as necessary, PL 91.20 Item 2 or PL 91.25 Item 2.
Go to the IQ 21 Oil on Output RAP.
Perform dC972 Printhead Uniformity, option 1 Printhead Replacement Uniformity. Select all
Perform dC965 Printhead Maintenance Cycle test. Observe wiper motion dur- printheads.
ing the test. Look for erratic wiper motion that may indicate wiper chatter or a 9201 or 9202 Machine
motor failure. The wiper moves smoothly across the printhead.
Follow the Procedure below:
Y N
Check the printhead maintenance wiper assembly.
Refer to:
Procedure
• 91-572-00, 91-573-00, 91-575-00 Wiper Vertical Error RAP. NOTE: Before printing TP 20 or TP 21, ensure that A4 or 8.5 x 11 inch plain paper is loaded
• 91-574-00, 91-576-00, 91-598-00 Wiper Horizontal Error RAP. long edge feed into tray 4. Use the best quality media available. Do not use hole punched
paper.
Print five copies of TP 11 colour bands and dithers test pages. The test pages
Fault code 91-638 is displayed in the fault history, dC122.
are good.
Y N
Y N
Perform dC972 Printhead Uniformity, option 6 Reset Head Uniformity Print the service jet test pages, TP 21. The chronic jet is a black jet or a colour jet
adjacent to another masked or chronic jet.
Data. Select the faulty printheads. Print five copies of TP 11 colour bands
Y N
and dithers test pages. The test pages are good.
Y N Mask the chronic jet, GP 30 How to Mask Jets / Jet Substitution.
Install new printheads as necessary, PL 91.20 Item 2 or PL 91.25
Go to Procedure A.
Item 2.
Print the service jet test pages, TP 21. The chronic jet is a colour (cyan, magenta or yel-
Perform dC972 Printhead Uniformity, option 1 Printhead Replacement
low) jet.
Uniformity. Select all printheads.
Y N
Install new printhead as necessary, PL 91.20 Item 2 or PL 91.25 Item 2.
Perform SCP 5 Final Actions. Go to Procedure A.

Procedure A
Perform SCP 5 Final Actions. Procedure
Print five copies of TP 11 colour bands and dithers test pages. The missing jet is visible on
Print the service jet test pages, TP 21. The chronic jet is in printhead 1 between 1 to 12 or
both solids and dithers.
in printhead 4 between 208 to 220. Y N
Y N
Go to IQ 9 Line Deletions in the Process Direction RAP. Perform the Missing Jet Check-
Evaluate the service jet test pages to determine which print heads are faulty. Perform
out.
dC972 Printhead Uniformity, option 6 Reset Head Uniformity Data. Select the faulty print-
heads. Print the service jet test pages, TP 21. The service test pages are good.
Empty the waste tray. Perform dC968 Head Purge and dC971 Head to Head Alignment Adjust-
Y N
ment on the faulty heads up to three times. After each purge / alignment cycle, print five copies
Install new printhead as necessary, PL 91.20 Item 2 or PL 91.25 Item 2. of TP 11 colour bands and dithers test pages. The test pages are good.
Y N
Perform dC972 Printhead Uniformity, option 1 Printhead Replacement Uniformity. Select
Remove the waste tray and check that ink is present. Ink is present.
all printheads.
C D
D
Y N 91-660-00 to 91-663-00, 91-820-00 to 91-823-00 Printhead
An empty waste tray can indicate a problem with the purge system. Refer to 93-549-
00 to 93-552-00 and 93-557-00 to 93-560-00 Printheads 1 and 3 Printhead Reser- Link Error RAP
voir Fill Error RAP or 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Print- 91-660-00 Printhead 1 link broken.
heads 2 and 4 Printhead Reservoir Fill Error RAP.
91-661-00 Printhead 2 link broken.
Print print five copies at A3 (11x17) or 10 copies at A4 (8.5x11) of TP 10 Solid Fill Test
Pages (refer to TP 2 to TP 10). Print five copies of TP 11 colour bands and dithers test 91-662-00 Printhead 3 link broken.
pages. Perform dC968 Head Purge. Print TP 21 Service Jet Test Pages. The chronic jet
is a black jet or a colour jet adjacent to another masked or chronic jet. 91-663-00 Printhead 4 link broken.
Y N
Mask the chronic jet, GP 30 How to Mask Jets / Jet Substitution. 91-820-00 Printhead 1 link error.
Perform dC959 cleaning unit exerciser self test. The self test was successful. 91-821-00 Printhead 2 link error.
Y N
Install a new cleaning unit, PL 94.10 Item 21. 91-822-00 Printhead 3 link error.
Print TP 20 oil bar chase test page. Evaluate the oil bar chase page only. Test page is 91-823-00 Printhead 4 link error.
good.
Y N Procedure
Go to the IQ 21 Oil on Output RAP.
Perform dC965 Printhead Maintenance Cycle test. Observe wiper motion during the test. WARNING
Look for erratic wiper motion that may indicate wiper chatter or a motor failure. The
wiper moves smoothly across the printhead.
Y N
Check the printhead maintenance wiper assembly. Refer to:
• 91-572-00, 91-573-00, 91-575-00 Wiper Vertical Error RAP. Go to the 91-519-00 to 91-522-00, 91-655-00 to 91-690-00, 91-807 to 91-811-00 Printhead
NVM Read or Write Error RAP.
• 91-574-00, 91-576-00, 91-598-00 Wiper Horizontal Error RAP.
Print five copies of TP 11 colour bands and dithers test pages. The test pages are good.
Y N
Perform dC972 Printhead Uniformity, option 6 Reset Head Uniformity Data. Select
the faulty printheads. Print five copies of TP 11 colour bands and dithers test pages.
The test pages are good.
Y N
Install new printheads as necessary, PL 91.20 Item 2 or PL 91.25 Item 2.
Perform dC972 Printhead Uniformity, option 1 Printhead Replacement Uniformity.

Select all printheads.

Xerox® ColorQube® 9203 Family 2-437 91-638-00, 91-660-00 to 91-663-00, 91-820-00 to 91-
91-669-00 Excessive Skew RAP 91-670-00 Scanned Image Out of Sequence RAP
91-669-00 The scanned image has too much skew to process 91-670-00 The expected image did not match the scanned image.
WARNING WARNING
• Check the CVT glass for contamination, if necessary clean the glass. Refer to ADJ 62.1 Load the test patterns correctly in the DADH, refer to dC972 Print Head Uniformity. Refer to the
Optics Cleaning Procedure. illustrations in Option 3 Manual and Option 4 Manual.
• Check the DADH operation.
• Check the media path for debris or wear.
• Check the media and the media settings.
Procedure
Remove the documents from the DADH. Perform dC608 DADH Registration and dC609 Docu-
ment Glass Registration
Check the document guides on the DADH. Make sure that they are correctly adjusted to the
document size. Re-scan the test patterns. The fault remains.
Y N
Perform dC972 Print Head Uniformity.
Go to IQ 10 Margin, Mis-registration or Skew RAP.

91-671-00 Fiducials Not Found RAP 91-672-00 Missing Jets RAP
91-671-00 The test pattern fiducials (on/off line pattern) for jet alignment could not be found. 91-672-00 Too many missing jets were detected to perform the operation.
Procedure Procedure
WARNING WARNING
Perform the following: This fault is only raised when running a head calibration service diagnostics routine. The fault
1. Check the CVT glass for contamination, if necessary clean the glass. Refer to ADJ 62.1 indicates that there are too many missing jets Go to 91-638-00 IOD Detects Chronic Jets Error
Optics Cleaning Procedure. RAP.
2. Remove the documents from the DADH. Perform dC608 DADH Registration and dC609
Document Glass Registration
3. Load the test patterns correctly in the DADH, refer to dC972 Print Head Uniformity. Refer
to the illustrations in Option 3 Manual and Option 4 Manual.
4. Check the contrast and print quality of the fiducials and the horizontal line above the fidu-
cials, Figure 1. If the print quality is poor, go to IQ 1 Image Quality Entry RAP. Perform the
procedure for ‘Deletions in the process direction’.
Horizontal line
Fiducials
Figure 1 Fiducials

91-673-00 Floating Point Error RAP 91-674-00 to 91-677-00, 91-812-00 to 91-815-00 Printhead
91-673-00 The machine has detected a floating point calculation error. Adjustment Error RAP
91-674-00 The required voltage or normal adjustment exceeds the maximum on printhead 1.
Procedure
91-675-00 The required voltage or normal adjustment exceeds the maximum on printhead 2.
WARNING 91-676-00 The required voltage or normal adjustment exceeds the maximum on printhead 3.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 91-677-00 The required voltage or normal adjustment exceeds the maximum on printhead 4.
1. Clean the DADH, ADJ 5.4 and the optics ADJ 62.1. Perform dC608 DADH Registration. NOTE: Faults 91-674-00 to 91-677-00 are raised when a manual dC972 option 3 Head to
Head Uniformity is performed and an unusually large adjustment is calculated. The routine will
2. Perform the 91-669-00 Excessive Media Skew RAP.
abort without saving changes.
3. Perform the 91-671-00 Fiducials Not Found RAP.
91-812-00 The required voltage adjustment exceeds the maximum on printhead 1.
NOTE: Faults 91-812-00 to 91-815-00 are raised when an automatic dC972 option 3 Head to
Head Uniformity is performed and errors are detected. The routine will abort without saving
changes.
Procedure
WARNING
Check the test pattern (TP 1) that was printed for evidence of colour mixing or wrong colours. If
necessary, the test pattern can be printed from dC972, option 3 Head to Head Uniformity.
Colour mixing or wrong colours are evident.
Y N
The best quality, bright white plain paper available must be used for the manual uniformity
calibration, go to dC972 Printhead Uniformity and refer to Media Requirements.
NOTE: Automatic uniformity has no specific media requirements.
The correct media is used.

Y N
Load the correct media, then perform the following dC972 routines:
1. Option 3 Head to Head Uniformity - manual.
2. Option 4 TRC Generation - manual.
3. Option 5 Y Dot Position Correction, select all heads.
Perform the following dC972 routines:

1. Option 6 Reset Head Uniformity Data.
A
91-673-00, 91-674-00 to 91-677-00, 91-812-00 to 91- 2-440 Xerox® ColorQube® 9203 Family
A
2. Option 3 Head to Head Uniformity - manual. 91-678-00 to 91-681-00, 91-816-00 to 91-819-00 Printhead
The fault remains.
Y N
Convergence Adjustment Error RAP
Perform the following dC972 routines: 91-678-00 Voltage and/or norm adjustment can not bring printhead 1 into tolerance.
91-679-00 Voltage and/or norm adjustment can not bring printhead 2 into tolerance.
Perform the relevant procedure:
• IQ 14 Uneven In Some Colours RAP. NOTE: Faults 91-678-00 to 91-681-00 are raised when an automatic dC972 option 3 Head to
• IQ 15 Wrong Colour RAP. Head Uniformity is performed and errors are detected. The machine will complete the routine
When the image quality fault is corrected, perform the following dC972 routines: but may have an image quality defect.
1. Option 3 Head to Head Uniformity - manual. 91-816-00 Voltage adjustment can not bring printhead 1 into tolerance.
3. Option 5 Y Dot Position Correction, select all heads. 91-817-00 Voltage adjustment can not bring printhead 2 into tolerance.
91-818-00 Voltage adjustment can not bring printhead 3 into tolerance.
91-819-00 Voltage adjustment can not bring printhead 4 into tolerance.
NOTE: Faults 91-816-00 to 91-819-00 are raised when an automatic dC972 option 3 Head to
Head Uniformity is performed and errors are detected. The routine will abort without saving
changes.
Procedure
WARNING
Check the test pattern (TP 1) that was printed for evidence of colour mixing or wrong colours. If
necessary, the test pattern can be printed from dC972, option 3 Head to Head Uniformity.
Image quality is good.
Y N
Colour mixing or wrong colours are evident.
Y N
The best quality, bright white plain paper available must be used for the manual uni-
formity calibration, go to dC972 Printhead Uniformity and refer to Media Require-
ments.
NOTE: Automatic uniformity has no specific media requirements.
The correct media is used.

Y N
Load the correct media, then perform the following dC972 routines:
A B C

A B C
Perform the following dC972 routines: 91-682-00 Ambient Thermistor Error RAP
1. Option 6 Reset Head Uniformity Data. 91-682-00 The ambient thermistor reading is invalid.
The fault remains. This fault is raised if the ADC reading for the ambient thermistor is not within the range of a
Y N valid temperature reading. The fault is not a fatal error and the operation of the printer will con-
Perform the following dC972 routines: tinue if this fault is reported.
The ambient thermistor is used to determine the marking unit fan speed that is needed to effec-
tively cool the wave amps. If the ambient thermistor is not operational the wave amp will still be
Perform Final Actions. cooled by the fan but possibly not as efficiently.
Perform the relevant procedure: Procedure

• IQ 14 Uneven In Some Colours RAP.
• IQ 15 Wrong Colour RAP.
WARNING
When the image quality fault is corrected, perform the following dC972 routines:
1. Option 3 Head to Head Uniformity - manual. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
2. Option 4 TRC Generation - manual. death or injury. Moving parts can cause injury.
3. Option 5 Y Dot Position Correction, select all heads. The ambient thermistor is mounted on the Marking Unit Driver PWB and if this thermistor goes
If the fault remains, perform Final Actions. open or short circuit it would be necessary to replace the PWB.
If this fault occurs, install a new Marking Unit Driver PWB, PL 92.10 Item 4.
If the fault remains, perform Final Actions.
Final Actions
For machines W/O TAG 007. Go to WD 6.2. Check the wiring between the LED exposure
lamps and PJ926 on the Scanner PWB. Install new components as necessary:
• LED exposure lamp, PL 62.15 Item 2.
For machines W/TAG 007. Go to WD 6.5. Check the wiring between the exposure lamp and
PJ926 on the scanner PWB. Install new components as necessary:
• Exposure lamp, PL 62.18 Item 1.

A
91-695-00, 91-696-00, 91-697-00 IOD Jet Position Noise Enter dC122 Fault History and observe the last fault shown. The fault is cleared.
Y N
RAP Perform dC972 Print Head uniformity and run option 5, Y-Dot Position Correction.
91-695-00 IOD excessive Y position noise. Enter dC122 Fault History and observe the last fault shown. The fault is cleared.
Y N
91-696-00 IOD excessive X position noise. Install a new printhead as required:
• Printhead upper carriage, PL 91.20 Item 2.
91-697-00 IOD excessive roll position noise. • Printhead lower carriage, PL 91.25 Item 2.
Position measurement errors (position noise) are caused by one or more pixels landing on the Enter dC612 Print Test Patterns. Select and print TP 16 Stitch Identification and
drum surface at a distance that is far from the expected position. This position noise causes check that print quality is good. Go to SCP 5 Final Actions.
the head to exceed the limits set for the jet position noise.
Enter dC612 Print Test Patterns. Select and print TP 16 Stitch Identification and check
Initial Actions that the print quality is good. Go to SCP 5 Final Actions.
Enter dC612 Print Test Patterns. Select and print TP 16 Stitch Identification and check that
WARNING print quality is good. Go to SCP 5 Final Actions.
CAUTION
could also occur.
CAUTION
Do not tilt the printhead excessively while warm. If possible, allow adequate time for the ink to
solidify before removing the printhead. Once removed, rest the printhead on the screws that
secure the lower (slave) circuit board.
CAUTION
Printhead ribbon cables are interchangeable. Damage to the IME controller PWB is likely if the
cables are installed incorrectly.
CAUTION
NOTE: The LED on upper (master) printhead circuit board indicates the presence of 3.3 VDC.
• Check in dC122 Fault History and note the last fault code.
Procedure
Enter dC971 Head to Head Alignment Adjustment
Enter dC122 Fault History and observe the last fault shown. The fault is cleared.
Y N
Perform dC968 Head Purge on all 4 Heads.
A

91-698-00 to 91-732-00 IOD Excessive Head Misalignment Procedure
RAP NOTE: The LED on upper (master) printhead circuit board indicates the presence of 3.3 VDC.
91-698-00 IOD excessive stitch or roll misalignment. NOTE: 91-698-00, 91-699-00 faults and dC971 Head to Head Alignment Adjustment routine
failures. Cracked black plastic couplers on the lead screws PL 91.20 Item 21, of the printhead
91-699-00 IOD stitch / roll motors not zeroed.
roll adjust motors and printhead stitch adjust motors are a known cause of these failures. Refer
to T7869-01-12 and ETI 1056514. for instructions on how to check the couplers.
91-706-00 The IOD detects printhead 1 Y axis is at the limit of travel.
Perform dC971 Head to Head Alignment Adjustment. The adjustment completed success-
91-712-00 The IOD detects printhead 2 Y-axis is at the limit of travel. fully.
Y N
91-720-00 The IOD detects printhead 4 Y axis is at the limit of travel. Check the fault history, dC122. A new fault code is listed.
Y N
91-729-00 The IOD target Y-position out of range Perform dC914 Head to Head Alignment Test. Follow the instructions to run the fol-
lowing motors:
91-732-00 The IOD detects printhead 3 Y axis is at the limit of travel.
NOTE: If the machine has SMP2 or later software, the stitch and roll motors are dis-
abled and will not operate in dC914. Use the dC330 component control chain 91 to
Initial Actions run these components.
• Printhead stitch adjust motor 2 (upper stitch motor), PL 91.20 Item 4,

WARNING (MOT91-030)
Ensure that the electricity to the machine is switched off while performing tasks that do • Printhead stitch adjust motor 1 (lower stitch motor), PL 91.25 Item 4,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause (MOT91-029)
CAUTION
CAUTION
Do not repeatedly operate a roll motor. Repeated operation of a roll motor can over-
Use care when opening the marking unit drawer when hot. Ink can spill from the ink reservoir heat and damage the motor.
• Printhead roll adjust motor 2, PL 91.20 Item 4, (MOT91-026)
could also occur.
CAUTION • Printhead roll adjust motor 3, PL 91.25 Item 4, (MOT91-027)
Do not tilt the printhead excessively while warm. If possible, allow adequate time for the ink to • X-axis drive motor upper (upper carriage motor), PL 91.20 Item 5, (MOT91-
solidify before removing the printhead. Once removed, rest the printhead on the screws that 033)
secure the lower (slave) circuit board.
• X-axis drive motor lower (lower carriage motor), PL 91.25 Item 5, (MOT91-034)
MOT91-030 runs and printhead 2 moves left or right.
CAUTION Y N
Printhead ribbon cables are interchangeable. Damage to the IME controller PWB is likely if the Perform the following:
cables are installed incorrectly. 1. Refer to WD 9.9, check MOT91-030.
Check the wiring between PJ102 on the marking unit driver PWB and
MOT91-030.
CAUTION
Refer to:
destroy the printhead. Printheads must only be cleaned by a purge cycle. • GP 10 How to Check a Motor.
• Check the wiring harnesses leading to carriage drive and sensing components. Focus on • 01H +24V Power Distribution RAP.
areas above and behind the umbilicals. • 01J +50V Power Distribution RAP.
• Check for damage or debris that restricts carriage movement. • 01L 0V Distribution RAP.
A B C
A B C A B D
• Marking unit driver PWB, PL 92.10 Item 4. • 01J +50V Power Distribution RAP.
2. Check the MOT91-030 lead screw, PL 91.20 Item 21 for cracks. If neces- • 01L 0V Distribution RAP.
sary, install a new lead screw. Install new components as necessary:
• Printhead roll adjust motor 4, PL 91.20 Item 4.
MOT91-029 runs and printhead 1 moves left or right.
Y N • Marking unit driver PWB, PL 92.10 Item 4.
Perform the following: 2. Check the MOT91-028 lead screw, PL 91.20 Item 21 for cracks. If neces-
sary, install a new lead screw.
1. Refer to WD 9.10, check MOT91-029.
MOT91-024 runs and printhead 1 moves up or down.
MOT91-029. Y N
Refer to: Perform the following:
• GP 10 How to Check a Motor. 1. Refer to WD 9.10, check MOT91-024.
• 01H +24V Power Distribution RAP. Check the wiring between PJ303 on the marking unit driver PWB and
• 01J +50V Power Distribution RAP. MOT91-024.
• 01L 0V Distribution RAP. Refer to:
• 01J +50V Power Distribution RAP.
2. Check the MOT91-029 lead screw, PL 91.25 Item 21 for cracks. If neces-
sary, install a new lead screw. • 01L 0V Distribution RAP.
MOT91-026 runs and printhead 2 moves up and down. • Printhead roll adjust motor 1, PL 91.25 Item 4.
2. Check the MOT91-024 lead screw, PL 91.25 Item 21 for cracks. If neces-
1. Refer to WD 9.9 check MOT91-026. sary, install a new lead screw.
MOT91-026. MOT91-027 runs and printhead 3 moves up and down.
Refer to: Y N
• 01H +24V Power Distribution RAP. 1. Refer to WD 9.10, check MOT91-027.
• 01J +50V Power Distribution RAP. Check the wiring between PJ303 on the marking unit driver PWB and
• 01L 0V Distribution RAP. MOT91-027.
• Printhead roll adjust motor 2, PL 91.20 Item 4. • GP 10 How to Check a Motor.
• Marking unit driver PWB, PL 92.10 Item 4. • 01H +24V Power Distribution RAP.
2. Check the MOT91-026 lead screw, PL 91.20 Item 21 for cracks. If neces- • 01J +50V Power Distribution RAP.
sary, install a new lead screw. • 01L 0V Distribution RAP.
MOT91-028 runs and printhead 4 moves up and down.
Y N • Printhead roll adjust motor 3, PL 91.25 Item 4.
Perform the following: • Marking unit driver PWB, PL 92.10 Item 4.
1. Refer to WD 9.9, check MOT91-028. 2. Check the MOT91-027 lead screw, PL 91.25 Item 21 for cracks. If neces-
sary, install a new lead screw.
MOT91-028.
MOT91-033 runs and the upper carriage moves left or right.
Refer to: Y N
• GP 10 How to Check a Motor. Refer to WD 9.9, check MOT91-033.
A B D A B E

A B E
Check the wiring between PJ102 on the marking unit driver PWB and MOT91- 91-701-00 to 91-705-00 Printhead 1 Converging Error RAP
033.
91-701-00 IOD Head 1 roll not converging.
Refer to:
91-702-00 IOD Head 1 roll position limit.
• 01J +50V Power Distribution RAP. 91-703-00 IOD Head 1 X not converging.
Install new components as necessary: 91-704-00 IOD Head 1 X position limit.
• X-axis drive motor upper, PL 91.20 Item 5.
• Marking unit driver PWB, PL 92.10 Item 4. 91-705-00 IOD Head 1 Y not converging.
MOT91-034 runs and the lower carriage moves left or right. Procedure
Y N These fault codes are for future use.
Refer to WD 9.11, check MOT91-034.
Check the wiring between PJ303 on the marking unit driver PWB and MOT91-034.
Refer to:
• X-axis drive motor lower, PL 91.25 Item 5.
1. Inspect the docking pins and docking surfaces for debris that could prevent the
carriage from fully docking. Clean the docking pins and surfaces as necessary,
GP 27.
2. Move the marking unit back into the operational position, refer to GP 6.
3. Observe the carriage as it moves into the docked position.
To do this enter the Diagnostic tab and select dC612 Print Test Patterns. Select
TP 16, Stitch Identification Test Pages. The carriage will move into the docked
position to enable printing.
The carriage docks correctly against the drum.
Y N
Inspect the marking unit drive system for broken or bound linkages. Install new
components necessary. PL 91.10.
Check the fault history, dC122.

If fault codes 91-712-00 and 91-720-00 are listed install a new upper carriage
If fault codes 91-706-00 and 91-732-00 are listed install a new upper carriage
If the fault is intermittent. Check the area surrounding the carriage and umbilicals for
wiring damage or obstructions. Repair the harness, REP 1.1 as necessary.
Go to the appropriate RAP.
Enter dC612 and print TP 16, Stitch Identification and check that the print quality is good.

91-707-00 to 91-711-00 Printhead 2 Converging Error RAP 91-713-00, 91-714-00 Printhead 3 Converging Error RAP
91-707-00 IOD Head 2 roll not converging. 91-713-00 IOD Head 3 roll not converging.
91-708-00 IOD Head 2 roll position limit 91-714-00 IOD Head 3 roll position limit.
91-709-00 IOD Head 2 X not converging. Procedure

91-710-00 IOD Head 2 X position limit.
91-711-00 IOD Head 2 Y not converging.
Procedure

91-715-00 to 91-717-00, 91-719-00 Printhead 4 Converging 91-718-00 IOD, Head X-Position Error RAP
Error RAP 91-718-00 IOD Head 4 X-position limit.
91-715-00 IOD Head 4 roll not converging.
Procedure
91-716-00 IOD Head 4 roll position limit.
91-717-00 IOD Head 4 X not converging. WARNING

91-719-00 IOD Head 4 Y not converging. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Procedure Enter dC330 code 091.033 to run the X-axis drive motor upper (MOT91-033), PL 91.20 Item
These fault codes are for future use. 5. The motor runs
Y N
Go to WD 9.9. Check the X-axis drive motor upper, MOT91-033.
Refer to:
• The X-axis drive motor upper PL 91.20 Item 5.
• Marking Unit driver PWB, PL 92.10 Item 4.
Perform dC971, Head to Head Alignment Adjustment.

91-721-00, 91-722-00, 91-735-00, 91-736-00 IOD 91-725-00, 91-726-00, 91-727-00, 91-728-00 IOD Bad Target
Contamination Error RAP Scan RAP
91-721-00 IOD calibration 91-725-00 IOD target
91-722-00 IOD calibration 2D
91-726-00 IOD target missing
91-735-00 IOD non-static scanbar artifact
91-727-00 IOD target corrupted
91-736-00 IOD static scanbar artifact
Procedure 91-728-00 IOD target missing or corrupted
Initial Actions
WARNING
WARNING
WARNING
CAUTION Take care during this procedure. The drum will become hot during normal operation.
Do not connect the harness to the IOD PWB with the machine powered on. This may damage
the IOD sensor.
WARNING
CAUTION
CAUTION
Do not connect the harness to the IOD PWB with the machine powered on. This may damage
CAUTION
the IOD sensor.
Do not disconnect and reconnect the flex cables at the IOD PWB. the flex cables are easily
Perform dC969 Cleaning Ink Smears. Check the prints. The prints are clean. CAUTION
Y N Use care when working near the drum. The drum can be damaged easily, which will cause
Repeat dC969 until the prints are clean. print quality defects.
Perform dC971 Head to Head Alignment. The routine completes successfully.

Y N CAUTION
Enter dC330 and select 94-009 Drum Drive Slew speed. Select start and inspect the drum Do not disconnect and reconnect the flex cables at the IOD PWB. the flex cables are easily
for contamination as it rotates. The drum is clean. damaged. The cable must only be handled in the area of the blue backer.
Y N
Clean the drum, GP 27. Procedure
Clean the IOD, GP 27. NOTE: Before printing the jet test page, ensure that A4 or 8.5 x11 inch plain paper is loaded
LEF into tray 4. Use the best quality media available. Do not use hole punched paper.
Check the wire routing under the IOD for abrasions. Repair the harness, REP 1.1 as neces-
sary. If the fault remains, install new components as necessary: Select dC968 Head Purge. Select Print Jet Test Pages. Check the prints for missing jets, refer
• IOD assembly, PL 94.15 Item 1. to IQ 1. The prints are good.

Y N 91-730-00 IOD Target Y Position Out Of Far Range RAP
Perform dC968 Head Purge.
91-730-00 IOD Target Y position out of far range.
If the head purge does not correct the missing jets, go to 91-638-00 IOD Detects Chronic
Jet Error RAP.
Procedure
Perform dC969 Clean Ink Smears. Check the prints. The prints are clean. This fault code is for future use.
Y N
Repeat dC969 until the prints are clean.
Perform dC971 Head to Head Alignment. The routine completes successfully.

Y N
Clean the IOD, GP 27.
Open the stripper blade, GP 31 and check for contamination. If the blade is contaminated,
install a new stripper blade, PL 10.12 Item 3
Check for components that could be rubbing on the drum. Correct as required.
Enter dC330 code 94-009 Drum Drive Slew speed. Select start and inspect the drum for con-
tamination as it rotates. The drum is clean.
Y N
Clean the drum, GP 27.

If the fault is intermittent. Check the harness under the IOD for abrasions. Repair the harness,
REP 1.1 as necessary.

A
91-805-00, 91-806-00 Printhead Communications RAP NOTE: Ignore any error messages associated with the disconnected heater har-
ness.
91-805-00 Head communications glitch.
• If any test point reads +0.3V go to dC335 and check all set point mode temperatures
91-806-00 Head communications failure. for the suspect printhead. Look for non responsive heaters, irregular temperature
fluctuations or other symptoms that would indicate a thermistor error on the print-
Initial Actions head. If necessary compare the results of the suspect printhead with temperatures
reported from a known good printhead. If thermistor errors are detected install a new
printhead, PL 91.20 Item 2, PL 91.25 Item 2.
WARNING
Check the system grounding, GP 7. The grounding is good.
Y N
Repair any ground issues found, GP 7.
Check the IME controller PWB to copy controller PWB or single board controller PWB comuni-
CAUTION cations. Connect a network cable from PJ401 on the IME controller PWB to PJ16 on the copy
controller PWB or single board controller PWB. The fault persists.
Y N
could also occur.
• Marking unit service loop, PL 92.10 Item 9.
• Draw service loop W/TAG 006, PL 3.11 Item 16.
CAUTION
• Draw service loop W/O TAG 006, PL 3.10 Item 20.
destroy the printhead. Printheads must only be cleaned by a purge cycle. Install new components as necessary:
• Check the harness leading to the indicated printhead. • Printhead, PL 91.20 Item 2 or PL 91.25 Item 2.
• Check for damage to surrounding harnesses. • IME controller PWB, PL 92.10 Item 1.
• Quad Waveamp PWB, PL 92.10 Item 3.
Procedure • Drum driver PWBA, PL 1.15 Item 4.
Check that the ribbon cables connecting the printheads to the waveamp PWB and IME control-
NOTE: Calibration of the registration/preheat assembly, dC625 is only required when:
ler PWB are securely connected and not damaged. Re-seat the ribbon cables as necessary.
The wiring is securely connected and undamaged. • The registration/preheat assembly is removed or replaced,
Y N • The horizontal transport assembly is removed or replaced.
Repair or replace the damaged cables as necessary, REP 1.1. Calibration of the registration / preheat assembly is NOT required when:
Check and note the voltages at the test points on the IME controller PWB, Figure 1. All 4 test
points read +2.9V to +3.2V.
Y N
NOTE: All IME controller PWB test point voltages should read the same. Differences of
+0.1V or more on one test point compared to the other 3 test points, indicate an associ-
ated printhead issue, likely to be at the cause of the above faults. i.e printhead test points
TP703, TP704 and TP 05 read +2.86V but TP706 reads +2.89V, printhead 2 is the likely
causal.
• If any test point reads +2.1V install a new video cable, PL 92.10 Item 7, for the indi-
cated printhead.
• If any test point reads 0V check the PEST error log for error 99-395-00. If error 99-
395-00 is found switch off the machine, GP 14, then disconnect the heater harness
to the affected printhead, Figure 2. Switch on the machine and check the test point
for the affected printhead. If the voltage is still 0V then install a new printhead, PL
91.20 Item 2, PL 91.25 Item 2.
A

Heater harnesses connections
Figure 1 IME controller PWB test points Figure 2 Heater harness connections to printheads

91-824-00 PQM Insufficient Ink RAP 91-825-00 PQM Insufficient Paper RAP
91-824-00 The machine has insufficient ink to perform the print quality maintenance routine. 91-825-00 The machine has insufficient paper to perform the print quality maintenance routine.
Procedure Procedure
WARNING WARNING
1. Load additional ink. 1. Load additional media into the relevant tray.
2. If the fault remains, go to the 93-871-00 to 93-874-00 Ink Level Sense Error RAP. 2. If the fault remains, go to the 73A Tray 3 Out of Paper RAP.

91-826-00 PQM Insufficient Jets RAP 91-827-00 PQM Align Needed RAP
91-826-00 Insufficient jets are available to perform the print quality maintenance routine. 91-827-00 A head to head alignment is required before the print quality maintenance routine
can be performed.
Procedure
Procedure
WARNING
Go to the 91-638-00 IOD Detects Chronic Jet Error RAP. death or injury. Moving parts can cause injury.
The dC971 Head to Head Alignment Adjustment is a prerequisite for the calibration that was
manually requested. The previous attempt may have aborted.
NOTE: dC971 Head to Head Alignment Adjustment routine failures. Cracked black plastic cou-
plers on the lead screws of the printhead roll adjust motors and printhead stitch adjust motors
are a known cause of these failures. Refer to T7869-01-12 and ETI 1056514. for instructions
on how to check the couplers.
1. Perform dC971 Head to Head Alignment Adjustment - manual.
2. Check the stitch adjust and roll adjust motor lead screws, PL 91.20 Item 21 or PL 91.25
Item 21 for cracks (see NOTE:). Install new components as necessary.
3. Enter dC122 Fault History. Check for device faults that prevent completion of the routine.

91-828-00 PQM Y-Dot Position Needed RAP 91-829-00 PQM Drum Runout Needed RAP
91-828-00 A Y dot position correction is required before the print quality maintenance routine 91-829-00 A drum runout calibration is required before the print quality maintenance routine
can be performed. can be performed.
Procedure Procedure
WARNING WARNING
The dC972 Printhead Uniformity, option 5 Y Dot Position Correction is a prerequisite for the Go to the 91-637-00 Drum Runout Calibration Needed RAP.
calibration that was manually requested. The previous attempt may have aborted.

1. dC972 Printhead Uniformity, option 5 Y Dot Position Correction. Select all printheads.

91-830-00 PQM Uniformity Needed RAP 91-831-00 PQM Uniformity Reset Needed RAP
91-830-00 Printhead uniformity is required before the print quality maintenance routine can be 91-831-00 A printhead uniformity reset is required before the print quality maintenance routine
performed. can be performed.
Procedure Procedure
WARNING WARNING
The dC972 Printhead Uniformity, option 3 Head to Head Uniformity is a prerequisite for the cal- The dC972 Printhead Uniformity, option 6 Reset Head Uniformity Data is a prerequisite for the
ibration that was manually requested. The previous attempt may have aborted. calibration that was manually requested. The previous attempt may have aborted.

1. Perform dC972 Printhead Uniformity, option 3 Head to Head Uniformity. 1. dC972 Printhead Uniformity, option 6 Reset Head Uniformity Data. Select all printheads.
2. Enter dC122 Fault History. Check for device faults that prevent completion of the routine. 2. dC972 Printhead Uniformity, option 1 Printhead Replacement Uniformity - manual and
Go to the appropriate RAP. select all printheads.

91-832-00 PQM Empty Waste Tray RAP 91-833-00 PQM Cleaning Pages Needed RAP
91-832-00 The waste tray must be emptied before the print quality maintenance routine can be 91-833-00 The cleaning pages requested by the print quality maintenance routine can not be
performed. printed.
Procedure Procedure
WARNING WARNING
1. Empty the ink waste tray and reset the waste counter. 1. Check that the machine has sufficient ink and A4 or letter size paper loaded.
2. Check that the machine has sufficient ink and A4 or letter size paper loaded. 2. Empty the ink waste tray and reset the waste counter.
3. Check that the machine is in a ready to copy state. If necessary, go to the OF 5 Boot Up
If the message to empty the waste tray or the message Waste Tray not detected (missing). Failure RAP.
Insert the Waste Tray, will not clear. Perform the following steps: 4. If the cleaning pages still fail to print, go to dC968 Head Purge and reprint the cleaning
1. Enter Service mode, GP 1. Select Call Closeout and select Reset Waste Counter. pages.
2. Check that the magnet is still located on the bottom of the waste tray. If necessary install
a new waste tray, PL 91.10 Item 15.
3. Refer to WD 9.4 and check the waste tray sensor and the wiring harness. Install new
components as necessary.
• Waste tray sensor, PL 91.05 Item 4.

91-834-00 PQM Tool Not Usable RAP 91-835-00 PQM Tool Manually Disabled RAP
91-834-00 The requested print quality maintenance routine is not usable. 91-835-00 A print quality maintenance routine has been manually disabled.
Procedure Procedure
WARNING WARNING
Perform the following: Go to the 91-636-00 IOD in Degraded Mode RAP.
1. Check that the machine has sufficient ink and A4 or letter size paper loaded.
2. Empty the ink waste tray.
3. Check that the machine is in a ready to copy state. If necessary, go to the OF 5 Boot Up
Failure RAP.
4. Enter dC122 Fault History. Check for a new fault code. Go to the appropriate RAP.
5. Re-run the diagnostic routine that failed.

91-836-00 PQM System Busy RAP 91-837-00 PQM Align Calibration Needed RAP
91-836-00 The print quality maintenance system is busy. 91-837-00 PQM align stitch offset out of calibration. A head to head alignment is required
before the print quality maintenance routine can be performed.
Procedure
Procedure
WARNING
The system is currently performing a previously requested dC971 Head to Head Alignment or death or injury. Moving parts can cause injury.
dC968 Head Purge. Wait for the system busy message (on the status lines) to clear and retry The dC971 Head to Head Alignment Adjustment is a prerequisite after heads are changed or
the aborted calibration. the NVRAM parameters have been reset (Reset All).
NOTE: dC971 Head to Head Alignment Adjustment routine failures. Cracked black plastic cou-
plers on the lead screws of the printhead roll adjust motors and printhead stitch adjust motors
are a known cause of these failures. Refer to T7869-01-12 and ETI 1056514. for instructions
on how to check the couplers.
1. Perform dC971 Head to Head Alignment Adjustment - manual.
2. Check the stitch adjust and roll adjust motor lead screws, PL 91.20 Item 21 or PL 91.25
Item 21 for cracks (see NOTE:). Install new components as necessary.

91-842-00 to 91-845-00 Printhead Nvram Read or Decode 91-848-00 to 91-851-00 IOD Align Calibration Error RAP
Error RAP 91-848-00 IOD align calibration: X stitch measurement limit excessive X stitch was measured
and the align calibration process cannot complete.
91-842-00 Printhead 1 Nvram jet mask section read or decode error.
91-849-00 IOD align calibration: Y stitch measurement limit excessive Y stitch was measured
and the align calibration process cannot complete.
91-850-00 IOD align calibration: X offset correction limit align calibration resulted in an X stitch
correction value that is too large.
91-851-00 IOD align calibration: Y offset correction limit align calibration resulted in an Y stitch
Procedure correction value that is too large.
Procedure
WARNING
This RAP is for information only, no service action is necessary. These fault codes will be auto-
matically cleared by the machine.
Enter dC612 and print TP 16. Check the stitch identification test pages. A stitch defect is
present
Y N
Manually disable the IOD align calibration:

1. Enter dC131 NVM read/write NVM ID 490-41 and change value to 3.
2. Enter dC971 and start the routine.
3. Enter dC612 and print TP 16 and check the identification test pages.
A stitch defect is present
Y N
Manually re-enable the IOD align calibration:

A stitch defect is present
Y N
Go to 91-698-00 to 91-732-00 IOD Excessive Head Misalignment RAP.

Enter dC612 and print TP 16 Stitch Identification and check that the print quality is good.
If the stitch defect is still present, swap the print heads around to move the artifact to the out-
side of the page.

92-505-00, 92-506-00 Marking Unit Communications Error 92-510-00, 92-511-00 Marking Unit Ink On Drum
RAP Communications Error RAP
92-505-00 Marker unit communications failure 92-510-00 Communications failure between marking unit and ink on drum unit
92-506-00 Marker unit communications failure 92-511-00 Communications failure between marking unit and ink on drum unit
WARNING WARNING
• If the fault 92-505-00 is accompanied by 92-510-00 and 92-575-00. Check for a loss of Perform the following:
connection on the cable between the IME controller and the marking unit driver PWB. 1. If the fault 92-510-00 is accompanied by 92-505-00 and 92-575-00. Check for a loss of
connection on the cable between the IME controller PWB and the Marking unit driver
Procedure PWB. Refer to the 92-505-00, 92-506-00 Marking Unit Communications Error RAP.
Go to wiring diagrams WD 9.7 and WD 9.10. Check for loose connections between: 2. Refer to WD 9.1 and WD 9.22. Check the IOD to drum driver PWB cable between PJ101
• The IME controller PWB and the marking unit driver PWB. on the drum driver PWB and PJ1 on the IOD Pre Amplifier PWB.
Refer to: NOTE: A standard network cable can be temporarily installed between PJ603 and PJ403 to
• PJ903, IME controller PWB. check for connectivity issues.
• PJ203, Marking unit driver PWB. 3. Refer to WD 9.2 and WD 9.6. Check the wiring of the service loop between PJ603 on the
If the fault persists, install new components as necessary: drum driver PWB and PJ403 on the IME controller PWB.
• Marking unit driver PWB cable (PJ203), PL 92.10 Item 14. If the fault persists, install new components as necessary:
• IME controller PWB, PL 92.10 Item 1. • IOD to drum driver PWB cable, PL 94.15 Item 5.
• Marking unit driver PWB, PL 92.10 Item 4. • Service loop, PL 92.10 Item 9.
• IOD assembly, PL 94.15 Item 1.

92-515-00, 92-516-00 Drum Driver Communications Error 92-520-00 Power Supply Communications Error RAP
RAP 92-520-00 Power supply communications error
92-515-00 Drum driver communications failure
Procedure
92-516-00 Drum driver communications error
Procedure WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Go to wiring diagrams WD 9.4 and WD 1.4. Check the connections between the PJ902 on the
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause drum driver PWB and PJDC2 on the power supply Unit.
If the fault persists, install new components as necessary:
Go to wiring diagrams WD 9.2 and WD 9.6. Check for loose connections between:
• The drum driver PWB and the IME controller PWB. • Drum driver power supply interface cable, PL 1.15 Item 10.
Refer to: • Drum driver PWB, PL 1.15 Item 4.
• PJ403, IME controller PWB. • Power supply unit, PL 1.15 Item 2.
• PJ603, Drum driver PWB.

92-525-00, 92-526-00 Media Path Communications Error 92-527-00, 92-528-00 ESD Count Exceeded RAP
RAP 92-527-00 ESD count 1 exceeded.
92-525-00 Media path communications failure
92-528-00 ESD count 2 exceeded.
92-526-00 Media path communications error
Procedure
Initial Actions If the above fault codes appear then the system grounding needs to be checked. Go to GP 7
System Grounding Verification and check the grounding connections on the machine.
WARNING
• Check the MU Drawer service loop harness for damage, PL 92.10 Item 9.
Procedure
Go to wiring diagrams WD 8.4 and WD 9.5. Check for bad wiring between PJ402, on the IME
controller PWB and PJ408 on the Media path driver PWB.


92-530-00 3TM Serial Link Error RAP 92-531-00 Paper Tray Module Communications Error RAP
92-530-00 Three trays module serial link error. 92-531-00 Paper tray module (3TM) communication error.
Procedure Procedure
WARNING WARNING
Go to wiring diagrams WD 8.2 and WD 7.3. Check the wiring between: Go to 92-530-00 3TM Serial Link Error RAP.
• The media path driver PWB and the 3 tray module (3TM) PWB.
Refer to:
• PJ950, 3TM PWB.

92-535-00, 92-536-00 Tray 5 Communications Error RAP 92-541-00, 92-570-00 Interrupt Storm Fault RAP
92-535-00 Tray 5 control PWB serial communications error. 92-541-00 ADC interrupt storm.
92-536-00 Tray 5 communications error. 92-570-00 Interrupt storm fault.
WARNING WARNING
Go to wiring diagrams WD 7.1 and WD 8.4. Check for loose connections between: • Switch off the machine, then switch on the machine, GP 14.
• The tray 5 control PWB and the marking unit driver PWB.
Refer to: Procedure
• PJ502, PJ513, Tray 5 control PWB. Perform the steps that follow before installing a new IME controller PWB, PL 92.10 Item 1.
If the fault persists, install new components as necessary: Remove and reinsert the following communication connectors. There should be a click when
the connector is correctly seated.
• Media path driver PWB, PL 1.15 Item 5. • Move the marking unit to the maintenance position, GP 6. Three connectors on the IME
controller PWB PJ401 / PJ402, WD 9.5 and PJ403, WD 9.6.
• PJ603 on the drum driver PWB, WD 9.2.
• PJ408 on the media path driver PWB, WD 8.4.
• Machine W/O TAG 006, PJ16 on the copy controller PWB, WD 3.2. Machine W/TAG 006,
PJ16 on the single board controller PWB, WD 3.5.
• The ribbon cable PJDC2 on the power supply unit, WD 1.4 and PJ902 on the drum driver
PWB, WD 9.4.
• The RJ45 type inline connector (part of the service loop), WD 9.5 located behind the
lower rear cover to the right of the power supply unit.
• Reseat the ribbon cable PJ903 on the IME controller PWB, WD 9.7 and PJ203 on the
marking unit driver PWB, WD 9.10.
• The ribbon cable PJ101 on the IME controller PWB, WD 9.5 and PJ590 on the quad wave
amplifier PWB, WD 9.13. Check for bent pins on the PWB and for damage to the ribbon
cable, PL 92.10 Item 13.
If the problem continues then reseat the print head video cables (marked with letter A). If this is
a hard failure then try reseating or install new print head video cables, one at a time. Install new
components as necessary, PL 92.10.

92-542-00 PS Interrupt Storm Fault RAP 92-543-00, 92-544-00 MU Interrupt Storm Faults RAP
92-542-00 PS interrupt storm. 92-543-00 MU interrupt storm.
Initial Actions 92-544-00 MUID interrupt storm.
Initial Actions
WARNING
• Switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

1. Install a new power supply unit, PL 1.15 Item 2.
Procedure
Install a new marking unit driver PWB, PL 92.10 Item 4.
2. If the fault persists, install a new IME controller PWB, PL 92.10 Item 1.

92-545-00 DD Interrupt Storm Fault RAP 92-546-00, 92-547-00 MP Interrupt Storm Faults RAP
92-545-00 DD interrupt storm. 92-546-00 MP interrupt storm.
Initial Actions 92-547-00 IMD interrupt storm.
Initial Actions
WARNING
• Switch off the machine, then switch on the machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause

Procedure
Install a new media path PWB, PL 1.15 Item 5.

92-548-00 TTM Interrupt Storm Fault RAP 92-549-00 PFP Interrupt Storm Fault RAP
92-548-00 TTM interrupt storm. 92-549-00 PFP (Tray 5) interrupt storm.
WARNING WARNING
Procedure Procedure
1. Refer to WD 7.3 and WD 8.2. Check the wiring between PJ401 on media path driver PWB 1. Refer to WD 7.1 and WD 8.4. Check the wiring between PJ704 on media path driver PWB
and PJ950 on 3 tray module PWB. Ensure the connectors are seated correctly. Repair the and PJ502 on the tray 5 control PWB. Ensure the connectors are seated correctly. Repair
wiring as necessary, REP 1.1. the wiring as necessary, REP 1.1.
2. Install new components as necessary: 2. If necessary, install a new media path driver PWB, PL 1.15 Item 5.
• Media path driver PWB to tray 3 module harness, PL 1.15 Item 21.

92-551-00 CIS Interrupt Storm Fault RAP 92-552-00 SBC Interrupt Storm Fault RAP
92-551-00 CIS interrupt storm. 92-552-00 SBC interrupt storm.
WARNING WARNING
Procedure Procedure
1. Check the following wiring. Ensure the connectors are seated correctly. Repair the wiring 1. Refer to WD 3.5 and WD 8.2. Check the ribbon cable between PJ402 on the media path
as necessary, REP 1.1. driver PWB and PJ20 on the single board controller PWB. Ensure the connectors are
a. Refer to WD 8.6 and WD 9.2. Between PJ2 on the registration / preheat Interface seated correctly.
PWB and PJ701 on the drum driver PWB. Between PJ1 on the registration / preheat 2. If necessary, install a new media path driver PWB, PL 1.15 Item 5.
interface PWB and the registration scan bar, PL 88.10 Item 2. If necessary, install a
new drum driver MR sensor harness, PL 1.15 Item 9.
b. Refer to WD 9.1 and WD 9.22. Between PJ101 on the drum driver PWB and PJ1 on
the IOD pre amp PWB. Between PJ2 on the IOD pre amp PWB and the IOD scan
bar, PL 94.15. If necessary, install a new IOD to drum driver PWB cable, PL 94.15
Item 5.
2. If necessary, install a new drum driver PWB, PL 1.15 Item 4.

92-550-00, 92-555-00 System Timer Error RAP 92-554-00 AC Line Failed RAP
92-550-00 Safety timer time out. 92-554-00 The AC power cord has been disconnected or the AC supply has failed.
92-555-00 System timer skipped. Initial Actions
Initial Actions
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Check that the AC power cord is correctly connected.
• Switch off the machine, then switch on the machine, GP 14. Procedure
Go to the 01A AC Power Distribution RAP.
Procedure
Re-install the machine software, GP 4. The fault remains.
Y N
Install a new IME control PWB, PL 92.10 Item 1.

92-556-00, 92-557-00, 92-558-00, 92-559-00 ECM Failure 92-560-00, 92-561-00 Marking Unit Firmware Version
RAP Mismatch RAP
92-556-00 ECM PCI access failure. 92-560-00 Marking unit firmware version mismatch.
92-557-00 ECM ADC failed. 92-561-00 Marking unit firmware version mismatch.
92-558-00 ECM Ps line cross failed. Procedure

92-559-00 ECM callisto access error.
WARNING
Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do
Switch Off the machine then switch On the Machine, GP 14. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Procedure Install a new marking unit driver PWB, PL 92.10 Item 4.
WARNING
Check the wiring and connectors to the IME control PWB. The wiring and connectors are
good.
Y N
Repair the wiring, Go to REP 1.1.
Install a new IME control PWB, PL 92.10 Item 1.

92-562-00 Drum Driver Firmware Version Mismatch RAP 92-563-00 Power Supply Firmware Version Mismatch RAP
92-562-00 Drum driver firmware version mismatch. 92-563-00 IME power supply firmware version mismatch.
Procedure Procedure
WARNING WARNING
Install a new drum driver PWB, PL 1.15 Item 4. Install a new power supply unit, PL 1.15 Item 2.

92-564-00 Media Path Firmware Version Mismatch RAP 92-565-00 3TM Firmware Version Mismatch RAP
92-564-00 Media path firmware version mismatch. 92-565-00 3 trays module firmware version mismatch.
Procedure Procedure
WARNING WARNING
Install a new media path driver PWB, PL 1.15 Item 5. Install a new 3 tray module PWB, PL 73.16 Item 4.

92-566-00 Tray 5 Firmware Version Mismatch RAP 92-567-00 Copy Controller Software Version Mismatch
92-566-00 Paper feeder platform firmware version mismatch. RAP
92-567-00 Copy controller software version incompatible with IME.
Procedure
Initial Actions
WARNING
Install a new tray 5 control PWB, PL 75.68 Item 8. death or injury. Moving parts can cause injury.
• The fault will occur If the copy controller PWB was replaced with an incompatible version
of software on it.
Procedure
Y N
Install a new copy controller PWB, PL 3.10 Item 17.

92-568-00 ECM Initialization Error RAP 92-569-00 Blackheart Version Mismatch RAP
92-568-00 IME controls did not initialize correctly. 92-569-00 Blackheart FPGA version mismatch.
WARNING WARNING
• The fault will occur if the IME controller PWB was replaced with an incompatible version
Procedure of software on it.
Procedure
Y N

92-571-00 Software Error RAP 92-575-00 ADC Out of Range RAP
92-571-00 Software error. 92-575-00 Analog to digital conversion of thermistor readings inconsistent with expected value.
WARNING WARNING
• Switch off the machine, then switch on the machine, GP 14. 1. Check the PEST log history dC123 to determine which thermistor is at fault. If a PEST
code is available then go the appropriate RAP.
Procedure 2. If the fault 92-575-00 is accompanied by 92-505-00 and 92-510-00. Check for a loss of
connection on the cable between the IME controller and the marking unit driver PWB. Go
This fault is caused by a hardware memory failure within the IME.
to 92-505-00, 92-506-00 Marking Unit Communications Error RAP.
Remove then reseat the 8 pin NVRAM, PL 92.10 Item 11 on the IME Controller PWB, PL 92.10
Item 1. The fault is cleared. 3. Install new components as necessary:
Install new components as necessary: • IME controller PWB, PL 92.10 Item 1.
• 8 pin NVRAM, PL 92.10 Item 11.

92-579-00 CDI Submit Sheet Error RAP 92-581-00 Image Transfer Error RAP
92-579-00 A CDI submit sheet error has been detected. 92-581-00 Image transfer failure from CBC to IME controller PWB.
WARNING WARNING
• Switch off the machine, then switch on the machine, GP 14. 1. For machines W/O TAG 006. Go to wiring diagrams WD 9.5 and WD 3.2. Check for loose
connections between the IME controller PWB and the copy controller PWB. Refer to:
Procedure • PJ401, IME controller PWB
Re-install the machine software, GP 4. • PJ16, Copy controller PWB
For machines W/TAG 006. Go to wiring diagrams WD 9.5 and WD 3.5. Check for loose
• PJ401, IME controller PWB.
• PJ16, Single board controller PWB.
2. For machines W/O TAG 006. Check the following components for damage:
• Check the RJ45 type in-line connector between PJ401 (IME controller PWB) and
PJ16 (copy controller PWB). The connector is behind the rear cover (PL 70.25 Item
8) of the 3 tray module to the right of the marking unit cooling fan, PL 1.15 Item 23.
• Check all ground connections in this area, refer to GP 7.
For machines W/TAG 006. Check the following components for damage:
• Check the RJ45 type in-line connector between PJ401 (IME controller PWB) and
PJ16 (single board controller PWB). The connector is behind the rear cover (PL
70.25 Item 8) of the 3 tray module to the right of the marking unit cooling fan, PL 1.15
Item 23.
• Check all ground connections in this area, refer to GP 7.
3. If the fault persists re-install the machine software, GP 4, then install new components as
necessary:
• SBC drawer service loop, PL 3.11 Item 16.
• CBC drawer loop, PL 3.10 Item 20.
• EPC memory PWB, PL 3.11 Item 21.
NOTE: dC640 can be used to isolate a defective EPC memory PWB. In the case of
a defective EPC PWB the procedure will stop at 99% of completion then the system
will hang. With a good EPC memory PWB the dC640 procedure will complete within
20 seconds.

92-583-00 Cold Temperature Boot Time-out RAP 92-585-00 LVDS Contone Terminal Error During Image
92-583-00 Cold temperature boot time-out. Transfer RAP
92-585-00 LVDS contone terminal error during image transfer.
Initial Actions
Initial Actions
WARNING
• Switch off the machine, then switch on the machine, GP 14. death or injury. Moving parts can cause injury.
• Check the MU Drawer service loop, PL 92.10 Item 9 for damage.
Procedure • Check all ground connections in this area, refer to GP 7.
Ensure the ambient temperature in the room is above 6 degrees C.
Procedure
If the machine temperature is above 5 C and the 92-583 fault occurs, it would indicate that the
1. For machines W/O TAG 006. Go to wiring diagrams WD 9.5 and WD 3.2. Check for loose
reservoir thermistor is at fault. Refer to wiring diagram WD 9.16. Install new components as
required:
• Solenoid Patch PWB, PL 93.10 Item 9. • PJ16, Copy controller PWB.
• Reservoir, PL 93.10 Item 10. For machines W/TAG 006. Go to wiring diagrams WD 9.5 and WD 3.5. Check for loose
• PJ16, Single board controller PWB.
2. Reseat the printhead ribbon cables, refer to REP 91.29.
3. If the fault persists, install new components as necessary:

92-586-00 Print Engine Speed Fault RAP 92-598-00, 92-599-00, 92-600-00 IME NVRAM Error RAP
92-586-00 The print engine is running at default speed. Critical system settings have been reset to their default values. The system can continue oper-
ating, but requires manual configuration to custom settings.
Procedure
92-598-00 NVM dynamic data corrupted.
WARNING 92-599-00 NVM system constants corrupted.

92-600-00 NVM critical settings corrupted.
Procedure
WARNING
These faults are raised during initialization if the CRC values for the described section of the
IME NVRAM are invalid. When this occurs, the IME sets defaults values.
These faults are for information only. If a service action is required, a separate fault code will be
raised.

92-803-00, 92-804-00 DSP2 Overlay Error RAP 92-805-00 Fuse A Blown RAP
92-803-00 DSP2 overlay setup time-out. 92-805-00 Fuse A on the drum driver PWB has blown.
92-804-00 DSP2 overlay cleanup time-out. Procedure

These faults are raised when a DSP2 motor is enabled during IOD calibration.
WARNING
NOTE: The DSP2 motors are:
• Tray 1 feed/elevator motor. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Tray 2 feed/elevator motor. death or injury. Moving parts can cause injury.
• Tray 3 feed motor. Check fuse A for continuity.
• Tray 5 feed motor.
NOTE: The fuse is located below PJ601 on the drum driver PWB and is marked F602. The
• Tray 5 transport motor. fuse is non-reparable.
• Cleaning unit motor.
Fuse A is blown.
• Front transfix motor.
Y N
• Rear transfix motor. Go to WD 9.2. +24V is available PJ602, pin 12.
Y N
Procedure
Go to WD 1.5. +24V is available at PJDC3, pin 15.
Y N
Go to 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload RAP and check
WARNING for a short circuit.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Check the wiring between the power supply unit, PL 1.15 Item 2, and the drum driver
death or injury. Moving parts can cause injury. PWB, PL 1.15 Item 4, for an open circuit. The wiring is good.
Switch off the machine, then switch on the machine, GP 14. Y N
Go to WD 9.2 and WD 9.6. Check the wiring between PJ603 on the drum driver PWB and
PJ403 on the IME controller PWB. The wiring is good.
Y N

Go to WD 9.2. Check the wiring between the cleaning unit connector, PL 94.10 Item 6 and
PJ601 on the drum driver PWB.
NOTE: If necessary, remove the drum drive motor to gain access to the cleaning unit connec-
tor, refer to REP 91.33.
The wiring is good.
Y N
Repair the wiring as necessary, REP 1.1. Install a new drum driver PWB, PL 1.15 Item 4.
A
A
Go to WD 9.1 and WD 9.22. Check the wiring between the IOD shuttle motor and PJ101 on the 92-806-00 Fuse B Blown RAP
drum driver PWB. The wiring is good.
92-806-00 Fuse B on the drum driver PWB has blown.
Y N
Procedure
Install a new drum driver PWB, PL 1.15 Item 4. The fault remains.
Y N
Perform SCP 5 Final Actions. WARNING
Install a new cleaning unit, PL 94.10 Item 21. The fault remains. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Y N death or injury. Moving parts can cause injury.
NOTE: Fuse B is non-reparable.
Install a new IOD assembly, PL 94.15 Item 1. Install a new drum driver PWB, PL 1.15 Item 4. Go to WD 9.2. +24V is available PJ602, pin 12.
Y N
Go to WD 1.5. +24V is available at PJDC3, pin 15.
Y N
Go to 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload RAP and check for a
short circuit.
Check the wiring between the power supply unit, PL 1.15 Item 2, and the drum driver
PWB, PL 1.15 Item 4, for an open circuit. The wiring is good.
Y N
Go to WD 9.2. Check the wiring between the cleaning unit connector, PL 94.10 Item 6 and
PJ601 on the drum driver PWB.
NOTE: If necessary, remove the drum drive motor to gain access to the cleaning unit connec-
tor, refer to REP 91.33.
The wiring is good.

Y N
Go to WD 9.4. Check the wiring between the abatement fan and PJ901 on the drum driver
PWB. The wiring is good.
Y N
Install a new drum driver PWB, PL 1.15 Item 4. The fault remains.
Y N
Install a new cleaning unit, PL 94.10 Item 21. The fault remains.
Y N
Install a new abatement fan assembly, PL 94.20 Item 11. Install a new drum driver PWB, PL
1.15 Item 4.

92-807-00 Diagnostic Routine Not Implemented RAP
92-807-00 In dC972 automatic TRC generation is not implemented.
Procedure
WARNING
Go to dC972 Printhead Uniformity. Perform a manual TRC generation.

93-501-00 to 93-516-00 Ink Loader Is Jammed RAP 93-520-00, 93-521-00, 93-522-00 Ink Melt Reservoir Thermal
93-501-00 Black ink loader is jammed. Error RAP
93-520-00 Ink melt reservoir heater is too hot
93-506-00 Magenta ink loader is jammed.
93-521-00 Ink melt reservoir is heating too slowly
93-511-00 Cyan ink loader is jammed.
93-522-00 Ink melt reservoir thermistor fault
93-516-00 Yellow ink loader is jammed.
Initial Actions
Initial Actions
WARNING
WARNING
WARNING
WARNING
Do not touch the ink loader melt plates while the machine is switched on. Dangerous
voltages may be present that could cause death or injury.
• Check that the machine is installed to allow adequate airflow. Refer to GP 21 Installation
Perform the following: Space Requirements.
• Check for jammed ink sticks.
• Check for non Xerox ink sticks and report as appropriate. Procedure
• Check for wrong colour ink sticks loaded. Check that the marking unit fan is running, Figure 1. The fan is running.
Y N
Procedure Go to WD 9.4. Check the marking unit fan.
Go to 93-891-00 Ink Transport Over Current RAP. Refer to:
• Marking unit fan, PL 1.15 Item 23.
Check the PEST fault history, dC123 for marking unit heater faults (umbilicals, printheads and
ink melt reservoir). All marking unit heaters have failed.
Y N
Go to WD 9.8. Check the resistance and continuity of the reservoir heaters and wiring.
The resistance should be approximately 45-55 ohms between pins 1 and 3 and between
pins 2 and 4 on PJ201 on the Marking Unit Heater PWB. The resistance is correct.
Y N
Install a new ink reservoir, PL 93.10 Item 10.
A B

Xerox® ColorQube® 9203 Family 2-483 93-501-00 to 93-516-00, 93-520-00, 93-521-00, 93-
A B
Check the wiring between the marking unit driver PWB, the solenoid patch PWB and the 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
ink melt reservoir thermistor. Check that the thermistor is not open or shorted. Refer to:
• WD 9.9, WD 9.12 and WD 9.16.
93-533-00 Ink Melt Error RAP
• PJ101, PJ801, Marking Unit Driver PWB. 93-523-00 Cyan ink melter is too hot
• PJ760, PJ910, PJ630 Solenoid patch PWB. 93-524-00 Cyan ink melter is heating too slowly
The wiring and thermistor is good.
Y N 93-526-00 Magenta ink melter is too hot
Install a new ink reservoir, PL 93.10 Item 10.
93-527-00 Magenta ink melter is heating too slowly
93-529-00 Yellow ink melter is too hot
• Marking unit driver PWB, PL 92.10 Item 4. 93-530-00 Yellow ink melter is heating too slowly
Refer to WD 1.1 and WD 9.8, check the wiring between PJ4AC on the Power Supply Unit and 93-532-00 Black ink melter is too hot
PJ101 on the Marking Unit Heater PWB. The wiring is good.
Y N 93-533-00 Black ink melter is heating too slowly
Initial Actions
Check the +3.3V ESTAR distribution to the marking unit heater PWB, refer to the 01B +3.3V
ESTAR Distribution RAP. If the fault is still present, install new components as necessary:
• Marking unit heater PWB cable, PL 92.10 Item 12. WARNING
• Marking unit heater PWB, PL 92.10 Item 5. Ensure that the electricity to the machine is switched off while performing tasks that do
• Marking unit driver PWB, PL 92.10 Item 4. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Power supply unit, PL 1.15 Item 2. death or injury. Moving parts can cause injury.
WARNING
• Check that the machine is installed to allow adequate airflow. Refer to GP 21 Installation
Space Requirements.
• Check that the ink sticks are not jammed in the ink stick transport and at the melt plate
assembly, below the ink low sensors.
• Check that the ink sticks are in contact with the melt plate.
Procedure
Check that the marking unit fan is running, Figure 1. The fan is running.
Marking Unit Fan Y N
Go to WD 9.4. Check the marking unit fan.
Refer to:
Figure 1 Component Location • 01L 0V Distribution RAP
A
93-520-00, 93-521-00, 93-522-00, 93-523-00 to 93-526- 2-484 Xerox® ColorQube® 9203 Family
A
Go to WD 1.2, WD 8.4 and WD 9.17. Check the wiring between: 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt
• The power supply unit and the ink melt heaters. Ensure that the ink melt heaters are cor-
rectly connected to PJ5AC on the Power supply unit.
Thermistor Error RAP
93-525-00 Cyan ink melter thermistor fault
NOTE: The 4 heater harnesses are colour coded to the corresponding letter on the ink
melt plate assembly. Refer to REP 91.16. 93-528-00 Magenta ink melter thermistor fault
• The media path driver PWB, the ink load entry PWB and the ink thermistors.
93-531-00 Yellow ink melter thermistor fault
Refer to:
• P/J5AC Power supply unit 93-534-00 Black ink melter thermistor fault
• P/J406 Media path driver PWB
• P/J301 Ink load entry PWB Initial Actions
• 01A AC Power Distribution RAP.
WARNING
The wiring is good.
Y N
Remove the ink loader melt plate assembly, PL 93.10 Item 3. Remove any debris on the ink
side of the ink melt heaters.
WARNING
Install new components as necessary. Do not touch the ink loader melt plates while the machine is switched on. Dangerous
• Ink loader melt plate assembly, PL 93.10 Item 3 voltages may be present that could cause death or injury.
• Ink load sensor assembly, PL 93.10 Item 7. • Check that the ink melt thermistors are connected.
Procedure
Go to WD 9.17 and WD 8.4. Check the following wiring:
• Between the ink melt thermistors and PJ301 on the Ink Load Entry PWB.
• Between PJ901 on the Ink Load Entry PWB and PJ406 on the Media Path Driver PWB.
The wiring is good.
Y N

• Ink loader melt plate assembly, PL 93.10 Item 3.
• Ink load sensor assembly, PL 93.10 Item 7.
Marking Unit Fan
Figure 1 Component Location

A B
93-535-00, 93-536-00, 93-537-00 Upper Umbilical Thermal • 01L 0V Distribution RAP
Error RAP
• Upper umbilical, PL 91.20 Item 10.
93-535-00 Upper umbilical heater is too hot
93-536-00 Upper umbilical is heating too slowly • Marking unit heater PWB, PL 92.10 Item 5
93-537-00 Upper umbilical thermistor fault Refer to WD 1.1 and WD 9.8, check the wiring between PJ4AC on the Power Supply Unit
and PJ101 on the Marking Unit Heater PWB. The wiring is good.
Initial Actions Y N
Check the +3.3V ESTAR distribution to the marking unit heater PWB, refer to the 01B
WARNING
+3.3V ESTAR Distribution RAP. If the fault is still present, install new components as nec-
Ensure that the electricity to the machine is switched off while performing tasks that do essary:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Marking unit heater PWB cable, PL 92.10 Item 12.
Check that the machine is installed to allow adequate airflow. Refer to GP 21 Installation Space
Requirements.
Procedure The fault may be intermittent. Go to WD 9.8 and WD 9.9. Check for loose connections
Check that the marking unit fan is running, Figure 1. The fan is running. between:
Y N • The marker unit driver PWB and the upper umbilical thermistor.
Go to WD 9.4. Check the marking unit fan.
• The marking unit heater PWB and the upper umbilical heater.
Refer to:
Refer to:
• P/J401, Marking Unit Heater PWB.
• P/J102, Marking Unit Driver PWB.
If the fault persists, install new components as necessary.
Enter dC335 Heater Monitor and Exerciser. Select Graph to run the Upper Umbilical Test.
The test is good (the heater reaches and remains at the set point).
Y N
Check the PEST fault history, dC123 for marking unit heater faults (umbilicals, printheads
Y N
• Between PJ102 on the Marking Unit Driver PWB and the upper umbilical ther-
mistor. Measure the resistance between PJ102 pins B9 and B10. The resis-
tance is widely variable, but must not be an open circuit.
• Between PJ401 on the Marking Unit Heater PWB and the upper umbilical
Marking Unit Fan
heater. Measure the resistance between PJ401 pins 1 and 7. The resistance
should be approximately 80-100 ohms.
Refer to:
• 01B +3.3V ESTAR Distribution RAP. Figure 1 Component Location
A B
A B
93-538-00, 93-539-00, 93-540-00 Lower Umbilical Thermal • Marking unit heater PWB, PL 92.10 Item 5.
Error RAP Refer to WD 1.1 and WD 9.8, check the wiring between PJ4AC on the Power Supply Unit
93-538-00 Lower umbilical heater is too hot and PJ101 on the Marking Unit Heater PWB. The wiring is good.
Y N
93-539-00 Lower umbilical is heating too slowly Repair the wiring, REP 1.1.
93-540-00 Lower umbilical thermistor is faulty Check the +3.3V ESTAR distribution to the marking unit heater PWB, refer to the 01B
+3.3V ESTAR Distribution RAP. If the fault is still present, install new components as nec-
Procedure essary:
• Marking unit heater PWB cable, PL 92.10 Item 12.
WARNING • Marking unit driver PWB, PL 92.10 Item 4.
Ensure that the electricity to the machine is switched off while performing tasks that do • Power supply unit, PL 1.15 Item 2.
death or injury. Moving parts can cause injury. The fault may be intermittent. Go to WD 9.8 and WD 9.10. Check for loose connections
Check that the marking unit fan is running, Figure 1. The fan is running. between:
Y N • The marker unit driver PWB and the lower umbilical thermistor.
Go to WD 9.4. Check the marking unit fan. • The marking unit heater PWB and the lower umbilical heater.
Refer to:
Refer to:
• PJ303, Marking unit driver PWB
• PJ701, Marking unit heater PWB
• Lower umbilical, PL 91.25 Item 10.
• Marking unit heater PWB, PL 92.10 Item 5
Enter dC335 Heater Monitor and Exerciser. Select Graph to run the Lower Umbilical Test.
The test is good.
Y N
Check the PEST fault history, dC123 for marking unit heater faults (umbilicals, printheads
Y N
• Between PJ303 on the Marking Unit Driver PWB and the lower umbilical ther-
mistor. Measure the resistance between PJ303 pins B4 and B5. The resistance
is widely variable, but must not be an open circuit.
• Between PJ701 on the Marking Unit Heater PWB and the lower umbilical
heater. Measure the resistance between PJ701 pins 1 and 8. The resistance
should be approximately 80-100 ohms.
Marking Unit Fan
Refer to:
• Lower umbilical, PL 91.25 Item 10. Figure 1 Component Location
A B

A
93-545-00 to 93-548-00 Ink Melt Reservoir Conductivity Go to WD 9.9 and WD 9.16. Check the wiring between the ink level sensors, the solenoid
patch PWB and the marking unit driver PWB.
Error RAP Refer to:
93-545-00 The black melt reservoir ink conductivity is out of usable range. • P/J101, Marking Unit Driver PWB.
• PJ380, PJ 760, PJ780 Solenoid Patch PWB.
93-546-00 The magenta melt reservoir ink conductivity is out of usable range.
93-547-00 The cyan melt reservoir ink conductivity is out of usable range. • 01L 0V Distribution RAP
93-548-00 The yellow melt reservoir conductivity is out of usable range. • Ink reservoir, PL 93.10 Item 10.
• Ink level sensor cable (Ribbon cable), PL 93.10 Item 18.
Initial Actions • Marking unit driver PWB, PL 92.10 Item 4.
• Check for ink stick jams.
• Check for non Xerox ink sticks and report as appropriate.
• Check for wrong colour ink sticks loaded.
• Check that the ink sticks are in contact with the melt plate.
• Check that the tips of the melt plates are the correct colour.
• Check for reservoir contamination from ink shards getting into the incorrect colour reser-
voir.
• If the fault is generated when the machine exits power save mode, switch off, then switch
on the machine, GP 14.
• Re-load the software GP 4.
NOTE: If a ink reservoir or umbilical has been recently replaced and contamination has
occurred it may be due to a missing reservoir gasket, PL 91.20 Item 18 or PL 91.25 Item 18.
Procedure
WARNING
If the fault is 93-547-00 or 93-548-00 check for pieces of incorrect coloured ink stick falling from
the ink loader into the cyan or yellow reservoir buckets. The cyan and yellow reservoir
buckets are uncontaminated.
Y N
Check for bent melt plates dripping ink into incorrect locations, refer to service bulletin
T81155-09-25.
install new components as necessary:
• Reservoir cover, W/TAG 019, PL 93.10 Item 28.
• Ink loader melt plate assembly, PL 93.10 Item 3.
Check that the ink reservoir, PL 93.10 Item 10 is in good condition with no ink overflow. Check
for damage that may cause the reservoir to leak. The reservoir is good.
Y N
Check that the umbilical clamp fasteners are tight, refer to REP 91.31. If the fasteners are
loose, clean the area, then firmly tighten the fasteners. If necessary, install a new umbili-
cal clamp, PL 93.10 Item 27.
A
93-549-00 to 93-552-00 and 93-557-00 to 93-560-00 Procedure
Printheads 1 and 3 Printhead Reservoir Fill Error RAP
93-549-00 Head 1 black reservoir did not fill within the correct time. WARNING
93-550-00 Head 1 magenta reservoir did not fill within the correct time.
93-551-00 Head 1 cyan reservoir did not fill within the correct time.
93-552-00 Head 1 yellow reservoir did not fill within the correct time. CAUTION
Do not remove the solenoid patch PWB, PL 93.10 Item 9.
93-557-00 Head 3 black reservoir did not fill within the correct time.
NOTE: If the printhead reservoirs do not fill, it can cause massive jet loss. If necessary, refer to
93-558-00 Head 3 magenta reservoir did not fill within the correct time. the IQ 9 Deletions in the Process Direction RAP.
93-559-00 Head 3 cyan reservoir did not fill within the correct time. NOTE: The following check should be made under good lighting conditions or with the use of a
flashlight.
93-560-00 Head 3 yellow reservoir did not fill within the correct time. Move the marking unit into the service position, GP 6. Check that the air channels from ink res-
ervoir solenoids 5, 7, 11, 12, 15, 16, 17, and 19 are free of ink, Figure 1.
Initial Actions If the ink has blocked the air channels then install a new umbilical and ink reservoir at the same
time. Failure to replace both units will cause another ink reservoir failure.
NOTE: If he either of the following two conditions occur refer to Critical Service Bulletin C8090-
05-07 Updated Cyan Ink Processes and Mod Tag 22: NOTE: Some ink discolouration of the air channels is normal.
• The machine has five or more missing jets in cyan only on any printhead or has a cyan
The channels are free of ink.
printhead fill timeout fault 93-551 or 93-559.
Y N
• You suspect the machine was exposed to suspect cyan ink. Install a new lower umbilical, PL 91.25 Item 10 and new ink reservoir, PL 93.10 Item 10.
NOTE: New printheads are supplied with the correct level of ink. If a printhead fill timeout fault
occurs soon after installation of a new printhead, the fault is probably within the ink delivery Check that the print heads, drum and waste tray are clean, without excessive ink contamina-
system. tion.
Move the marking unit into the service position, GP 6, then check: NOTE: Excessive ink contamination will be obvious.
• The 4 screws securing the solenoid patch PWB (PL 93.10 Item 9) are not loose. If neces- The print heads, drum and waste tray are clean.
sary tighten the screws, then power the machine off and power the machine back on. If Y N
the faults remain continue with the procedure below. The print area is contaminated with excessive ink. The purge line is blocked. Perform the
• The check valves on the umbilicals are securely fixed to the umbilicals (PL 91.25 Item steps that follow:
19). If the clips are damaged install a new umbilical. • GP 27 Cleaning Procedure.
• Install a new purge line filter, PL 91.25 Item 9.
• Install a new purge line, PL 91.25 Item 11.
• If the ink contamination has reached the ink reservoir through the purge line, install a
new ink reservoir, PL 93.10 Item 10.
Go to WD 9.6, WD 9.7, WD 9.20, WD 9.21. Check the ribbon cables between the printheads
and the IME Controller PWB. Refer to:
• P/J101, P/J301, Printhead PWB
• P/J902, P/J904 IME controller PWB
The ribbon cables are good.
Y N
Re-seat the ribbon cables or install new cables, PL 92.10.

Xerox® ColorQube® 9203 Family 2-489 93-549-00 to 93-552-00 and 93-557-00 to 93-560-00
A B
Check that the level sense connection at PJ601 on the Printhead PWB is in good condition and • 01L 0V Distribution RAP
is properly and securely connected. The connection is good. Install new components as necessary:
Y N
• Ink Reservoir, PL 93.10 Item 10.
Install a new printhead, PL 91.20 Item 2, PL 91.25 Item 2.
Switch off the machine then switch on the machine GP 14. Allow the printheads to try and
Disconnect the air hose between the lower and upper purge hoses on the ink reservoir, Figure
2. recover. The fault is cleared
Y N
Enter dC330 and stack the code 93-050 to run the reservoir pump MOT93-050, PL 93.10 Item
Install a new ink reservoir PL 93.10 Item 10.
11 and code 91-045 low pressure assist valve SOL 91.045, PL 93.10 Item 15. The pump will
run for approximately 10 seconds. If the pump runs check the air pressure from the discon- NOTE: Before installing a new ink reservoir. Check that the 4 screws securing the sole-
nected air hose is sufficient to feel on the skin or partially inflate a rubber glove sealed to the air noid patch PWB are not loose. If necessary tighten but do not overtighten the screws.
hose. The pump runs sufficiently.
Y N The fault is still present.
Go to WD 9.14. Check the connection from the solenoid patch PWB to the reservoir pump Y N
motor (MOT93-050) at PJ130. Perform dC972 Printhead Uniformity.
Go to WD 9.14 and WD 9.12. Check the ink reservoir pump motor.
Refer to: Install new components;
• GP 10, How to Check a Motor. 1. Install the relevant new printhead PL 91.25 Item 2.
• P/J130, Solenoid patch PWB. NOTE: A new printhead is filled with the correct level of ink when installed. If a print-
• P/J801, Marking unit driver PWB head fill timeout occurs soon after replacing a printhead then suspect a fault in the
• 01E +12V Distribution RAP. components of the ink delivery system (Ink Reservoir, Umbilicals and Purge lines,
Marking Unit Driver PWB PL 92.10 Item 5).
Install new components as necessary: 2. Install a new IME controller PWB, PL 92.10 Item 1.
Reconnect the air hose from the pump to the ink reservoir, Figure 2.
Enter the correct dC330 code to check the ink reservoir solenoids:
• Purge solenoid valve 3, SOL93-061.
• Black ink solenoid valve 5, SOL93-063.
• Yellow ink solenoid valve 11, SOL93-069.
• Cyan ink solenoid valve 15, SOL93-073.
• Magenta ink solenoid valve 17, SOL93-075.
All solenoids energize
Y N
Go to WD 9.14, WD 9.15 and WD 9.12. Check the ink reservoir solenoids.
Refer to:
• P/J430, P/J110, P/J410, P/J610, P/J810 Solenoid patch PWB.
• P/J801, Marking unit driver PWB
B
93-549-00 to 93-552-00 and 93-557-00 to 93-560-00 2-490 Xerox® ColorQube® 9203 Family
Black ink reservoir
Solenoid patch
PWB
Lower purge hose pair

for the lower umbilical
Upper purge hose pair Disconnect the air hose
for the upper umbilical from the ink reservoir
Ink reservoir solenoids and the relevant channels
Figure 1 Component location Figure 2 Reservoir pump air hose

93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Procedure
Printheads 2 and 4 Printhead Reservoir Fill Error RAP
93-553-00 Head 2 black reservoir did not fill within the correct time. WARNING
93-554-00 Head 2 magenta reservoir did not fill within the correct time.
93-555-00 Head 2 cyan reservoir did not fill within the correct time.
93-556-00 Head 2 yellow reservoir did not fill within the correct time. CAUTION
Do not remove the solenoid patch PWB, PL 93.10 Item 9.
93-561-00 Head 4 black reservoir did not fill within the correct time.
NOTE: If the printhead reservoirs do not fill, it can cause massive jet loss. If necessary, refer to
93-562-00 Head 4 magenta reservoir did not fill within the correct time. the IQ 9 Deletions in the Process Direction RAP.
93-563-00 Head 4 cyan reservoir did not fill within the correct time. NOTE: The following check should be made under good lighting conditions or with the use of a
flashlight.
93-564-00 Head 4 yellow reservoir did not fill within the correct time. Move the marking unit into the service position, GP 6. Check that the air channels from ink res-
ervoir solenoids 6, 8, 9, 10, 13, 14, 18 and 20 are free of ink, Figure 1.
Initial Actions If the ink has blocked the air channels then install a new umbilical and ink reservoir at the same
time. Failure to replace both units will cause another ink reservoir failure.
NOTE: New printheads are supplied with the correct level of ink. If a printhead fill timeout fault
occurs soon after installation of a new printhead, the fault is probably within the ink delivery NOTE: Some ink discolouration of the air channels is normal.
system.
The channels are free of ink.
NOTE: If either of the following two conditions occur refer to Critical Service Bulletin C8090-05- Y N
07 Updated Cyan Ink Processes and Mod TAG 022: Install a new upper umbilical, PL 91.20 Item 10 and a new ink reservoir, PL 93.10 Item 10.
• The machine has five or more missing jets in cyan only on any printhead or has a cyan
printhead fill timeout fault 93-555 or 93-563. Check that the print area is clean, without excessive ink contamination.
• You suspect the machine was exposed to suspect cyan ink. NOTE: Excessive ink contamination will be obvious.
Move the marking unit into the service position, GP 6, then check: The print area is clean.
• The 4 screws securing the solenoid patch PWB (PL 93.10 Item 9) are not loose. If neces- Y N
sary tighten the screws, then power the machine off and power the machine back on. If The print area is contaminated with excessive ink. The purge line may be blocked. Per-
the faults remain continue with the procedure below. form the steps that follow:
• The check valves on the umbilicals are securely fixed to the umbilicals (PL 91.20 Item • GP 27 Cleaning Procedure.
19). If the clips are damaged install a new umbilical. • Install a new purge line filter PL 91.20 Item 9.
• If the ink contamination has reached the melt reservoir through the purge line, install
a new ink reservoir, PL 93.10 Item 10.
Move the marking unit to the service position, GP 6. Go to WD 9.5, WD 9.20, WD 9.21. Check
the ribbon cables between the printheads and the IME Controller PWB. Refer to:
• P/J101, P/J301, Printhead PWB
• P/J201, P/J301 IME controller PWB
The ribbon cables are good.
Y N
Re-seat the ribbon cables or install new cables, PL 92.10.
Check that the level sense connection at PJ601 on the Printhead PWB is in good condition and
is properly and securely connected. The connection is good.

93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 2-492 Xerox® ColorQube® 9203 Family
A
Install a new printhead, PL 91.20 Item 2.
Switch off, then switch on the machine GP 14, to try and allow the printheads to recover. The
Disconnect the air hose between the lower and upper purge hoses on the ink reservoir, Figure fault is cleared
2. Y N
Enter dC330 and stack the code 93-050 to run the reservoir pump MOT93-050, PL 93.10 Item Install a new ink reservoir PL 93.10 Item 10.
11 and code 91-045 low pressure assist valve SOL 91.045, PL 93.10 Item 15. The pump will Before installing a new ink reservoir. Check that the 4 screws securing the solenoid patch
run for approximately 10 seconds. If the pump runs check the air pressure from the discon- PWB are not loose. If necessary tighten but do not overtighten the screws. The fault is
nected air hose is sufficient to feel on the skin or partially inflate a rubber glove sealed to the air still present.
hose. The pump runs sufficiently. Y N
Y N Perform dC972 Printhead Uniformity.
Go to WD 9.14. Check the connection from the solenoid patch PWB to the reservoir pump
motor MOT93-050 at PJ130. Install new components as necessary:
Go to WD 9.14 and WD 9.12. Check the ink reservoir pump motor. • Install the relevant printhead PL 91.20 Item 2.
Refer to:
• P/J130, Solenoid patch PWB. Perform SCP 5 Final Actions.
Install new components as necessary: Black ink reservoir
• ink reservoir, PL 93.10 Item 10. Solenoid patch
PWB
All solenoids energise
Y N
Go to WD 9.12, WD 9.14 and WD 9.15. Check the ink reservoir solenoids. Ink reservoir solenoids and the relevant channels
Refer to:
• P/J430, P/J110, P/J410, P/J610, P/J810 Solenoid patch PWB.
A

93-565-00 to 93-599-00 and 93-800-00 to 93-812-00
Printheads 1, 2, 3 & 4 Ink Level Sense Error RAP
93-565-00 Head 1 black reservoir level sense failure
93-566-00 Head 1 magenta reservoir level sense failure
93-567-00 Head 1 cyan reservoir level sense failure
93-568-00 Head 1 yellow reservoir level sense failure
Lower purge hose pair 93-577-00 Head 4 black reservoir level sense failure
for the lower umbilical 93-578-00 Head 4 magenta reservoir level sense failure
for the upper umbilical from the reservoir 93-579-00 Head 4 cyan reservoir level sense failure
93-581-00 Head 1 black reservoir level sense open circuit
93-582-00 Head 1 magenta reservoir level sense open circuit
Figure 2 Reservoir pump air hose
93-583-00 Head 1 cyan reservoir level sense open circuit
93-584-00 Head 1 yellow reservoir level sense open circuit
93-597-00 Head 1 black reservoir level sense short circuit

93-553-00 to 93-556-00 and 93-561-00 to 93-564-00, 93- 2-494 Xerox® ColorQube® 9203 Family
93-598-00 Head 1 magenta reservoir level sense short circuit 93-813-00 to 93-820-00 Ink Melt Reservoir Level Sense
93-599-00 Head 1 cyan reservoir level sense short circuit Failure RAP
93-800-00 Head 1 yellow reservoir level sense short circuit 93-813-00 Black melt reservoir level sense open circuit
93-814-00 Magenta melt reservoir level sense open circuit
93-802-00 Head 2 magenta reservoir level sense short circuit
93-815-00 Cyan melt reservoir level sense open circuit
93-803-00 Head 2 cyan reservoir level sense short circuit
93-804-00 Head 2 yellow reservoir level sense short circuit 93-816-00 Yellow melt reservoir level sense open circuit
93-817-00 Black melt reservoir level sense short circuit
93-818-00 Magenta melt reservoir level sense short circuit
93-807-00 Head 3 cyan reservoir level sense short circuit
93-808-00 Head 3 yellow reservoir level sense short circuit 93-819-00 Cyan melt reservoir level sense short circuit
93-820-00 Yellow melt reservoir level sense short circuit
93-811-00 Head 4 cyan reservoir level sense short circuit Procedure
93-812-00 Head 4 yellow reservoir level sense short circuit
Procedure WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 1. If the ink sticks are not in contact with the melt plate correct the ink stick jam. Install new
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause components as necessary PL 93.10.
death or injury. Moving parts can cause injury. 2. Go to WD 9.9 and WD 9.16. Check the wiring between the ink level sensors, the solenoid
Verify the fault code. Go to the relevant RAP: patch PWB and the marking unit driver PWB.
• Head 1 and head 3 faults. Refer to:
– 93-549-00 to 93-552-00 and 93-557-00 to 93-560-00 Printheads 1 and 3 Printhead • P/J101, Marking unit driver PWB
Reservoir Fill Error RAP • P/J380, P/J760, P/J780 Solenoid patch PWB.
• Head 2 and head 4 faults. • 01B +3.3V ESTAR Distribution RAP.
– 93-553-00 to 93-556-00 and 93-561-00 to 93-564-00 Printheads 2 and 4 Printhead • 01L 0V Distribution RAP
Reservoir Fill Error RAP 3. If the sensor continues to report a fault, install a new ink melt reservoir, PL 93.10 Item 10.
4. Install new components as necessary:
• Ink reservoir, PL 93.10 Item 10.

Xerox® ColorQube® 9203 Family 2-495 93-565-00 to 93-599-00 and 93-800-00 to 93-812-00,
93-825-00, 93-892-00 Ink Key Plate Motor Over Current 93-871-00 to 93-874-00 Ink Level Sense Error RAP
RAP 93-871-00 Black melt reservoir level sense failure.
93-825-00 The ink key plate motor is over current.
93-872-00 Magenta melt reservoir level sense failure
93-892-00 Indicates an over current interrupt from the motor driver chip.
93-873-00 Cyan melt reservoir level sense failure
Initial Actions 93-874-00 Yellow melt reservoir level sense failure
Procedure
WARNING
• Clean the ink loading area to ensure that the ink key plate moves smoothly. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Procedure Go to WD 9.9 and WD 9.16. Check the wiring between the ink level sensors, the solenoid
patch PWB and the marking unit driver PWB.
CAUTION
Refer to:
The ink key motor can overheat if run repeatedly. Allow 2 minutes between each run of the ink
• P/J101, Marking Unit Driver PWB
key motor.
• P/J380, P/J760, P/J780 Solenoid Patch PWB.
Enter dC330 code 93-051 or 052 or 053, to run the ink key plate motor, MOT93-051, PL 93.10
Item 14. MOT93-051 runs. • 01B +3.3V ESTAR Distribution RAP.
Y N • 01L 0V Distribution RAP
Go to WD 8.4. Check MOT93-051. Install new components as necessary.
Refer to: • Ink reservoir, PL 93.10 Item 10.
• GP 10 How to Check a Motor. • Marking unit driver PWB, PL 92.10 Item 4.
• P/J406, Media path driver PWB.
NOTE: Ink level sense errors can be caused by ink cross contamination. If the machine was
recently moved, cross contamination may have occurred. If the cross contamination is severe,
• 01L 0V Distribution RAP it may be necessary to install a new ink reservoir, PL 93.10 Item 10.
• Ink key plate motor, PL 93.10 Item 14.
• Ink loader upper assembly, PL 93.10 Item 1.
The key plate moves when the motor runs.

Y N
Clean the ink loading area to ensure that the ink key plate moves smoothly. If necessary,
install a new ink loader upper assembly, PL 93.10 Item 1.
The fault may be intermittent, check the wiring to the ink key plate motor. If necessary, install a
new ink loader upper assembly, PL 93.10 Item 1.

93-890-00 Marking Unit Air Solenoid Over Current RAP 93-891-00 Ink Transport Over Current RAP
93-890-00 The marking unit air solenoid is taking too much current. 93-891-00 The ink transport motor is taking too much current.
WARNING WARNING
Go to the 91-516-00 Low Pressure Assist Over Current RAP. • Check the ink loader assembly for debris blocking the transport belts.
• Check the ink loader for damage close to the transport motor.
Procedure
Enter dC330 codes 93-048 and 93-049 to run the ink transport motor PL 93.10 Item 5, forward
and in reverse. The motor runs.
Y N
Go to WD 8.4. Check the ink transport motor.
Refer to:
• 01H +24V Distribution RAP
• Ink transport motor, PL 93.10 Item 5.
The ink stick transport belts move.

Y N
• Ink transport drive gear, PL 93.10 Item 6.
• Ink loader upper assembly, PL 93.10 Item 1.
• Check for obstructions and debris that may cause the transport belts to jam intermittently.
• Check for damage to the ink loader upper assembly, PL 93.10 Item 1.

93-901-00 to 93-904-00 Ink Melt Reservoir Fill Failure RAP 93-909-00 to 93-924-00 Printhead Reservoir Level Failure
93-901-00 Black melt reservoir over fill failure RAP
93-902-00 Magenta melt reservoir over fill failure 93-909-00 Head 1 black reservoir level sense failure
93-903-00 Cyan melt reservoir over fill failure
93-904-00 Yellow melt reservoir over fill failure
Procedure
WARNING 93-913-00 Head 2 black reservoir level sense failure

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 93-914-00 Head 2 magenta reservoir level sense failure
WARNING 93-916-00 Head 2 yellow reservoir level sense failure

Ensure that the melt plates on the ink loader are operating correctly. Check the last 40 faults for 93-918-00 Head 3 magenta reservoir level sense failure
the following codes:
• 93-523 to 534, 93-861 to 864 and 866 to 869 93-919-00 Head 3 cyan reservoir level sense failure
The last 40 faults is clear of ink melt plate faults
Y N 93-920-00 Head 3 yellow reservoir level sense failure
Perform the relevant RAP:
• 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00, 93-533-00 Ink Melt 93-921-00 Head 4 black reservoir level sense failure
Error RAP
• 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Thermistor Error RAP
Perform dC612 Print Test Pattern. Run 100 solid fills of the affected colour. Check the ink 93-923-00 Head 4 cyan reservoir level sense failure
melt reservoir for overfill. The ink reservoir is good.
Y N 93-924-00 Head 4 yellow reservoir level sense failure
Go back to the beginning of this RAP.
Procedure
Go to WD 9.9 and WD 9.16. Check the wiring between the ink level sensors, the solenoid
patch PWB and the marking unit driver PWB. Refer to: WARNING
• P/J101, Marking unit driver PWB Ensure that the electricity to the machine is switched off while performing tasks that do
• P/J380, P/J760, P/J780 Solenoid patch PWB.
Clear the fault code by:
• Power the machine off and power the machine back on.
The wiring is good.
Y N
Repair the wiring REP 1.1.


93-933-00 to 93-936-00 Head Purge Failure RAP 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP
93-933-00 Head 1 purge failure 93-937-00 A leak has been detected in the black melt reservoir
93-934-00 Head 2 purge failure 93-938-00 A leak has been detected in the magenta melt reservoir
93-935-00 Head 3 purge failure 93-939-00 A leak has been detected in the cyan melt reservoir
93-936-00 Head 4 purge failure 93-940-00 A leak has been detected in the yellow melt reservoir
WARNING WARNING
Check that all purge lines are connected. Re-install all purge lines as necessary.
Procedure WARNING
Check the purge line components for damage. Ensure that the purge lines are clean and not
contaminated. Ensure that the purge line is connected to the ink melt reservoir The purge Clean ink leakages as necessary, refer to GP 27.
line are clean and undamaged
Y N Procedure
Install new components as necessary: Check the following:
• Purge line, PL 91.20 Item 11. • That the ink reservoir, PL 93.10 Item 10 is installed correctly and not damaged.
• Purge line filter, PL 91.20 Item 9. • That the upper umbilical, PL 91.20 Item 10 is installed correctly and not damaged. Also
• Ink reservoir, PL 93.10 Item 10 check the connection between the upper umbilical to ink melt reservoir. Ensure the gasket
• Printhead, PL 91.20 Item 2 is installed correctly. Refer to REP 91.31.
• That the lower umbilical, PL 91.25 Item 10 is installed correctly and not damaged. Also
Perform 93A Ink melt reservoir check. check the connection between the lower umbilical to ink melt reservoir. Ensure the gasket
is installed correctly. Refer to REP 91.31.
The components are good
Y N
• Umbilical clamp, PL 93.10 Item 27.
• Lower umbilical, PL 91.25 Item 10.
Check the wiring and connectors between PJ101 on the Marking Unit Driver PWB and PJ760
on the Solenoid patch PWB. Repair the wiring as necessary, REP 1.1. If necessary install new
components:

A
93A Ink Melt Reservoir Check Install new components as necessary:
Procedure
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do • Purge solenoid valve 1, SOL93-059.
WARNING • Black ink solenoid valve 5, SOL93-063.
Do not touch the ink loader melt plates while the machine is switched on. Dangerous • Black ink solenoid valve 6, SOL93-064.
voltages may be present that could cause death or injury. • Black ink solenoid valve 7, SOL93-065.
Check the following: • Black ink solenoid valve 8, SOL93-066.
• That the ink melt reservoir, PL 93.10 Item 10 is installed correctly and not damaged. • Yellow ink solenoid valve 9, SOL93-067.
• That the upper umbilical, PL 91.20 Item 10 is installed correctly and not damaged. Also • Yellow ink solenoid valve 10, SOL93-068.
check for leaks at the connection between the upper umbilical to ink melt reservoir. Refer • Yellow ink solenoid valve 11, SOL93-069.
to REP 91.31.
• That the lower umbilical, PL 91.25 Item 10 is installed correctly and not damaged. Also
check for leaks at the connection between the lower umbilical to ink melt reservoir. Refer
to REP 91.31. • Cyan ink solenoid valve 14, SOL93-072.
• That the air tubes, part of the ink reservoir, PL 93.10 Item 10 are installed correctly and • Cyan ink solenoid valve 15, SOL93-073.
not damaged. • Cyan ink solenoid valve 16, SOL93-074.
The components are good • Magenta ink solenoid valve 17, SOL93-075.
Y N • Magenta ink solenoid valve 18, SOL93-076.
Install new components as necessary: • Magenta ink solenoid valve 19, SOL93-077.
• Umbilical clamp, PL 93.10 Item 27. • Magenta ink solenoid valve 20, SOL93-078.
• Ink reservoir, PL 93.10 Item 10. All solenoids energise
• Upper umbilical, PL 91.20 Item 10. Y N
• Lower umbilical, PL 91.25 Item 10. Go to WD 9.14, WD 9.15 and WD 9.12. Check the ink reservoir solenoids.
Refer to:
Move the marking unit to the service position, GP 6. • GP 12, How to Check a Solenoid.
Disconnect the air hose between the lower and upper purge hoses on the ink reservoir, Figure • P/J430, P/J110, P/J410, P/J610, P/J810 Solenoid patch PWB.
1.
Enter dC330 and stack the code 93-050 to run the ink reservoir pump MOT93-050, PL 93.10
Item 11 and code 91-045 low pressure assist valve SOL 91.045, PL 93.10 Item 15. The pump • 01H +24V Distribution RAP.
will run for approximately 10 seconds. If the pump runs, then the air pressure from the discon- • 01L 0V Distribution RAP
nected air hose is sufficient to feel on the skin. The pump runs Install new components as necessary:
Y N • Ink Reservoir, PL 93.10 Item 10.
Go to WD 9.14 and WD 9.12. Check the ink reservoir pump.
Refer to:
• GP 10, How to Check a Motor. Turn the machine off, then on, GP 14. Check the PEST log for the following codes:
• P/J130, Solenoid patch PWB. • For 99-150-00 to 99-153-00, go to the 99-142-00 to 99-168-00 PEST Error 4 RAP.
• P/J801, Marking unit driver PWB • For 99-292-00 to 99-312-00, go to the 99-293-00 to 99-312-00 PEST Error 9 RAP.
• 01E +12V Distribution RAP. • For 99-460-00, go to the 99-444-00 to 99-460-00 PEST Error 16 RAP.
• 01L 0V Distribution RAP • For 99-461-00 to 99-467-00 or 99-470-00 to 99-477-00, go to the 99-461-00 to 99-477-00
PEST Error 17 RAP.
A
• For 99-480-00 to 99-496-00, go to the 99-480-00 to 99-496-00 PEST Error 18 RAP. 93B Ink Leak Checkout RAP
• For 99-497-00 to 99-507-00, go to the 99-497-00 to 99-515-00 PEST Error 19 RAP. This RAP is to be used when an ink leak is present in the machine.
• For 99-530-00 to 99-533-00, go to the 99-516-00 to 99-533-00 PEST Error 20 RAP.
• For 99-564-00, 99-565-00 or 99-568-00 to 99-580-00, go to the 99-564-00 to 99-580-00 Procedure
PEST Error 23 RAP.
• For 99-680-00 to 99-685-00, go to the 99-671-00 to 99-685-00 PEST Error 30 RAP.
• For 99-686-00 to 99-700-00, go to the 99-686-00 to 99-700-00 PEST Error 31 RAP. WARNING
• For 99-701-00 to 99-706-00, go to the 99-701-00 to 99-722-00 PEST Error 32 RAP. Ensure that the electricity to the machine is switched off while performing tasks that do
CAUTION
Wait for the ink and other components to cool before attempting the removal procedures.
Check the following areas for leaking ink:
• Umbilical / Ink reservoir connection. If present perform the following:
1. Remove the umbilicals, refer to REP 91.31.
2. Check the connection and gasket. Clean as necessary, refer to GP 27.
3. Reassemble the components.
• Umbilical / printhead connection, If present perform the following:
1. Remove the printhead, refer to REP 91.29.
2. Check the connection and gasket. Clean as necessary, refer to GP 27.
3. Reassemble the components.
• Ink reservoir or umbilical leaking elsewhere, If present perform the following:
– Umbilical clamp, PL 93.10 Item 27.
– Upper umbilical, PL 91.20 Item 10.
Lower purge hose pair – Lower umbilical, PL 91.25 Item 10.
for the lower umbilical – Ink reservoir, PL 93.10 Item 10.
for the upper umbilical from the ink reservoir 2. Clean ink leakages as necessary, refer to GP 27.
• Printheads leaking elsewhere, if present perform the following:
– Upper printhead, PL 91.20 Item 2.
– Lower printhead, PL 91.25 Item 2.
Figure 1 Reservoir pump air hose 2. Clean ink leakages as necessary, refer to GP 27.
• Check melt plates and melt plate housing for debris that can cause incorrect delivery of
ink from loader to ink reservoir.
• Check for correct ink loader installation.

94-504-00, 94-505-00 Cleaning Unit Reservoir Pressure 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00
Error RAP Cleaning Unit Over Current RAP
94-504-00 Cleaning unit reservoir pressure is too low 94-506-00 Cleaning unit pressure sensor open.
94-505-00 Cleaning unit reservoir pressure is too high 94-527-00 Oil delivery pump (early life) is taking too much current
Procedure 94-528-00 Drum driver oil pump 1 is taking too much current.
94-531-00 Oil removal pump (early life) is taking too much current
WARNING
94-532-00 Drum driver oil pump 2 is taking too much current.
94-533-00 Drum driver oil valve is taking too much current.
Procedure
CAUTION
print quality defects. WARNING
CAUTION
Do not re-use a cleaning unit that has oil contamination.
Install a new cleaning unit, PL 94.10 Item 21, then continue with the procedure.
CAUTION
NOTE: Ensure the new cleaning unit is above 6 degrees Celsius or 43 degrees Fahrenheit. Do Use care when working near the drum. The drum can be damaged easily, which will cause
not install a very cold cleaning unit. print quality defects.
Cheat the front door interlock. Listen at the front of the cleaning unit. The cleaning unit can Install a new Cleaning Unit, PL 94.10 Item 21 and continue with the procedure.
be heard running.
NOTE: Ensure the new cleaning unit is above 6 degrees Celsius or 43 degrees Fahrenheit. Do
Y N
not install a very cold cleaning unit.
The fault is still present with the new cleaning unit.
If the sound of the pump can be heard, immediately remove the front door interlock cheat. Y N
Remove the new cleaning unit. Remove the drum drive motor and belt, refer to REP 91.24. Perform SCP 5 Final Actions.
Check that the 12 pin connector on the rear of the machine is not contaminated, damaged and
connected correctly. If necessary, install a new 12 pin connector, PL 94.10 Item 6. Remove the cleaning unit, refer to REP 94.1. Remove the drum drive motor and belt, refer to
Go to WD 9.2, WD 9.4 and WD 9.19. Check the wiring between the cleaning unit and the drum REP 91.24. Check the 12 pin connector, PL 94.10 Item 6. Go to WD 9.2. Check the wiring
driver PWB. Repair the wiring as necessary, REP 1.1 or install a new harness, PL 1.15 Item between the cleaning unit and the drum driver PWB. Repair the wiring as necessary, REP 1.1
17. Cheat the front door interlock. Listen at the front of the cleaning unit. The cleaning unit or install a new harness, PL 1.15 Item 17.
can be heard running. Install new components as necessary:
Y N • 12 pin connector, PL 94.10 Item 6.
If the sound of the pump can be heard, immediately remove the front door interlock cheat.
Remove the new cleaning unit. Install a new drum driver PWB, PL 1.15 Item 4. Cheat the front
door interlock. Listen at the front of the cleaning unit. The cleaning unit can be heard run-
ning.
Y N
Check for grounding faults, go to GP 7 System Grounding Verification.

94-510-00, 94-512-00 Drum Image Initial Position Error RAP 94-514-00, 94-518-00 Drum Imaging Error RAP
94-510-00 The imaging software detected the drum at the wrong position. 94-514-00 Image data not ready when needed during drum revolution
94-512-00 The drum has stalled during imaging. 94-518-00 Software timing error during imaging
Procedure Procedure
WARNING WARNING
1. Perform the 94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP. 1. Reload the software, GP 4 Machine Software.
2. If the fault remains, reload the software, GP 4 Machine Software. 2. If the fault remains, install a new IME controller PWB, PL 92.10 Item 1.

94-519-00 Drum Imaging Error RAP 94-520-00 Cleaning Unit Drive Error RAP
94-519-00 Drum Imaging Failure 94-520-00 Cleaning unit motor is taking too much current.
Procedure Procedure
WARNING WARNING
1. Perform the 94B Drum Drive Control Test Actions RAP. Go to dC123 Pest Fault History and check for faults related to the drum, drum drive or drum
2. If the fault remains, install a new IME controller PWB, PL 92.10 Item 1. control components.
Go to dC959 Cleaning Unit Exerciser. Perform a full speed exercise. The fault remains.
Y N
Go to dC959 Cleaning Unit Exerciser. Perform a slow speed exercise. The fault remains.
Y N

1. Remove the drum drive motor and belt, refer to REP 91.24. Check the 12 pin connector,
PL 94.10 Item 6.
2. Go to WD 9.2. Check the wiring between the cleaning unit and the drum driver PWB.
Repair the wiring as necessary, REP 1.1 or install a new harness, PL 1.15 Item 17.
• 12 pin connector, PL 94.10 Item 6.
• Cleaning unit motor assembly, PL 94.10 Item 19.

A B
94-522-00 Cleaning Unit Motor Stall RAP Enter dC330 code 94-105 to monitor the cleaning unit home sensor, PL 94.10 Item 17.
Use a screwdriver to manually rotate the camshaft. Ensure that cam rotates through the
94-522-00 Cleaning unit motor stall.
whole of allowable travel. The display changes.
Y N
Procedure Go to WD 9.3. Check the cleaning unit motor and encoder.
Refer to:
WARNING
• P/J802 Drum driver PWB.
Go to dC123 Pest Fault History and check for faults related to the drum, drum drive or drum Reinstall the original cleaning unit. Install new components as necessary:
control components. • Cleaning unit home sensor, PL 94.10 Item 17.
Go to dC959 Cleaning Unit Exerciser. Perform a full speed exercise. The fault remains. • Cleaning unit motor assembly, PL 94.10 Item 19.
Y N • Drum driver PWB, PL 1.15 Item 4.
Check that the camshaft rotates freely. The camshaft rotates freely.
Go to dC959 Cleaning Unit Exerciser. Perform a slow speed exercise. The fault remains. Y N
Y N Perform the following:
1. Inspect the camshaft for obstructions that would prevent it from moving freely.
Print TP 20 Oil Bar Chase and Metering Blade Timing Test Pages. Evaluate the metering blade 2. Remove the camshaft assembly, PL 94.10 Item 4, REP 91.32. Check the bush-
timing test page only. The metering blade engages and disengages with the drum cor- ings, PL 94.10 Item 8 and PL 94.10 Item 14 for wear or damage. Install new
rectly. components as necessary:
Y N • Camshaft assembly, PL 94.10 Item 4.
Remove the cleaning unit, refer to REP 94.1. Ensure the cleaning unit camshaft is • Cleaning unit motor assembly, PL 94.10 Item 19.
unlocked, refer to REP 91.32, Figure 4. If necessary, use a screwdriver to manually rotate
the cam shaft, Figure 1. Go to dC959 Cleaning Unit Exerciser. Perform a full speed exer- Remove the drum drive motor and belt, refer to REP 91.24. Check the 12 pin connector,
ciser. The fault remains. PL 94.10 Item 6. Go to WD 9.2. Check the wiring between the cleaning unit and the drum
Y N driver PWB. Repair the wiring as necessary, REP 1.1 or install a new harness, PL 1.15
Install a new cleaning unit, PL 94.10 Item 21. Go to dC959 Cleaning Unit Exerciser. Item 17.
Perform a full speed exercise. The fault remains. Install new components as necessary:
Y N • 12 pin connector, PL 94.10 Item 6.
Reinstall the original cleaning unit.
Enter dC140 code 94-103 to monitor the cleaning unit motor encoder, PL 94.10 Item 20.
Use a screwdriver to manually rotate the cam shaft. The display changes.
Y N
Go to WD 9.2 and WD 9.3. Check the cleaning unit motor and encoder.
Refer to:
• P/J601, P/J802 Drum driver PWB.
• 01D+5V Distribution RAP.
Reinstall the original cleaning unit. Install new components as necessary:
• Cleaning unit motor assembly, PL 94.10 Item 19.
A B
94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP
94-524-00 Drum drive motor is taking too much current.
94-526-00 Drum has stalled
94-534-00 Drum belt is slipping
Initial Actions
WARNING
CAUTION
• Check that the print media loaded into all of the trays matches the UI display for each tray.
If necessary correct the settings or load the correct media. Media that is too thick for the
machine settings will cause drive errors.
• Check the trays for mixed media weights and correct if necessary.
• Check for evidence of multi-feeds. Multiple sheets of media may cause drum drive errors.
If multi-feeds are indicated go to OF 8 Multi-feed RAP.
Procedure
Go to dC123 Pest Fault History and check for faults related to the drum, drum drive or drum
control components.
Go to 94B Drum Drive Control Test Actions RAP. Return to this RAP if the drum drive control
test does not resolve the problem.
Refer to Figure 1. Perform the following:

Cam shaft
1. While the transfix roller is not loaded, spin the roller. Check that the roller spins freely
without binding or generating unusual noise. Check the surface of the transfix roller for
contamination or damage. Install new components as necessary, PL 10.20.
2. Re-enter the transfix calibration values, dC978.
NOTE: The calibration values are found on a label on the drum frame behind the inner
cover, PL 81.11 Item 2.
3. Go to WD 1.1, WD 9.1 and WD 9.3. Check the wiring between the drum drive motor
encoder and the Drum driver PWB, PJ501 and PJ802. Repair the wiring as necessary,
REP 1.1. If necessary install a new harness:
• Drum driver to front components harness (PJ501), PL 1.15 Item 14.
• Cleaning unit interface harness (PJ601, PJ802), PL 1.15 Item 17.

4. Remove the drum and abatement fan assembly, refer to REP 91.24. Manually rotate the
drum. If the drum motor abruptly rotates about the motor pivot, check for contamination of
the drum pulley and contamination or damage to the drum belt. If a thump is felt or a
Rear transfix motor and
squeak is heard every drum cycle install a new drum position encoder assembly, PL encoder
94.20 Item 8.
Perform the necessary actions:
• Clean the drum pulley, GP 27.
Rear transfix flexure
• Clean inside surface of the drum belt, GP 27, and remove any loose fibers. encoder
• If necessary install a new belt, PL 94.20 Item 2.
5. Check the drum belt tensioner. Make sure that the tensioner is latched correctly and
applying tension to the drum belt. Release the drum belt tension. Make sure that the drum
drive motor pivots freely.
6. Remove the drum drive motor, REP 91.24. Perform the following:
• Check that the motor shaft rotates freely.
Front transfix motor and
• Check for a resistance of 510 to 1800 ohms across pins 1 and 6 of the drum drive
encoder
motor encoder.
• Check the resistance of the winding on the drum drive motor. The resistance should
be in the range 9 to 12 ohms. Check across pin 1 and pin 2, pin 2 and pin 3 and pin
Screwdriver slot (also at Front transfix flexure
1 and pin 3, all three values should be the same. If the resistance is outside of this
rear) encoder
range, install a new drum drive motor, PL 94.20 Item 6.
• If necessary, install a new drum drive motor, PL 94.20 Item 6.
NOTE: A defective or dirty drum position encoder may be the cause of drum drive faults.
The machine compares the output of the drum position encoder, PL 94.20 Item 8 with the
drum drive motor encoder situated within the drum drive motor, PL 94.20 Item 6. When
the two outputs do not correlate as expected the machine assumes the difference is
caused by a drum drive belt slip.
7. Go to WD 1.1 and WD 9.1. Check the wiring between the drum position encoder and the
drum driver PWB. Refer to:
• ETI #1274748 encoder full of dust or oil
• Drum position encoder assembly, PL 94.20 Item 8. Transfix value label (on
• Drum driver PWB, PL 1.15 Item 4. front of drum frame)
8. Check system grounds, refer to GP 7. Pay particular attention to the media path baffles,
transfix roller, and drum ground connections.
9. Install new components as necessary: Figure 1 Transfix component locations
• Drum drive motor, PL 94.20 Item 6.

94-535-00 Drum Driver Command Current Error RAP 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
94-535-00 The drum driver PWB fails to monitor the drum drive current. 546-00, 94-632-00, 94-633-00 Drum Heat Error RAP
94-536-00 Drum front heater is too hot
Procedure
94-538-00 Drum front heater is heating too slowly
NOTE: If this fault occurs immediately after installing a new power supply unit, refer to Eureka
TIP 1322829 for additional information.
94-540-00 Drum front thermistor is faulty
94-542-00 Drum rear heater is too hot

WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 94-544-00 Drum rear heater is heating too slowly
death or injury. Moving parts can cause injury. 94-546-00 Drum rear thermistor is faulty
Refer to:
NOTE: Field engineering have reported that the following two fault codes 94-632-00 and 94-
• P/JDC2, Power supply unit.
633-00 have appeared during the normal printing process, with 99% of their occurrences hav-
• P/J603, Drum driver PWB. ing no consequences. Therefore, it is advised that either code can be treated as a soft fault
Perform the following: code and generally ignored unless either fault code reoccurs persistently.
1. Switch off the machine, then switch on the machine, GP 14. Check for PEST faults then
94-632-00 Drum front heater went unstable while printing
perform the relevant RAP.
2. Go to WD 9.2. Check the ribbon cable, PL 1.15 Item 10 between the power supply unit 94-633-00 Drum rear heater went unstable while printing
and the drum driver PWB.
3. Install new components as necessary: Initial Actions
• Drum driver power supply interface cable, PL 1.15 Item 10. Check that the machine is installed to allow adequate airflow. Refer to GP 21 Installation Space
• Drum driver PWB, PL 1.15 Item 4. Requirements.
• Power supply unit, PL 1.15 Item 2. Procedure
WARNING
Enter dC330 code 42-064 to run the drum fan, PL 94.20 Item 4. The fan runs.
Y N
Go to WD 9.1. Check the drum fan.
Refer to:
• OF 6 Fans and Air Systems RAP.
• Drum fan, PL 94.20 Item 4.

A
Enter dC335 Heater Monitor and Exerciser. Select the front drum heater. Set the Setpoint 94-545-00 Drum Runout Calibration Error RAP
Mode to Ready. Select Graph to run the test. Check that the temperature is correct and stable.
94-545-00 Drum runout calibration error - Drum motor encoder
Repeat the test for the rear drum heater.
NOTE: If the drum heater test fails to work correctly. Switch the machine off and then on, GP Procedure
14. Enter dC335 and rerun the drum heater test.
The tests were good.

Y N WARNING
Go to WD 1.2, WD 9.1 and WD 9.3. Check the wiring between: Ensure that the electricity to the machine is switched off while performing tasks that do
• The power supply unit and the drum heaters. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• The power supply unit and the thermal cutout PWB.
Go to dC123 Pest Fault History and check for faults related to the drum, drum drive or drum
• The drum driver PWB and the front and rear thermistors.
control components.
Refer to: Enter dC140 code 94-101 to monitor the drum drive motor encoder. Manually rotate the drum.
• P/J5AC, Power supply unit. The display changes
• P/J501, P/J801 Drum Driver PWB Y N
• 01A AC Power Distribution RAP. Go to WD 1.1 and WD 9.3. Check the wiring between the drum drive motor encoder and
the drum driver PWB.
Refer to:
• Front drum thermistor PL 94.20 Item 9
• Rear drum thermistor, PL 94.20 Item 10.
• Drum, PL 94.20 Item 1.
• Thermal cutout PWB, PL 88.10 Item 11. Go to 94B Drum Drive Control Test Actions RAP. Return to this RAP if the drum drive control
test does not resolve the problem.
The fault may be intermittent. Go to WD 1.2, WD 9.1 and WD 9.3. Check for loose connections
between:
• The power supply unit and the drum heaters.
• The power supply unit and the thermal cutout PWB.
• The drum driver PWB and the front and rear thermistors.
Refer to:
• P/J5AC Power supply unit.
• P/J501, P/J801 Drum driver PWB
• 01A, AC Power Distribution RAP.
• 01B, +3.3V ESTAR Distribution RAP.
• Front drum thermistor, PL 94.20 Item 9.
• Drum, PL 94.20 Item 1.
• Thermal cutout PWB, PL 88.10 Item 11.

94-547-00, 94-555-00 Y-Axis Belt Ratio Error RAP 94-548-00 Y-Axis Position Error RAP
94-547-00 Y-axis belt ratio error. 94-548-00 The drum position was incorrect after repositioning.
94-555-00 Y-axis belt ratio hard error. Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1. Perform the 94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP.
2. If the fault remains, reload the software, GP 4 Machine Software.
1. Check the drum belt tensioner. Make sure that the tensioner is latched correctly and
applying tension to the drum belt. Release the drum belt tension. Make sure that the drum
drive motor pivots freely.
2. Remove the drum belt, PL 94.20 Item 2. Check the drum belt for contamination or dam-
age. Clean the drum belt as necessary, GP 27.
3. For fault 94-547-00. Check the drum drive motor pulley for contamination, clean as nec-
essary, GP 27.
4. Install a new drum belt, PL 94.20 Item 2.

94-549-00 Drum Runout Calibration Error RAP 94-551-00, 94-552-00, 94-553-00 Drum Y-Axis Error RAP
94-549-00 Drum runout calibration - drum encoder 94-551-00 Drum Y-axis home calculation error.
Procedure 94-552-00 Drum Y-axis Initialization error.
94-553-00 Drum Y-axis home data error.

WARNING
Go to dC123 Pest Fault History and check for faults related to the drum, drum drive or drum WARNING
control components.
Enter dC140 code 94-102 to monitor the drum encoder. Manually rotate the drum. The dis-
play changes
Y N
Go to WD 9.1. Check the wiring between the drum encoder and the drum driver PWB 1. Perform the 94-524-00, 94-526-00, 94-534-00 Drum Drive Error RAP.
Refer to: 2. If the fault remains, reload the software, GP 4 Machine Software.
• Drum encoder, PL 94.20 Item 8.
The wiring is good.
Y N
Remove the drum drive motor, PL 94.20 Item 6. Check that the motor shaft rotates freely. The
motor shaft rotates freely.
Y N
Install a new drum drive motor, PL 94.20 Item 6.
With the drum drive motor removed, check rotation of the drum. The drum rotates freely.
Y N
Go to WD 9.1. Check the wiring between the drum position encoder and the drum driver PWB.
Refer to:
The wiring is good.
Y N

94-558-00, 94-560-00, 94-562-00, 94-564-00, 94-566-00 94-568-00, 94-570-00, 94-572-00, 94-573-00 Cleaning Unit I/
Cleaning Unit Position Error RAP O Error RAP
94-558-00 Cleaning unit timing error 94-568-00 Cleaning unit usage data read error
94-560-00 Cleaning unit position error 94-570-00 Cleaning unit usage data write error
94-562-00 Cleaning unit fast forward home time-out 94-572-00 Cleaning unit usage data detect error
94-564-00 Cleaning unit slow forward home time-out 94-573-00 Cleaning unit usage data version error
94-566-00 Cleaning unit reverse home time-out Procedure
Procedure
WARNING
CAUTION
1. Remove the cleaning unit, refer to REP 94.1 and inspect for damage, torn paper or debris
in the cleaning unit. Install a new cleaning unit as necessary, PL 94.10 Item 21. Use care when working near the drum. The drum can be damaged easily, which will cause
2. Go to the 94-520-00 Cleaning Unit Drive Error RAP.
Install a new cleaning unit, PL 94.10 Item 21 and continue with the procedure.
The fault is still present.

Y N
Remove the cleaning unit. Remove the drum drive motor and belt, refer to REP 91.24. Check
the 12 pin connector, PL 94.10 Item 6. Go to WD 9.2 and WD 9.4. Check the wiring between
the cleaning unit and the drum driver PWB. Repair the wiring as necessary, REP 1.1 or install a
new harness, PL 1.15 Item 17.
• 12 pin connector, PL 94.10 Item 6.

94-574-00 Cleaning Unit Sync Error RAP 94-610-00 to 94-612-00 Cleaning Unit Error RAP
94-574-00 Cleaning unit sync access error 94-610-00 Cleaning unit delivery pump test fail
Procedure 94-611-00 Cleaning unit removal pump test fail
94-612-00 Cleaning unit valve test fail

WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause For error code 94-610-00, 94-611-00 or 94-612-00, immediately perform REP 94.1 Cleaning
death or injury. Moving parts can cause injury. Unit, then return to this RAP and perform the procedure.
Procedure
WARNING
Go to the 94-504-00, 94-505-00 Cleaning Unit Reservoir Pressure Error RAP.

94-615-00 Non Xerox Cleaning Unit Detected RAP 94-616-00 Cleaning Unit Low Oil Detected RAP
94-615-00 A non Xerox cleaning unit is detected 94-616-00 Low oil is detected in the cleaning unit, before the scheduled end of life.
Procedure Procedure
WARNING WARNING
NOTE: This procedure is only for when the machine does not recognize a genuine Xerox
cleaning unit. CAUTION
Verify that the cleaning unit is a Xerox item. Remove, then re-install the cleaning unit. If the Use care when working near the drum. The drum can be damaged easily, which will cause
fault remains, install a new cleaning unit, PL 94.10. print quality defects.
CAUTION
Install a new cleaning unit, PL 94.10 Item 21 and continue with the procedure.
Cheat the front door interlock. Listen at the front of the cleaning unit. The cleaning unit can
be heard running.
Y N
Go to and perform the Second Procedure.
Remove the new cleaning unit. Remove the drum drive motor and belt, refer to REP 91.24.
Check that the 12 pin connector on the rear of the machine is connected correctly and not
damaged. If necessary, install a new connector 12 pin, PL 94.10 Item 6.
Go to WD 9.2, WD 9.4 and WD 9.19. Check the wiring between the cleaning unit and the drum
driver PWB. Repair the wiring as necessary, REP 1.1 or install a new harness, PL 1.15 Item
17. Cheat the front door interlock. Listen at the front of the cleaning unit. The cleaning unit
can be heard running.
Y N
Remove the new cleaning unit. Install a new drum driver PWB, PL 1.15 Item 4. Cheat the front
door interlock. Listen at the front of the cleaning unit. The cleaning unit can be heard run-
ning.
Y N
Check for grounding faults, go to GP 7 System Grounding Verification.

Second Procedure 94-617-00, 94-618-00 Oil Pump Error RAP
Procedure 94-617-00 Oil delivery pump stalled
Remove the cleaning unit. Inspect the bottom of the cleaning unit (do not tip over) and drip tray
for a spill / leak (significant amount of oil). The tray is free of oil. 94-618-00 Oil removal pump stalled
Y N
Clean the drip tray and install a new cleaner unit, PL 94.10 Item 21. Procedure
Slide the cleaning unit in and out two times to improve the connection between the cleaning
unit and the connector on the back of machine. Switch off the machine and then switch on the WARNING
machine GP 14. If the fault is still present, repeat for two more times. The fault is still Ensure that the electricity to the machine is switched off while performing tasks that do
present. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Y N death or injury. Moving parts can cause injury.
Go to the 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 Cleaning Unit Over Cur-
rent RAP
Inspect the drum for damage. Large gouges or dents can cause damage to the metering blade
in the cleaning unit and cause high oil consumption. The drum is good.
Y N
Install a new drum, PL 94.20 Item 1 and install a new cleaning unit, PL 94.10 Item 21.
Install a new cleaning unit, PL 94.10 Item 21. The fault is still present.
Y N
Perform SCP 5 Final actions
Reinstall the original cleaning unit and continue.

Switch off the machine, GP 14. Install a new connector PL 94.10 Item 6. Switch on the
machine, GP 14. The fault is still present.
Y N
Inspect the wiring. Go to WD 9.2, WD 9.4 and WD 9.19. Check the wiring between the cleaning
unit and the drum driver PWB. Repair the wiring as necessary, REP 1.1 or install a new clean-
ing unit interface harness, PL 1.15 Item 17. The fault is still present.
Y N

94-619 Cleaning Unit Delivery Line Blocked RAP 94-620-00 Drum Fan Stall RAP
94-619-00 Oil delivery line blocked. 94-620-00 The drum fan has stalled.
WARNING WARNING
CAUTION • Check for damage or debris that restricts movement of the fan.
Install a new cleaning unit, PL 94.10 Item 21. Procedure
Enter dC330 code 42-064 to run the drum fan, PL 94.20 Item 4. The drum fan runs.
Y N
Go to WD 9.1. Check the drum fan.
Refer to:
• Drum fan, PL 94.20 Item 4.
Y N
as necessary, REP 1.1. If necessary install a new drum fan PL 94.20 Item 4.

Xerox® ColorQube® 9203 Family 2-517 94-619, 94-620-00
94-621-00 Abatement Fan Stall RAP
94-621-00 The abatement fan has stalled.
Initial Actions
WARNING
• Check for damage or debris that restricts movement of the fan.
Procedure
Enter dC330 code 42-062 to run the abatement fan, Figure 1. The abatement fan runs.
Y N
Go to WD 9.4. Check the abatement fan.
Refer to:
• PJ901, Drum Driver PWB. Abatement fan
• 01E +12V Power Distribution RAP.
• Abatement fan assembly, PL 94.20 Item 11.
Y N
as necessary, REP 1.1. If necessary install a new abatement fan, PL 94.20 Item 11.

94-622-00 Cleaning Unit Previously Marked Unusable RAP 94-634-00, 94-635-00 DMU Thermistor Failure RAP
94-622-00 Cleaning Unit Previously Marked Unusable. 94-634-00 DMU Thermistor Fail. The IME timed out waiting for the cleaning unit to warm-up.
The IME has assumed that the cleaning unit thermistor has failed, although the cleaning unit is
Procedure at operational temperature.
94-635-00 DMU thermistor sensor fail. Anomalous data received when using pressure sensor
WARNING to determine CU oil level. The IME will revert to open loop oil consumption algorithm.
death or injury. Moving parts can cause injury. These faults are shown for information only. No corrective actions are necessary.
CAUTION
Immediately perform REP 94.1 Cleaning Unit.

94A Enclosure Fan Error RAP 94B Drum Drive Control Test Actions RAP
Use this RAP to troubleshoot problems with the drum driver enclosure fan, MOT 42-063. Use this RAP to resolve problems identified by dC708 Drum Drive Control Test.
Procedure Procedure
NOTE: The results of dC708 Drum Drive Control Test are considered unreliable. Therefore, it
is advisable to go to dC122 Fault History and dC123 PEST Fault History and check for drum
WARNING
drive related faults.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Run dC708 Drum Drive Control Test. Observe the results of the test and perform the relevant
death or injury. Moving parts can cause injury. actions. On completion repeat the dC708 Drum Drive Control Test, and check for additional
actions, then return to the originating RAP.
NOTE: If the enclosure fan is running and the machine displays the 99-710 fault assume the
fan is defective and not creating enough airflow. Install a new enclosure fan. 0 Drum drive test normal
Referring to WD 9.4 and PL 1.15, check the enclosure fan is running. Check the wiring to the Passed test successfully
drum driver PWB. Install new components as necessary:
1 Low power slew test failed
• Enclosure fan, MOT42-063, PL 1.15 Item 6. Check the following for damage:
• Drum driver PWB, PL 1.15 Item 4. 1. The wiring between PJ6AC on the power supply unit and the drum drive motor.
Refer to WD 1.1. Repair as necessary, REP 1.1.
2. The drum driver power supply interface cable, PL 1.15 Item 10, install a new cable if nec-
essary.
3. The cleaning unit interface harness, PL 1.15 Item 17. Check between the drum drive
motor and the drum driver PWB. Repair the harness if necessary, REP 1.1. Refer to WD
1.1 and WD 9.3, PJ 802.
4. If the no obvious damage is found replace the drum drive motor then the drum drive PWB.
2 Hall analog signal out of range
1. Go to WD 1.1 and WD 9.3. Check the wiring between the drum motor and the drum driver
PWB. Repair the harness if necessary, REP 1.1.
2. Go to dC122 Fault History and dC123 PEST Fault History and check for drum drive
related faults.
3. Install a new drum drive motor, PL 94.20 Item 6.
4. Install a new drum driver PWB, PL 1.15 Item 4.
3 Analog sine or cosine drum encode signals out of range
1. Install a new drum encoder, PL 94.20 Item 8.
2. If the fault persists install a new drum drive PWB, PL 1.15 Item 4.
4 Drum home failed on index calibration
Clean the drum encoder or replace if necessary, PL 94.20 Item 8.
5 Drum calibrate failed on hall signal

• Go to WD 1.1 and WD 9.1. Check the wiring between the drum motor and the drum driver
PWB.
Refer to:
– P/J501, Drum driver PWB.

– Drum encoder, PL 94.20 Item 8.
– Drum driver PWB, PL 1.15 Item 4.
• Install a new drum drive motor, PL 94.20 Item 6.
• Install a new drum driver PWB, PL 1.15 Item 4.
6 Drum calibrate failed on encoder signal
• Go to WD 9.1. Check the wiring between the drum encoder and the drum driver PWB
Refer to:
– P/J501, Drum driver PWB.
– Drum encoder, PL 94.20 Item 8.
– Drum driver PWB, PL 1.15 Item 4.
• Install a new drum drive motor, PL 94.20 Item 6.
• Install a new drum driver PWB, PL 1.15 Item 4.
7 Drum following error higher than normal
1. Remove the drum fan shroud, PL 94.20 Item 5 and manually rotate the drum.
• If the drum rotates freely install a new drum drive motor, PL 94.20 Item 6.
• If the drum does not rotate freely remove the drum drive belt, PL 94.20 Item 2.
– Manually rotate the drum. If the drum spins freely install a new drum drive
motor.
– If the drum does not spin freely inspect the drum for obstructions and correct as
necessary.
8 Belt slip test failed
Inspect, clean or replace the drum belt as required, PL 94.20 Item 2.
9 Slew under load test failed: excessive motor torque with transfix loaded
• Check the transfix roller, PL 10.20 Item 1, for free rotation.
• If the transfix roller does not rotate freely check for obstructions and repair as necessary
or install a new transfix roller.

99-000-00 to 99-070-00 PEST Error 1 RAP Procedure
99-000-00 PEST test started
99-052-00 Board link, MUD Link broken WARNING

99-053-00 Board Link, PS Link broken not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
99-055-00 Cable Video, Printhead 1 Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-056-00 Cable Video, Printhead 2
Table 1 PEST Hard and Soft Fault Codes
Code Hard/Soft Action
99-058-00 Cable Video, Printhead 4 99-000 Soft Information only: indicates the start of the PEST procedure
99-052 Hard Go to WD 9.7 and WD 9.10. Check wiring between Marking Unit
99-059-00 Cable Video, Printhead 1 Driver PWB and IME Controller PWB. If the wiring harness is good,
then install new marking unit driver PWB, PL 92.10 Item 4 or IME con-
99-060-00 Cable Video, Printhead 2 troller PWB, PL 92.10 Item 1.
99-053 Hard Go to 92-520-00 RAP. Check for loose connections.
99-055 Hard Go to 91-805-00, 91-806-00 RAP. Check video cable from IME con-
troller to Printhead 1 PWB, pins 7 to 11.
99-063-00 Quad Waveamp PWB Cable troller to Printhead 2 PWB, pins 7 to 11.
99-066-00 Board link, 3TM Link broken troller to Printhead 3PWB, pins 7 to 11
99-067-00 Board link, PFP Link broken troller to Printhead 4 PWB, pins 7 to 11
99-070-00 Board link, MPD Link error troller to Printhead 1 PWB, pins 14 to 27.
99-063 Hard Go to 91-587-00, 91-588-00 RAP. Check wave amp cables from Print-
head PWB’s to Quad Waveamp PWB, and ribbon cable from Quad
Waveamp PWB to IME controller PWB.
99-066 Hard Go to 92-530-00 RAP. Check the 3 tray module harness for damage.
99-067 Hard Go to 92-535-00, 92-536-00 RAP. Check for loose connections.
99-070 Soft Check PJ 408 on the Media Path Driver PWB to PJ 402 on the IME
Controller PWB. See WD 8.4 and WD 9.5.

99-071-00 to 99-112-00 PEST Error 2 RAP Initial Actions
99-071-00 Board link, DDB Link error
99-072-00 Board link, MUD link error WARNING

99-073-00 Board link, PS Link error not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
99-074-00 Board link, Head 1 slow Link error count
Procedure
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-078-00 Board link, TTM Link error count 99-071 Soft Check PJ 603 on the drum driver PWB to PJ 403 on the IME PWB.
See WD 9.2.
99-079-00 Board link, PFP Link error count
99-072 Soft Go to WD 9.7 and WD 9.10. Check wiring between Marking Unit
Driver PWB and IME Controller PWB.
99-081-00 Wave amp cable, VPP or VSS head 1 open
99-073 Soft Go to 92-520-00. Check for loose connections.
99-082-00 Wave amp cable, VPP or VSS head 2 open 99-074 Soft Go to 91-501-00 to 91-502-00 and 91-805-00, 91-806-00.
99-075 Soft Go to 91-501-00 to 91-502-00 and 91-805-00, 91-806-00.
99-083-00 Wave amp cable, VPP or VSS head 3 open 99-076 Soft Go to 91-501-00 to 91-502-00 and 91-805-00, 91-806-00.
99-077 Soft Go to 91-501-00 to 91-502-00 and 91-805-00, 91-806-00.
99-084-00 Wave amp cable, VPP or VSS head 4 open
99-078 Soft Go to 92-530-00 and check the connections and wiring.
99-085-00 Wave amp cable, VPP or VSS head 1 short 99-079 Soft Go to 92-535-00, 92-536-00 and check the connections and wiring.
99-081 Hard Go to 91-610-00 to 91-613-00 and check the video and wave amp
99-086-00 Wave amp cable, VPP or VSS head 2 short cables to the printhead.
The fault indicates a failure of the wave amp power signals
99-087-00 Wave amp cable, VPP or VSS head 3 short between the wave amp PWB and the IME controller PWB.
99-088-00 Wave amp cable, VPP or VSS head 4 short cables to the printhead.
The fault may show an incorrect description on the user interface
99-100-00 Board link, DDB Safe mode touch screen.
99-101-00 Motor, H Bridge enable DDB Open
cables to the printhead.
99-102-00 Motor, H Bridge enable DDB Short
between the wave amp PWB and the IME controller PWB.
99-110-00 Solenoid, DMU Valve Over current 99-084 Hard Go to 91-610-00 to 91-613-00 and check the video and wave amp
99-111-00 Stripper solenoid Over current The fault indicates a failure of the wave amp power signals
99-112-00 Pump, DMU Delivery Over current 99-085 Hard Go to 91-610-00 to 91-613-00 and check the video and wave amp

Table 1 PEST Hard and Soft Fault Codes 99-113-00 to 99-141-00 PEST Error 3 RAP
Code Hard/Soft Action 99-113-00 Pump, DMU Return Over current
cables to the printhead. 99-114-00 Rear fan error
between the wave amp PWB and the IME controller PWB. 99-115-00 MU fan error
99-116-00 Abatement fan error
between the wave amp PWB and the IME controller PWB. 99-120-00 Board link, MPD Safe mode
99-121-00 Motor, H Bridge enable MPD Open
The fault indicates a failure of the wave amp power signals 99-122-00 Motor, H bridge enable MPD Short
99-100 Hard Safe mode indicates a firm ware mismatch. Check code version 99-130-00 Solenoid, Nip C Over Current
and upgrade or revert as appropriate. If problem continues install a
new drum driver PWB, PL 1.15 Item 4. 99-131-00 Solenoid, Nip D Over Current
99-101 Hard Install new drum driver PWB, PL 1.15 Item 4
99-102 Hard Install new drum driver PWB, PL 1.15 Item 4 99-133-00 Solenoid, Duplex Over Current
99-110 Hard Go to 94-504-00, 94-505-00 RAP. Check the solenoid.
99-134-00 Solenoid, CAR Diverter Over Current
99-111 Hard Install a new drum driver PWB, PL 1.15 Item 4.
99-112 Hard Go to 94-504-00, 94-505-00 RAP. Check the wiring between the 99-135-00 Pump, Ralph Air pumps Over Current
cleaning unit and the drum driver PWB.
99-140-00 Board link, MUD Safe mode
99-141-00 Motor H, bridge enable MUD Open
Initial Actions
WARNING
Procedure
dC123.

99-113 Hard Go to 94-504-00, 94-505-00 RAP. Check the pump can be heard.
99-114 Soft Go to 94A. Check the enclosure fan.
99-115 Soft Go to 91-586-00 RAP. Check the fan runs.
99-116 Soft Go to 91-682-00 RAP. Check the fan runs.

Code Hard/Soft Action 99-142-00 Motor H, bridge enable MUD Short
99-120 Hard Safe mode indicates a firm ware mismatch. Check code version and
upgrade or revert as appropriate. If problem continues install a new 99-143-00 Thermistor, MU Ambient Open
media path driver PWB, PL 1.15 Item 5.
99-144-00 Thermistor, MU Ambient Short
99-121 Hard Go to 82-132-00, 82-155-00 RAP. Check the horizontal transport
motor.
99-150-00 Solenoid, Ink delivery valves Over current
99-122 Hard Go to 82-132-00, 82-155-00 RAP. Check the horizontal transport
motor.
99-151-00 Solenoid, LPA valve Over current
99-130 Hard Install a new media path driver PWB, PL 1.15 Item 5.
99-131 Hard Install a new media path driver PWB, PL 1.15 Item 5. 99-152-00 Solenoid, Waste tray lock Over current
99-153-00 Pump, Ink delivery air Over current
99-135 Hard Go to 88-508-00 RAP. Check the pumps run.
Initial Actions
99-140 Hard Safe mode indicates a firm ware mismatch. Check code version and
upgrade or revert as appropriate. If problem continues install a new
marking unit driver PWB, PL 92.10 Item 4.
WARNING
99-141 Hard This fault code is for future use and is included for reference only.
Procedure
dC123.

99-143 Soft Go to 91-682-00 RAP. Check the temperature reading is within
range.
99-144 Soft Go to 91-682-00 RAP. Check the temperature reading is within
range.
99-150 Hard Install a new marking unit driver PWB, PL 92.10 Item 4.
99-151 Hard Go to 91-516-00 RAP. Check the solenoid.
99-152 Hard Go to 01J +50V Distribution RAP. Go to the Marking Unit Driver PWB
check out and refer to WD 9.11. Check the solenoid, SOL91-044.
99-153 Hard Go to 93A RAP. Check the ink delivery pump.

99-180-00 Board link 3TM safe mode Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-185-00 Board link PFP safe mode Table 1 PEST Hard and Soft Fault Codes
99-200-00 Drum Driver Power Supply Interface Cable
99-180 Hard Safe mode indicates a firm ware mismatch. Check IME code ver-
99-201-00 Drum Driver Power Supply Interface Cable sion vs. 3TM PLD version and upgrade or revert as appropriate. If
problem continues install a new 3 Trays module PWB, PL 73.16
99-210-00 Power DDB ADC ref to 1.2255V out Item 4.
99-185 Hard Safe mode indicates a firm ware mismatch. Check IME code ver-
99-211-00 Power DDB ADC ref to 24V out of range sion vs. tray 5 PLD version and upgrade or revert as appropriate. If
problem continues install a new tray 5 control PWB, PL 75.68 Item
99-212-00 Power 24V base above max 8.
99-200 Hard Go to 01J RAP and 01K RAP. Check cable from power supply to
99-213-00 Power 24V base below min drum driver board for a bad wire, pin 26.
99-201 Hard Go to 01J RAP and 01K RAP. Check cable from power supply to
99-214-00 Power 24V base not stable drum driver board for a bad wire, pin 28.
99-210 Soft Go to 01B RAP
99-215-00 Power DDB ADC 50V APG out of range 99-211 Soft Go to 01H RAP
99-216-00 Power 50V base above max
99-217-00 Power 50V base below min
99-218-00 Power 50V base not stable
Initial Actions
WARNING
• If the PEST code is 99-214-00. For W/O TAG 006 machines, pull out the image process-
ing PWB module. Check that the fan heatsink assembly, PL 3.10 Item 10 and the chassis
fan assembly, PL 3.10 Item 6 are running. Install new assemblies as necessary
• If the PEST code is 99-214-00. For W/ TAG 006 machines, pull out the image processing
PWB module. Check that the heatsink assembly, PL 3.11 Item 8 and the chassis fan
assembly, PL 3.11 Item 5 are running. Install new assemblies as necessary

Table 1 PEST Hard and Soft Fault Codes Table 1 PEST Hard and Soft Fault Codes
Code Hard/Soft Action Code Hard/Soft Action
99-212 Soft Switch off the machine, GP 14. Check all 24V devices for heat or 99-216 Soft Switch off the machine, GP 14. Check all 50V devices for heat or
noise and the harnesses for damage or short circuits (i.e. chaff- noise and the harnesses for damage or short circuits (i.e. chaff-
ing). If a 24V component has been replaced then check that har- ing). If a 50V component has been replaced then check that har-
ness first. ness first.
To isolate 5 major areas: To isolate 4 major areas:
1. Unplug all drum driver PWB connectors except PJ602, 1. Unplug all drum driver PWB connectors except PJ602,
PJ603 and PJ 902. PJ603 and PJ 902.
If the fault 99-212 is removed but other 99-xxx errors occur, If the fault 99-216 is removed but other 99-xxx errors occur,
Then check all 24V components and harnesses to the drum Then check all 50V components and harnesses to the drum
driver PWB. driver PWB.
2. Unplug all media path driver PWB connectors except PJ803, 2. Unplug all media path driver PWB connectors except PJ803,
PJ408 and PJ 402. PJ408 and PJ 402.
Then check all 24V components and harnesses to the media Then check all 50V components and harnesses to the media
path driver PWB. path driver PWB.
3. Unplug all marking unit driver PWB connectors except 3. Unplug all marking unit driver PWB connectors except
PJ203. PJ203.
Then check all 24V components and harnesses to the mark- Then check all 50V components and harnesses to the mark-
ing unit driver PWB. ing unit driver PWB.
4. Remove power to the quad wave amp PWB, by disconnect- 4. Remove power to the quad wave amp PWB, by disconnect-
ing PJ101 on the IME controller PWB. ing PJ101 on the IME controller PWB.
If the fault 99-212 is removed and no 99 errors occur, but a If the fault 99-216 is removed and no 99 errors occur, but a
91-610 error occurrs.Then check all 24V components and 91-610 error occurrs.Then check all 50V components and
harnesses to the quad wave amp PWB. harnesses to the quad wave amp PWB.
5. Remove power to the CBC tray by disconnecting PJ1 on the The error could be internal to one of the PWB’s, refer to the 01J
power distribution PWB. RAP and 01K RAP
If the fault 99-212 is removed and replaced by a soft error 99- 99-217 Soft Go to 01J RAP and 01K RAP
213. Then check all 24V components and harnesses. 99-218 Soft Go to 01J RAP and 01K RAP. Check the 50V distribution for
If none of those solve the problem, then try disconnecting the devices always on/variations in power load or bad power gauge
printhead connectors from the IME controller PWB. This will also circuit in power supply.
raise head link errors so check for both.
The error could be internal to one of the PWB’s, refer to the 01H
RAP.
99-213 Soft Go to 01H RAP
99-214 Soft Go to 01H RAP. If the fault remains, a faulty CPU cooling fan may
be the cause on either the SBC PWB, PL 3.11 Item 13, the copy
controller PWB, PL 3.10 Item 17 or the network controller PWB,
PL 3.10 Item 4.
99-215 Soft Go to 01J RAP and 01K RAP

99-220-00 Main board 12.3mV out of range Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-221-00 Main board 1.225V out of range Table 1 PEST Hard and Soft Fault Codes
99-225-00 Power TTM-PFP 3.3V base above max
99-226-00 Power TTM-PFP 3.3V base 99-221 Soft Go to 01B RAP
99-225 Soft Go to 01B and check the +3.3V ESTAR supply to the 3TM PWB
99-230-00 Power AC voltage below min 99-226 Soft Go to 01B and check the +3.3V ESTAR supply to the 3TM PWB
99-230 Soft Go to 01A RAP
99-231-00 Power AC voltage middle error 99-231 Soft Go to 01A RAP
99-232-00 Power AC voltage above max
99-235-00 Power AC base below min 99-236 Soft Go to 01A RAP
99-236-00 Power AC base above max 99-240 Hard The power supply is good and believes the voltage is OK. But check
for a wiring harness failure between the power supply and the drum
99-237-00 AC power gauge is not stable driver PWB or an internal failure of the drum driver PWB. Check and
repair the drum driver / media path power harness, PL 1.15 Item 15.
99-240-00 Power DDB ADC 5V off missing Install a new Drum driver PWB, PL 1.15 Item 4.
Refer to 01D +5V Distribution RAP
99-241-00 Power DDB ADC +12V off missing 99-241 Hard The power supply is good and believes the voltage is OK. But check
99-242-00 Power DDB ADC -12V off missing driver PWB or an internal failure of the drum driver PWB. Check and
99-243-00 Power DDB ADC +50V off missing Install a new Drum driver PWB, PL 1.15 Item 4.
Refer to 01E +12V Distribution RAP
99-244-00 Power IMEC ADC -50V off missing 99-242 Hard The power supply is good and believes the voltage is OK. But check
Initial Actions driver PWB or an internal failure of the drum driver PWB. Check and
Install a new Drum driver PWB, PL 1.15 Item 4.
WARNING Refer to 01F -12V Distribution RAP
Ensure that the electricity to the machine is switched off while performing tasks that do 99-243 Hard The power supply is good and believes the voltage is OK. But check
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause for a wiring harness failure between the power supply and the drum
death or injury. Moving parts can cause injury. driver PWB or an internal failure of the drum driver PWB. Check and
Install a new Drum driver PWB, PL 1.15 Item 4.
Refer to 01J +50V Distribution RAP
99-244 Hard The power supply is good and believes the voltage is OK. But check
for a wiring harness failure between the power supply at PJDC1 and
the IME controller PWB at PJ701 or an internal failure of the IME con-
troller PWB. Check and repair the harness, REP 1.1. Install a new IME
controller PWB, PL 92.10 Item 1.
refer to 01K -50V Distribution RAP

99-245-00 Sensor ADC MUD 3.3V open Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-246-00 Sensor ADC MUD 3.3V short
99-250-00 Power IMEC ADC 1.1V out of range Code Hard/Soft Action
99-251-00 Power 1.2V out of range 99-245 Hard Go to 01B RAP

99-246 Hard Go to 01B RAP
99-252-00 Power IMEC ADC 1.8V out of range 99-250 Soft Go to 01B RAP
99-253-00 Power IMEC ADC 2.5V out of range
99-254-00 Power IMEC ADC 3.3V out of range 99-253 Soft Go to 01B RAP
99-255-00 Power IMEC ADC -50V out of range 99-255 Soft Go to 01K RAP
99-256 Soft Go to 01D RAP
99-256-00 Power DDB ADC 5.0V out of range
99-257 Soft Go to 01E RAP
99-257-00 Power DDB ADC +12V out of range 99-258 Soft Go to 01F RAP
99-259 Soft Go to 01H RAP
99-258-00 Power DDB ADC -12V out of range 99-260 Soft Go to 01J RAP
99-270 Soft Go to 01D RAP. Check downstream devices for short circuits and
99-259-00 Power DDB ADC +24V out of range bad wiring harnesses.
99-271 Soft Go to 01E RAP. Check downstream devices for short circuits and
99-260-00 Power DDB ADC +50V out of range
bad wiring harnesses.
99-270-00 Fuse DDB 5V open
99-271-00 Fuse DDB 12V open
Initial Actions
WARNING

99-272-00 to 99-292-00 PEST Error 8 RAP Table 1 PEST Hard and Soft Fault Codes
99-272-00 Drum driver PWB, 24V fuse A open Code Hard/Soft Action
99-273 Soft Go to 01H RAP. Check downstream devices for short circuits and bad
99-273-00 Drum driver PWB, 24V fuse B open wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
Overload RAP.
99-274-00 Drum driver PWB, 50V fuse open
99-274 Hard Go to the 01J RAP. Refer to WD 9.1 and WD 9.2. Check down stream of
the drum driver PWB for short circuits and bad wiring harnesses. Refer
99-280-00 Media path driver PWB, 3.3V over current detected
to the 01-530-00 +/- 50V Short Circuit and Overload RAP. If no direct
short is found, first replace the stripper solenoid assembly (PL 10.10
99-281-00 Media path driver PWB, 5V fuse open Item 3) before any other suspect 50V components. After the short has
been repaired install a new drum driver PWB, PL 1.15 Item 4.
99-282-00 Media path driver PWB, 12V fuse open
99-280 Hard Go to 01B RAP. Check downstream for short circuits and bad wiring har-
99-283-00 Media path driver PWB, 24V fuse A open nesses.
99-281 Hard Go to 01D RAP. Check down stream for short circuits and bad wiring
99-284-00 Media path driver PWB, 24V fuse B open harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and Over-
load RAP.
99-285-00 Media path driver PWB, 24V fuse C open 99-282 Hard Go to 01E RAP. Check downstream for short circuits and bad wiring har-
nesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and Overload
99-286-00 Media path driver PWB, 50V fuse A open RAP.
99-283 Hard Go to 01H RAP. Check downstream devices for short circuits and bad
99-287-00 Media path driver PWB, 50V fuse B open wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
Overload RAP.
99-288-00 Media path driver PWB, 50V fuse C open
99-284 Hard Go to 01H RAP. Check down stream devices for short circuits and bad
wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
99-290-00 Marking unit driver PWB, 12V fuse 3.3V open
Overload RAP.
99-285 Hard Go to 01H RAP. Check downstream devices for short circuits and bad
99-291-00 Marking unit driver PWB, 12V fuse open
wiring harnesses refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
Overload RAP.
99-292-00 Marking unit driver PWB, 24V fuse open
Check for +12V at the media path driver PWB, PJ 803, WD 8.5.
If the voltage is good refer to 01H RAP.
Initial Actions If the voltage is not good refer to 01E +12v Distribution RAP.
99-286 Hard Go to 01D RAP. Check downstream devices for short circuits and bad
WARNING
Overload RAP.
Overload RAP.
Procedure wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to Overload RAP.
dC123. 99-290 Hard Go to 01B RAP. Check downstream devices for short circuits and bad
wiring harnesses.
99-291 Hard Go to 01E RAP. Check downstream devices for short circuits and bad
Code Hard/Soft Action wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
99-272 Soft Go to 01H RAP. Check downstream devices for short circuits and bad Overload RAP.
wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and 99-292 Hard Go to 01H RAP. Check downstream devices for short circuits and bad
Overload RAP. wiring harnesses, refer to 01-525-00 +24V, +/-12V, +5V Short Circuit and
Overload RAP.

99-293-00 Fuse MUD 50V open Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-300-00 Connector MU other open
99-301-00 Connector, Marking Unit Driver PWB
99-302-00 Connector, Marking Unit Driver PWB 99-293 Hard Perform the following:
99-303-00 Connector, Marking Unit Driver PWB 1. Refer to WD 9.10. Check for +50V at PJ203 pin 26 on the marking
unit driver PWB. If not present, go to the 01J +50V Distribution
99-304-00 Connector, Marking Unit Driver PWB RAP. If present, go to Step 2.
2. Refer to WD 9.11. Check for +50V at PJ304 pin 13 on the marking
99-305-00 Connector, Marking Unit Driver PWB unit driver PWB. If present, go to the 01J +50V Distribution RAP. If
not present, go to Step 3.
99-306-00 Connector, Marking Unit Heater PWB
3. Refer to WD 9.11. Check the resistance between pins 1 and 3 of
99-307-00 Connector, Marking Unit Heater PWB the waste tray lock solenoid. The resistance should be approxi-
mately 330 ohms. If the resistance is low, install a new waste tray
99-308-00 Connector, Marking Unit Heater PWB lock solenoid assembly, PL 91.10 Item 11 and marking unit driver
99-309-00 Connector, Marking Unit Heater PWB
4. If the fault remains, install a new marking unit driver PWB, PL
99-310-00 Connector, MU Solenoid Patch PWB 92.10 Item 4.
99-311-00 Connector, MU Solenoid Patch PWB 99-301 Hard Check PJ 303 on the MU Driver PWB and its wiring. (WD 9.10)
99-312-00 Connector, MU Solenoid Patch PWB 99-302 Hard Check PJ 102 on the MU Driver PWB and its wiring. (WD 9.9)
99-303 Hard Check PJ 304 to the Marking Unit Driver PWB is unplugged or all
Initial Actions matching devices are open, (WD 9.11)
99-304 Hard Check PJ 801 to the Marking Unit Driver PWB is unplugged or all
matching devices are open. (WD 9.12)
WARNING 99-305 Hard Check PJ 101 to the Marking Unit Driver PWB is unplugged or all
Ensure that the electricity to the machine is switched off while performing tasks that do matching devices are open. (WD 9.9 and WD 9.16)
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 99-306 Hard Check PJ 901 to the Marking Unit Heater PWB is unplugged or all
death or injury. Moving parts can cause injury. matching devices are open. (WD 9.8 and WD 9.12)
99-307 Hard Check PJ 701 to the Marking Unit Heater PWB is unplugged or all
99-310 Hard Check PJ 430 to the Solenoid Patch PWB is unplugged or all matching
devices are open. (WD 9.14)

99-313-00 Connector, MU Solenoid Patch PWB Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-314-00 Connector, MU Solenoid Patch PWB
99-315-00 Connector, MU Solenoid Patch PWB Code Hard/Soft Action
99-316-00 Connector, MU Solenoid Patch PWB 99-313 Hard Check PJ 610 to the Solenoid Patch PWB is unplugged or all matching
99-317-00 Connector, MU Solenoid Patch PWB 99-314 Hard Check PJ 810 to the Solenoid Patch PWB is unplugged or all matching
99-320-00 Connector IME other open 99-315 Hard Check PJ 130 to the Solenoid Patch PWB is unplugged or all matching
99-321-00 Connector, Drum Driver PWB 99-316 Hard Check PJ 380 to the Solenoid Patch PWB is unplugged or all matching
99-322-00 Connector, Drum Driver PWB 99-317 Hard Check PJ 780 to the Solenoid Patch PWB is unplugged or all matching
99-323-00 Connector, Drum Driver PWB
99-324-00 Connector, Drum Driver PWB 99-321 Hard Check PJ 902 to the Drum Driver PWB is unplugged or all matching
devices are open. (WD 1.4 and WD 9.4)
devices are open. (WD 9.4 and WD 9.19)
devices are open. (WD 9.2, WD 9.3 and WD 9.19)
99-324 Hard Check PJ 701 to the Drum Driver PWB is unplugged or all matching
devices are open. (WD 9.2, and WD 8.6)
Initial Actions devices are open. (WD 9.3 and WD 9.1)
WARNING 99-328 Hard Check PJ 501 to the Drum Driver PWB is unplugged or all matching
Ensure that the electricity to the machine is switched off while performing tasks that do devices are open. (WD 9.1 and WD 1.1)
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 99-329 Hard Check PJ 101to the Drum Driver PWB is unplugged or all matching
death or injury. Moving parts can cause injury. devices are open. (WD 9.1 and WD 9.22)

99-330-00 Connector, IOD Pre-amplifier PWB Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-331-00 Connector DMU hot plug open
99-332-00 Connector, Registration / Preheat Interface PWB Code Hard/Soft Action
99-333-00 Connector, Registration / Preheat Interface PWB 99-330 Hard Check PJ 2 to the IOD Pre-Amp PWB (WD 9.22 and WD 9.1) or PJ 1
on the Registration / Pre-heat Interface PWB (WD 8.6) is unplugged
or all matching devices are open.
99-334-00 Connector, Registration / Preheat Interface PWB
99-340-00 Connector, Media Path Driver PWB 99-332 Hard Check PJ 4 to the Registration / Preheat Interface PWB is unplugged
or all matching devices are open. (WD 8.6)
99-343-00 Connector, Media Path Driver PWB
99-340 Hard Check PJ 202 to the Media Path Driver PWB is unplugged or all
99-344-00 Connector, Media Path Driver PWB matching devices are open. (WD 8.1)
99-345-00 Connector, Media Path Driver PWB matching devices are open. (WD 8.1 and WD 8.6)
99-346-00 Interface Harness matching devices are open. (WD 8.1 and WD 8.5)
99-347-00 Interface Harness matching devices are open. (WD 8.5)
99-348-00 Interface Harness matching devices are open. (WD 8.4, WD 9.17 and WD 9.18)
99-349-00 Interface Harness
Initial Actions 99-346 Hard This fault code is for future use and is included for reference only.
WARNING 99-349 Hard This fault code is for future use and is included for reference only.

99-360-00 Connectors TTM 1 open Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-361-00 Connector TTM 2 open
99-362-00 Connector TTM 3 open Code Hard/Soft Action
99-365-00 Power Supply Unit 99-360 Hard This fault code is for future use and is included for reference only.
99-366-00 Connector, Media Path Driver PWB 99-362 Hard This fault code is for future use and is included for reference only.
99-365 Hard Go to 01A RAP. Check the power cord for the finisher is not plugged
99-370-00 Connector, PS J 4AC Marking Unit into the IME.
99-366 Hard LCSS: Go to 12-199-00-110
99-371-00 Connector, PS J 5AC
OCT: Go to 12-701-00-65
HVF: Go to 12-762-00-171, 12-764-00-171, 12-765-00-171. Check
99-372-00 Connector AC PS heater 3 open the data cable for the finisher is not present, but a load was detected
on the finisher power cord.
99-373-00 Connector AC PS fuse 1 open
99-370 Hard Check connector PJ4AC to the power supply is unplugged or all
99-374-00 Connector AC PS fuse 2 open matching devices are open. (WD 1.1)
99-371 Hard Check the connector PJ5AC to the power supply is unplugged or all
99-375-00 Connector AC PS fuse 3 open matching devices are open. (WD 1.2)
99-380-00 Fan power supply short 99-373 Hard This fault code is for future use and is included for reference only.
99-381-00 Fan power supply open
99-382-00 Fan power supply stalled 99-380 Hard Install new power supply, PL 1.15 Item 2
99-381 Hard Install new power supply, PL 1.15 Item 2
Initial Actions 99-382 Soft Check fan movement, if necessary, install new power supply, PL 1.15
Item 2
WARNING

99-394-00 Power Triacs PS Short triac Code Hard/Soft Action

99-402 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
99-395-00 Power, Triacs MUH Short triac
to 91-804-00 RAP. Check thermistor connections on head 2 board.
99-400-00 Power, Drum Driver interface cable 99-403 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
99-401-00 Power, Printhead 1 PWB 99-404 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
to 91-804-00 RAP. Check thermistor connection on head 4 board.
99-402-00 Power, Printhead 2 PWB
99-405 Hard Refer to IME Controller PWB test points TP703 to 706 (Lower Left
99-403-00 Power, Printhead 3 PWB corner of the board, with labels HD1-HD4 to indicate which head)
Check at each test point.
99-404-00 Power, Printhead 4 PWB • If the voltage is ~2.9V, then that head is good.
99-405-00 Power, Head thermistors Safety circuit error • If the voltage is ~2.1V then the video cable has an open con-
tact. Install a new video cable, PL 92.10 Item 7, for the indi-
99-410-00 Heater, Head reservoir 1 Open cated printhead.
• A test point voltage reading of ~0V with the suspect printhead
99-411-00 Heater, Head reservoir 2 Open heater unplugged indicates a short on the marking unit heater
PWB. Replace the marking unit heater PWB, PL 92.10.
99-412-00 Heater, Head reservoir 3 Open
• Check the ribbon cables and AC harness to any printhead that
99-413-00 Heater, Head reservoir 4 Open has suspect voltage readings. If no problem found reseat the
ribbon and AC harnesses on the other printheads, then recheck
Initial Actions the voltages. If the problem continues replace the marking unit
heater PWB, PL 92.10.
• Refer to WD 9.8. Switch off the machine GP 14. Check the
WARNING printhead heater resistances at PJ401 and PJ 701 of the mark-
Ensure that the electricity to the machine is switched off while performing tasks that do ing unit heater PWB. Typical resistance (cold) is ~100 ohms for
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause the jetstack heater and ~500 ohms for the reservoir heater. If no
death or injury. Moving parts can cause injury. short is found then replace the marking unit heater PWB, PL
92.10.
If all 4 voltages are OK, it may be intermittent, try POPO to catch the
Procedure
fault again and measure immediately.
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to Refer to 91-805-00, 91-806-00 Printhead Communications RAP.
dC123.
99-410 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
to 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is
open or short replace cable, otherwise replace the printhead.
Code Hard/Soft Action 99-411 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
99-394 Hard Check the PEST fault history, dC123 for power supply heater faults to 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is
(ink melt plates, pre heater, drum heater). open or short replace cable, otherwise replace the printhead.
Then install a new power supply, PL 1.15 Item 2. 99-412 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
99-395 Hard Check the PEST fault history, dC123 for marking unit heater faults to 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is
(umbilicals, printheads and ink melt reservoir). Identify which heater open or short replace cable, otherwise replace the printhead.
is open and install new components as necessary. 99-413 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00
Then install a new marking unit heater PWB, PL 92.10 Item 5. to 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is
99-400 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 open or short replace cable, otherwise replace the printhead.
to 91-804-00 RAP. Check cable from power supply to Drum Driver
board for a bad wire, pin 4.
99-401 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00

99-414-00 Heater, Head reservoir 1 Short Code Hard/Soft Action

99-415 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-415-00 Heater, Head reservoir 2 Short 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is open
or short replace cable, otherwise replace the printhead.
99-416-00 Heater, Head reservoir 3 Short
99-416 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
91-804-00 RAP. Check the AC / heater cabling to printhead. If it is open
99-417-00 Heater, Head reservoir 4 Short
99-417 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-418-00 Heater, Head reservoir 1 Below min
99-419-00 Heater, Head reservoir 2 Below min
99-418 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-420-00 Heater, Head reservoir 3 Below min 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is open
99-421-00 Heater, Head reservoir 4 Below min 99-419 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-422-00 Heater, Head reservoir 1 Above max or short replace cable, otherwise replace the printhead.
99-420 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-423-00 Heater, Head reservoir 2 Above max 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is open
99-424-00 Heater, Head reservoir 3 Above max 99-421 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-425-00 Heater, Head reservoir 4 Above max
99-426-00 Heater, Jet stack H1 left Open 99-422 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-427-00 Heater, Jet stack H1 right Open
99-423 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-428-00 Heater, Jet stack H2 left Open 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is open
Initial Actions 99-424 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
WARNING 99-425 Soft Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
Ensure that the electricity to the machine is switched off while performing tasks that do 91-804-00 RAP. Check the AC / heater cabling to printhead. If it is open
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause or short replace cable, otherwise replace the printhead.
death or injury. Moving parts can cause injury. 99-426 Hard Go to 01A RAP. Check the AC / heater cabling to printhead. If it is open
or short replace cable, otherwise replace printhead.
Procedure 99-427 Hard Go to 01A RAP. Check the AC / heater cabling to printhead. If it is open
dC123. 99-428 Hard Go to 01A RAP. Check the AC / heater cabling to printhead. If it is open
99-414 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to

99-429-00 Heater, Jet stack H2 right Open Code Hard/Soft Action

99-430 Hard Go to the 01A AC Power Distribution RAP. Select the Head 3 Reser-
99-430-00 Heater, Jet stack H3 left Open voir and Jetstack Heaters Check. Install new components as
required.
voir and Jetstack Heaters Check. Install new components as
99-432-00 Heater, Jet stack H4 left Open
required.
required.
99-434-00 Heater, Jet stack H1 left Short
99-435-00 Heater, Jet stack H1 right Short voir and Jetstack Heaters Check. Install new components as
required.
99-436-00 Heater, Jet stack H2 left Short 99-434 Hard Go to the 01A AC Power Distribution RAP. Select the Head 1 Reser-
99-437-00 Heater, Jet stack H2 right Short required.
99-438-00 Heater, Jet stack H3 left Short voir and Jetstack Heaters Check. Install new components as
required.
99-439-00 Heater, Jet stack H3 right Short 99-436 Hard Go to the 01A AC Power Distribution RAP. Select the Head 2 Reser-
99-440-00 Heater, Jet stack H4 left Short
required.
99-441-00 Heater, Jet stack H4 right Short 99-437 Hard Go to the 01A AC Power Distribution RAP. Select the Head 2 Reser-
required.
99-442-00 Heater, Jet stack H1 left Below min
99-443-00 Heater, Jet stack H1 right Below min voir and Jetstack Heaters Check. Install new components as
required.
Initial Actions 99-439 Hard Go to the 01A AC Power Distribution RAP. Select the Head 3 Reser-
required.
WARNING 99-440 Hard Go to the 01A AC Power Distribution RAP. Select the Head 4 Reser-
Ensure that the electricity to the machine is switched off while performing tasks that do voir and Jetstack Heaters Check. Install new components as
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause required.
death or injury. Moving parts can cause injury. 99-441 Hard Go to the 01A AC Power Distribution RAP. Select the Head 4 Reser-
required.
Procedure
99-442 Soft Go to the 01A AC Power Distribution RAP. Select the Head 1 Reser-
dC123.
required.
Table 1 PEST Hard and Soft Fault Codes 99-443 Soft Go to the 01A AC Power Distribution RAP. Select the Head 1 Reser-
Code Hard/Soft Action required.
required.

99-444-00 Heater, Jet stack H2 left Below min Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-445-00 Heater, Jet stack H2 right Below min
99-446-00 Heater, Jet stack H3 left Below min Code Hard/Soft Action
99-447-00 Heater, Jet stack H3 right Below min 99-444 Soft Go to the 01A AC Power Distribution RAP. Select the Head 2 Reser-
voir and Jetstack Heaters Check. Install new components as required.
99-448-00 Heater, Jet stack H4 left Below min 99-445 Soft Go to the 01A AC Power Distribution RAP. Select the Head 2 Reser-
99-449-00 Heater, Jet stack H4 right Below min 99-446 Soft Go to the 01A AC Power Distribution RAP. Select the Head 3 Reser-
99-450-00 Heater, Jet stack H1 left Above max 99-447 Soft Go to the 01A AC Power Distribution RAP. Select the Head 3 Reser-
99-451-00 Heater, Jet stack H1 right Above max 99-448 Soft Go to the 01A AC Power Distribution RAP. Select the Head 4 Reser-
99-452-00 Heater, Jet stack H2 left Above max
99-453-00 Heater, Jet stack H2 right Above max voir and Jetstack Heaters Check. Install new components as required.
99-454-00 Heater, Jet stack H3 left Above max voir and Jetstack Heaters Check. Install new components as required.
99-456-00 Heater, Jet stack H4 left Above max voir and Jetstack Heaters Check. Install new components as required.
99-460-00 Heater, Umbilical upper Open
Initial Actions 99-455 Soft Go to the 01A AC Power Distribution RAP. Select the Head 3 Reser-
WARNING voir and Jetstack Heaters Check. Install new components as required.
Ensure that the electricity to the machine is switched off while performing tasks that do 99-457 Soft Go to the 01A AC Power Distribution RAP. Select the Head 4 Reser-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause voir and Jetstack Heaters Check. Install new components as required.

Code Hard/Soft Action 99-461-00 Heater, Umbilical lower Open
99-460 Hard Check the dC123 PEST log for addition heater faults.
If there are multiple heater open faults for the marking unit (12 head 99-462-00 Heater, Umbilical upper Short
heaters, 2 umbilical heaters and 2 melt reservoir heaters).
• Refer to WD 9.8. Check the upper carriage harness (PL 91.20 99-463-00 Heater, Umbilical lower Short
Item 12) at PJ401 on the Marking Unit Heater PWB.
99-464-00 Heater, Umbilical upper Below min
• Refer to 01A AC Power Distribution RAP then perform the Upper
Umbilical Heater Check.
99-465-00 Heater, Umbilical lower Below min
• Enter dC335 Heater Monitor and Exerciser then activate print-
head 1.
99-466-00 Heater, Umbilical upper Above max
Select;
– Component, then choose Printhead. 99-467-00 Heater, Umbilical lower Above max
– Printhead, then choose 2.
– Setpoint Mode, then choose Low. 99-470-00 Heater, Melt reservoir 1 Open
– Graph, then choose Graph.
99-471-00 Heater, Melt reservoir 2 Open
This will enable the AC relay in the PSU and provide AC line volt-
age for the line 1 printhead heaters. 99-472-00 Heater, Melt reservoir 1 Short
• Refer to WD 1.1. and WD 9.8. Check that AC voltage is at the
Marking Unit Heater PWB at PJ101. 99-473-00 Heater, Melt reservoir 2 Short
• If voltages are not present, check the AC cable between the
Marking Unit Heater PWB at PJ101 and the Power Supply at 99-474-00 Heater, Melt reservoir 1 Below min
PJ4AC.
99-475-00 Heater, Melt reservoir 2 Below min
If the cable is good, check the power supply unit fuses. These
fuses are inside the power supply unit and not replaceable.
99-476-00 Heater, Melt reservoir 1 Above max
If a power supply fuse has blown, isolate and repair the cause of
the blown fuse and then install a new power supply unit, PL 1.15
99-477-00 Heater, Melt reservoir 2 Above max
Item 2.
• If voltages are present at the Marking Unit Heater PWB. Initial Actions
Refer to WD 9.8. Check the line 1 fuse on the Marking Unit
Heater PWB. Check for open circuit or very low resistance at
PJ401 pins 1 and 7. WARNING
If a fuse is blown, isolate and repair the cause of the blown fuse Ensure that the electricity to the machine is switched off while performing tasks that do
and then install a new marking unit heater PWB, PL 92.10 Item 5. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• If there is only this one heater fault, check the AC / heater cabling death or injury. Moving parts can cause injury.
to the umbilical. If it is open or short replace the cable, otherwise • PEST fault 99-471 can be raised as a hard or a soft fault. Enter dC123 PEST Fault His-
install a new umbilical. tory. A hard fault will appear before the 99-999 separator and a soft fault will appear after
Refer to 93-535-00, 93-536-00, 93-537-00 RAP. Run the upper umbili- the 99-999 separator.
cal test.

Procedure Table 1 PEST Hard and Soft Fault Codes
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to Code Hard/Soft Action
dC123. 99-475 Soft Go to 93-520-00, 93-521-00, 93-522-00 RAP.Check the AC / heater
cabling umbilical. If it is open or short replace cable, otherwise
replace the reservoir.
Code Hard/Soft Action 99-476 Soft Go to 93-520-00, 93-521-00, 93-522-00 RAP. Check the AC / heater
99-461 Hard Go to 93-538-00, 93-539-00, 93-540-00 RAP. Check the AC / heater cabling umbilical. If it is open or short replace cable, otherwise
cabling umbilical. If it is open or short replace cable, otherwise replace the reservoir.
replace the umbilical. 99-477 Soft Go to 93-520-00, 93-521-00, 93-522-00 RAP.Check the AC / heater
99-462 Hard Go to 93-535-00, 93-536-00, 93-537-00 RAP. Check the AC / heater cabling umbilical. If it is open or short replace cable, otherwise
cabling umbilical. If it is open or short replace cable, otherwise replace the reservoir.
replace the umbilical.
99-463 Hard Go to 93-538-00, 93-539-00, 93-540-00 RAP. Check the AC / heater
99-464 Soft Go to 93-535-00, 93-536-00, 93-537-00 RAP. Check the AC / heater
replace the reservoir. The soft fault is raised if only the reservoir 2
heater is open.
replace the reservoir. The hard fault is raised if both the reservoir 1
and 2 heaters are open.

99-480-00 to 99-496-00 PEST Error 18 RAP Table 1 PEST codes and action
99-480-00 Heater, Ink melter cyan Open Code Hard/Soft Action
99-481-00 Heater, Ink melter magenta Open 99-483 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
99-482-00 Heater, Ink melter yellow Open or short replace cable, otherwise replace the ink melt plate assembly.
99-483-00 Heater, Ink melter black Open 99-484 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
99-484-00 Heater, Ink melter cyan Short
or short circuit replace cable. Go to 01A AC Power Distribution RAP,
99-485-00 Heater, Ink melter magenta Short then perform the black ink melt heater check. If necessary replace the
ink melt plate assembly, PL 93.10 Item 3.
99-486-00 Heater, Ink melter yellow Short
99-485 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
99-487-00 Heater, Ink melter black Short 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
99-490-00 Heater, Ink melter cyan Below min. or short replace cable, otherwise replace the ink melt plate assembly.
99-486 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
99-491-00 Heater, Ink melter magenta Below min 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
99-492-00 Heater, Ink melter yellow Below min or short replace cable, otherwise replace the ink melt plate assembly,
PL 93.10 Item 3.
99-493-00 Heater, Ink melter black Below min
99-487 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
99-494-00 Heater, Ink melter cyan Above max 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
or short replace cable, otherwise replace the ink melt plate assembly.
99-495-00 Heater, Ink melter magenta Above max
99-490 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
99-496-00 Heater, Ink melter yellow Above max 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
or short replace cable, otherwise replace the ink melt plate assembly,
Initial Actions
PL 93.10 Item 3.
99-491 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
WARNING 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
or short replace cable, otherwise replace the ink melt plate assembly.
99-492 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
PL 93.10 Item 3.
Procedure 99-493 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
dC123. or short replace cable, otherwise replace the ink melt plate assembly.
99-494 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
Table 1 PEST codes and action 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
Code Hard/Soft Action or short replace cable, otherwise replace the ink melt plate assembly,
PL 93.10 Item 3.
99-480 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open 99-495 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
or short replace cable, otherwise replace the ink melt plate assembly, 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
PL 93.10 Item 3. or short replace cable, otherwise replace the ink melt plate assembly.
99-481 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00, 99-496 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open 93-533-00 RAP. Check the AC / heater cabling umbilical. If it is open
or short replace cable, otherwise replace the ink melt plate assembly. or short replace cable, otherwise replace the ink melt plate assembly,
PL 93.10 Item 3.
99-482 Hard Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
PL 93.10 Item 3.

99-497-00 Heater, Ink melter black Above max Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-500-00 Thermistor, Ink melter cyan Open
Table 1 PEST codes and action
99-501-00 Thermistor, Ink melter magenta Open Code Hard/Soft Action
99-502-00 Thermistor, Ink melter yellow Open 99-497 Soft Go to 93-523-00 to 93-526-00, 93-527-00 to 93-530-00, 93-532-00,
93-533-00, Ink Melt Error RAP.
99-503-00 Thermistor, Ink melter black Open 99-500 Hard Go to 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Ther-
mistor Error RAP.
99-504-00 Thermistor, Ink melter cyan Short 99-501 Hard Go to 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Ther-
mistor Error RAP.
99-505-00 Thermistor, Ink melter magenta Short 99-502 Hard Go to 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Ther-
mistor Error RAP.
99-506-00 Thermistor, Ink melter yellow Short 99-503 Hard Go to 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Ther-
mistor Error RAP.
99-507-00 Thermistor, Ink melter black Short
99-504 Hard Go to 93-525-00, 93-528-00, 93-531-00, 93-534-00 Ink Melt Ther-
99-510-00 Heater, Drum front Open mistor Error RAP.
99-511-00 Heater, Drum rear Open mistor Error RAP.
99-512-00 Heater, Drum front Short mistor Error RAP.
99-513-00 Heater, Drum rear Short mistor Error RAP.
99-510 Hard Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
99-514-00 Heater, Drum front Below min temp 546-00, 94-632-00, 94-633-00 RAP.
99-511 Hard Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
99-515-00 Heater, Drum rear Below min temp
546-00, 94-632-00, 94-633-00 RAP.
Initial Actions 99-512 Hard Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
546-00, 94-632-00, 94-633-00 RAP.Check the AC / heater cabling to
the drum heater. If it is open, check the drum thermal cutout board,
PL 88.10 Item 11.
WARNING
99-513 Hard Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
546-00, 94-632-00, 94-633-00 RAP. Check the AC / heater cabling
to the drum heater. If it is open, check the drum thermal cutout
board, PL 88.10 Item 11.
99-514 Soft Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
99-515 Soft Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-

99-516-00 Heater, Drum front Above max Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to dC123.
99-517-00 Heater, Drum rear Above max Table 1 PEST codes and action
99-520-00 Heater, Media preheat 1 Open
99-516 Soft Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
546-00, 94-632-00, 94-633-00 RAP. Check the AC / heater cabling to
99-521-00 Heater, Media preheat 2 Open
the drum heater. If it is open, check the drum thermal cutout board.
99-522-00 Heater, Media preheat 1 and 2 Open 99-517 Soft Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-
546-00, 94-632-00, 94-633-00 RAP.Check the AC / heater cabling to
99-523-00 Heater, Media preheat 1 Short the drum heater. If it is open, check the drum thermal cutout board.
99-520 Soft Go to 88-500-00 to 88-502-00 RAP. Check the registration / preheat
99-524-00 Heater, Media preheat 2 Short thermistor.
99-521 Soft Go to 88-500-00 to 88-502-00 RAP. Check the registration / preheat
99-525-00 Heater, Media preheat 1 Below min sensor.
99-522 Soft Go to 88-500-00 to 88-502-00 RAP. Check the resistance of the
99-526-00 Heater, Media preheat 2 Below min lower heat plate (pre-heater 1) and Upper heat plate (pre-heater 2) of
the Registration/Pre-heat assembly, PL 88.10.
99-527-00 Heater, Media preheat 1 Above max 99-523 Hard Go to 88-500-00 to 88-502-00 RAP. Check the AC / heater cabling to
Registration / Preheat sensor. If it is open or short, replace cable,
99-528-00 Heater, Media preheat 2 Above max otherwise replace Registration / Preheat sensor.
99-524 Hard Go to 88-500-00 to 88-502-00 RAP. Check the AC / heater cabling to
99-530-00 Thermistor, Umbilical upper Open
otherwise replace Registration / Preheat sensor.
99-531-00 Thermistor, Umbilical lower Open
99-525 Soft Go to 88-500-00 to 88-502-00 RAP. Check the AC / heater cabling to
99-532-00 Thermistor, Umbilical upper Short
99-533-00 Thermistor, Umbilical lower Short 99-526 Soft Go to 88-500-00 to 88-502-00 RAP. Check the AC / heater cabling to
Initial Actions
WARNING
99-530 Hard Go to 93-535-00, 93-536-00, 93-537-00 RAP. Check the DC cabling
to the umbilical. If it is open or short replace cable, otherwise replace
the umbilical.
the umbilical.
the umbilical.
the umbilical.

99-534-00 Front drum thermistor, open circuit Code Hard/Soft Action

99-535 Hard Refer to WD 9.1. Disconnect PJ501 on the Drum driver PWB. Check
99-535-00 Front drum thermistor, short circuit the resistance to the front drum thermistor at the PJ501 harness, pin A5
to A6. If the front drum thermistor reads in the 80K Ohms range replace
99-536-00 Rear drum thermistor, short circuit the Drum driver PWB, PL 1.15. If the front drum thermistor reads infinity
or OL repair the wiring or replace the front drum thermistor, PL 94.20.
99-537-00 Rear drum thermistor, open circuit 99-536 Hard Refer to WD 9.3. Disconnect PJ801 on the Drum driver PWB. Check
the resistance to the rear drum thermistor at the PJ801 harness, pin 14
99-538-00 Waveamp thermistor, open circuit to 15. If the rear drum thermistor reads in the 80K Ohms range replace
the Drum driver PWB, PL 1.15. If the rear drum thermistor reads infinity
99-539-00 Waveamp thermistor, short circuit or OL repair the wiring or replace the rear drum thermistor, PL 94.20.
99-537 Hard Refer to WD 9.3. Disconnect PJ801 on the Drum driver PWB. Check
99-540-00 Thermistor, jet stack H1 right open circuit the resistance to the rear drum thermistor at the PJ801 harness, pin 14
to 15. If the rear drum thermistor reads in the 80K Ohms range replace
99-541-00 Thermistor, jet stack H1 left open circuit the Drum driver PWB, PL 1.15. If the rear drum thermistor reads infinity
or OL repair the wiring or replace the rear drum thermistor, PL 94.20.
99-542-00 Thermistor, jet stack H2 right open circuit 99-538 Hard Go to 91-587-00, 91-588-00 RAP. Check the quad waveamp PWB
cable, PL 92.10 Item 13. Go to 01E +12V Distribution RAP. Go to 01F -
99-543-00 Thermistor, jet stack H2 left open circuit 12V Distribution RAP.
If an open circuit or a short circuit is detected install a new quad
99-544-00 Thermistor, jet stack H3 right open circuit waveamp PWB cable.
If the circuit is good install a new quad waveamp, PL 92.10 Item 3.
99-545-00 Thermistor, jet stack H3 left open circuit
99-539 Hard Go to 91-587-00, 91-588-00 RAP. Check the quad waveamp PWB
cable, PL 92.10 Item 13. Go to 01E +12V Distribution RAP.
99-546-00 Thermistor, jet stack H4 right open circuit
Go to 01F -12V Distribution RAP.
If an open circuit or a short circuit is detected install a new quad
99-547-00 Thermistor, jet stack H4 left open circuit
waveamp PWB cable.
If the circuit is good install a new quad waveamp, PL 92.10 Item 3.
99-548-00 Thermistor, jet stack H1 right short circuit
99-540 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
91-804-00 RAP. Check the small ribbon cable on the right side of the
Initial Actions printhead to verify it is seated. If the problem persists, replace the print-
head.
99-541 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
WARNING 91-804-00 RAP. Check the small ribbon cable on the right side of the
Ensure that the electricity to the machine is switched off while performing tasks that do printhead to verify it is seated. If the problem persists, replace the print-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause head.
death or injury. Moving parts can cause injury. 99-542 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
Procedure printhead to verify it is seated. If the problem persists, replace the print-
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to head.
dC123. 99-543 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
Table 1 PEST codes and action 91-804-00 RAP. Check the small ribbon cable on the right side of the
printhead to verify it is seated. If the problem persists, replace the print-
Code Hard/Soft Action head.
99-534 Hard Refer to WD 9.1. Disconnect PJ501 on the Drum driver PWB. Check 99-544 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
the resistance to the front drum thermistor at the PJ501 harness, pin A5 91-804-00 RAP. Check the small ribbon cable on the right side of the
to A6. If the front drum thermistor reads in the 80K Ohms range replace printhead to verify it is seated. If the problem persists, replace the print-
the Drum driver PWB, PL 1.15. If the front drum thermistor reads infinity head.
or OL repair the wiring or replace the front drum thermistor, PL 94.20.

Table 1 PEST codes and action 99-549-00 to 99-563-00 PEST Error 22 RAP
Code Hard/Soft Action 99-549-00 Thermistor, Jet stack H1 left Short
99-545 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
91-804-00 RAP. Check the small ribbon cable on the right side of the 99-550-00 Thermistor, Jet stack H2 right Short
head. 99-551-00 Thermistor, Jet stack H2 left Short
99-546 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-547 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
99-548 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
91-804-00 RAP. Check the small ribbon cable on the right side of the 99-556-00 Thermistor, Head reservoir H1 Open
head. 99-557-00 Thermistor, Head reservoir H2 Open
99-558-00 Thermistor, Head reservoir H3 Open
99-559-00 Thermistor, Head reservoir H4 Open
99-560-00 Thermistor, Head reservoir H1 Short
Initial Actions
WARNING
Procedure
dC123.

99-549 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.

Table 1 PEST codes and action Table 1 PEST codes and action
99-550 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to 99-562 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
91-804-00 RAP. Check the small ribbon cable on the right side of the 91-804-00 RAP. Check the small ribbon cable on the right side of the
printhead to verify it is seated. If the problem persists, replace the print- printhead to verify it is seated. If the problem persists, replace the print-
head. head.
99-551 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to 99-563 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
91-804-00 RAP. Check the small ribbon cable on the right side of the 91-804-00 RAP. Check the small ribbon cable on the right side of the
printhead to verify it is seated. If the problem persists, replace the print- printhead to verify it is seated. If the problem persists, replace the print-
head. head.
99-552 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-553 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-554 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-555 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-556 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-557 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-558 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-559 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-560 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.
99-561 Hard Go to 91-523-00 to 91-558-00, 91-664-00 to 91-667-00, 91-800-00 to
head.

99-564-00 Thermistor, Melt reservoir Open Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-565-00 Thermistor, Melt reservoir Short
99-568-00 Sensor, ADC ink level Head1cyan Open Code Description Hard/Soft Action
99-569-00 Sensor, ADC ink level Head1magenta Open 99-564 Thermistor, Melt Hard Go to 93-520-00, 93-521-00, 93-522-00 RAP.
reservoir_Open Check the DC cabling to the reservoir. If it is
open or short replace the cable
99-570-00 Sensor, ADC ink level Head1yellow Open
99-565 Thermistor, Melt Hard Go to 93-520-00, 93-521-00, 93-522-00 RAP.
99-571-00 Sensor, ADC ink level Head1black Open reservoir_Short Check the DC cabling to the reservoir. If it is
open or short replace the cable, otherwise
99-572-00 Sensor, ADC ink level Head2cyan Open replace the reservoir.
99-568 Sensor, ADC ink level Hard Go to 93-871-00 to 93-874-00 RAP.Check wir-
99-573-00 Sensor, ADC ink level Head2magenta Open Head1cyan_Open ing around ink level sensors.
99-569 Sensor, ADC ink level Hard Go to 93-871-00 to 93-874-00 RAP. Check wir-
99-574-00 Sensor, ADC ink level Head2yellow Open Head1magenta_Open ing around ink level sensors.
99-575-00 Sensor, ADC ink level Head2black Open
Head1yellow_Open ing around ink level sensors.
99-576-00 Sensor, ADC ink level Head3cyan Open
Head1black_Open ing around ink level sensors.
99-577-00 Sensor, ADC ink level Head3magenta Open 99-572 Sensor, ADC ink level Hard Go to 93-871-00 to 93-874-00 RAP. Check wir-
Head2cyan_Open ing around ink level sensors.
99-578-00 Sensor, ADC ink level Head3yellow Open 99-573 Sensor, ADC ink level Hard Go to 93-871-00 to 93-874-00 RAP. Check wir-
Head2magenta_Open ing around ink level sensors.
99-579-00 Sensor, ADC ink level Head3yellow Open 99-574 Sensor, ADC ink level Hard Go to 93-871-00 to 93-874-00 RAP. Check wir-
99-580-00 Sensor, ADC ink level Head4cyan Open
Initial Actions 99-576 Sensor, ADC ink level Hard Go to 93-871-00 to 93-874-00 RAP. Check wir-
WARNING
Head3magenta_Open ing around ink level sensors.

99-581-00 Sensor, ADC ink level Head4 magenta Open Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-582-00 Sensor, ADC ink level Head4 yellow Open
99-583-00 Sensor, ADC ink level Head4 black Open Code Hard/Soft Action
99-584-00 Sensor, ADC ink level Head1 cyan Short 99-581 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-582 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-585-00 Sensor, ADC ink level Head1 magenta Short 99-583 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-586-00 Sensor, ADC ink level Head1 yellow Short
99-587-00 Sensor, ADC ink level Head1 black Short 99-586 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-588-00 Sensor, ADC ink level Head2 cyan Short 99-588 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-589-00 Sensor, ADC ink level Head2 magenta Short
99-590-00 Sensor, ADC ink level Head2 yellow Short 99-591 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-591-00 Sensor, ADC ink level Head2 black Short 99-593 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sensors.
99-592-00 Sensor, ADC ink level Head3 cyan Short
99-593-00 Sensor, ADC ink level Head3 magenta Short
99-594-00 Sensor, ADC ink level Head3 yellow Short
99-595-00 Sensor, ADC ink level Head3 black Short
Initial Actions
WARNING

99-596-00 Sensor, ADC ink level Head4 cyan short Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-597-00 Sensor, ADC ink level Head4 magenta short
99-598-00 Sensor, ADC ink level Head4 yellow short Code Hard/Soft Action
99-599-00 Sensor, ADC ink level Head4 black short 99-596 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sen-
sors.
99-600-00 Purge Solenoid Valve Head 1 99-597 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sen-
sors.
99-601-00 Solenoid, Ink purge valve H2 open 99-598 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sen-
sors.
99-602-00 Solenoid, Ink purge valve H3 open 99-599 Hard Go to 93-871-00 to 93-874-00 RAP. Check wiring around ink level sen-
sors.
99-603-00 Solenoid, Ink purge valve H4 open 99-600 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
short replace the cable, otherwise replace the reservoir.
99-604-00 Solenoid, Ink dose valve H1 yellow open
99-601 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-605-00 Solenoid, Ink dose valve H1 cyan open short replace the cabling, otherwise replace the reservoir.
99-606-00 Solenoid, Ink dose valve H1 magenta open short replace the cable, otherwise replace the reservoir.
99-607-00 Solenoid, Ink dose valve H1 black open short replace the cable, otherwise replace the reservoir.
99-608-00 Solenoid, Ink dose valve H2 cyan yellow open short replace the cable, otherwise replace the reservoir.
99-609-00 Solenoid, Ink dose valve H2 cyan open short replace the cable, otherwise replace the reservoir.
99-606 Hard Go to 93A RAP.Check the DC cabling to the reservoir. If it is open or
99-610-00 Solenoid, Ink dose valve H2 magenta open
Initial Actions 99-607 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
WARNING short replace the cable, otherwise replace the reservoir.
Ensure that the electricity to the machine is switched off while performing tasks that do 99-609 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause short replace the cable, otherwise replace the reservoir.
death or injury. Moving parts can cause injury. 99-610 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or

99-611-00 Solenoid, Ink dose valve H2 black open. Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-612-00 Solenoid, Ink dose valve H3 yellow open.
99-613-00 Solenoid, Ink dose valve H3 cyan open. Code Hard/Soft Action
99-614-00 Solenoid, Ink dose valve H3 magenta open. 99-611 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-615-00 Solenoid, Ink dose valve H3 black open. 99-612 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-616-00 Solenoid, Ink dose valve H4 yellow open. 99-613 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-617-00 Solenoid, Ink dose valve H4 cyan open. 99-614 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-618-00 Solenoid, Ink dose valve H4 magenta open. 99-615 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-619-00 Solenoid, Ink dose valve H4 black open.
99-620-00 Solenoid, Ink purge valve H1 short. short replace the cable, otherwise replace the reservoir.
99-624-00 Solenoid, Ink dose valve H1 cyan short. short replace the cable, otherwise replace the reservoir.
99-625-00 Solenoid, Ink dose valve H1 magenta short.
Ensure that the electricity to the machine is switched off while performing tasks that do 99-624 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
death or injury. Moving parts can cause injury. 99-625 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or

NOTE: The dose valves are the 16 solenoids on the 4 air manifolds of the ink reservoir.
dC123.
99-626-00 Solenoid, Ink dose valve H1 yellow Short
99-627-00 Solenoid, Ink dose valve H1 black Short Code Hard/Soft Action
99-628-00 Solenoid, Ink dose valve H2 cyan Short 99-626 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-629-00 Solenoid, Ink dose valve H2 magenta Short 99-627 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-630-00 Solenoid, Ink dose valve H2 yellow Short 99-628 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-631-00 Solenoid, Ink dose valve H2 black Short 99-629 Hard Go to 93A RAP.Check the DC cabling to the reservoir. If it is open or
99-632-00 Solenoid, Ink dose valve H3 cyan Short 99-630 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-633-00 Solenoid, Ink dose valve H3 magenta Short
99-634-00 Solenoid, Ink dose valve H3 yellow Short short replace the cable, otherwise replace the reservoir.
99-635-00 Solenoid, Ink dose valve H3 black Short short replace the cable, otherwise replace the reservoir.
99-633 Hard Go to 93A RAP.Check the DC cabling to the reservoir. If it is open or
99-636-00 Solenoid, Ink dose valve H4 cyan Short short replace the cable, otherwise replace the reservoir.
99-637-00 Solenoid, Ink dose valve H4 magenta Short short replace the cable, otherwise replace the reservoir.
99-638-00 Solenoid, Ink dose valve H4 yellow Short short replace the cable, otherwise replace the reservoir.
99-639-00 Solenoid, Ink dose valve H4 black Short
99-640-00 Solenoid, Ink purge valve H1 Below min 99-637 Hard Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
Ensure that the electricity to the machine is switched off while performing tasks that do 99-640 Soft NOTE: This is a soft fault and can generally be ignored. If the Service
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Code (OF 17) indicates a PEST fault and this is the only PEST fault,
death or injury. Moving parts can cause injury. then that can be ignored as well.
Go to 93A RAP.Check the DC cabling to the reservoir. If it is open or


99-641-00 Solenoid, Ink purge valve H2 Below min Code Hard/Soft Action
99-642-00 Solenoid, Ink purge valve H3 Below min 99-643 Soft NOTE: This is a soft fault and can generally be ignored. If the Service
Code (OF 17) indicates a PEST fault and this is the only PEST fault,
99-643-00 Solenoid, Ink purge valve H4 Below min then that can be ignored as well.
99-644-00 Solenoid, Ink dose valve H1cyan Below min Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-645-00 Solenoid, Ink dose valve H1magenta Below min short replace the cable, otherwise replace the reservoir.
99-644 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-646-00 Solenoid, Ink dose valve H1yellow Below min
99-647-00 Solenoid, Ink dose valve H1black Below min 99-645 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-648-00 Solenoid, Ink dose valve H2cyan Below min short replace the cable, otherwise replace the reservoir.
99-649-00 Solenoid, Ink dose valve H2magenta Below min
99-650-00 Solenoid, Ink dose valve H2yellow Below min 99-647 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-651-00 Solenoid, Ink dose valve H2black Below min short replace the cable, otherwise replace the reservoir.
99-652-00 Solenoid, Ink dose valve H3cyan Below min short replace the cable, otherwise replace the reservoir.
99-653-00 Solenoid, Ink dose valve H3magenta Below min 99-649 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-654-00 Solenoid, Ink dose valve H3yellow Below min
99-655-00 Solenoid, Ink dose valve H3black Below min short replace the cable, otherwise replace the reservoir.
Initial Actions 99-651 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
Ensure that the electricity to the machine is switched off while performing tasks that do 99-653 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
death or injury. Moving parts can cause injury. 99-654 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
Procedure 99-655 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
dC123.

99-641 Soft NOTE: This is a soft fault and can generally be ignored. If the Service
then that can be ignored as well.
Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or

99-642 Soft NOTE: This is a soft fault and can generally be ignored. If the Service
then that can be ignored as well.
Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or


99-656-00 Solenoid, Ink dose valve H4 cyan Below min Code Hard/Soft Action
99-657-00 Solenoid, Ink dose valve H4 magenta Below min short replace the cable, otherwise replace the reservoir.
99-658-00 Solenoid, Ink dose valve H4 yellow Below min
99-659-00 Solenoid, Ink dose valve H4 black Below min 99-660 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-660-00 Solenoid, Ink purge valve H1 Above max 99-661 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-664-00 Solenoid, Ink dose valve H1cyan Above max
99-665-00 Solenoid, Ink dose valve H1 magenta Above max short replace the cable, otherwise replace the reservoir.
99-666-00 Solenoid, Ink dose valve H1 yellow Above max short replace the cable, otherwise replace the reservoir.
99-667-00 Solenoid, Ink dose valve H1 black Above max short replace the cable, otherwise replace the reservoir.
99-668-00 Solenoid, Ink dose valve H2 cyan Above max short replace the cable, otherwise replace the reservoir.
99-669-00 Solenoid, Ink dose valve H2 magenta Above max short replace the cable, otherwise replace the reservoir.
99-670-00 Solenoid, Ink dose valve H2 yellow Above max
Initial Actions
WARNING
Procedure
dC123.


99-671-00 Solenoid, Ink dose valve H2 black Above max Code Hard/Soft Action
99-672-00 Solenoid, Ink dose valve H3 cyan Above max short replace the cable, otherwise replace the reservoir.
99-673-00 Solenoid, Ink dose valve H3 magenta Above max
99-674-00 Solenoid, Ink dose valve H3 yellow Above max 99-675 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-675-00 Solenoid, Ink dose valve H3 black Above max 99-676 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-676-00 Solenoid, Ink dose valve H4 cyan Above max 99-677 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-677-00 Solenoid, Ink dose valve H4 magenta Above max 99-678 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-678-00 Solenoid, Ink dose valve H4 yellow Above max 99-679 Soft Go to 93A RAP. Check the DC cabling to the reservoir. If it is open or
99-679-00 Solenoid, Ink dose valve H4 black Above max
99-680 Hard Go to 91-516-00. Check the low pressure assist solenoid valve.
99-680-00 Solenoid, LPA valve Open 99-681 Hard Go to 91-516-00. Check the low pressure assist solenoid valve.
99-682 Soft Go to 91-516-00. Check the low pressure assist solenoid valve.
99-681-00 Solenoid, LPA valve Short 99-683 Soft Go to 91-516-00. Check the low pressure assist solenoid valve.
99-684 Hard Go to 93-545-00 to 93-548-00 RAP. Check the DC cabling to the reser-
99-682-00 Solenoid, LPA valve Below min
voir. If it is open or short replace the cable, otherwise replace the reser-
voir.
99-683-00 Solenoid, LPA valve Above max
99-685 Hard Go to 93-545-00 to 93-548-00 RAP. Check the DC cabling to the reser-
voir. If it is open or short replace the cable, otherwise replace the reser-
99-684-00 Sensor, ADC ink level MeltResRef cyan Open
voir.
99-685-00 Sensor, ADC ink level MeltResRef magenta Open
Initial Actions
WARNING
Procedure
dC123.

99-672 Soft Go to 93A RAP.Check the DC cabling to the reservoir. If it is open or

99-686-00 Sensor, ADC ink level MeltResRef yellow Open Code Hard/Soft Action
99-687 Hard Check the DC cabling to the reservoir. If it is open or short replace the
99-687-00 Sensor, ADC ink level MeltResRef black Open cable, otherwise replace the reservoir. Go to 93-545-00 to 93-548-00
RAP for related wiring diagrams.
99-688-00 Sensor, ADC ink level MeltResFull cyan Open
cable, otherwise replace the reservoir. Go to 93-545-00 to 93-548-00
99-689-00 Sensor, ADC ink level MeltResFull magenta Open
99-690-00 Sensor, ADC ink level MeltResFull yellow Open
99-691-00 Sensor, ADC ink level MeltResFull black Open
99-692-00 Sensor, ADC ink level MeltResRef cyan Short cable, otherwise replace the reservoir. Go to 93-545-00 to 93-548-00
99-693-00 Sensor, ADC ink level MeltResRef magenta Short 99-691 Hard Check the DC cabling to the reservoir. If it is open or short replace the
99-694-00 Sensor, ADC ink level MeltResRef yellow Short RAP for related wiring diagrams.
99-695-00 Sensor, ADC ink level MeltResRef black Short cable, otherwise replace the reservoir. Go to 93-545-00 to 93-548-00
99-696-00 Sensor, ADC ink level MeltResFull cyan Short 99-693 Hard Check the DC cabling to the reservoir. If it is open or short replace the
99-697-00 Sensor, ADC ink level MeltResFull magenta Short
99-698-00 Sensor, ADC ink level MeltResFull yellow Short 99-694 Hard Check the DC cabling to the reservoir. If it is open or short replace the
99-699-00 Sensor, ADC ink level MeltResFull black Short
99-700-00 Pump, Ink delivery Air Open cable, otherwise replace the reservoir. Go to 93-545-00 to 93-548-00
Initial Actions 99-696 Hard Check the DC cabling to the reservoir. If it is open or short replace the
WARNING 99-697 Hard Check the DC cabling to the reservoir. If it is open or short replace the
Ensure that the electricity to the machine is switched off while performing tasks that do cable, otherwise replace the reservoir. Go to 93-545-00 to 93-548-00
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause RAP for related wiring diagrams.
death or injury. Moving parts can cause injury. 99-698 Hard Check the DC cabling to the reservoir. If it is open or short replace the
Procedure
dC123.
Table 1 PEST codes and action 99-700 Hard Check the DC cabling to the reservoir. If it is open or short replace the
cable, otherwise replace the reservoir. Go to 91-517-00 RAP for related
Code Hard/Soft Action wiring diagrams.

99-701-00 Pump, Ink delivery Air Short Code Hard/Soft Action

99-703 Soft Go to 91-517-00 RAP. Check the DC cabling to the reservoir. If it is open
99-702-00 Pump, Ink delivery Air Stall or short replace the cable, otherwise replace the reservoir.
99-703-00 Pump, Ink delivery Air Below min
or short replace the cable, otherwise replace the reservoir.
99-704-00 Pump, Ink delivery Air Above max 99-705 Hard Go to 91-517-00 RAP. Check the DC cabling to the reservoir. If it is open
99-705-00 Sensor, ADC ink delivery air pump current Open 99-706 Hard Go to 91-517-00 RAP. Check the DC cabling to the reservoir. If it is open
99-706-00 Sensor, ADC ink delivery air pump current Short 99-710 Hard Go to 94A RAP. Check the cabling to the fan. If it is open or short replace
the cable, otherwise replace the fan.
99-710-00 Fan, Rear closure Open 99-711 Hard Go to 94A RAP. Check the cabling to the fan. If it is open or short replace
99-711-00 Fan, Rear closure Short 99-712 Soft Go to 94A RAP. Check the cabling to the fan. If it is open or short replace
99-712-00 Fan, Rear closure Stall
99-715 Soft Go to 93-520-00, 93-521-00, 93-522-00 RAP. Check the cabling to the
99-715-00 Fan, Marking drawer Open fan. If it is open or short replace the cable, otherwise replace the fan.
99-716 Hard Go to 93-520-00, 93-521-00, 93-522-00 RAP. Check the marking unit
99-716-00 Fan, Marking drawer Short fan.
99-717 Soft Go to 93-520-00, 93-521-00, 93-522-00 RAP. Check the marking unit
99-717-00 Fan, Marking drawer Stall fan.
99-720 Soft Go to OF 6 RAP. Check the cabling to the fan. If it is open or short
99-720-00 Fan, Drum cooling open replace the cable, otherwise replace the fan.
99-721 Hard Go to OF 6 RAP. Check the cabling to the fan. If it is open or short
99-721-00 Fan, Drum cooling Short replace the cable, otherwise replace the fan.
99-722-00 Fan, Drum cooling Tach stall
replace the cable, otherwise replace the fan.
Initial Actions
WARNING
Procedure
dC123.

99-701 Hard Go to 91-517-00 RAP. Check the DC cabling to the reservoir. If it is open

99-723-00 Fan, Drum cooling Stall Code Hard/Soft Action

99-725-00 Fan, Abatement Open replace the cable, otherwise replace the fan.
99-726-00 Fan, Abatement Short
99-727-00 Fan, Abatement Tach stall 99-728 Soft Go to OF 6 RAP. Check the cabling to the fan. If it is open or short
99-728-00 Fan, Abatement Stall 99-730 Soft Go to 89-125-00 to 89-128-00, 89-130-00 RAP. Check the cable to the
pumps. Reseat if unseated. If shorted replace the pump. If the problem
99-730-00 Pump, Ralph Air pumps Open persists, check the DC cabling to registration/preheat transport.
99-731 Hard Go to 89-125-00 to 89-128-00, 89-130-00 RAP. Check the cabling to
99-731-00 Pump, Ralph Air pumps Short the fan. If it is short or open replace the cable, otherwise replace the
fan.
99-732-00 Pump, Ralph Air pumps Stall 99-732 Soft Go to 89-125-00 to 89-128-00, 89-130-00 RAP. Check the cabling to
the fan. If it is short or open replace the cable, otherwise replace the
99-733-00 Pump, Ralph Air pumps Below min fan.
99-733 Soft Go to 89-125-00 to 89-128-00, 89-130-00 RAP. Check the cabling to
99-734-00 Pump, Ralph Air pumps Above max
fan.
99-735-00 Thermistor, Media preheat Short
99-734 Soft Go to 89-125-00 to 89-128-00, 89-130-00 RAP. Check the cabling to
99-736-00 Thermistor, Media preheat Open
fan.
99-740-00 Solenoid, CAR diverter Open 99-735 Hard Go to 88-500-00 to 88-502-00 RAP. Check the DC cabling to the regis-
tration/preheat transport. If open or short, replace the cable. If the prob-
99-741-00 Solenoid, CAR diverter Short lem persists, replace the registration/preheat transport.
99-736 Hard Go to 88-500-00 to 88-502-00 RAP. Check the DC cabling to the regis-
99-742-00 Solenoid, CAR diverter Below min tration/preheat transport. If open or short, replace the cable. If the prob-
lem persists, replace the registration/preheat transport.
Initial Actions 99-740 Hard Go to 83-504-00 RAP. Check the DC cabling/pins to the solenoid. If
open or short replace the cable, otherwise replace the solenoid.
99-741 Hard Go to 83-504-00 RAP. Check the DC cabling/pins to the solenoid. If
WARNING open or short replace the cable, otherwise replace the solenoid.
Ensure that the electricity to the machine is switched off while performing tasks that do 99-742 Soft Go to 83-504-00 RAP. Check the DC cabling/pins to the solenoid. If
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause open or short replace the cable, otherwise replace the solenoid.
Procedure
dC123.


99-743-00 Solenoid, CAR diverter Above max Code Hard/Soft Action

99-745 Hard Go to 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 RAP.
99-745-00 Solenoid, Duplex Open Check the DC cabling/pins to the solenoid. If open or short replace the
cable, otherwise replace the solenoid.
99-746-00 Solenoid, Duplex Short
99-746 Hard Go to 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 RAP.
Check the DC cabling/pins to the solenoid. If open or short replace the
99-747-00 Solenoid, Duplex Below min
99-747 Soft Go to 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 RAP.
99-748-00 Solenoid, Duplex Above max
Check the DC cabling/pins to the solenoid. If open or short replace the
99-750-00 Solenoid, Nip C Open
99-748 Soft Go to 83-110-00, 83-111-00, 83-113-00, 83-114-00, 83-118-00 RAP.
99-751-00 Solenoid, Nip C Short Check the DC cabling/pins to the solenoid. If open or short replace the
99-752-00 Solenoid, Nip C Below min 99-750 Hard Go to 89-550-00, 89-551-00 RAP. Check the DC cabling/pins to the
solenoid. If open or short replace the cable, otherwise replace the sole-
99-753-00 Solenoid, Nip C Above max noid.
99-751 Hard Go to 89-550-00, 89-551-00 RAP. Check the DC cabling/pins to the
99-755-00 Solenoid, Nip D Open solenoid. If open or short replace the cable, otherwise replace the sole-
noid.
99-756-00 Solenoid, Nip D Short 99-752 Soft Go to 89-550-00, 89-551-00 RAP. Check the DC cabling/pins to the
99-757-00 Solenoid, Nip D Below min
noid.
99-758-00 Solenoid, Nip D Above max 99-753 Soft Go to 89-550-00, 89-551-00 RAP. Check the DC cabling/pins to the
noid.
99-765-00 Solenoid, Stripper Open
99-755 Hard Go to 83-506-00 and 89-550-00, 89-551-00 RAP. Check the DC cabling/
99-766-00 Solenoid, Stripper Short pins to the solenoid. If open or short replace the cable, otherwise
replace the solenoid.
Initial Actions 99-756 Hard Go to 83-506-00 and 89-550-00, 89-551-00 RAP. Check the DC cabling/
pins to the solenoid. If open or short replace the cable, otherwise
WARNING 99-757 Soft Go to 83-506-00 and 89-550-00, 89-551-00 RAP. Check the DC cabling/
Ensure that the electricity to the machine is switched off while performing tasks that do pins to the solenoid. If open or short replace the cable, otherwise
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause replace the solenoid.
death or injury. Moving parts can cause injury. 99-758 Soft Go to 83-506-00 and 89-550-00, 89-551-00 RAP. Check the DC cabling/
pins to the solenoid. If open or short replace the cable, otherwise
Procedure
dC123.
Table 1 PEST codes and action open or short replace the cable, otherwise replace the solenoid.

99-743 Soft Go to 83-504-00 RAP. Check the DC cabling/pins to the solenoid. If

99-767-00 Solenoid, Stripper Below min Code Hard/Soft Action

99-768-00 Solenoid, Stripper Above max check out and refer to WD 9.11. Check the solenoid, SOL91-044.
99-770-00 Solenoid, waste tray lock Open
99-771-00 Solenoid, waste tray lock Short 99-772 Hard Go to 01J +50V Distribution RAP. Go to the Marking Unit Driver PWB
99-772-00 Solenoid, waste tray lock Below min 99-773 Hard Go to 01J +50V Distribution RAP. Go to the Marking Unit Driver PWB
99-773-00 Solenoid, waste tray lock Below max 99-775 Hard Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
Check the cleaning unit oil valve.
99-775-00 Solenoid, DMU valve Open 99-776 Hard Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-776-00 Solenoid, DMU valve Short 99-777 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-777-00 Solenoid, DMU valve Below min
99-778 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-778-00 Solenoid, DMU valve Above max Check the cleaning unit oil valve.
99-780 Hard Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-780-00 Pump, DMU Delivery Open Check the DC cabling/pins to the cleaning unit. If open or short replace
the cabling, otherwise replace the cleaning unit.
99-781-00 Pump, DMU Delivery Short 99-781 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
Check the DC cabling/pins to the cleaning unit. If open or short replace
99-782-00 Pump, DMU Delivery Stall the cabling, otherwise replace the cleaning unit.
99-782 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-783-00 Pump, DMU Delivery Below min Check the DC cabling/pins to the cleaning unit. If open or short replace
99-784-00 Pump, DMU Delivery Above max
99-783 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
Initial Actions the cabling, otherwise replace the cleaning unit.
99-784 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
WARNING the cabling, otherwise replace the cleaning unit.
Procedure
dC123.


99-785-00 Pump, DMU return Open Code Hard/Soft Action

99-786 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-786-00 Pump, DMU return Short Check the DC cabling/pins to the cleaning unit. If open or short replace
99-787-00 Pump, DMU return Stall
99-787 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-788-00 Pump, DMU return Below min
99-788 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-789-00 Pump, DMU return Above max
99-790-00 Sensor, ADC DMU oil res level sense Open
99-789 Soft Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.
99-791-00 Sensor, ADC DMU pressure sense Open Check the DC cabling/pins to the cleaning unit. If open or short replace
99-792-00 Sensor, ADC DMU oil res level sense Short 99-790 Hard This fault code is for future use and is included for reference only.
99-793-00 Sensor, ADC DMU pressure sense Short
99-795-00 Sensor, DMU I-button IIC failure 99-793 Hard This fault code is for future use and is included for reference only.
99-795 Hard Go to 94-504-00, 94-505-00 RAP. Check the cleaning unit.
99-796-00 Sensor, DMU I-button Present failure 99-796 Hard Go to 94-504-00, 94-505-00 RAP. Check the cleaning unit.
99-801 Hard Refer to WD 9.2 and WD 9.3. Check the DC cabling to the cleaning unit
99-801-00 Motor, Drum maint Open motor. Measure the resistance between PJ601 pins 5 and 10 on the
drum driver PWB for an open or short circuit and to the chassis for a
99-802-00 Motor, Drum maint Short short circuit.
If a fault is found, repeat the measurement at the cleaning unit motor. If
99-803-00 Motor, Drum maint Encoder a short is measured, the drum driver PWB may be damaged and be
reported as an ‘open’ error. If short error is reported, the cleaning unit
99-804-00 Motor, Drum maint Below min motor is drawing excessive power. Install new components as neces-
sary, cleaning unit motor assembly, PL 94.10 Item 19, Drum driver
Initial Actions PWB, PL 1.15 Item 4.
99-802 Hard Refer to WD 9.2 and WD 9.3. Check the DC cabling to the cleaning unit
motor. Measure the resistance between PJ601 pins 5 and 10 on the
WARNING drum driver PWB for an open or short circuit and to the chassis for a
Ensure that the electricity to the machine is switched off while performing tasks that do short circuit.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause If a fault is found, repeat the measurement at the cleaning unit motor. If
death or injury. Moving parts can cause injury. a short is measured, the drum driver PWB may be damaged and be
reported as an ‘open’ error. If short error is reported, the cleaning unit
motor is drawing excessive power. Install new components as neces-
Procedure
sary, cleaning unit motor assembly, PL 94.10 Item 19, Drum driver
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to PWB, PL 1.15 Item 4.
dC123.
99-803 Hard Go to 94-520-00 RAP. Check the cleaning unit motor encoder.
Table 1 PEST codes and action 99-804 Soft Go to 94-520-00 RAP. Check the cleaning unit motor.

99-785 Hard Go to 94-506-00, 94-527-00, 94-528-00, 94-531-00 to 94-533-00 RAP.

99-805-00 Motor, Drum maint Above max Code Hard/Soft Action

99-811 Hard Refer to WD 9.10. Check the DC cabling to the printhead roll adjust
99-810-00 Motor, Head roll 1 Open motor 1. Measure the resistance at PJ303 on the marking unit driver
PWB for an open or short circuit and to the chassis for a short circuit.
99-811-00 Motor, Head roll 1 Short If a fault is found, repeat the measurement at the printhead roll adjust
motor 1. If a short is measured, the marking unit driver PWB may be
99-812-00 Motor, Head roll 2 Open damaged and be reported as an ‘open’ error. If short error is reported,
the printhead roll adjust motor 1. is drawing excessive power.
99-813-00 Motor, Head roll 2 Short Install new components as necessary, printhead roll adjust motor 1, PL
91.25 Item 4, marking unit driver PWB, PL 92.10 Item 4.
99-814-00 Motor, Head roll 3 Open Refer to 91-506-00 to 91-509-00 RAP.
99-812 Soft Go to 91-506-00 to 91-509-00 RAP. Check the printhead roll adjust
99-815-00 Motor, Head roll 3 Short
motor.
99-813 Hard Refer to WD 9.9. Check the DC cabling to the printhead roll adjust motor
99-816-00 Motor, Head roll 4 Open
2. Measure the resistance at PJ102 on the marking unit driver PWB for
an open or short circuit and to the chassis for a short circuit.
99-817-00 Motor, Head roll 4 Short
If a fault is found, repeat the measurement at the printhead roll adjust
99-818-00 Motor, Head roll 1-4 power fault motor 2. If a short is measured, the marking unit driver PWB may be
damaged and be reported as an ‘open’ error. If short error is reported,
the printhead roll adjust motor 2 is drawing excessive power.
99-819-00 Motor, Head roll 1-4 power fault
Install new components as necessary, printhead roll adjust motor 2, PL
99-820-00 Motor, Head stitch 1 Open
Refer to 91-506-00 to 91-509-00 RAP.
99-821-00 Motor, Head stitch 1 Short 99-814 Soft Go to 91-506-00 to 91-509-00 RAP. Check the printhead roll adjust
motor.
99-822-00 Motor, Head stitch 2 Open 99-815 Hard Refer to WD 9.10. Check the DC cabling to the printhead roll adjust
motor 3. Measure the resistance at PJ303 on the marking unit driver
99-823-00 Motor, Head stitch 2 Short PWB for an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the printhead roll adjust
Initial Actions motor 3. If a short is measured, the marking unit driver PWB may be
the printhead roll adjust motor 3. is drawing excessive power.
WARNING Install new components as necessary, printhead roll adjust motor 3, PL
Refer to 91-506-00 to 91-509-00 RAP.
death or injury. Moving parts can cause injury. 99-816 Soft Go to 91-506-00 to 91-509-00 RAP. Check the printhead roll adjust
motor.
99-817 Hard Refer to WD 9.9. Check the DC cabling to the printhead roll adjust motor
Procedure
4. Measure the resistance at PJ102 on the marking unit driver PWB for
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to an open or short circuit and to the chassis for a short circuit.
dC123. If a fault is found, repeat the measurement at the printhead roll adjust
Table 1 PEST codes and action damaged and be reported as an ‘open’ error. If short error is reported,
Code Hard/Soft Action the printhead roll adjust motor 4 is drawing excessive power.
Install new components as necessary, printhead roll adjust motor 4, PL
99-805 Soft Go to 94-520-00 RAP. Check the cleaning unit motor.
99-810 Soft Go to 91-506-00 to 91-509-00 RAP. Check the printhead roll adjust Refer to 91-506-00 to 91-509-00 RAP. Check the printhead roll adjust
motor. motor.

Code Hard/Soft Action 99-824-00 Motor, Head stitch 1-2 power fault
motor. 99-825-00 Motor, Carriage restraint lower Open
99-826-00 Motor, Carriage restraint lower Short
motor.
99-820 Soft Go to 91-504-00, 91-505-00 RAP. Check the printhead stitch adjust 99-827-00 Motor, Carriage restraint upper Open
motor.
99-821 Hard Refer to WD 9.10. Check the DC cabling to the printhead stitch adjust 99-828-00 Motor, Carriage restraint upper Short
motor 1. Measure the resistance at PJ303 on the marking unit driver
PWB for an open or short circuit and to the chassis for a short circuit. 99-829-00 Motor, Carriage restraint upper/lower Fault
If a fault is found, repeat the measurement at the printhead stitch adjust
motor 1. If a short is measured, the marking unit driver PWB may be 99-830-00 Motor, Carriage select Open
the printhead stitch adjust motor 1. is drawing excessive power. 99-831-00 Motor, Carriage select Short
Install new components as necessary, printhead stitch adjust motor 1,
PL 91.25 Item 4, marking unit driver PWB, PL 92.10 Item 4. 99-832-00 Motor, Carriage drive Open
Refer to 91-504-00, 91-505-00, RAP. Check the printhead stitch adjust
motor. 99-833-00 Motor, Carriage drive Short
99-822 Soft Go to 91-504-00, 91-505-00, RAP. Check the printhead stitch adjust
motor. 99-834-00 Motor, Carriage drive power fault
99-823 Hard Refer to WD 9.9. Check the DC cabling to the printhead stitch adjust
motor 2. Measure the resistance at PJ102 on the marking unit driver 99-835-00 Motor, Head maint vertical Open
PWB for an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the printhead stitch adjust 99-836-00 Motor, Head maint vertical Short
damaged and be reported as an ‘open’ error. If short error is reported, 99-837-00 Motor, Head maint horizontal Open
the printhead roll adjust motor 2 is drawing excessive power.
Install new components as necessary, printhead stitch adjust motor 2, 99-838-00 Motor, Head maint horizontal Short
PL 91.20 Item 4, marking unit driver PWB, PL 92.10 Item 4.
Refer to 91-504-00, 91-505-00, RAP. Check the printhead stitch adjust Initial Actions
motor.
WARNING
Procedure
dC123.

99-824 Soft Go to 91-504-00, 91-505-00 RAP. Check the printhead stitch adjust
motor.
99-825 Soft Go to 91-512-00, 91-605-00 RAP. Check the lower carriage restraint
motor.

99-826 Hard Go to 91-512-00, 91-605-00 RAP. Check the lower carriage restraint 99-833 Hard Refer to WD 9.11. Check the DC cabling to the carriage docking motor.
motor. Measure the resistance at PJ605 on the marking unit driver PWB for an
99-827 Soft Go to 91-512-00, 91-605-00 RAP. Check the upper carriage restraint open or short circuit and to the chassis for a short circuit.
motor. If a fault is found, repeat the measurement at the carriage docking
motor. If a short is measured, the marking unit driver PWB may be dam-
99-828 Hard Go to 91-512-00, 91-605-00 RAP. Check the upper carriage restraint
motor. aged and be reported as an ‘open’ error.
If short error is reported, the motor is drawing excessive power.
99-829 Soft Go to 91-512-00, 91-605-00 RAP. Check the upper/lower carriage
Install new components as necessary, carriage docking motor, PL 91.10
restraint motor.
Item 16, marking unit driver PWB, PL 92.10 Item 4.
99-830 Hard Refer to WD 9.11. Check the DC cabling to the carriage drive select Refer to 91-567-00 to 91-568-00 RAP. Check the carriage drive select
motor. Measure the resistance at PJ607 on the marking unit driver PWB motor.
for an open or short circuit and to the chassis for a short circuit. If the fault remains, install a new IME controller PWB, PL 92.10 Item 1.
If a fault is found, repeat the measurement at the carriage drive select
99-834 Soft Go to 91-567-00 to 91-568-00 RAP. Check the carriage drive select
motor. If a short is measured, the marking unit driver PWB may be dam- motor.
aged and be reported as an ‘open’ error.
99-835 Hard Refer to WD 9.11. Check the DC cabling to the HM vertical motion
motor. Measure the resistance at PJ401 on the marking unit driver PWB
Install new components as necessary, carriage drive chain, PL 91.10
Item 1, marking unit driver PWB, PL 92.10 Item 4. for an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the HM vertical motion
Refer to 91-560-00 RAP. Check the carriage driver select motor.
99-831 Hard Refer to WD 9.11. Check the DC cabling to the carriage drive select
motor. Measure the resistance at PJ607 on the marking unit driver PWB If short error is reported, the motor is drawing excessive power.
for an open or short circuit and to the chassis for a short circuit.
Install new components as necessary, HM vertical motion motor, PL
If a fault is found, repeat the measurement at the carriage drive select
motor. If a short is measured, the marking unit driver PWB may be dam- Refer to 91-559-00 RAP. Check the vertical motion motor.
99-836 Hard Refer to WD 9.11. Check the DC cabling to the HM vertical motion
Install new components as necessary, carriage drive chain, PL 91.10
Item 1, marking unit driver PWB, PL 92.10 Item 4. for an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the HM vertical motion
Refer to 91-560-00 RAP. Check the carriage drive select motor.
99-832 Hard Refer to WD 9.2 and WD 9.6. Check the cable between PJ603 on the
drum driver PWB and PJ403 on the IME controller PWB. Ensure the If short error is reported, the motor is drawing excessive power.
connectors are fully seated.
Install new components as necessary, HM vertical motion motor, PL
Refer to WD 9.11. Check the DC cabling to the carriage docking motor.
Measure the resistance at PJ605 on the marking unit driver PWB for an Refer to 91-559-00 RAP. Check the vertical motion motor.
open or short circuit and to the chassis for a short circuit.
99-837 Hard Refer to WD 9.11. Check the DC cabling to the HM horizontal motion
If a fault is found, repeat the measurement at the carriage docking
aged and be reported as an ‘open’ error. for an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the HM horizontal motion
Install new components as necessary, carriage docking motor, PL 91.10
Item 16, marking unit driver PWB, PL 92.10 Item 4. aged and be reported as an ‘open’ error.
Refer to 91-567-00 to 91-568-00 RAP. Check the carriage drive select
Install new components as necessary, HM horizontal motion motor, PL
motor.
If the fault remains, install a new IME controller PWB, PL 92.10 Item 1. 91.15 Item 15, marking unit driver PWB, PL 92.10 Item 4.
Refer to 91-512-00, 91-605-00 RAP. Check the horizontal motion motor.

Code Hard/Soft Action 99-839-00 Motor, Head maint vertical Short
99-838 Hard Refer to WD 9.11. Check the DC cabling to the HM horizontal motion 99-840-00 Motor, X axis upper Open
for an open or short circuit and to the chassis for a short circuit. 99-841-00 Motor, X axis upper Short
If a fault is found, repeat the measurement at the HM horizontal motion 99-842-00 Motor, X axis upper Power low
aged and be reported as an ‘open’ error. 99-843-00 Motor, X axis upper Power high
If short error is reported, the motor is drawing excessive power. 99-845-00 Motor, X axis lower Open
Install new components as necessary, HM horizontal motion motor, PL
91.15 Item 15, marking unit driver PWB, PL 92.10 Item 4. 99-846-00 Motor, X axis lower Short
Refer to 91-512-00, 91-605-00 RAP. Check the horizontal motion motor. 99-847-00 Motor, X axis lower Power low
99-848-00 Motor, X axis lower Power high
99-860-00 Motor, IOD Shuttle Open
99-861-00 Motor, IOD Shuttle Short
99-862-00 Motor, IOD Shuttle Encoder
99-863-00 Motor, IOD Shuttle Power low
99-864-00 Motor, IOD Shuttle Power high
99-870-00 Motor, Ink Keyplate Open
99-871-00 Motor, Ink Keyplate Short
Initial Actions
WARNING
Procedure
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to dC123.

99-839 Soft Go to 91-559-00 RAP. Check the vertical motion motor.
99-840 Hard Refer to WD 9.9. Check the DC cabling to the X axis drive motor upper.
Measure the resistance at PJ102 on the marking unit driver PWB for an
If a fault is found, repeat the measurement at the X axis drive motor
upper. If a short is measured, the marking unit driver PWB may be dam-
Install new components as necessary, X axis drive motor upper, PL
Refer to 91-510-00, 91-511-00 RAP. Check the upper X axis drive motor.

99-841 Hard Refer to WD 9.9. Check the DC cabling to the X axis drive motor upper. 99-861 Hard Refer to WD 9.22. Check the DC cabling to the IOD shuttle motor. Mea-
Measure the resistance at PJ102 on the marking unit driver PWB for an sure the resistance at PJ660 on the IOD pre-amplifier PWB for an open
open or short circuit and to the chassis for a short circuit. or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the X axis drive motor If a fault is found, repeat the measurement at the IOD shuttle motor. If a
upper. If a short is measured, the marking unit driver PWB may be dam- short is measured, the IOD pre-amplifier PWB may be damaged and be
aged and be reported as an ‘open’ error. reported as an ‘open’ error.
If short error is reported, the motor is drawing excessive power. If short error is reported, the motor is drawing excessive power.
Install new components as necessary, X axis drive motor upper, PL Install new components as necessary, IOD assembly, PL 94.15 Item 1.
91.20 Item 5, marking unit driver PWB, PL 92.10 Item 4. Refer to 91-513-00, 91-514-00, 91-581-00, 91-583-00 RAP. Check the
Refer to 91-510-00, 91-511-00 RAP. Check the upper X axis drive motor. IOD shuttle motor.
99-842 Soft Go to 91-510-00, 91-511-00 RAP. Check the upper X axis drive motor. 99-862 Hard Go to 91-513-00, 91-514-00, 91-581-00, 91-583-00 RAP. Check the IOD
99-843 Soft Go to 91-510-00, 91-511-00 RAP. Check the upper X axis drive motor. shuttle motor and encoder.
99-845 Hard Refer to WD 9.11. Check the DC cabling to the X axis drive motor lower. 99-863 Soft Go to 91-513-00, 91-514-00, 91-581-00, 91-583-00 RAP. Check the IOD
Measure the resistance at PJ303 on the marking unit driver PWB for an shuttle motor.
open or short circuit and to the chassis for a short circuit. 99-864 Soft Go to 91-513-00, 91-514-00, 91-581-00, 91-583-00 RAP. Check the IOD
If a fault is found, repeat the measurement at the X axis drive motor shuttle motor.
lower. If a short is measured, the marking unit driver PWB may be dam- 99-870 Soft Go to 93-825-00, 93-892-00 RAP. Check the ink key plate motor.
aged and be reported as an ‘open’ error. 99-871 Hard Refer to WD 8.4. Check the DC cabling to the ink key plate motor. Mea-
sure the resistance at PJ406 on the media path driver PWB for an open
Install new components as necessary, X axis drive motor lower, PL
or short circuit and to the chassis for a short circuit.
91.25 Item 5, marking unit driver PWB, PL 92.10 Item 4. If a fault is found, repeat the measurement at the ink key plate motor. If a
Refer to 91-510-00, 91-511-00 RAP. Check the lower X axis drive motor.
short is measured, the media path driver PWB may be damaged and be
99-846 Hard Refer to WD 9.11. Check the DC cabling to the X axis drive motor lower. reported as an ‘open’ error.
Measure the resistance at PJ303 on the marking unit driver PWB for an If short error is reported, the motor is drawing excessive power.
open or short circuit and to the chassis for a short circuit. Install new components as necessary, ink key plate motor, PL 93.10
If a fault is found, repeat the measurement at the X axis drive motor Item 14, media path driver PWB, PL 1.15 Item 5.
lower. If a short is measured, the marking unit driver PWB may be dam- Refer to 93-825-00, 93-892-00 RAP. Check the ink key plate motor.
Install new components as necessary, X axis drive motor lower, PL
Refer to 91-510-00, 91-511-00 RAP. Check the lower X axis drive motor.
99-847 Soft Go to 91-510-00, 91-511-00 RAP. Check the lower X axis drive motor.
99-848 Soft Go to 91-510-00, 91-511-00 RAP. Check the lower X axis drive motor.
99-860 Hard Refer to WD 9.22. Check the DC cabling to the IOD shuttle motor. Mea-
sure the resistance at PJ660 on the IOD pre-amplifier PWB for an open
If a fault is found, repeat the measurement at the IOD shuttle motor. If a
short is measured, the IOD pre-amplifier PWB may be damaged and be
reported as an ‘open’ error.
Install new components as necessary, IOD assembly, PL 94.15 Item 1.
Refer to 91-513-00, 91-514-00, 91-581-00, 91-583-00 RAP. Check the
IOD shuttle motor.

99-872-00 Motor, Ink SKU Power low Code Hard/Soft Action
99-873-00 Motor, Ink SKU Power high 99-876 Hard Refer to WD 8.4. Check the DC cabling to the ink transport motor. Mea-
sure the resistance at PJ406 on the media path driver PWB for an open or
99-875-00 Motor, Ink load belt drive Open short circuit and to the chassis for a short circuit.
99-876-00 Motor, Ink load belt drive Short If a fault is found, repeat the measurement at the ink transport motor. If a
99-877-00 Motor, Ink load belt drive Power low reported as an ‘open’ error.
99-878-00 Motor, Ink load belt drive Power high If short error is reported, the motor is drawing excessive power.
Install new components as necessary, ink transport motor, PL 93.10 Item
99-880-00 Motor, Drum drive Open 5, media path driver PWB, PL 1.15 Item 5.
99-881-00 Motor, Drum drive Short Refer to 93-891-00 RAP. Check the ink transport motor.
99-877 Soft Go to 93-891-00 RAP. Check the ink transport motor.
99-882-00 Motor, Drum drive Power low
99-883-00 Motor, Drum drive Power high 99-880 Hard Enter dC123 Pest fault history and check for PEST error 99-886 or 99-
99-884-00 Motor, Drum drive Motor encoder 887, if present then follow those RAPs first.
Refer to WD 1.1. Then check the resistance at the drum motor leads
99-885-00 Motor, Drum drive Drum encoder (should be 10.5 ohms typical, valid range 9.0 to 12.0 ohms, between any 2
99-886-00 Motor, Drum drive Current feedback of the 3 leads, 3 measurements). Refer to WD 1.4 and WD 9.4. Check the
Interface harness and connectors for damage between the drum driver
99-887-00 Motor, Drum drive Thermal fuse PWB at PJ902 and the power supply at PJDC2 (pins 11, 13, 15, 17). If
99-888-00 Motor, Transfix front Force encoder above are OK, install a new power supply, PL 1.15 Item 2.
If fault still present, install a new drum driver PWB, PL 1.15 Item 4.
Initial Actions Note: This motor is disabled by front door interlock; soft error 99-992 will
be given instead, the drum motor test will be skipped. This error will only
be activated if door interlock is OK.
WARNING Refer to 94-524-00, 94-526-00, 94-534-00 RAP. Check the drum drive
Ensure that the electricity to the machine is switched off while performing tasks that do motor.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 99-881 Hard Refer to WD 1.1. Then check the resistance at the drum motor leads
death or injury. Moving parts can cause injury. (should be 10.5 ohms typical, valid range 9.0 to 12.0 ohms, between any 2
of the 3 leads, 3 measurements). Refer to WD 1.4 and WD 9.4. Check the
Procedure Interface harness and connectors for damage between the drum driver
PWB at PJ902 and the power supply at PJDC2 (pins 11, 13, 15, 17). If
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to above are OK, install a new power supply, PL 1.15 Item 2.
dC123. If fault still present, install a new drum driver PWB, PL 1.15 Item 4.
Note: This motor is disabled by front door interlock; soft error 99-992 will
Table 1 PEST codes and action be given instead, the drum motor test will be skipped. This error will only
Code Hard/Soft Action be activated if door interlock is OK.
Refer to 94-524-00, 94-526-00, 94-534-00 RAP. Check the drum drive
99-872 Soft Go to 93-825-00, 93-892-00 RAP. Check ink key plate motor.
motor.
99-873 Soft Go to 93-825-00, 93-892-00 RAP. Check ink key plate motor.
99-882 Soft Go to 94-524-00, 94-526-00, 94-534-00 RAP. Check the drum drive motor.
99-883 Soft Go to 94-524-00, 94-526-00, 94-534-00 RAP. Check the drum drive motor.
99-884 Hard Go to 10-545-00 and 94-545-00 RAP. Check the drum drive motor
encoder.
99-885 Hard Go to 10-545-00 and 94-549-00 RAP. Check the drum encoder.
99-886 Soft Go to 94-524-00, 94-526-00, 94-534-00 RAP. Check the drum drive current.
99-887 Soft If persistent, install new drum motor, PL 94.20 Item 6

99-889-00 Motor, Transfix rear Force encoder Code Hard/Soft Action

99-890 Hard Refer to WD 9.1. Check the DC cabling to the front transfix motor. Mea-
99-890-00 Motor, Transfix front Open sure the resistance at PJ401 on the drum driver PWB for an open or
short circuit and to the chassis for a short circuit.
99-891-00 Motor, Transfix front Short If a fault is found, repeat the measurement at the front transfix motor. If a
short is measured, the drum driver PWB may be damaged and be
99-892-00 Motor, Transfix front Motor encoder reported as an ‘open’ error.
99-893-00 Motor, Transfix front Below min Install new components as necessary, front transfix motor, PL 10.20
Item 11, Drum driver PWB, PL 1.15 Item 4.
99-894-00 Motor, Transfix front Above max Refer to 10-500-00 to 10-540-00 RAP. Check the front transfix motor.
99-891 Hard Refer to WD 9.1. Check the DC cabling to the front transfix motor. Mea-
99-895-00 Motor, Transfix rear Open
sure the resistance at PJ401 on the drum driver PWB for an open or
99-896-00 Motor, Transfix rear Short If a fault is found, repeat the measurement at the front transfix motor. If a
99-897-00 Motor, Transfix rear Motor encoder
99-898-00 Motor, Transfix rear Below min
Install new components as necessary, front transfix motor, PL 10.20
99-899-00 Motor, Transfix rear Above max Refer to 10-500-00 to 10-540-00 RAP. Check the front transfix motor.
99-892 Hard Refer to WD 9.1 and WD 9.3. Check the DC cabling to the front transfix
99-901-00 Motor, MP2 Open
flexure encoder. Measure the resistance at PJ801 on the drum driver
99-902-00 Motor, MP2 Short PWB for an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the front transfix flexure
encoder. If a short is measured, the drum driver PWB may be damaged
99-903-00 Motor, MP2 Encoder
and be reported as an ‘open’ error.
If short error is reported, the encoder is drawing excessive power.
99-904-00 Motor, MP2 Power fault
Install new components as necessary, front transfix encoder, PL 10.20
Initial Actions Refer to 10-500-00 to 10-540-00 RAP. Check the front transfix motor
encoder. If the fault remains, install a new front transfix motor, PL 10.20
Item 11.
WARNING
99-983 Soft Go to 10-500-00 to 10-540-00 RAP. Check the front transfix motor.
99-894 Soft Go to 10-500-00 to 10-540-00 RAP. Check the front transfix motor.
death or injury. Moving parts can cause injury. 99-895 Hard Refer to WD 9.1. Check the DC cabling to the rear transfix motor. Mea-
Procedure If a fault is found, repeat the measurement at the rear transfix motor. If a
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to short is measured, the drum driver PWB may be damaged and be
dC123. reported as an ‘open’ error.
Table 1 PEST codes and action Install new components as necessary, rear transfix motor, PL 10.20 Item
Code Hard/Soft Action 11, Drum driver PWB, PL 1.15 Item 4.
Refer to 10-500-00 to 10-540-00 RAP. Check rear transfix motor.

Code Hard/Soft Action 99-905-00 Motor, MP6 Open
99-896 Hard Refer to WD 9.1. Check the DC cabling to the rear transfix motor. Mea- 99-906-00 Motor, MP6 Short
short circuit and to the chassis for a short circuit. 99-907-00 Motor, MP6 Encoder
If a fault is found, repeat the measurement at the rear transfix motor. If a 99-908-00 Motor, MP6 Power low
reported as an ‘open’ error. 99-909-00 Motor, MP6 Power high
If short error is reported, the motor is drawing excessive power. 99-910-00 Motor, M3A1 Open
Install new components as necessary, rear transfix motor, PL 10.20 Item
11, Drum driver PWB, PL 1.15 Item 4. 99-911-00 Motor, M3A1 Short
Refer to 10-500-00 to 10-540-00 RAP. Check rear transfix motor. 99-912-00 Motor, M3A1 Power low
99-897 Hard Refer to WD 9.1 and WD 9.3. Check the DC cabling to the front transfix
99-913-00 Motor, M3A1 Power high
flexure encoder. Measure the resistance at PJ801 on the drum driver
PWB for an open or short circuit and to the chassis for a short circuit. 99-915-00 Motor, M3A2 Open
If a fault is found, repeat the measurement at the front transfix flexure
99-916-00 Motor, M3A2 Short
encoder. If a short is measured, the drum driver PWB may be damaged
and be reported as an ‘open’ error. 99-917-00 Motor, M3A2 Power low
If short error is reported, the encoder is drawing excessive power.
99-918-00 Motor, M3A2 Power high
Install new components as necessary, front transfix encoder, PL 10.20
Item 5, Drum driver PWB, PL 1.15 Item 4. 99-920-00 Motor, MP4 Open
Refer to 10-500-00 to 10-540-00 RAP. Check rear transfix motor. If the
99-921-00 Motor, MP4 Short
fault remains, install a new rear transfix motor, PL 10.20 Item 11.
99-898 Soft Go to 10-500-00 to 10-540-00 RAP. Check rear transfix motor. Initial Actions
99-899 Soft Go to 10-500-00 to 10-540-00 RAP. Check rear transfix motor.
99-901 Hard Refer to WD 8.1. Check the DC cabling to the vertical transport motor.
Measure the resistance at PJ202 on the media path driver PWB for an WARNING
open or short circuit and to the chassis for a short circuit. Ensure that the electricity to the machine is switched off while performing tasks that do
If a fault is found, repeat the measurement at the vertical transport not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
motor. If a short is measured, the media path driver PWB may be dam- death or injury. Moving parts can cause injury.
If short error is reported, the motor is drawing excessive power. Procedure
Install new components as necessary, vertical transport motor, PL 82.10
Item 12, media path driver PWB, PL 1.15 Item 5. Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
Refer to 82-132-00, 82-155-00 RAP. Check transport motor. dC123.
99-902 Hard Refer to WD 8.1. Check the DC cabling to the vertical transport motor.
Measure the resistance at PJ202 on the media path driver PWB for an
open or short circuit and to the chassis for a short circuit. Code Hard/Soft Action
If a fault is found, repeat the measurement at the vertical transport 99-905 Hard Refer to WD 8.1 and WD 8.5. Check the DC cabling to the horizontal
motor. If a short is measured, the media path driver PWB may be dam- transport motor. Measure the resistance at PJ303 on the media path
aged and be reported as an ‘open’ error. driver PWB for an open or short circuit and to the chassis for a short
If short error is reported, the motor is drawing excessive power. circuit.
Install new components as necessary, vertical transport motor, PL 82.10 If a fault is found, repeat the measurement at the horizontal transport
Item 12, media path driver PWB, PL 1.15 Item 5. motor. If a short is measured, the media path driver PWB may be dam-
Refer to 82-132-00, 82-155-00 RAP. Check transport motor. aged and be reported as an ‘open’ error.
99-903 Hard Go to 82-132-00, 82-155-00 RAP. Check transport motor. If short error is reported, the motor is drawing excessive power.
99-904 Soft Go to 82-132-00, 82-155-00 RAP. Check transport motor. Install new components as necessary, horizontal transport motor, PL
82.15 Item 9, media path driver PWB, PL 1.15 Item 5.
Refer to 82-132-00, 82-155-00 RAP. Check horizontal transport motor.

99-906 Hard Refer to WD 8.1 and WD 8.5. Check the DC cabling to the horizontal 99-915 Hard Refer to WD 8.1. Check the DC cabling to the registration motor A2.
transport motor. Measure the resistance at PJ303 on the media path Measure the resistance at PJ202 on the media path driver PWB for an
driver PWB for an open or short circuit and to the chassis for a short open or short circuit and to the chassis for a short circuit.
circuit. If a fault is found, repeat the measurement at the registration motor A2.
If a fault is found, repeat the measurement at the horizontal transport If a short is measured, the media path driver PWB may be damaged
motor. If a short is measured, the media path driver PWB may be dam- and be reported as an ‘open’ error.
aged and be reported as an ‘open’ error. If short error is reported, the motor is drawing excessive power.
If short error is reported, the motor is drawing excessive power. Install new components as necessary, registration / preheat assembly,
Install new components as necessary, horizontal transport motor, PL PL 88.10 Item 1, media path driver PWB, PL 1.15 Item 5.
82.15 Item 9, media path driver PWB, PL 1.15 Item 5. Refer to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registra-
Refer to 82-132-00, 82-155-00 RAP. Check horizontal transport motor. tion motor.
99-907 Hard Go to 82-132-00, 82-155-00 RAP. Check horizontal transport motor. 99-916 Hard Refer to WD 8.1. Check the DC cabling to the registration motor A2.
99-908 Soft Go to 82-132-00, 82-155-00 RAP. Check horizontal transport motor Measure the resistance at PJ202 on the media path driver PWB for an
encoder. open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the registration motor A2.
99-909 Soft Go to 82-132-00, 82-155-00 RAP. Check horizontal transport motor.
If a short is measured, the media path driver PWB may be damaged
99-910 Hard Refer to WD 8.1. Check the DC cabling to the registration motor A1. and be reported as an ‘open’ error.
Measure the resistance at PJ202 on the media path driver PWB for an
Install new components as necessary, registration / preheat assembly,
If a fault is found, repeat the measurement at the registration motor A1. PL 88.10 Item 1, media path driver PWB, PL 1.15 Item 5.
If a short is measured, the media path driver PWB may be damaged
Refer to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registra-
tion motor.
Install new components as necessary, registration / preheat assembly, 99-917 Soft Go to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registration
motor.
PL 88.10 Item 1, media path driver PWB, PL 1.15 Item 5.
Refer to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registra- 99-918 Soft Go to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registration
tion motor. motor.
99-911 Hard Refer to WD 8.1. Check the DC cabling to the registration motor A1. 99-920 Hard Refer to WD 8.2. Check the DC cabling to the post transfix motor (M4).
Measure the resistance at PJ202 on the media path driver PWB for an Measure the resistance at PJ303 on the media path driver PWB for an
open or short circuit and to the chassis for a short circuit. open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the registration motor A1. If a fault is found, repeat the measurement at the post transfix motor
If a short is measured, the media path driver PWB may be damaged (M4). If a short is measured, the media path driver PWB may be dam-
and be reported as an ‘open’ error. aged and be reported as an ‘open’ error.
If short error is reported, the motor is drawing excessive power. If short error is reported, the motor is drawing excessive power.
Install new components as necessary, registration / preheat assembly, Install new components as necessary, post transfix motor (M4), PL
PL 88.10 Item 1, media path driver PWB, PL 1.15 Item 5. 10.10 Item 5, media path driver PWB, PL 1.15 Item 5.
Refer to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registra- Refer to 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00,
tion motor. 10-148-00 RAP. Check the post transfix motor.
99-912 Soft Go to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registration 99-921 Hard Refer to WD 8.2. Check the DC cabling to the post transfix motor (M4).
motor. Measure the resistance at PJ303 on the media path driver PWB for an
99-913 Soft Go to 89-110-00 to 89-113-00, 89-129-00 RAP. Check the registration
motor. If a fault is found, repeat the measurement at the post transfix motor
(M4). If a short is measured, the media path driver PWB may be dam-
Install new components as necessary, post transfix motor (M4), PL
10.10 Item 5, media path driver PWB, PL 1.15 Item 5.
Refer to 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00,
10-148-00 RAP. Check the post transfix motor.

99-922-00 Motor, MP4 Power low Code Hard/Soft Action

99-923 Soft Go to 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00, 10-
99-923-00 Motor, MP4 Power high 148-00 RAP. Check the run motor.
99-925 Hard Refer to WD 8.2. Check the DC cabling to the exit motor (M5). Measure
99-925-00 Motor, MP5 Open
the resistance at PJ303 on the media path driver PWB for an open or
99-926-00 Motor, MP5 Short
If a fault is found, repeat the measurement at the exit motor (M5). If a
99-927-00 Motor, MP5 Power low reported as an ‘open’ error.
99-928-00 Motor, MP5 Power high
Install new components as necessary, exit motor (M5), PL 10.15 Item
11, media path driver PWB, PL 1.15 Item 5.
99-930-00 Motor (M7), MSI Tray 4 Feed Open
Refer to 83-500-00 RAP. Check the output transport motor.
99-926 Hard Refer to WD 8.2. Check the DC cabling to the exit motor (M5). Measure
99-931-00 Motor (M7), MSI Tray 4 Feed Short
the resistance at PJ303 on the media path driver PWB for an open or
99-932-00 Motor (M7), MSI Tray 4 Feed Power low
If a fault is found, repeat the measurement at the exit motor (M5). If a
99-933-00 Motor (M7), MSI Tray 4 Feed Power high short is measured, the media path driver PWB may be damaged and be
99-934-00 Motor, 3TM Horizontal transport Power low
Install new components as necessary, exit motor (M5), PL 10.15 Item
11, media path driver PWB, PL 1.15 Item 5.
99-935-00 Motor, 3TM Horizontal transport Open
Refer to 83-500-00 RAP. Check the output transport motor.
99-936-00 Motor, 3TM Horizontal transport Short 99-927 Soft Go to 83-500-00 RAP. Check the output transport motor.
99-928 Soft Go to 83-500-00 RAP. Check the output transport motor.
99-937-00 Motor, 3TM Tray3 elevator Open 99-930 Soft Go to 74-101-00 RAP. Check the bypass feed motor.
99-931 Hard Refer to WD 8.3. Check the DC cabling to the bypass feed motor. Mea-
99-938-00 Motor, 3TM Tray3 elevator Short
sure the resistance at PJ405 on the media path driver PWB for an open
Initial Actions If a fault is found, repeat the measurement at the bypass feed motor. If a
WARNING If short error is reported, the motor is drawing excessive power.
Ensure that the electricity to the machine is switched off while performing tasks that do Install new components as necessary, bypass module, PL 74.10 Item 1,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause media path driver PWB, PL 1.15 Item 5.
death or injury. Moving parts can cause injury. Refer to 74-101-00 RAP. Check the bypass feed motor.
• Check connections of the indicated component 99-932 Soft Go to 74-101-00 RAP. Check the bypass feed motor.
99-933 Soft Go to 74-101-00 RAP. Check the bypass feed motor.
Procedure 99-934 Soft Go to 71-101-00, 71-106-00 RAP. Check the 3 tray transport motor.
Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to 99-935 Soft Go to 71-101-00, 71-106-00 RAP. Check the 3 tray transport motor.
dC123.

99-922 Soft Go to 10-110-00 to 10-113-00, 10-125-00 to 10-128-00, 10-147-00, 10-
148-00 RAP. Check the run motor.

Code Hard/Soft Action 99-939-00 Motor, 3TM Tray 3 elevator Power fault
99-936 Hard Refer to WD 7.5. Check the DC cabling to the 3 tray transport motor. 99-940-00 Motor, 3TM Tray 1 feed Open
Measure the resistance at PJ956 on the 3 tray module PWB for an open
or short circuit and to the chassis for a short circuit. 99-941-00 Motor, 3TM Tray 1 feed Short
If a fault is found, repeat the measurement at the 3 tray transport motor. 99-942-00 Motor, 3TM Tray 1 feed Power low
If a short is measured, the 3 tray module PWB may be damaged and be
reported as an ‘open’ error. 99-943-00 Motor, 3TM Tray 2 feed Open
If short error is reported, the motor is drawing excessive power. 99-944-00 Motor, 3TM Tray 2 feed Short
Install new components as necessary, 3 tray transport motor, PL 73.16
Item 3, 3 tray module PWB, PL 73.16 Item 4. 99-945-00 Motor, 3TM Tray 2 feed Power low
Refer to 71-101-00, 71-106-00 RAP. Check the 3 tray transport motor. 99-946-00 Motor, 3TM Tray 3 feed Open
99-937 Soft Go to 73-215-00 RAP. Check tray 3 elevator motor.
99-947-00 Motor, 3TM Tray 3 feed Short
99-938 Hard Refer to WD 7.5. Check the DC cabling to the tray 3 elevator motor.
Measure the resistance at PJ957 on the 3 tray module PWB for an open 99-948-00 Motor, 3TM Tray 3 feed Power low
or short circuit and to the chassis for a short circuit. 99-950-00 Motor, PFP Tray 5 transport Open
If a fault is found, repeat the measurement at the tray 3 elevator motor.
If a short is measured, the 3 tray module PWB may be damaged and be 99-951-00 Motor, PFP Tray 5 transport Short
reported as an ‘open’ error. 99-952-00 Motor, PFP Tray 5 transport Power fault
Install new components as necessary, tray 3 elevator motor, PL 73.16 99-953-00 Motor, PFP Tray 5 elevate Open
Item 2, 3 tray module PWB, PL 73.16 Item 4. 99-954-00 Motor, PFP Tray 5 elevate Short
Refer to 73-215-00 RAP. Check tray 3 elevator motor.
Initial Actions
WARNING
Procedure
dC123.
99-939 Soft Go to 73-215-00 RAP. Check tray 3 elevator motor.
99-940 Soft Go to 71-101-00, 71-106-00 RAP. Check tray 1 feed motor.
99-941 Hard Refer to WD 7.3. Check the DC cabling to the tray 1 feed / elevate
motor. Measure the resistance at PJ951 on the 3 tray module PWB for
an open or short circuit and to the chassis for a short circuit.
If a fault is found, repeat the measurement at the tray 1 feed / elevate
motor. If a short is measured, the 3 tray module PWB may be damaged
Install new components as necessary, tray 1 feed / elevate motor, PL
81.25 Item 22, 3 tray module PWB, PL 73.16 Item 4.
Refer to 71-101-00, 71-106-00 RAP. Check tray 1 feed motor.
99-942 Soft Go to 71-101-00, 71-106-00 RAP. Check tray 1 feed motor.

Code Hard/Soft Action 99-955-00 Motor, PFP Tray 5 elevate Power fault
99-943 Soft Go to 72-215-00 RAP. Check tray 2 feed motor.
99-944 Hard Refer to WD 7.3. Check the DC cabling to the tray 2 feed / elevate 99-956-00 Motor, PFP Tray 5 feed Open
motor. Measure the resistance at PJ952 on the 3 tray module PWB for
an open or short circuit and to the chassis for a short circuit. 99-957-00 Motor, PFP Tray 5 feed Short
If a fault is found, repeat the measurement at the tray 2 feed / elevate
motor. If a short is measured, the 3 tray module PWB may be damaged 99-958-00 Motor, PFP Tray 5 feed Power low
If short error is reported, the motor is drawing excessive power. 99-960-00 Motor, OCT offset Open
Install new components as necessary, tray 2 feed / elevate motor, PL
81.26 Item 22, 3 tray module PWB, PL 73.16 Item 4. 99-961-00 Motor, OCT offset Short
Refer to 72-215-00 RAP. Check tray 2 feed motor.
99-945 Soft Go to 72-215-00 RAP. Check tray 2 feed motor. 99-962-00 Motor, OCT offset Power low
99-946 Soft Go to 73-101-00, 73-106-00, 73-110-00 RAP. Check tray 3 feed motor.
99-947 Hard Refer to WD 7.4. Check the DC cabling to the tray 3 feed motor. Mea- Initial Actions
sure the resistance at PJ953 on the 3 tray module PWB for an open or
If a fault is found, repeat the measurement at the tray 3 feed motor. If a WARNING
short is measured, the 3 tray module PWB may be damaged and be Ensure that the electricity to the machine is switched off while performing tasks that do
reported as an ‘open’ error. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
If short error is reported, the motor is drawing excessive power. death or injury. Moving parts can cause injury.
Install new components as necessary, tray 3 feed motor, PL 81.30 Item
22, 3 tray module PWB, PL 73.16 Item 4.
Procedure
Refer to 73-101-00, 73-106-00, 73-110-00 RAP. Check tray 3 feed
motor. Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-948 Soft Go to 73-101-00, 73-106-00, 73-110-00 RAP. Check tray 3 feed motor.
99-950 Soft Go to 75-101-00 RAP. Check tray 5 transport motor.
99-951 Hard Refer to WD 7.1. Check the DC cabling to the tray 5 transport motor.
Measure the resistance at PJ503 on the tray 5 control PWB for an open Code Hard/Soft Action
or short circuit and to the chassis for a short circuit. 99-955 Soft Go to 75-212-00, 75-215-00 RAP. Check tray 5 elevator motor.
If a fault is found, repeat the measurement at the tray 5 transport motor. 99-956 Soft Go to 75-101-00 RAP. Check tray 5 feed motor.
If a short is measured, the tray 5 control PWB may be damaged and be
99-957 Hard Go to 75-101-00 RAP. Check tray 5 feed motor.
If short error is reported, the motor is drawing excessive power. 99-958 Soft Go to 75-101-00 RAP. Check tray 5 feed motor.
Install new components as necessary, tray 5 transport motor, PL 81.40 99-960 Soft Go to 12-701-00-65 RAP. Check Offset Catch Tray motor.
Item 2, tray 5 control PWB, PL 75.68 Item 8. 99-961 Hard Refer to WD 12.23. Check the DC cabling to the OCT offset motor.
Refer to 75-101-00 RAP. Check tray 5 transport motor. Measure the resistance at PJ495 on the OCT PWB for an open or
99-952 Soft Go to 75-101-00 RAP. Check tray 5 transport motor. short circuit and to the chassis for a short circuit.
99-953 Soft Go to 75-212-00, 75-215-00 RAP. Check tray 5 elevator motor. If a fault is found, repeat the measurement at the OCT offset motor.
99-954 Hard Refer to WD 7.1. Check the DC cabling to the tray 5 elevator motor. If a short is measured, the OCT PWB may be damaged and be
Measure the resistance at PJ504 on the tray 5 control PWB for an open reported as an ‘open’ error.
or short circuit and to the chassis for a short circuit. If short error is reported, the motor is drawing excessive power.
If a fault is found, repeat the measurement at the elevator motor. If a Install new components as necessary, OCT module, PL 12.00 Item
short is measured, the tray 5 control PWB may be damaged and be 1.
reported as an ‘open’ error. Refer to 12-701-00-65 RAP. Check Offset Catch Tray motor.
If short error is reported, the motor is drawing excessive power. 99-962 Soft Go to 12-701-00-65 RAP. Check Offset Catch Tray motor.
Install new components as necessary, elevator motor, PL 75.68 Item 4,
tray 5 control PWB, PL 75.68 Item 8.
Refer to 75-212-00, 75-215-00 RAP. Check tray 5 elevator motor.

99-992-00 PEST Error 46 RAP 99-996-00 to 99-999-00 PEST Error 47 RAP
99-992-00 Front door interlock open 99-996-00 PEST failed to complete
Initial Actions 99-997-00 Misc
99-999-00 Hard / soft fault separator

WARNING
WARNING
dC123.
Table 1 PEST codes and action Procedure

Code Hard/Soft Action Refer to Table 1. Perform the relevant action. For an explanation of PEST codes refer to
dC123.
99-992 Soft Go to 01-510-00 RAP. Check the front door interlock switch.
Code Description Hard/Soft Action
99-996 PEST failed to Hard View the last indicated PEST faults, dC123, to find the
complete failure area
99-997 Misc Hard This fault code is for future use and is included for ref-
erence only.
99-999 Hard / soft fault Soft Information only: indicates change from a hard fault to
separator a soft fault and vice versa in the PEST fault list,
dC123

OF 1 Unusual Noise RAP • Enter dC330 code 05-074 and add code 05-098 nudger motor, to energize the nudger
motor, PL 5.15 Item 5.
Use this RAP to isolate unusual noises in the machine.
Possible causes and potential solutions are:
NOTE: Due to the intermittent nature of unusual noises, this RAP can only give guidance on • Grinding noise.
how to isolate noises. This RAP will not find all possible causes. When machines become old Possible causes are:
and worn, unusual noises may arise that are not covered in this RAP. – The intermediate feed bearing, PL 5.15 Item 22 can stick, preventing the feed roll
from free wheeling as the document is transported by takeaway roll.
Procedure
– Large flat spots, confined to one or two areas on the retard roll, which causes feed
noise and an increase in 05-330, 05-331and 05-335 jams.
WARNING Solution:
Ensure that the electricity to the machine is switched off while performing tasks that do – Install a new the feed assembly, PL 5.15 Item 18.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Noise from the DADH input tray.
death or injury. Moving parts can cause injury. Possible causes are:
1. Ask the customer if there are any specific machine functions that are noisy. – Document guides.
2. Ask the customer to demonstrate the function of the machine that generates the unusual Solution:
noise. – Clean the DADH input tray in the area below the input guides with antistatic fluid, PL
3. Check the Fault and Error logs. 26.10 Item 11.
4. Switch off the machine, GP 14. Wait for two minutes, switch on the machine and allow the • Squeaks from the DADH.
machine to perform a normal initialization and warm-up. Possible causes are:
5. Run the machine in all modes. Also use the diagnostics to run individual components. Go – DADH exit roll assembly or takeaway roll assembly, PL 5.35 Item 6.
to the relevant subsection:
Solution:
• DADH
– Remove and clean the shafts and plastic bushes with antistatic fluid, PL 26.10 Item
• Scanner (W/O TAG 007) 11.
• Scanner (W/TAG 007) • Knocking noise.
• Tray 1 and 2 Assembly Possible causes are:
• Tray 3 Assembly – The feed motor and CVT motor are not tensioned correctly, causing the drive belts to
• Tray 4 Assembly slip.
• Tray 5 Assembly Solution:
• Vertical Paper Path – Adjust the DADH drive belts, ADJ 5.1.
• Horizontal Paper Path • Gear rattle.
• Exit Paper Path Possible causes are:
• Registration / pre-heat Assembly – A loose meshing of the clutch and motor gears PL 5.15 Item 9 and PL 5.15 Item 16.
• Nips / Diverters Solution:
• Drum Drive motor / transfix motor / stripper assembly – Adjust the DADH drive belts, ADJ 5.1.
• Fans Scanner (W/O TAG 007)
• Stripper Blade Possible causes and potential solutions are:
• LCSS • Grinding.
• HVF / HVF BM Possible causes are:
DADH – The scan carriage is moving erratically and the scan motor is generating a grinding
Run the following components: sound. The teeth of the scanner drive belt are not engaging with the capstan on the
• Enter dC330 code 05-099 DADH CVT motor to rotate the DADH CVT roll, PL 5.25 Item 5. scan motor. PL 62.16 Item 12.
• Enter dC330 code 05-074 feed motor, to run the DADH takeaway rolls, PL 5.35 Item 6. Solution:
• Enter dC330 code 05-074 and add code 05-062 feed clutch, to energize the feed clutch – Perform ADJ 62.3 Scan Motor and Scanner Drive Belt adjustment.
and run the drive shaft, PL 5.15 Item 9.

Xerox® ColorQube® 9203 Family 2-575 OF 1
Scanner (W/TAG 007) Solution:
Possible causes and potential solutions are: – Check the drive belt and gears, PL 73.16.
• Grinding. – Check that the paper trays are correctly positioned and that the tray moves freely
inside the tray assembly.
Possible causes are:
– Adjust or install new components as necessary.
– The scan carriage is moving erratically and the scan motor is generating a grinding
sound. The teeth of the scanner drive belt are not engaging with the capstan on the Tray 4 Assembly
scan motor. PL 62.18 Item 9. Run the following components:
Solution: • Enter dC330 code 74-420 Bypass Feed Motor, to run the bypass feed motor, PL 74.10
– Install new components as necessary. Item 2.
Tray 1 and 2 Assembly Possible causes and potential solutions are:
Remove tray 1 and tray 2 and run the following components: • No drive or a knocking noise from the bypass feed motor.
• Enter code dC330 code 71-002 T1 Feed / Elevate Motor, to run the tray 1 feed motor, PL Possible causes are:
81.25 Item 22. – Incorrectly aligned or damaged parts.
• Enter code dC330 code 72-001 T2 Feed / Elevate Motor, to run the tray 2 feed motor, PL – Contamination of the drive shafts and the bearings.
81.26 Item 22. Solution:
• Open left hand door. – Check the bypass feed motor, rolls and bearings, PL 73.16.
• Enter dC330 code 70-025 3 tray transport motor, to run tray 1 and tray 2 transport rolls, – Adjust or install new components as necessary.
PL 73.16 Item 3.
Tray 5 Assembly
Possible causes and potential solutions are:
Run the components as follows:
• Squeaks.
• Open the tray 5 door to lower the elevator.
• Close the door or actuate the interlock.
– Contamination of the drive shafts and bearings.
• Enter dC330 code 75-019 Tray 5 Elevator Motor Up to drive the tray up, PL 75.68 Item 4.
– Incorrectly adjusted or worn drive belts.
• Enter dC330 code 75-020 Tray 5 Elevator Motor Down to drive the tray down.
– Incorrectly aligned or damaged parts.
• Enter dC330 code 75-018 Tray 5 Transport Motor to operate the tray 5 transport motor,
Solution: PL 81.40 Item 2.
– Remove and clean the drive shafts, bearings, GP 27. • Enter dC330 code 75-117 Tray 5 Feed Motor to operate the tray 5 feed motor, PL 81.40
– Check 3 tray transport drive belt. Install new parts as necessary, PL 73.16 Item 7. Item 3.
– Check for parts that are damaged or out of position. Possible causes are:
– Adjust or install new components as necessary. • Incorrectly aligned or damaged parts.
Tray 3 Assembly • Contamination of the drive shafts and the bearings.
Run the following components: Solution:
• Enter dC330 code 73-001 T3 Feed Motor, to operate the tray 3 feed motor, PL 81.30 Item • Check the motor, rolls, bearings, PL 73.16. Clean as necessary, GP 27.
22. The paper tray must be open when motor is running. Check the gear 30T bearing, PL 81.40 Item 18 for damage.
• Pull out tray 3 and let the tray drop, then push the tray back in. • Adjust or install new components as necessary.
• Enter dC330 code 73-002 T3 Elevate Motor, to elevate tray 3, PL 73.16 Item 2. Vertical Paper Path
• Enter dC330 code 70-025 3 Tray Transport motor to run the 3 tray transport motor, PL
73.16 Item 3. NOTE: A door cheat for the main door is not required.
Possible causes and potential solutions are: Run the components as follows:
• No drive or a knocking noise from the 3 tray transport motor. • Enter dC330 code 82-001 Vertical Trans Motor Fwd (M2) to run the vertical transport
Possible causes are: motor forward, PL 82.10 Item 12. To diagnose the source of the noise, run the motor with
– The 3 tray transport motor, PL 73.16 Item 3. the upper left door and mid left door closed, then opened.
– Worn or stretched elevator cables, PL 73.15 Item 17, PL 73.15 Item 18, PL 73.15 • Enter dC330 code 82-002 Vertical Trans Motor Rev (M2) to run the vertical transport
Item 19. motor in reverse.

OF 1 2-576 Xerox® ColorQube® 9203 Family
Possible causes are: • If the noise repeats, the source is the M4 motor or gear assembly. Install new parts as
• Incorrectly aligned or damaged parts. necessary.
• Contamination of the drive shafts, idler rolls or bearings. • If the noise does not repeat, the source is one of the idlers in the stripper gate and baffle
assembly, PL 10.12.
Solution:
• Close stripper gate and baffle assembly.
• Check the motor, rolls, bearings, and drive belts, PL 82.10. Clean as necessary, GP 27.
• Enter dC330 code 10-023 Strip Gate Latch.
• Check the idler rolls in the upper left door assembly, PL 70.30. Clean as necessary, GP
27. If the noise repeats perform the following:
• Check the bearings on the end of the transport roller drive 2, PL 82.10 Item 1 and the
• Open horizontal paper path assembly, PL 82.15 Item 1.
transport roller TAR vertical, PL 82.10 Item 2. Clean as necessary, GP 27.
• If the noise repeats, the source is the M5 motor, idlers or gear assembly, PL 10.15. Adjust
• Adjust or install new components as necessary.
or install new components as necessary.
Horizontal Paper Path • If the noise does not repeat, the source is the exit paper path, PL 10.15 Item 19. Adjust or
Run the following components: install new components as necessary.
• Enter dC330 code 82-003 Horizontal Trans Motor Fwd (M6), to run the horizontal trans- Registration / pre-heat Assembly
port motor forward, PL 82.15 Item 9. To diagnose the source of the noise, run the motor
with the horizontal paper path (handle 4b) closed, then opened. NOTE: A door cheat for the main door is not required.
• Enter dC330 code 82-004 Horizontal Trans Motor Rev (M6), to run the horizontal trans- Run the following components:
port motor in reverse.
• Enter dC330 code 89-007 Registration Motor A1 to run registration motor A1, PL 88.11
Item 8.
• Incorrectly aligned or damaged parts.
• Enter dC330 code 89-008 Registration Motor A2 to run registration motor A2, PL 88.11
• Contamination of the drive shafts, idler rolls or bearings. Item 8.
Solution: Possible causes:
• Check the motor, takeaway rolls, bearings, and drive belts, PL 82.15. Clean as necessary, • Registration motor A1 and A2, PL 88.11 Item 8.
GP 27.
• Incorrectly adjusted of worn drive belts, PL 88.11 Item 4.
• Check the idler rolls in the horizontal paper path assembly, PL 82.15. Clean as necessary,
Solution:
GP 27.
• Clean contamination on the drive shafts and the bearings
Exit Paper Path If the noise repeats perform the following:
Run the following components:
• Enter dC330 code 10-018 Post Transfix Motor (M4) to run the post-transfix motor forward, • Enter dC330 code 89-011 Nip A: Open to disengage all of the registration/ pre-heat
PL 10.10 Item 5. Assembly idlers, PL 88.10 Item 20.
• Enter dC330 code 83-001 Exit Motor Fwd (M5) to run the exit motor forward, PL 10.15 • Enter dC330 code 89-012 Nip A: Narrow to engage idlers 3 and 4, PL 88.10 Item 20.
Item 11. • Enter dC330 code 89-013 Nip A: Medium to engage idlers 2 and 5, PL 88.10 Item 20.
• Enter dC330 code 83-002 Exit Motor Rev (M5) to run the exit motor in reverse. Used for • Enter dC330 code 89-014 Nip A: Wide to engage idlers 1 and 6, PL 88.10 Item 20.
duplex and paper invert.
Possible causes:
Possible causes:
• Incorrectly aligned or damaged registration/ pre-heat Assembly idlers, PL 88.10 Item 20.
• Post-transfix motor (M4), PL 10.10 Item 5.
Solution:
• Exit motor (M5), PL 10.15 Item 11.
• Gear drive, PL 10.10 Item 13.
If the noise repeats perform the following:
• Idlers in stripper gate and baffle assembly, PL 10.12 Item 1.
Solution: • Enter dC330 code 88-008 Reg/Preheat Air Pumps to switch on the registration/pre-heat
• Enter dC330 code 10-025 Strip Gate Unlatch and open the stripper gate and baffle air pump, PL 88.10 Item 5.
assembly, PL 10.12 Item 1. Possible causes:
• Stack the code 10-018 Post Transfix Motor (M4) to run the post-transfix motor forward, PL • Registration/pre-heat air pump.
10.10 Item 5. Solution:

Nips / Diverters Possible causes:
• Front and rear transfix motors, PL 10.20 Item 11.
NOTE: A door cheat for the main door is not required.
Run the following components: Solution:
• Enter dC330 code 82-008 Nip D Solenoid to open the nip 'D' release solenoid, PL 70.30 • Adjust or install new components as necessary.
Item 13. Used for short-edge feed and fast color mode.
Fans
• Enter dC330 code 82-007 Nip C Release Solenoid to open the nip 'C' release solenoid,
PL 82.15 Item 4. Used for short-edge feed and fast color mode. NOTE: A door cheat for the main door is not required.
• Enter dC330 code 83-004 HPP Diverter Solenoid to run the HPP diverter solenoid, PL Run the following components:
82.15 Item 5. Used for duplex only.
• Enter dC330 code 83-006 Exit Duplex Diverter Solenoid to run the exit/duplex diverter • Enter dC330 code 42-062 Abatement Fan to run the abatement fan, PL 94.20 Item 11.
solenoid, PL 10.15 Item 14. Used for duplex and paper invert.
• Enter dC330 code 42-063 Enclosure Fan to run the enclosure fan, PL 1.15 Item 6.
Possible causes:
• Enter dC330 code 42-064 Drum Fan to run the drum fan, PL 94.20 Item 4.
Possible causes:
Solution:
– Bearings in the cooling fans have worn or failed.
– Incorrectly aligned or damaged parts.
Drum Drive motor / transfix motor / stripper assembly Solution:
NOTE: A door cheat for the main door is required. – Check for parts that are damaged or out of position.
– Adjust or install new components as necessary.
• W/O TAG 006 machines only - Open the image processing module tray and check the
• Enter dC330 code 94-009 Drum Drive Motor Slew Speed to run the drum drive motor at copy controller and network controller fans are running and not making a noise. If the fan
slew speed, PL 94.20 Item 6.
is noisy then install a new fan, PL 3.10 Item 10.
• Enter dC330 code 94-017 Drum Drive Motor Transfix Speed to run the drum drive motor
at transfix speed, PL 94.20 Item 6.
Stripper Blade
• Scraping noise.
• Enter dC330 code 94-018 Drum Drive Motor Imaging Speed to run the Drum drive motor
at print speed, PL 94.20 Item 6. Possible causes are:
Possible causes: – The noise is caused by the stripper blade PL 10.12 Item 3 pressing to heavily on the
drum PL 94.20 Item 1.
• Large vibrations that can shake the printer are only caused by contamination on the drum
drive motor pulley. These vibrations are intermittent as the print cycle can temporarily Solution:
clear the contamination. – Ensure the stripper blade is correctly latched, refer to GP 31.
• Watch the drum spin. If the noise is cyclic and repeats once per drum revolution, the noise – Adjust or install new components as necessary.
is associated with the drum, PL 94.20 Item 1, drum position encoder assembly, PL 94.20 LCSS
Item 8 or drum heater, PL 94.20 Item 28.
• If the noise repeats ~10x per drum revolution, the noise is associated with the drum
• Enter dC330 code 12-223 Transport Motor 1, to run the entry transport rolls, PL 12.40
motor, PL 94.20 Item 6.
Item 2.
Solution:
• Enter dC330 code 12-224 Transport Motor 2, to run the entry rolls, PL 12.60 Item 5.
• Remove the drum belt, PL 94.20 Item 2 and repeat the noise evaluation to further isolate
• Enter dC330 code 12-238 Paddle Roll Motor run, rotates the paddle wheel, PL 12.25 Item
the noise source.
10.
• Clean contamination on the drive shafts and the bearings
• Enter dC330 code 12-232 Tamp Mot Cycle, cycles the front and rear tampers, PL 12.45
• Adjust or install new components as necessary. Item 1.
If the noise repeats perform the following: • Enter dC330 code 12-236 Eject Mot Cycle, cycles the eject assembly, PL 12.50 Item 1.
• Enter dC330 code 12-242 Bin 1 Elevator Motor Cycle, to move bin 1 up and down, PL
• Enter dC330 code 10-024 Transfix Front and Back to operate the front and rear transfix
12.30 Item 8.
motors, PL 10.20 Item 11 and run a transfix cycle.
• Enter dC330 code 10-021 Stripper Solenoid to engage the stripper system, PL 10.10 Item NOTE: The bin will move down and then move up to the home position.
3.
• Enter dC330 code 12-244 Punch Head run, rotates the punch head, PL 12.20 Item 2.

• Enter dC330 code 12-250 SU1 Mot Cycle, cycles the stapler from the front to the rear, PL • Enter dC330 code 12-227 Rear Tamper Motor Home, to move the rear tamper to the
12.55 Item 5. home position, PL 12.125 Item 6.
Possible causes and potential solutions are: • Enter dC330 code 12-228 Front Tamper Motor Move, to move the front tamper to the cen-
• 2 knocks for each stapled set. tre of the compiler, PL 12.125 Item 6
Solution: • Enter dC330 code 12-229 Rear Tamper Motor Move, to move the rear tamper to the cen-
– Go to the 12-340-00-110, 12-341-00-110, 12-342-00-110 Ejector Movement Failure tre of the compiler tray, PL 12.125 Item 6.
RAP. • Enter dC330 code 12-238 Paddle Roll Motor Run, to lift the paddle unit and rotate the
paddle rolls, PL 12.115 Item 2.
• Noise from the right hand side of the machine.
• Enter dC330 code 12-237 Paddle Motor Home, to lift the paddle unit to the up position, PL
12.115 Item 2.
– The LCSS is not aligned correctly.
• Enter dC330 code 12-241 Bin 1 Elevator Motor Home, to move Bin 1 up to the home posi-
Solution:
tion, PL 12.105 Item 10.
– Check the machine to LCSS alignment, ADJ 12.2-110.
• Enter dC330 code 12-242 Bin 1 Elevator Motor Cycle, to move Bin 1 up / down until time
– Adjust or install new components as necessary. out or stop, PL 12.105 Item 10.
• Clicking noise from the LCSS • Enter dC330 code 12-249 SU1 Motor Fwd, to move the stapler unit to the front, PL 12.110
Possible causes are: Item 12.
– The staple head continually operating for approximately 15 seconds. This occurs • Enter dC330 code 12-248 SU1 Motor Rev Home, to move the stapler unit to the rear, PL
every time the LCSS top cover or front door is opened then closed, because the sta- 12.110 Item 12.
pler is attempting to prime the staple head, by indexing the staple stick forward and • Enter dC330 code 12-250 SU1 Motor Cycle, to run the stapler unit cycle routine, PL
pre-forming two staples. 12.110 Item 12.
Solution: • Enter dC330 code 12-251 BM Compiler Motor, runs the compiler BM entry roll, PL 12.175
– Check the staple cartridge for jammed staples and remove any that are found. Item 1.
– Ensure the staple cartridge is fully seated.
NOTE: The tray moves down for 15 seconds and then stops.
– Ensure that the correct staple cartridge is installed.
• Enter dC330 code 12-252 BM Crease Blade Motor, to move crease blade assembly, PL
– Perform 12L-110 Stapling Failure RAP.
12.175 Item 8.
• Loud grinding/binding noise from the LCSS
• Enter dC330 code 12-273 BM Crease Roll Gate Motor, to move the crease blade assem-
bly, PL 12.175 Item 8 and the crease roll gate, PL 12.180 Item 19.
– The ejector shafts are dry, gummy or dirty, PL 12.50 Item 10.
• Enter dC330 code 12-253 BM Crease Roll Motor, to rotate the two crease rolls, PL 12.175
– The ejector bearings are dry, gummy or dirty, PL 12.50 Item 11 and PL 12.50 Item Item 12.
12. • Enter dC330 code 12-255 BM Back Stop Motor, to move the back stop assembly, PL
Solution: 12.160, PL 12.165.
– Clean then lubricate the drive shafts and bearings. Refer to ADJ 4.1 Machine Lubri- • Enter dC330 code 12-256 BM Tamper 1 Motor, to move the tamper rack and fingers, PL
cation. 12.155 Item 3.
HVF / HVF BM • Enter dC330 code 12-274 BM Conveyor Drive motor, to run the output tray conveyor
Run the following components: belts, PL 12.190 Item 4.
• Enter dC330 code 12-271 BM flapper Motor, to run the BM flapper, PL 12.175 Item 1.
• Enter dC330 code 12-273 BM Crease Roll Gate Motor, to move the crease roll gate up
CAUTION
and down, PL 12.180 Item 19.
Ensure that the first tamper in the compiler carriage is returned to the home position before the
• Enter dC330 code 12-261 Inserter Motor, to run inserter main drives, PL 12.315 Item 1.
second tamper is checked in diagnostics.
• Enter dC330 code 12-253 BM Crease Roll Motor, to run the tri-roller drives, PL 12.175
• Enter dC330 code 12-223 Transport Motor 1, to run the input transport roll, PL 12.120
Item 12.
Item 2.
• Enter dC330 code 12-269 Clutch Drive, to engage the HVF clutch drive to drive tri folding
• Enter dC330 code 12-224 Transport Motor 2, to run the exit drive shafts to feed paper to
rolls, PL 12.175 Item 12.
the top tray or to the stacker tray, PL 12.120 Item 1.
• Enter dC330 code 12-226 Front Tamper Motor Home, to move the front tamper to the
home position PL 12.125 Item 6.

Possible causes and potential solutions are: OF 2 UI Touch Screen Failure RAP (W/O TAG 006)
• Noise from the right hand side of the machine. Use this RAP to solve user interface touch screen problems when the machine has power but
Possible causes are: either the display is missing, is too dark or the user interface touch screen responds incorrectly
– The HVF BM is not aligned correctly. or does not refresh.
– Bin 1 not aligned correctly on the main drive belts, PL 12.105 Item 6.
Initial Actions
Solution:
– Check the machine to HVF BM alignment, ADJ 12.1-171.
– Check that the Bin 1 is level, refer to REP 12.38-171 HVF Stacker Drive Belts. WARNING
– Adjust the components if appropriate. Ensure that the electricity to the machine is switched off while performing tasks that do
– Install new parts as necessary. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Knocking. death or injury. Moving parts can cause injury.
– Mis-adjusted or worn drive belts. PL 12.120.
– The support fingers on the ejector hit bin1 each time they are moved out.
Solution:
– Adjust the belt tension as required.
– Pre-load bin 1 with 30 sheets of paper this acts a a damper and will stop the noise.
– Install new parts as necessary. Figure 1 ESD Symbol
• Squeak.
Possible causes are: CAUTION
– The transport drive shaft or bearings. PL 12.130. Ensure that ESD procedures are observed during the removal and installation of the software
– Check that the paper guides are closed and located correctly. and DIMM modules.
Solution: • If the UI is blank, check the;
– Install new parts as necessary. – User interface harness, PL 2.10 Item 7 is securely connected.
• Clicking Noise from the HVF BM. – Software module, PL 3.10 Item 9 is seated correctly.
NOTE: The software module is functioning correctly if the machine is able to print
– The noise is caused by the transport motor 2, dC330 code 12-224, continually oper- cleaning pages, configuration sheets (if programmed) or the customer can still print
ating for approximately 15 seconds. This occurs every time the top tray, PL 12.100 to the device.
Item 9, or the front door, PL 12.100 Item 3, is opened then closed.
Solution: – DIMM module, PL 3.10 Item 5 is seated correctly.
– Ensure the staple cartridge is fully seated and that the correct cartridge is installed. NOTE: Due to board flex, the DIMM module may not make good contact in the cen-
tre. Support the board underneath and then reseat the DIMM module. Check that the
NOTE: When a new staple cartridge is installed the stapler makes a repeating noise.
amount of gold contact visible is equal across the width of the DIMM module.
This is normal it is the stapler performing a priming cycle.
• Refer to GP 1 to access the user interface diagnostics.
– Perform 12-369-00-171 to 12-377-00-171 HVF Stapler Position and Priming RAP.
• Press the Machine Status key. Select the Tools tab. Select Device Settings, then Display
Brightness. Adjust the brightness level.
• Refer to REP 2.1 to access the user interface assembly.
• Check and re-seat the PJ’s on the user interface control PWB.
• If the UI fails to boot, observe the progress icon on the screen to determine the failure.
– Yellow progress block = XUI code booting up.
– Non moving green block = Code loaded but not communicating.
– Moving green block = ESS / NC is operational and XUI is trying to communicate with
IME, CCS and NC.
• If the problem occurs while entering or exiting sleep mode, go to the OF 7 Sleep Mode RAP.

OF 1, OF 2 2-580 Xerox® ColorQube® 9203 Family
Procedure OF 3 Unresponsive Machine RAP
Refer to WD 3.1. Check the +3.3V from PJ19 on the Copy Controller PWB to PJ900 on the Use the following procedure if the machine fails to reach an operational state when switched
user interface control PWB. +3.3V is measured. on.
Y N
Check the wiring and harness between the copy controller PWB and the user interface Initial Actions
control PWB. Repair the wiring as necessary, REP 1.2, or install a new harness, PL 2.10
Item 7. If the wiring is good, go to 01C +3.3V Distribution RAP.
WARNING
Refer to WD 3.2. Check the +12V from PJ19, pin 17 on the Copy Controller PWB to PJ901, pin
5 on the user interface control PWB. +12V is measured. Ensure that the electricity to the machine is switched off while performing tasks that do
Y N not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Check the wiring and harness between the copy controller PWB and the user interface death or injury. Moving parts can cause injury.
control PWB. Repair the wiring as necessary, REP 1.2, or install a new user interface har- • Check that the customer supply is good. If necessary, connect the machine to a known
ness, PL 2.10 Item 7. If the wiring is good, go to 01E +12V Distribution RAP. good AC supply. If the machine operates correctly at the new supply, inform the customer
that the original supply is at fault.
Reload the machine software, GP 4. The fault remains. • Check that the power cord is connected to the machine.
Y N
Perform SCP 5 Final Actions. NOTE: If the power lead is removed from the outlet due to a POPO. Wait for at least 1
minute before reinstalling the power lead. This allows time for the power supplies to dis-
Check that the ribbon cables between the user interface control PWB and the touch screen are charge and reset.
in good condition and are securely and correctly connected. Check the wiring and ribbon • Check the IME POST LED’s for a POST error code, OF 16.
cables on the touch screen assembly. As necessary, install new components:
• If the problem occurs while entering or exiting sleep mode, go to OF 7 Sleep Mode RAP.
• LCD to PWB harness, (40-way ribbon cable), PL 2.10 Item 11.
• Check that the SIM card is inserted correctly in the back of the machine. Refer to GP 19.
• User interface touch screen assembly, PL 2.10 Item 3.
• For machines W/O TAG 006. Open the image processing module, PL 3.10.
– Reseat the DIMM module on the network controller PWB, PL 3.10 Item 5.
NOTE: Due to board flex, the DIMM module may not make good contact in the cen-
– Reseat the EPC memory PWB, PL 3.10 Item 28 on the copy controller PWB.
20 seconds.
– Reseat the NVM, PL 3.10 Item 21 and Software module, PL 3.10 Item 9 and connec-
tors on the copy controller PWB, PL 3.10 Item 17.
For machines W/TAG 006. Open the image processing module, PL 3.11.
– Reseat the system memory PWB, PL 3.11 Item 4.
– Reseat the EPC memory PWB, PL 3.11 Item 21.
– Reseat the NVM, PL 3.11 Item 17 and Software module, PL 3.11 Item 7.
– Reseat the connectors on the single board controller PWB, PL 3.11 Item 13.
• Open the UI control panel, REP 2.1. Check and reseat all the PJ’s on the UI control PWB,
PL 2.10 Item 2.
• Go to the 01A AC Power Distribution RAP and check the power to the power supply unit.

Xerox® ColorQube® 9203 Family 2-581 OF 2, OF 3
A B
Procedure Y N
Install a new IME controller PWB PL 92.10 Item 1.
Switch on the machine, GP 14. Observe the power light button on the UI. The power button
flashes.
Y N Go to the relevant procedure:
• OF 2 UI Touch Screen Failure RAP (W/O TAG 006).
Observe the LEDs on the IME controller, Figure 2. Either the red or green LED is blink-
ing. • OF 18 UI Touch Screen Failure RAP (W/TAG 006).
Y N
Remove the rear cover, PL 81.10 Item 1. Observe the green LED on the power sup- Go to the OF 16 Post Error RAP.
ply unit, Figure 1. The green LED on the power supply unit is lit.
Y N Remove the rear cover, PL 81.10 Item 1. The power on self test (POST) starts. Check the
Disconnect PJDC4 on the Power Supply Unit. Toggle the power switch. The LEDs on the power supply unit, Figure 1.
green LED is lit. • Orange LED indicates +24V, +/-12V and +5V are good.
Y N • Green LED indicates +3.3V ESTAR and +17V are good.
Reconnect PJDC4. Disconnect PJDC3 on the Power Supply Unit. Toggle
• Red LED indicates +/-50V are good.
the power switch. The green LED is lit.
Y N All LEDs are lit
Y N
Connect PJDC3 and disconnect PJDC1. Toggle the power switch.
Observe the Red LED on the IME Controller PWB, PL 92.10 Item 1. Go to OF 16 POST
The green LED is lit.
Y N Error RAP if a blink code is indicated.
Go to the relevant voltage distribution RAP:
Install a new power supply unit, PL 1.15 Item 2. Go to 01A AC
Power Distribution RAP and perform the Main Power Rocker • 01B +3.3V ESTAR Distribution RAP.
Switch check. The switch is good • 01D +5V Distribution RAP.
Y N • 01E +12V Distribution RAP.
Install a new main power rocker switch, PL 1.15 Item 3. • 01F -12V Distribution RAP.
• 01G +17V Distribution RAP
The +3.3V ESTAR has a short circuit. Check for short circuits to • 01J +50V Distribution RAP.
chassis at PJDC1 pins 14,15 and 16 refer to WD 1.4. Go to 01B • 01K -50V Distribution RAP.
+3.3V ESTAR Distribution RAP. Check the supply to the IME control- • 01L 0V Distribution RAP.
ler PWB, PL 92.10 Item 1.
• Refer to 01-540-00, 01-544-00 RAP and 01-542-00, 01-546-00 RAP.
There is a short or an over load in the marking unit on 3.3V ESTAR. Dis-
connect all PJs from the Media Path Driver PWB and the Drum Driver The green ‘Xerox’ screen is displayed.
Y N
PWB until the short is found. If necessary refer to the following RAPs:
Go to the relevant procedure and check that the UI is good:
• 01B +3.3V ESTAR Distribution RAP, refer to Drum driver PWB and
• OF 2 UI Touch Screen Failure RAP (W/O TAG 006).
Media path driver PWB checkouts.
• OF 18 UI Touch Screen Failure RAP (W/TAG 006).
There is a short or an overload on the +17V or +3.3V supplies from the Power The UI is good
Distribution PWB or the power distribution PWB is faulty. Disconnect all PJs Y N
until the fault is found. If necessary refer to the following RAPs: Go to the relevant procedure and perform the necessary actions:
• 01G +17V Distribution RAP. • OF 2 UI Touch Screen Failure RAP (W/O TAG 006).
• 01C +3.3V Distribution RAP. • OF 18 UI Touch Screen Failure RAP (W/TAG 006).
For machines W/O TAG 006.Check the red LED CR30 on the copy controller PWB, Fig-
Go to the 01B 3.3V ESTAR Distribution RAP.
ure 3.
For machines W/TAG 006.Check the red LED CR30 on the single board controller PWB,
The red LED on the IME controller is blinking.
Figure 4. CR30 is flashing in a heartbeat pattern
Y N
Check that the green LED on the IME controller is blinking in a heart beat pattern.
The green LED is blinking.
A B C
C D
Y N – For machines W/O TAG 006 and W/TAG 007. Check the power supplies to the
For machine W/O TAG 006. Go to the 01C +3.3V Distribution RAP and check the power distribution PWB, copy controller PWB, network controller PWB, HDD’s,
+3.3V supply to the copy controller PWB. If the +3.3V supply to the PWB is good scanner and DADH PWB.
install a new copy controller PWB, PL 3.10 Item 17. Go to the relevant voltage distribution RAP:
For machines W/TAG 006. Go to the 01C +3.3V Distribution RAP and check the
01D +5V Distribution RAP.
+3.3V supply to the single board controller PWB. If the +3.3V supply to the PWB is
01E +12V Distribution RAP.
good install a new single board controller PWB, PL 3.11 Item 13.
01G +17V Distribution RAP
For machines W/O TAG 006. Check the connections to the copy controller HDD, PL 3.10 01H +24V Distribution RAP.
Item 2. If the connections are good perform the actions that follow: – Go to OF 16 POST Error RAP.
• Reload the software, GP 4.
• If there are no LEDs blinking, install a new IME controller PWB, PL 92.10 Item 1.
• Install a new HDD copy controller assembly, PL 3.10 Item 2.
For machines W/O TAG 006. Check the connections to the copy controller HDD and har-
For machines W/TAG 006. Check the connections to the single board controller HDD, PL ness PJ 5, PL 3.10 Item 2. If the connections are good perform the actions that follow:
3.11 Item 2. If the connections are good perform the actions that follow: • Harness HDD 1, PL 3.10 Item 3.
• Reload the software, GP 4. • Reload the software, GP 4.
• Install a new HDD single board controller assembly, PL 3.11 Item 2. • Install a new HDD copy controller assembly, PL 3.10 Item 2.
For machines W/TAG 006. Check the connections to the single board controller HDD and
The green progress screen is displayed.
harness PJ 5, PL 3.11 Item 2. If the connections are good perform the actions that follow:
Y N
The display stays at the green ‘Xerox’ screen. Observe the LEDs on the IME controller, • Harness HDD 1, PL 3.11 Item 3.
Figure 2. Perform the relevant action: • Reload the software, GP 4.
• If the green LED is blinking, reload the software, GP 4. • Install a new HDD single board controller assembly, PL 3.11 Item 2.
• If the red LED is blinking, the copy controller / single board controller is not booting
or there is a communication problem between the copy controller PWB / single Listen for the sound of solenoids energizing as the machine enters print engine self test
board controller PWB and the IME controller PWB. (PEST) mode. The machine enters PEST mode.
Y N
– Check for copy controller / single board controller blink codes, OF 16 POST
Observe the LEDs on the IME controller, Figure 2. Perform the relevant action:
Error RAP.
• If the green LED is blinking, reload the software, GP 4.
– Reboot in diagnostics state, GP 1 and refer to How to enter directly into service
mode. Enter dC123 PEST Fault History and dC122 Fault History. Review the • If the red LED is blinking, go to OF 16 POST Error RAP.
fault history then go to the indicated RAP. • If there are no LEDs blinking install a new IME controller PWB, PL 92.10 Item 1.
– For machines W/O TAG 006 and W/O TAG 007. Check the power supplies to
PEST is completed correctly without any fault codes displayed on the UI.
the power distribution PWB, copy controller PWB, network controller PWB,
HDD’s, scanner and DADH PWB. Y N
If the machine boots up without completing the PEST sequence, go directly into service
mode, GP 1. Review the fault history then go to the indicated RAP.
01D +5V Distribution RAP. If necessary use the fast time to ready mode dC113. This will avoid waiting for the IME to
01E +12V Distribution RAP. heat the ink system.
01H +24V Distribution RAP. Perform SCP 5 Final Actions.
– For machines W/TAG 006 and W/TAG 007. Check the power supplies to the
power distribution PWB, single board controller PWB, HDD, scanner and
DADH PWB.
01D +5V Distribution RAP.
01E +12V Distribution RAP.
01H +24V Distribution RAP.

Green Orange Red Green LED
Figure 1 Power LEDs Red LED blink code.
Figure 2 IME Controller LEDs

Red LED CR 30
Red LED CR 30.
Figure 3 Copy Board Controller LEDs Figure 4 Single board controller LED.

OF 4 Status Codes and Messages RAP OF 4a Status Codes in Numerical Order
Use this RAP for faults and messages without fault codes. Status Message Tables
• Table 1 Chain 01 Status codes
The status code format is HCC-LLL-EE where HCC is the chain, LLL is the link and EE is the
extension number. The hundreds digit H is not used and can be ignored. This digit is not shown • Table 2 Chain 02 Status codes
on any status codes in this manual. • Table 3 Chain 03 Status codes
Example: Status code 01-510-00 Front door is open. Video displayed requesting the front door • Table 5 Chain 05 Status codes
to be closed.
The fault code format is HCC-LLL-EE where HCC is the chain, LLL is the link and EE is the • Table 7 Chain 12 Status codes
extension number. All faults are displayed with hundred digit 3 which can be ignored. This digit • Table 8 Chain 14 Status codes
is not shown on any fault codes in this manual. • Table 9 Chain 16 Status codes
Example: Fault code 301-510-00 Front door is open when machine running.
Refer to GP 2 Fault Codes and History Files. • Table 12 Chain 20 Status codes
Most recent fault and messages can be displayed on the UI without entering diagnostics, by • Table 14 Chain 70 to 78 Status codes
pressing the Machine Status button on the keypad, touching the Fault tab on the UI, then select • Table 15 Chain 82 to 89 Status codes
as appropriate:
• Table 16 Chain 91 to 94 Status codes
• Current Faults.
• Current Messages. Table 1 Chain 01 Status codes
• Fault History. Status
The tables in this procedure bring together the status codes, the relevant RAP or procedure Code UI Message Reason for Message Reference / Action
references, and some of the UI messages. 01-101-00 Paper Jam in Area IME jam at zone 4b Clear the paper jam in area 4b. Print
4b. (horizontal), open front and copy services are disabled.
NOTE: Not all status codes are shown in the active message window. Some status codes have
door. Refer to 82-145-00, 82-146-00, 82-
no messages. 150-00, 82-151-00, 82-156-00 RAP,
Procedure 82-145-00, 82-146-00, 82-150-00,
82-151-00, 82-156-00 RAP, 82-149-
00 RAP
WARNING 01-102-00 Paper Jam in Area IME jam at zone 4a Clear the paper jam in area 4a. Print
4a. (exit), open front door. and copy services are disabled.
Refer to 10-110-00 to 10-113-00,
10-125-00 to 10-128-00, 10-147-00,
10-148-00 RAP, 10-140-00 to 10-
Enter the Fault Codes and History Files, GP 2 and identify and clear any active faults. Go to 146-00, 10-149-00 to 10-151-00
the following RAPs to identify a status code or message: RAP, 83-110-00, 83-111-00, 83-113-
• OF 4a Status Codes in Numerical Order 00, 83-114-00, 83-118-00 RAP
• OF 4b Status Messages in Alphabetical Order 01-103-00 Paper Jam in IME jam at zone 4a Clear the paper jam in area 4a and
Areas 4a and 4b. (exit) and 4b (horizon- 4b. Print and copy services are dis-
tal), open front door. abled.
Refer to 10-110-00 to 10-113-00,
10-125-00 to 10-128-00, 10-147-00,
10-148-00 RAP, 10-140-00 to 10-
146-00, 10-149-00 to 10-151-00
RAP, 83-110-00, 83-111-00, 83-113-
00, 83-114-00, 83-118-00 RAP

OF 4, OF 4a 2-586 Xerox® ColorQube® 9203 Family
Table 1 Chain 01 Status codes Table 1 Chain 01 Status codes
Status Status
Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action
01-104-00 Paper Jam in Area IME jam at zone 3b Clear the paper jam in area 3b. Print 01-111-00 Paper Jam in IME jam at zone 3a Clear the paper jam in area 3a, 4a
3b. (post transfix), open and copy services are disabled. Areas 3a, 4a and (registration), 4a (exit) and 4b. Print and copy services are
front door. 4b. and 4b (horizontal), disabled.
01-105-00 Paper Jam in Area IME jam at zone 3b Clear the paper jam in area 3b and open front door. Refer to 10-110-00 to 10-113-00,
3b and 4b. (post transfix) and 4b 4b. Print and copy services are dis- 10-125-00 to 10-128-00, 10-147-00,
(horizontal), open front abled. 10-148-00 RAP, 10-140-00 to 10-
door. 146-00, 10-149-00 to 10-151-00
01-106-00 Paper Jam in IME jam at zone 3b Clear the paper jam in area 3b and RAP, 83-110-00, 83-111-00, 83-113-
00, 83-114-00, 83-118-00 RAP
Areas 3b and 4a. (post transfix) and 4a 4a. Print and copy services are dis-
(exit), open front door. abled. 01-112-00 Paper Jam in IME jam at zone 3a Clear the paper jam in area 3a and
Refer to 10-110-00 to 10-113-00, Areas 3a and 3b. (registration) and 3b 3b. Print and copy services are dis-
10-125-00 to 10-128-00, 10-147-00, (post transfix), open abled.
10-148-00 RAP, 10-140-00 to 10- front door. Refer to 10-110-00 to 10-113-00,
146-00, 10-149-00 to 10-151-00 10-125-00 to 10-128-00, 10-147-00,
RAP, 83-110-00, 83-111-00, 83-113- 10-148-00 RAP, 10-140-00 to 10-
00, 83-114-00, 83-118-00 RAP 146-00, 10-149-00 to 10-151-00
RAP, 83-110-00, 83-111-00, 83-113-
01-107-00 Paper Jam in IME jam at zone 3b Clear the paper jam in area 3b, 4a
Areas 3b, 4a and (post transfix), 4a (exit) and 4b. Print and copy services are 00, 83-114-00, 83-118-00 RAP
4b. and 4b (horizontal), disabled. 01-113-00 Paper Jam in IME jam at zone 3a Clear the paper jam in area 3a, 3b
open front door. Refer to 10-110-00 to 10-113-00, Areas 3a, 3b and (registration), 3b (post and 4b. Print and copy services are
10-125-00 to 10-128-00, 10-147-00, 4b. transfix) and 4b (hori- disabled.
10-148-00 RAP, 10-140-00 to 10- zontal), open front door. Refer to 10-110-00 to 10-113-00,
146-00, 10-149-00 to 10-151-00 10-125-00 to 10-128-00, 10-147-00,
RAP, 83-110-00, 83-111-00, 83-113- 10-148-00 RAP, 10-140-00 to 10-
00, 83-114-00, 83-118-00 RAP 146-00, 10-149-00 to 10-151-00
RAP, 83-110-00, 83-111-00, 83-113-
01-108-00 Paper Jam in Area IME jam at zone 3a Clear the paper jam in area 3a. Print
00, 83-114-00, 83-118-00 RAP
3a (registration / preheat), and copy services are disabled.
open front door. Refer to 89-110-00 to 89-113-00, 01-114-00 Paper Jam in IME jam at zone 3a Clear the paper jam in area 3a, 3b
89-129-00 RAP, 89-125-00 to 89- Areas 3a, 3b and (registration), 3b (post and 4a. Print and copy services are
128-00, 89-130-00 RAP 4a. transfix) and 4a (exit), disabled.
open front door. Refer to 10-110-00 to 10-113-00,
01-109-00 Paper Jam in IME jam at zone 3a Clear the paper jam in area 3a and
Areas 3a and 4b. (registration) and 4b 4b. Print and copy services are dis- 10-125-00 to 10-128-00, 10-147-00,
10-148-00 RAP, 10-140-00 to 10-
(horizontal), open front abled.
146-00, 10-149-00 to 10-151-00
door. Refer to 10-110-00 to 10-113-00,
10-125-00 to 10-128-00, 10-147-00, RAP, 83-110-00, 83-111-00, 83-113-
00, 83-114-00, 83-118-00 RAP
10-148-00 RAP, 10-140-00 to 10-
146-00, 10-149-00 to 10-151-00 01-115-00 Paper Jam in IME jam at zone 3a Clear the paper jam in area 3a, 4a
RAP, 83-110-00, 83-111-00, 83-113- Areas 3a, 3b, 4a (registration), 4a (exit) and 4b. Print and copy services are
00, 83-114-00, 83-118-00 RAP and 4b. and 4b (horizontal), disabled.
open front door. Refer to 10-110-00 to 10-113-00,
01-110-00 Paper Jam in Area IME jam at zone 3a Clear the paper jam in area 3a and
10-125-00 to 10-128-00, 10-147-00,
3a and 4a. (registration) and 4a 4a. Print and copy services are dis-
(exit), open front door. abled. 10-148-00 RAP, 10-140-00 to 10-
146-00, 10-149-00 to 10-151-00
Refer to 89-110-00 to 89-113-00,
RAP, 83-110-00, 83-111-00, 83-113-
89-129-00 RAP, 89-125-00 to 89-
128-00, 89-130-00 RAP 00, 83-114-00, 83-118-00 RAP

Xerox® ColorQube® 9203 Family 2-587 OF 4a
Status Status
01-500-00 Do not switch the IME power switch is Print jobs sent to the device will not 02-518-00 - Page Pack Grace Period
power on again moved to the off posi- print and may be lost. Expired
while powering tion 02-520-00 Software error Software error has occurred. Switch the machine off,
down is in progress then switch the machine
01-505-00 Middle left side The IME middle left Copying and printing are not avail- on GP 14.
door is open door (below Bypass able. Perform the 01-505-00 Middle 02-521-00 - XEIP Browser is dead or not Perform the 02-321-00
tray) is open Left Door Open RAP. responding XEIP Browser Dead
(without Tray 5 RAP.
installed) 02-590-00 Configurable services Configurable services not Switch the machine off,
01-506-00 Top left side door is The IME upper left door Copying and printing are not avail- error stable at power on. then switch the machine
open (Bypass tray) is open able. Perform the 01-506-00 Upper on GP 14. If the problem
Left Door Open RAP. persists, perform the 02-
01-510-00 Front door is open The front door is open. Copying and printing are not avail- 390-00 Configurable
able. Perform the 01-510-00 Front Services RAP.
Door Open RAP.
01-540-01 Paper removed or Check the settings for Confirm tray 1 settings.
added to tray 1 tray 1.
01-540-02 Paper removed or Check the settings for Confirm tray 2 settings. Table 3 Chain 03 Status codes
added to tray 2 tray 2. Status
01-540-03 Paper removed or Check the settings for Confirm tray 3 settings. Code UI Message Reason for Message Reference / Action
added to tray 3 tray 3.
03-504-00 - Unknown Switch the machine off, then
01-540-04 Paper removed or Check the settings for Confirm tray 4 settings. switch the machine on GP 14.
added to tray 4 the bypass tray.
03-505-00 System fault. Call for A system fault has Perform 03-325-00 RAP and 03-
01-540-05 Paper removed or Check the settings for Confirm tray 5 settings. assistance occurred 355-00 RAP
added to tray 5 tray 5. 03-518-00 Network controller Network controller not Switch the machine off, then
01-540-06 Paper removed or Check the settings for Confirm tray 6 settings. communication error available. switch the machine on GP 14. If
added to tray 6 tray 6. the fault remains, reinstall soft-
01-545-01 Tray 1 is a dedi- Tray 1 is a dedicated Reload required paper and correctly ware, GP 4.
cated paper paper tray. adjust the paper guides. 03-538-00 - Machine Active Regis-
01-545-02 Tray 2 is a dedi- Tray 2 is a dedicated Reload required paper and correctly tration has been dis-
cated paper paper tray. adjust the paper guides. abled via the dC715
01-550-00 The machine is in Machine is in power - Active Registration
power saver mode. saver mode. Control Routine.
01-551-00 The machine is in Machine is in sleep - 03-546-00 Incompatible FAX Incompatible fax soft- The embedded fax software ver-
sleep mode mode. Software Detected ware detected at power sion is incompatible with the sys-
(Upgrade Required) on tem. A software upgrade should
be performed.
Refer to 03-417-00 RAP.
Table 2 Chain 02 Status codes 03-547-00 A Fax Service error Basic fax card failure Switch the machine off, then
has occurred. Call detected switch the machine on GP 14. If
Status
for assistance. the problem persists, perform the
Code UI Message Reason for Message Reference / Action
20-331-00, 20-338-00, 20-339-
02-517-00 - Page Pack Grace Period - 00, 20-341-00 Fax Network Line
Active 1 Fault RAP.

OF 4a 2-588 Xerox® ColorQube® 9203 Family
Status Status
03-548-00 Fax line 2 is unavail- Extended fax not Check fax line connection 03-559-01 Provide payment. Walk Up FDI. Unable to Your Job cannot be completed
able. Notify your detected/confirmed complete the current due to insufficient funds.
System Administra- job.
tor. Please insert card into the exter-
03-549-00 Fax memory error. Fax POST failure sta- Switch the machine off, then nal accounting device to continue
tus. switch the machine on GP 14. your job.
03-550-00 A Fax Service error The fax card was not Switch the machine off, then
has occurred. Call detected switch the machine on GP 14. If To cancel this job, press the hard-
panel Job Status button, select
for assistance. the problem persists, perform the
the job and then the Delete but-
20-331-00, 20-338-00, 20-339-
00, 20-341-00 Fax Network Line ton.
1 Fault RAP. 03-559-02 Enter your access Walk Up Code Entered Your Job cannot be completed
code or the current FDI. Not Defined due to insufficient funds.
03-551-00 A Fax Service error The fax service is Switch the machine off, then
job may be deleted.
has occurred. Call unavailable switch the machine on GP 14. If
for assistance. the problem persists, perform the Please enter access code on the
external accounting device to
20-331-00, 20-338-00, 20-339-
continue your job.
00, 20-341-00 Fax Network Line
1 Fault RAP. 03-559-03 Provide payment. Walk Up Coin Entered Your Job cannot be completed
03-555-00 - Machine has entered Go to dC301. Perform a Copier FDI. Not Defined due to insufficient funds.
intrusive customer tools NVM Initialization and NVM data
Please insert money into the
mode. select All.
After Initialization perform rou- external accounting device to
continue your job.
tines dC977 and dC978.
03-556-00 Please wait… The Power on while the IIT -
To cancel this job, press the hard-
scanner is initializ- is being initialized panel Job Status button, select
ing.
the job and then the Delete but-
03-558-00 - Not Defined - ton.
03-558-01 - Not Defined - 03-559-04 Provide payment or Walk Up Key Entered Your Job cannot be completed
03-558-02 - Not Defined - the current job may FDI. Not Defined due to insufficient funds.
03-558-03 - Not Defined - be deleted.
03-558-04 - Not Defined - Please insert Key Counter into
the external accounting device to
03-559-00 Provide payment or Generic FDI. Unable to Your Job cannot be completed
continue your job.
the current job may complete the current due to insufficient funds.
be deleted. job.
Please complete all steps
required by the external account-
ing device to continue your job.

Status Status
03-559-05 Provide payment or Walk Up FDI. Unable to Your Job cannot be completed 03-597-00 Notify your System The Document Feeder Perform 05-250-00, 05-251-00
the current job may complete the current job due to insufficient funds. Administrator or call is not available. Use the RAP
be deleted. - FDI Inactivity Timer for assistance. Document Glass.
Enabled Please insert card into the exter-
nal accounting device to continue
your job.
Table 4 Chain 04 Status codes
To immediately delete this job, Status
select the Close button, then the
Job Status button located on the
control panel and then your job.If 04-565-00 System fault. Notify IME controller commu- System fault. Switch the machine
no action is taken, the job will be your system admin- nication failure off, then switch the machine on
deleted in the following number of istrator GP 14.
minutes: 04-568-00 The output tray is full The OCT is full. Empty the tray.
03-559-06 Provide payment or Walk Up Coin Entered Your Job cannot be completed 04-569-00 The output tray is The OCT detects that it The Tray is almost full. Empty the
the current job may FDI. Not Defined - FDI due to insufficient funds. almost full is 90% full tray when it is full. Copy and print
be deleted. Inactivity Timer Dis- services available. Scan service
abled Please insert money into the is available.
external accounting device to
continue your job.
To immediately delete this job, Table 5 Chain 05 Status codes

select the Close button, then the
Status
Job Status button located on the Code UI Message Reason for Message Reference / Action
control panel and then your job.
05-501-00 The document handler is DADH is open. Close the DADH. If the
If no action is taken, the job will raised fault remains, perform
be deleted in the following num- the 05-300-00 DADH
ber of minutes: Open RAP.
03-561-00 Please wait... the The system is recover- Wait until the system recovers 05-502-00 The document handler DADH top cover open. Close the DADH top
system is attempting ing top cover is open cover. If the fault
to recover remains, perform the
03-562-00 Some jobs may have - Removed upon user intervention 05-258-00, 05-307-00
DADH Cover Interlock
been deleted
Open RAP.
03-563-00 - Network service are Please wait, the Network Control-
05-520-00 Paper jam in the Docu- Post feed and takeaway roll Remove the sheet.
being established, print ler is initializing. No user interven-
jobs maybe delayed tion is required. Printing is ment Feeder jam Perform 05-330-00,
05-331-00 Feed Sen-
currently unavailable.
sor Failure RAP
Refer to 03-331-00, 03-332-00
RAP 05-522-00 Paper jam in the Docu- Sheet left over DADH CVT Remove sheet. Per-
03-564-00 Image rotation is not Image rotation is not Image rotation is not available. ment Feeder sensor after jam. form 05-350-00, 05-
DADH post feed sensor or 352-00 RAP
available. Call for available
TAR sensor
assistance
05-525-00 - Document feeder tray empty Perform 05B DADH
03-565-00 System fault. Notify System fault System fault. Notify your system
your system admin- administrator Document Sensor Fail-
ure RAP.
istrator

Status Status
05-526-00 Paper jam in the Docu- DADH - sheet left over DADH Reset when DADH top 05-585-00 Select Confirm if the When Status 05-579 is active Select Confirm if the
ment Feeder document present sensor cover closed after jam Document Feeder - Feed and the DADH Top cover is Document Feeder -
after jam. 05-330 fault is cleared. Perform 05- Roller was replaced. opened (status 05-502) Feed Roller was
raised 330-00, 05-331-00 replaced.
RAP
05-527-00 Reload sheets in Docu- Document in the DADH at Remove the sheets
ment Feeder. power on or exit from power from the Original Input Table 6 Chain 10 Status codes
save Tray.
Status
05-535-00 - Document feeder tray loaded - Code UI Message Reason for Message Reference / Action
05-538-00 Notify your System DADH not available. A document feeder
10-536-00 - Transfix Calibration Refer to OF 17 Service Code
Administrator or call for fault has occurred, NVRAM parameters are RAP
assistance. copy jobs can only be
reset.
made from the docu-
ment glass. Printing
can continue.
05-539-00 Document Feeder - Feed DADH feed head CRU None
Roller has been replaced. Message automati-
replaced. cally cleared half a second Status
after setting Code UI Message Reason for Message Reference / Action
05-542-00 Notify your System DADH document transport Perform 05A RAP 12-410-00 - PTU selected whilst marking Pressing the Pause to
Administrator or call for needs service job is running Unload button will
assistance. cancel this request.
05-546-00 The document size was On pre-feed the DADH fails to Reload originals or 12-411-00 The current job exceeds Copy Job will exceed the out- Empty the tray
different than expected. recognize the size of the doc- select size. Perform the tray capacity, you will put destination’s capacity
The job has been ument 05-257-00 RAP be prompted to empty the
deleted. tray.
05-547-00 - DADH feed roll assembly Re-order feed roll 12-564-00 Finisher Front Door Open Finisher front door open Close the finisher
near end of life assembly PL 5.15 Item (LCSS) front door
1. 12-564-01 Finisher Front Door Open Finisher front door open Close the finisher
05-560-00 Remove the document. It Document too short for Remove document (HVF) front door
is too short to be fed by DADH, use document glass. from DADH during jam 12-564-02 Finisher Front Door Open Finisher front door open Close the finisher
Document Feeder. Fault 05-310 raised clearance, Perform 05- (HVF with tri-folder) front door
310-00 RAP
12-579-00 Hole Punching not avail- Hole punching is not available Check that the hole
05-570-00 Paper jam in the docu- DADH jam. Remove, then re-load able. Power machine Off punch unit is cor-
ment feeder. all document in the then On. If problem per- rectly installed. Switch
DADH. sists, call for assistance. off the machine then
05-578-00 - DADH roller feeds reaches Order new DADH feed switch on the
near end of life. Do not roll assembly, PL 5.15 machine, GP 14. Per-
replace until prompted. Item 1. form 12-043-00-110,
05-579-00 Replace the Document DADH roller feeds reaches Install new DADH feed 12-046-00-110 RAP
Feed Roller. end of life roll assembly, PL 5.15 for LCSS, 12-044-00-
Item 1. 171 to 12-047-00-171
RAP for HVF

Status Status
12-600-00 Finisher is not docked. The finisher unit (LCSS) is not Dock the output mod- 12-612-00 Paper Jam in the Finisher Paper is detected over the Clear the paper jam.
Re-dock finisher now. correctly docked. Printing has ule. Perform 12-310- hole punch position sensor at Perform 12-043-00-
stopped. 00-110, 12-312-00- power-up, interlock status 110, 12-046-00-110
110, 12-313-00-110 change or after shutdown. RAP
RAP (LCSS)
12-600-01 Finisher is not docked. The finisher unit (HVF without Dock the output mod- 12-617-00 Tray 6 (Inserter) is empty. Tray 6 (Inserter) detects no Add paper to tray 6.
Re-dock finisher now. tri-folder) is not correctly ule. Perform 12-310- Add paper paper present Perform 12J-171
docked. Printing has stopped. 00-171, 12-312-00- RAP.
171, 12-313-00-171 12-618-00 Paper Jam in the Finisher Paper is detected over the top Clear the paper jam.
RAP tray exit sensor at power-up, Perform 12-171-00-
12-600-02 Finisher is not docked. The finisher unit (HVF with tri- Dock the output mod- interlock status change or 110, 12-172-00-110
Re-dock finisher now. folder) is not correctly docked. ule. Perform 12-310- after shutdown. (LCSS) RAP
Printing has stopped. 00-171, 12-312-00- 12-618-01 Paper Jam in the Finisher Paper is detected over the top Clear the paper jam.
171, 12-313-00-171 tray exit sensor at power-up, Perform 12-125-00-
RAP interlock status change or 171, 12-126-00-171
12-601-00 Close the Finisher Top Finisher Top Cover Open Close the top cover after shutdown. (HVF) RAP
Tray. (Cover over output tray) 12-619-00 Paper Jam in the Finisher Paper jam near the output to Clear the paper jam.
12-602-00 Close Finisher Top Cover. Top Cover Open Close the Finisher the top tray. (LCSS) Perform 12-171-00-
Top Cover. 110, 12-172-00-110
12-606-00 Close Finisher Top Cover. Inserter Top Cover open Close the inserter top RAP
cover 12-619-01 Paper Jam in the Finisher Paper jam near the output to Clear the paper jam.
12-607-00 Close the Finisher Folder Tri-folder top cover open Close the tri-folder top the top tray. (HVF) Perform 12-171-00-
Top Cover. cover 171, 12-172-00-171
RAP
12-608-00 Close the Finisher Folder The Tri-Folder Unit Front Close the tri-folder
Front Door. Door is open front door 12-620-00 Paper Jam in the Finisher Paper is detected over the Clear the paper jam.
12-609-00 Close Finisher Inserter Inserter Left Cover open Close inserter left stacker exit sensor at power- Perform 12-151-00-
up, interlock status change or 110, 12-152-00-110
Left Side Door. (HVF without Tri-folder) cover
after shutdown. (LCSS) RAP
12-610-00 Paper Jam in the Finisher Paper is detected over the Clear the paper jam.
12-620-01 Paper Jam in the Finisher Paper jam near the output to Clear the paper jam.
entry sensor (LCSS) Perform 12-199-00-
110 RAP the stacker tray. Sheet over Perform 12-151-171,
2nd top exit sensor 12-152-171 RAP
12-610-01 Paper Jam in the Finisher Paper is detected over the Clear the paper jam.
12-621-00 Paper Jam in the Finisher If Entry sensor made to the Clear the paper jam.
entry sensor (HVF) Perform 12-125-00-
Stacker Bin Exit sensor made Perform 12-171-00-
171, 12-126-00-171
RAP exceeds 1600 ms (A4 LEF 110, 12-172-00-110
1st page/A3 SEF all pages) or RAP
12-611-00 Paper Jam in the Finisher After receiving the Paper at Clear the paper jam.
1100 ms (A4 LEF mid set
IOT Exit sensor Command Perform 12-199-00-
page) or 900 ms (A4 LEF last
the Entry sensor is not made 110 RAP page of set). (LCSS)
within 1000 ms. (LCSS).
12-621-01 Paper Jam in the Finisher Paper jam near the output to Clear the paper jam.
Paper jam near the entry to
the stacker tray. Sheet over Perform 12-151-171,
the finisher unit.
2nd top exit sensor 12-152-171 RAP
12-611-01 Paper Jam in the Finisher Paper jam near the entry to Clear the paper jam.
the finisher unit (HVF without Perform 12-125-00- 12-624-00 Paper Jam in the Finisher Sheet over the inserter pickup Clear the area or per-
sensor form 12-479-00-171
tri-folder) 171, 12-126-00-171
RAP
RAP

Status Status
12-625-00 Paper Jam in the Finisher Sheet over the inserter tab Clear the area or per- 12-641-00 The Hole Punch Waste The chad bin has been Reinstall the chad bin.
standby sensor form 12-191-00-171, Container is not detected. removed from the finisher Perform 12-043-00-
12-193-00-171, 12- Please re-insert. 110, 12-046-00-110
194-00-171, 12-196- RAP
00-171 RAP 12-642-00 Booklet Maker staples BM staples low The booklet maker
12-626-00 Paper Jam in the Finisher Sheet over the buffer position Clear the area or per- low. Re-order Booklet Sta- staple cartridge sup-
sensor form 12-198-00-171, ple Cartridge. plies are low. Re-
12-199-00-171 RAP order staple car-
12-627-00 Paper Jam in the Finisher Sheet over the HVF exit into Clear the area or per- tridge, PL 12.185 Item
BM sensor form 12-198-00-171, 8.
12-199-00-171 RAP 12-643-00 Booklet maker staple car- BM staples empty The booklet maker
12-627-01 Paper jam in the Finisher. Page over exit HVF into BM Open the Finisher tridge is empty. staple cartridge is
Sensor (Sensor in Area 6a) Front Door. empty. Follow the
Cleared via area 6a instructions at the
printer to load a new
12-627-02 Paper jam in the Finisher. Page over exit HVF into BM Open the Finisher
Sensor (Sensor in Area 6a) Front Door. staple cartridge, PL
12.185 Item 8. Print-
Cleared via area 6a
ing can continue, but
12-628-00 Paper Jam in the Finisher Sheet over the stacker bin Clear the area or per-
stapled booklet mak-
exit sensor form 12-151-171, 12- ing is unavailable
152-171
12-643-01 - Booklet Maker Staples Empty -
12-629-00 Paper Jam in the Finisher Sheet over the tri-folder entry Clear the area or per-
12-644-00 Booklet Maker Staple Booklet Maker Staples Empty The Booklet Maker
sensor form 12-183-00-171,
Cartridge is empty. AND HVF Finisher front door Staple Cartridge is
12-184-00-171 RAP
Replace now. open. empty. User interven-
12-630-01 Paper Jam in the Finisher Sheet over the booklet maker Clear the area or per- tion is required to
entry sensor (without tri- form 12-183-00-171,
install a new Booklet
folder) 12-184-00-171 RAP
Maker Staple Car-
12-630-02 Paper Jam in the Finisher Sheet over the booklet maker Clear the area or per- tridge, PL 12.185 Item
entry sensor (with tri-folder) form 12-183-00-171, 8. Printing and Copy-
12-184-00-171 RAP ing can continue with-
12-636-01 Paper Jam in the Finisher Sheet over the booklet maker Open and close the out stapled booklet
exit sensor. (without tri-folder) finisher front door, making.
clear the area or per- 12-649-00 The Hole Punch Waste Hole punch chad bin is full Hole punch waste
form 12-181-00-171, Container is full. Empty and needs emptying. (LCSS) container is full, jobs
12-182-00-171 RAP Hole Punch Waste Con- requesting hole
12-636-02 Paper Jam in the Finisher Sheet over the booklet maker Open and close the tainer. punching will be held.
exit sensor. (with tri-folder) finisher front door, Empty the chad bin
clear the area or per- 12-649-01 The Hole Punch Waste Hole punch chad bin is full Hole punch waste
form 12-181-00-171, Container is full. Empty and needs emptying. (HVF) container is full, jobs
12-182-00-171 RAP Hole Punch Waste Con- requesting hole
12-640-00 Hole Punch not detected Finisher punch unit is missing Make sure that the tainer. punching will be held.
(Missing). Please insert or incorrectly installed. punch unit is cor- Empty the chad bin
the Hole Punch. rectly installed. 12-653-00 Stapling not available. Stapling disabled, out of ser- Perform 12-371-00-
Perform 12-043-00- Please call for assistance vice. (LCSS) 110, 12-372-00-110,
110, 12-046-00-110 12-378-00-110 RAP
RAP

Status Status
12-665-00 Finisher Main Tray is out Bin status message received Perform 12-151-00- 12-720-00 Booklet Stapler not avail- Failure of any BM or TF func- Check for obstruc-
of service. from the finisher indicating bin 110, 12-152-00-110 able. Power off then on. If tion. tions in the HVF BM
1 out of service (LCSS) RAP problem persists, call for The Booklet Maker and Tri- and the tri-folder.
12-692-00 Finisher Top Tray is full. Top tray is full Empty top tray service. folder are currently unavail- Check that the HVF
Empty Top Tray. able BM and tri-folder
interlocks are made.
12-701-00 Offsetting is not available OCT offset failure occurred Perform 12-701-00-65
Switch the machine
at the Output Tray. RAP
OFF and ON, GP 14.
12-715-00 Staple Cartridge is empty. The finisher's main staple car- Install new staple car- Check the current
Replace now. tridge is empty. Follow the tridge, PL 12.55 Item
fault codes list for
instructions at the printer to 7.
HVF BM or tri-folder
load a new staple cartridge. faults and perform the
Non- staple printing can con-
appropriate RAP.
tinue. (LCSS)
12-721-00 Stapling not available. Stapler not in position -
12-715-01 Staple Cartridge is empty. HVF staple cartridge empty Install a new staple
Call for assistance.
Replace now. cartridge. Perform 12-
369-00-171 to 12- 12-726-00 Booklet Stapler not avail- Failure of the booklet maker Perform 12-063-00-
able. Power off then on. If stapling functions. 171, 12-411-00-171
377-00-171 RAP
problem persists, call for RAP for staple unit 1,
12-716-00 Staple Cartridge supplies LCSS and HVF staples low The finisher's main
service. and 12-403-00-171,
are low. staple cartridge sup- 12-413-00-171, 12-
plies are low. Re-
414-00-171 RAP for
order staple car-
staple unit 2
tridge. Printing can
continue. LCSS PL 12-727-00 The Booklet Maker Tray Booklet Maker Output Tray The Booklet Maker
in the Finisher is nearly Nearly Full Tray is near full. User
12.55 Item 7, HVF PL
full. intervention will be
12.110 Item 31.
HVFBM PL 12.185 required soon to
empty the tray to
Item 8.
allow continued book-
12-717-01 Paper Jam in the Finisher. Sheet over HVF BM compiler Clear the HFV BM
let making. Print and
paper present sensor (without paper present sensor Copy services can
tri-folder) area. Perform 12-166-
continue; other
00-171 RAP
machine services are
12-717-02 Paper Jam in the Finisher. Sheet over HVF BM compiler Clear the HFV BM unaffected.
paper present sensor (with tri- paper present sensor 12-728-00 The Booklet Maker Tray Booklet maker output tray is Empty the tray. If nec-
folder) area. Perform 12-166-
in the Finisher is full. full essary, perform 12C-
00-171 RAP
Empty the Tray. 171 RAP
12-718-00 Paper Jam in Finisher Sheet over tri- folder assist Clear the paper jam.
12-729-00 Finisher Top Tray is The top output bin is nearly The top output bin is
Folder Unit. sensor Perform 12-185-00- nearly full. full nearly full. This output
171 to 12-187-00-171
bin may need to be
RAP
unloaded soon. Print-
12-719-00 Paper Jam in Finisher Sheet over tri- folder exit sen- Clear the paper jam. ing can continue.
Folder Unit. sor Perform 12-185-00-
171 to 12-187-00-171
RAP

Status Status
12-730-00 Finisher Main Tray is full. The stacker tray is full The middle output bin 12-736-02 Paper jam in the Finisher Sheet detected near Exit HVF Clear the sheet. If
(LCSS and HVF) is full. This output bin to BM entry sensor. necessary, perform
needs to be unloaded. (with tri-folder) 12-113-00-171, 12-
Printing to this output 114-00-171, 12-190-
bin is disabled. 00-171, 12-192-00-
Perform 12-462-00- 171 RAP
110 RAP or 12-460- 12-740-00 - Tray ready for unloading Follow the instruc-
00-171 to 12-462-00- tions to unload the
171 RAP tray.
12-730-01 Finisher Main Tray is full. The stacker tray is full The middle output bin 12-741-00 - Machine is paused for Follow the instruc-
(HVF) is full. This output bin unloading. Need to press but- tions. If necessary,
needs to be unloaded. ton on pop up screen perform 12H-171
Printing to this output
12-742-00 - Pause To Unload Time-out Follow the instruc-
bin is disabled.
Warning tions.
Perform 12-460-00-
171 to 12-462-00-171
12-743-00 Booklet Stapler not avail- Booklet Making & Tri-folding Booklet Making and
RAP
able. Power off then on. If unavailable. Tri-folding is unavail-
12-731-00 Tray 6 (Inserter) is empty. Post Process Inserter Tray Load more paper. If
problem persists, call for able. Switch the
Load more media for (tray 6) is empty. Jobs will be necessary, perform service. machine off and on,
Insertion. held if inserts are required. 12J-171 RAP
GP 14. Check the cur-
12-732-00 Paper Jam in the Finisher. Sheet detected near the PPI Clear the sheet. If rent fault code list for
pickup sensor necessary, perform HVF BM or tri-fold
12-191-00-171, 12- faults and go to
193-00-171, 12-194- appropriate RAP.
00-171, 12-196-00- Printing can continue
171 RAP to all available output
12-733-00 Paper Jam in the Finisher. Sheet detected near the PPI Check the paper. If tray
tab standby sensor necessary, perform 12-744-00 Tray 6 (Inserter) is Inserter Unavailable The Post Process
12-191-00-171, 12- unavailable. Check for Inserter is not avail-
193-00-171, 12-194- obstructions. Power off able. Switch the
00-171, 12-196-00- then on. machine off and on,
171 RAP GP 14. Check the cur-
12-734-00 Finisher Main Tray is Stacker Tray Bin Nearly Full - rent fault code list for
nearly full. inserter faults and go
12-735-00 Paper jam in the Finisher Sheet detected near the Clear the sheet. If to appropriate RAP.
buffer sensor necessary, perform
12-157-00-171, 12-
158-00-171 RAP and
12-141-00-171, 12-
142-00-171 RAP
12-736-01 Paper jam in the Finisher Sheet detected near Exit HVF Clear the sheet. If
to BM entry sensor. necessary, perform
(without tri-folder) 12-113-00-171, 12-
114-00-171, 12-190-
00-171, 12-192-00-
171 RAP

Status Status
12-745-00 Finisher Top Tray and Top tray and Stacker unavail- Check for obstruc- 12-755-00 - The finisher has detected a Install 100 sheet sta-
Main Tray are not available (Only Booklet Maker tions in the HVF BM 50 sheet staple. 100 sheet ple cartridge
able. Tray available) and the tri-folder. staple cartridge should be
Check that the HVF used
BM and tri-folder 12-762-00 The Finisher is not avail- Communication failure Switch the machine
interlocks are made. able. Notify your Adminis- between IME and Finisher off and on, GP 14.
Switch the machine trator. Check the finisher
OFF and ON, GP 14. communication lead.
Check the current If the problem per-
fault codes list for sists, perform 12-762-
HVF BM or tri-folder 00-110, 12-764-00-
faults and perform the 110, 12-765-00-110
appropriate RAP. RAP for LCSS. 12-
12-746-00 Paper jam in the Finisher. Sheet detected near the tri- Clear the sheet. If 762-00-171, 12-764-
fold entry sensor necessary, perform 00-171, 12-765-00-
12-183-00-171, 12- 171 RAP for HVF.
184-00-171 RAP 12-764-00 The Finisher is not cor- The IME cannot detect a fin- Switch the machine
12-747-00 Paper jam in the Finisher. Sheet detected near the tri- Clear the sheet. If rectly connected. Notify isher plugged in (including off and on, GP 14.
fold exit sensor necessary, perform your Administrator. catch tray) Check the finisher
12-185-00-171 to 12- communication lead.
187-00-171 If the problem per-
12-748-00 Paper jam in the Finisher. Sheet detected near the tri- Clear the sheet. If sists, perform 12-762-
fold assist sensor necessary, perform 00-110, 12-764-00-
12-185-00-171 to 12- 110, 12-765-00-110
187-00-171 RAP RAP for LCSS. 12-
762-00-171, 12-764-
12-749-00 Insert sheet sent to a dif- An insert sheet has not See the message
00-171, 12-765-00-
ferent tray to the rest of arrived at its intended output text. If necessary, per-
the job. destination form 12-191-00-171, 171 RAP for HVF.
12-193-00-171, 12- 12-765-00 Incompatible or unknown The IME interface indicates Switch the machine
194-00-171, 12-196- finisher detected. Check that the finisher is incompati- off then on, GP 14.
00-171 RAP and 12- finisher compatibility ble / unknown. Check the finisher
125-00-171, 12-126- communication lead.
00-171 RAP If the problem per-
sists, perform 12-762-
12-750-00 Unexpected paper size or A shorter than expected sheet Follow the message
type detected from the has been fed from the inserter text. Check the size of 00-110, 12-764-00-
110, 12-765-00-110
Tray 6 (Inserter) the paper in the
RAP for LCSS. 12-
inserter. Refer to 12J-
171 RAP 762-00-171, 12-764-
00-171, 12-765-00-
12-752-00 Paper jam in the Finisher Page over Buffer Path Sensor Clear the area or per-
171 RAP for HVF.
form 12-198-00-171,
12-901-00 Unable to staple. Check Finisher is in degraded mode, Switch the machine
12-199-00-171 RAP
for obstructions in the out- unable to staple. off and on, GP 14. If
12-753-00 Paper jam in the Finisher Page near Buffer Path Sensor Clear the area or per- put trays. the problem persists,
form 12-198-00-171,
perform the 12-369-
12-199-00-171 RAP
00-171 to 12-377-00-
171 RAP, then the
12F-171 RAP.

Status Status
12-902-00 Finisher Main Tray out of Finisher is in degraded mode, Switch the machine 12-943-00 Booklet Making and Tri- Booklet making or tri-folding Check for obstruc-
service. Check for top tray is out of service. off and on, GP 14. folding are unavailable. capability degraded tions in the HVF BM
obstructions in the Main Check for obstruc- Check for obstructions and the tri-folder.
Tray. tions in the tray. Check that the HVF
12-906-00 Finisher Main Tray out of Right center tray out of ser- Switch the machine BM and tri-folder
service. Check for vice, tray home fault off and on, GP 14. interlocks are made.
obstructions in the Main Check for obstruc- Switch the machine
Tray. tions in the tray. OFF and ON, GP 14.
Check the current
12-908-00 Hole punching is unavail- Punch head motor fails Clear the paper jam.
fault codes list for
able. Check for obstruc- Switch off the
tions in the hole puncher machine then switch HVF BM or tri-folder
faults and perform the
on the machine, GP
appropriate RAP.
14. Perform 12-043-
00-110, 12-046-00- 12-944-00 Tray 6 (Inserter) is Inserter capability degraded Check for obstruc-
110 RAP for LCSS unavailable. Check for tions in the inserter. If
obstructions in the necessary, perform
12-909-00 All output trays are Punch head home sensor not Clear the paper jam.
Inserter. 12-191-00-171, 12-
unavailable. Check for made Switch off the
obstructions in the finisher machine then switch 193-00-171, 12-194-
00-171, 12-196-00-
on the machine, GP
171 RAP and 12J-171
14. Perform 12-462-
00-110 RAP for LCSS RAP
12-913-00 Booklet making is unavail- Back stop motor fails to move Clear the paper jam. 12-945-00 Booklet Making available. All trays have degraded capa- Check for obstruc-
All other output trays bility, except booklet maker tions in the buffer,
able. Check for obstruc- or not home Switch off the
unavailable stacker and top tray
tions in the BM machine then switch
on the machine, GP areas. Switch the
machine OFF and
14.
ON, GP 14. Check
12-921-00 Stapling not available. The stapler position sensor Close the BM stapler
the current fault codes
Call for assistance. indicates the stapler module module. If necessary, list for faults in the
is not closed in initialisation perform 12-063-00-
buffer, stacker and top
171, 12-411-00-171
tray areas and per-
RAP for staple unit 1, form the appropriate
and 12-403-00-171,
RAP.
12-413-00-171, 12-
414-00-171 RAP for
staple unit 2

Status
14-517-00 Scanner Fault. Call for Scanner fault. Switch the machine
assistance. off, then switch the
machine on GP 14.

Status
Status
16-510-00 Network services involving Scan to E-mail process Switch the machine off, then
Scan to E-mail are not failed switch the machine on GP
16-501-00 Network services with Job Job Based Accounting Not enough CCM memory to available. Notify the Sys- 14. If the problem persists
Based Accounting not not enough DC mem- run the Network Accounting tem Administrator check network connections
available. Please notify ory. Some Network feature 16-511-00 Network services related Internet fax process Switch the machine off, then
the machine administrator Controller services are to Internet Fax are not failed switch the machine on GP
not available available. Please notify 14. If the problem persists
16-502-00 The network controller is Status active when Cleared when the network the System Administrator check network connections
about to be reset ever the network con- controller reset is initiated 16-513-00 Some network services Simple service discov- Switch the machine off, then
troller detects that a involving SSDP are not ery protocol (SSDP) switch the machine on GP
platform reset is about available. Please notify failed 14.
to occur the System Administrator
16-503-00 System fault. Call for Incomplete system Switch the machine off, then 16-514-00 Network Services involv- Post office protocol Switch the machine off, then
assistance information switch the machine on GP ing Scan to Email are not (POP3) (for inbound switch the machine on GP
14. available. Please notify IFAX messages) pro- 14.
16-504-00 Some network services DDNS error. Some net- The DDNS address resolu- the System Administrator cess failed
involving DDNS are not work controller ser- tion process has failed. 16-517-00 Network Services involv- SMTP process failed Switch the machine off, then
available. Notify your Sys- vices are not available Switch the machine off, then ing Scan to E-mail are not switch the machine on GP
tem Administrator switch the machine on GP available. Please notify 14.
14. If the problem persists the System Administrator
check the DDNS server’s
16-518-00 Network Services using Web Services Edge Switch the machine off, then
network connections
WS Edge Client are not Client interface does switch the machine on GP
16-505-00 Some network services Insufficient memory for Switch the machine off, then available. Please notify not work 14. If the problem persists
involving Scan to E-mail E-mail switch the machine on GP the System Administrator check network connections
are not available. Notify 14. If the problem persists
16-519-00 Network Services using Web Services Client Switch the machine off, then
your System Administrator check the network connec-
WS Edge Client are not controller does not switch the machine on GP
tions available. Please notify work 14. If the problem persists
16-506-00 Your Administrator is Your Administrator is The system administrator is the System Administrator check network connections
reconfiguring the system. reconfiguring the sys- saving the Machine Configu-
16-520-00 Network Services using Web Services Server Switch the machine off, then
Services will not be avail- tem ration to a remote station.
WS Edge Client are not controller interface switch the machine on GP
able available. Please notify does not work. 14. If the problem persists
16-507-00 Some network services SLP process stopped. Switch the machine off, then the System Administrator check network connections
involving SLP are not Some network control- switch the machine on GP
16-521-00 Some Network Controller The network control- Some Network Services are
available. Notify your Sys- ler services are not be 14.
services involving CPI are ler’s CPI service pro- not available. The Network
tem Administrator available not available. Please cess has stopped Controller connection is
16-508-00 Autonet functions are not Autonet is not avail- Switch the machine off, then notify the System Adminis- about to be reset
available. Notify your Sys- able. switch the machine on GP trator
tem Administrator 14. Printing can continue if
16-522-00 Some Network Services The network control- Some Network Service are
other network protocols are involving Job Log are not ler’s Job Log service not available. The Network
used
available. Please notify process has stopped Controller connection is
16-509-00 Some network services Insufficient memory for Switch the machine off, then the System Administrator about to be reset
involving Internet Fax are internet fax switch the machine on GP
16-523-00 Some Network Services The network control- Some Network Service are
not available. Notify the 14. Printing can continue if with Job Tracker are not ler’s Job Tracker ser- not available. The Network
System Administrator other network protocols are
available. Please notify vice process has Controller connection is
used
the System Administrator stopped about to be reset

Status Status
16-524-00 Some Network Services The network control- Some Network Service are 16-553-00 Additional memory is Network controller - not Hardware must be added or
with Kerberos are not ler’s Kerberos service not available. The Network required to support Scan enough physical mem- replaced.
available. Please notify process has stopped Controller connection is to File. Notify the System ory is configured on the
the System Administrator about to be reset Administrator platform to support
16-525-00 Scan to Distribution Ser- The network control- Some Network Service are scan to file
vices are not available. ler’s Scan to Distribu- not available. The Network 16-554-00 Network scanning hard- Network controller - Hardware must be added or
Please notify the System tion service process Controller connection is ware must be added or Hardware must be replaced.
Administrator has stopped about to be reset replaced. Notify the Sys- added or replaced
16-526-00 Some Network Services The network control- Some Network Service are tem Administrator
involving SMB are not ler’s SMB service pro- not available. The Network 16-555-00 Insufficient memory for Network controller - not Additional memory required
available. Please notify cess has stopped. Controller connection is Fax job. Notify your Sys- enough physical mem- to support fax. The Fax ser-
the System Administrator about to be reset tem Administrator. ory is configured on the vice is not available
16-527-00 Some Network Services The network control- Some Network Service are platform to support Lan
involving TCP/IP are not ler’s TCP/IP service not available. The Network Fax
available. Please notify process has stopped. Controller connection is 16-557-00 Network Services using Network controller - Switch the machine off, then
the System Administrator about to be reset DC Platform recovery not DC platform failed switch the machine on GP
16-528-00 Network Services using The network control- Some Network Service are available. Notify the Sys- 14.
WS Scan Temp are not ler’s WS Scan Temp not available. The Network tem Administrator
available. Please notify service process has Controller connection is 16-558-00 Network Services using Network controller - Switch the machine off, then
the System Administrator stopped. about to be reset DC Platform recovery not DC communications switch the machine on GP
16-529-00 Network Services with The network control- Some Network Service are available. Notify the Sys- failed 14.
Scan Compressor are not ler’s Scan Compres- not available. The Network tem Administrator
available. Please notify sor service process Controller connection is 16-559-00 Network Services using Network controller - Check the BOOTP Server
the System Administrator has stopped. about to be reset BOOTP initialization not BOOTP initialization and its network connection.
16-533-00 Service limit exceeded. Unknown Service limit exceeded. New available. Notify the Sys- failure Switch the machine off, then
New services will not be services will not be available tem Administrator switch the machine on GP
available until some ser- until some services are 14.
vices are removed removed 16-560-00 Some Network Services Some processes on Switch the machine off, then
16-535-00 Immediate Job Overwrite Immediate Job Over- Immediate Job Overwrite are not available due to a the network controller switch the machine on GP
failed. Please perform and write failed failed. Please perform and process error. Notify your have failed 14.
On Demand Overwrite On Demand Overwrite System Administrator.
immediately immediately 16-561-00 Scan to File Services are Network controller - Switch the machine off, then
16-536-00 Network controller error. The ESS XSA service Switch the machine off, then not available. Notify the Scan to File processes switch the machine on GP
Some network services is unavailable. Network switch the machine on GP System Administrator have failed 14.
not available Please con- controller error 14. 16-562-00 Some network services Network controller - the Switch the machine off, then
tact the system adminis- involving LPD are not Line Printer Deamon switch the machine on GP
trator. available. Notify the Sys- (LPD) process has 14. Printing can continue if
16-544-00 Network Cable unplugged Ethernet cable is Ensure cables are properly tem Administrator failed other submission methods
unplugged connected are used
16-551-00 Accounting out of memory. Network controller - Accounting Administrator 16-563-00 Some network services Network controller - the Switch the machine off, then
Please notify machine accounting log is full or needs to retrieve accounting involving Novell are not Novell Netware con- switch the machine on GP
administrator a hard disk full state data log from the system available. Notify the Sys- nectivity process has 14. Printing can continue if
exists tem Administrator failed other submission methods
are used

Status Status
16-564-00 Some network services Network controller - the Switch the machine off, then 16-576-00 Network controller con- The network controller Automatic network controller
involving NetBios are not NetBIOS connectivity switch the machine on GP nection is about to be ESS event notification reset
available. Notify the Sys- process has failed 14. Printing can continue if reset service process has
tem Administrator other submission methods stopped
are used 16-577-00 Network controller con- The network controller Automatic network controller
16-565-00 Network services involving Network controller - the Switch the machine off, then nection is about to be ESS platform manager reset. Machine is unavailable
Apple Talk are not avail- Postscript connectivity switch the machine on GP reset service process has
able. Notify the System process has failed 14. Printing can continue if stopped
Administrator other submission methods 16-578-00 Incomplete system infor- The network controller Switch the machine off, then
are used mation. Notify the System ESS fault log service switch the machine on GP
16-567-00 Some network services Network controller - a Switch the machine off, then Administrator process has stopped 14. Printing and scanning
involving Postscript are Postscript interpreter switch the machine on GP can continue
not available. Notify the error has occur, caus- 14. Printing can continue if 16-579-00 Job status information not The network controller Switch the machine off, then
System Administrator ing the process to fail other submission methods available. Notify the Sys- ESS completed job log switch the machine on GP
are used tem Administrator service has stopped 14. Printing and scanning
16-568-00 Some network services Network controller - a Switch the machine off, then can continue
involving PCL are not PCL interpreter error switch the machine on GP 16-580-00 Incomplete system infor- The network controller Switch the machine off, then
available. Notify the Sys- has occurred, causing 14, to enable PCL printing. mation. Please notify the ESS configuration util- switch the machine on GP
tem Administrator the process to fail Printing can continue if other System Administrator ity process has 14. Printing and scanning
job format methods are used stopped can continue
16-569-00 Some network services Network controller - Switch the machine off, then 16-581-00 Some network diagnostic The network controller Switch the machine off, then
involving Parallel Port are Parallel Ports are not switch the machine on GP services unavailable. ESS diagnostic ser- switch the machine on GP
not available. Notify the available 14. Notify the System Admin- vice process has 14. Printing and scanning
System Administrator istrator stopped can continue
16-570-00 Some network services Network controller - an Switch the machine off, then 16-582-00 Some network authentica- The network controller Switch the machine off, then
involving HTTP are not HTTP interpreter error switch the machine on GP tion services unavailable. ESS authentication switch the machine on GP
available. Notify the Sys- has occurred, causing 14. Printing can continue if Notify the System Admin- SPI process has 14. Printing cannot continue
tem Administrator the process to fail other submission methods istrator stopped
are used
16-583-00 Incomplete system infor- The network controller Switch the machine off, then
16-571-00 Network printing disabled. Network controller - Switch the machine off, then mation. Notify the System ESS counters utility switch the machine on GP
Notify the System Admin- print service has failed switch the machine on GP Administrator process has stopped 14. Printing and scanning
istrator 14. Printing cannot continue can continue
16-572-00 Network printing disabled. Network controller - Switch the machine off, then 16-584-00 Network controller con- The network controller Automatic network controller
Notify the System Admin- print service has failed switch the machine on GP nection is about to be document manager reset. Machine is unavailable
istrator 14. Printing cannot continue reset agent process has
16-573-00 Network Printing dis- Network controller - Switch the machine off, then stopped
abled. Notify your System ESS print service has switch the machine on GP 16-585-00 Incomplete system infor- The network controller Switch the machine off, then
Administrator. failed 14. Printing cannot continue mation. Notify the System ESS configuration syn- switch the machine on GP
16-574-00 Only a partial list is avail- ESS queue utility has Switch the machine off, then Administrator chronization process 14. Printing and scanning
able for display failed switch the machine on GP has stopped can continue
14. 16-586-00 Incomplete system infor- The network controller -
16-575-00 Network controller con- The network controller Automatic network controller mation. Notify the System agent process has
nection is about to be ESS registration ser- reset Administrator stopped
reset vice process has
stopped

Status Status
16-589-00 Network Services involv- The network controller Switch the machine off, then 16-599-00 Network Services with Raw TCP/IP printing Switch the machine off, then
ing a Serial Port are not serial port connectivity switch the machine on GP Port 9100 Process are not (port 9100) process switch the machine on GP
available. Notify your Sys- has failed 14. Printing can continue available. Notify your Sys- has failed. 14. Other printing and can
tem Administrator. tem Administrator. continue
16-590-00 Network connectivity con- The network controller Switch the machine off, then
figuration server not avail- CCS process has switch the machine on GP
able. Notify the System failed 14. Printing and scanning
Administrator can continue Table 10 Chain 17 Status codes
16-591-00 Some Network Services Network controller Check Ethernet connection. Status
involving Ethernet are not Ethernet process has Switch the machine off, then Code UI Message Reason for Message Reference / Action
available. Notify your Sys- failed switch the machine on GP
17-510-00 - Duplicate IPv6 address -
tem Administrator. 14. Local printing can con-
detected
tinue
17-512-00 DHCPv6 services are not DHCPv6 Failure status -
16-593-00 Some Network Services Network controller - Check DHCP server network
involving DHCP are not DHCP address resolu- connection. Switch the available. Notify your
System Administrator.
available. Notify your Sys- tion has failed machine off, then switch the
tem Administrator. machine on GP 14. Other 17-513-00 Internet protocol (IPv6) Duplicate IPv6 address Reconfigure with a
network printing can con- duplicate address detected. unique address.
tinue detected. Switch off, then switch
on the machine, GP
16-594-00 Some Network Services Network controller - Check RARP server net-
14.
involving RARP are not RARP address resolu- work connection. Switch the
available. Notify your Sys- tion has failed machine off, then switch the 17-551-00 - Server Fax Service cannot -
tem Administrator. machine on GP 14. Other Register
network printing can con- 17-553-00 - Internet Fax Service cannot -
tinue Register
16-595-00 Some Lan Fax Services The network controller Switch the machine off, then 17-554-00 - Email Service cannot Regis- -
are not available. Notify Lan-Fax service has switch the machine on GP ter.
your System Administra- failed 14. 17-556-00 - Server Fax Service cannot -
tor. Un-Register
16-596-00 Some Network Accounting ACCOUNTING_DEAT Network Accounting error. 17-557-00 - Internet Fax Service cannot -
Services are not available. H_STATUS. User intervention is required Un-Register
Notify your System Admin- to switch the machine off, 17-558-00 - Email Service cannot Un-Reg- -
istrator. then switch the machine on
ister.
GP 14. Print and other
17-559-00 - Network Scanning Service -
machine services are unaf-
fected. cannot Register.
16-597-00 Some Network Services The network controller Switch the machine off, then 17-560-00 - Network Scanning Service -
cannot Un-Register.
involving TIFF are not TIFF interpreter has switch the machine on GP
available. Notify your Sys- failed 14. Other network printing 17-561-00 - Reprint Saved Jobs Service -
tem Administrator. can continue cannot Un-Register.
16-598-00 Some Network Services Network controller - Another IP address needs to 17-562-00 - Registration with edge server -
involving TCP/IP are not TCP / IP address is be used. Switch the machine fails
available. Notify your Sys- already in use on the off, then switch the machine 17-563-00 - Communication with edge -
tem Administrator. network on GP 14. server fails

Status Status
17-565-00 The Extensible Interface EIP service not responding Switch off, then switch 19-512-00 Image Disk is offline. Call The image disk cannot read The system is unable
Platform (EIP) browser is on the machine, GP for assistance. or write and must be ser- to read from the
not responding. 14. viced. PO / PO will tempo- image disk. Printing
17-570-00 - Communication with NNTP - rarily alleviate the problem. has stopped. Per-
server failed form the 19-300-00 to
19-310-00 Image
17-580-00 Please Wait… Disk Disk Encryption is in progress -
Disk (HDD 1) Failure
encryption operation in
progress. RAP.
17-590-00 Image Overwrite is in Image Overwrite (ODIO) is in - 19-513-00 Please wait...... The image The image disk is full The printer has
disk is full. detected either an
progress… the machine Progress
image disk read /
is Offline.
write problem or has
received bad data
from the image disk.
Printing has stopped.
Table 11 Chain 19 Status codes Switch off, then
Status switch on the
Code UI Message Reason for Message Reference / Action machine, GP 14.
19-502-00 Please wait, freeing mem- Out of memory resources. Current job has been 19-514-00 All incomplete jobs have Video job integrity fault Resubmit the job
ory The machine has run out of terminated and been deleted. detected.
image processing memory for moved to the job log. 19-550-00 Configuration mismatch The copy controller / single Switch the machine
the current job. board controller cannot off, then switch the
19-505-00 Some jobs may have been Compressor DVMA time-out. Confirm that UI mes- access the EPC memory or machine on, GP 14.
deleted. Current job has been deleted sage has been seen. the image disk. For machines W/O
Rescan the job. TAG 006. Install a
19-506-00 Immediate job overwrite Immediate job overwrite Perform an on new EPC memory
module, PL 3.10 Item
failed. Notify the System failed. demand overwrite
28. Install a new hard
Administrator immediately
disk drive, PL 3.10
19-510-00 Please wait.... the system Please wait.... the system is Please wait.... the Item 2. Install a new
is attempting to recover. attempting to recover. system is attempting
copy control PWB, PL
to recover.
3.10 Item 17.
19-511-00 Image disk is offline. Image disk unavailable. Per- The system is unable For machines W/TAG
Job(s) may take longer formance is degraded. Ser- to read from the 006. Install a new
than normal. Notify the vice is required. image disk. Jobs may EPC memory module,
System Administrator take longer than nor- PL 3.11 Item 21.
mal. Perform the 19- Install a new hard
300-00 to 19-310-00 disk drive, PL 3.11
Image Disk (HDD 1) Item 2. Install a new
Failure RAP. single board control
PWB, PL 3.11 Item
13.

Status
Codes UI Message Reason for Message Reference / Action
Status
20-571-00 A fax memory error has Fax memory error Switch the machine
Codes UI Message Reason for Message Reference / Action
occurred. Notify the sys- off, then switch the
20-544-00 - Please wait.....The fax ser- Please wait.....The fax tem administrator. machine on GP 14.
vice is initializing service is initializing Printing can continue
20-545-00 - Fax job could not be sent at Fax job could not be 20-572-00 Fax line 2 is unavailable. Fax service error Fax line 1 is still avail-
this time. Please try again sent at this time. Fax line 1 is still available. able.
Please try again 20-580-00 Fax service is unavailable See if the NVM values sup- Fax service is unavail-
20-546-00 - Not enough memory to use - plied by the Fax are invalid able
fax service
20-547-00 - Fax memory is low -
20-550-00 Fax line 2 is unavailable. Extended card failure Fax is available using
Notify your System Admin- detected fax line 1 Table 13 Chain 22 Status codes
istrator. Status
20-556-00 A fax memory error has Fax service error. Reset fax Switch the machine Codes UI Message Reason for Message Reference / Action
occurred. Notify the Sys- service off, then switch the
22-502-04 - An active message has been Go to the Status
tem Administrator machine on, GP 14. produced. screen and select the
Printing can continue
Faults tab. Press the
20-558-00 A fax memory error has Fax memory error Switch the machine Active Messages
occurred. Notify the sys- off, then switch the button and perform
tem administrator. machine on, GP 14. the action appropriate
Printing can continue to the message.
20-559-00 A fax memory error has Fax memory error Switch the machine 22-503-04 All incomplete jobs have System error. Jobs have No user intervention is
occurred. Notify the sys- off, then switch the been deleted. been lost and must be resub- required. Machine is
tem administrator. machine on, GP 14. mitted temporarily unavail-
Printing can continue able
20-562-00 Fax line 1 is unavailable. No communication on fax line Fax is available using 22-503-05 The number of originals Insufficient originals detected Re-sort and reload all
Check line connection Or 1 fax line 2 was less than the number in the DADH. originals.
notify your System Admin- originally scanned
istrator.
22-504-04 No tray is configured with No paper tray is configured to Job must be deleted.
20-563-00 Fax line 2 is unavailable. No communication on fax line Fax is available using the required paper size. run the stock size required for Paper tray must be
Check line connection Or 2 fax line 1 this job. configured to run the
notify your System Admin- stock size.
istrator.
22-504-05 Original size not detected Invalid Mixed Size Original Make sure the origi-
20-565-00 Fax job limit has been All jobs IDs allocated cannot Switch the machine Pair detected. It will be nals are not creased
reached. Notify the system create any more off, then switch the treated as the next largest or folded
administrator. machine on GP 14. standard size. Perform 05-257-00
Cleared when fax job RAP
IDs become available
22-504-16 Machine is in a non cus- Non customer mode. Auto Enter customer mode.
20-570-00 A fax memory error has Fax memory error Switch the machine tomer mode. configuration is disabled. Enter dC131 Read/
occurred. Notify the sys- off, then switch the Wait for machine to exit Diag- Write and check that
tem administrator. machine on GP 14. nostics mode. The machine NVM ID 425-001 = 0,
Printing can continue is unavailable 425-003 = 0 and 616-
14 = 4

Status Status
Codes UI Message Reason for Message Reference / Action Codes UI Message Reason for Message Reference / Action
22-505-00 Remove documents from Documents Sensed in the To scan from the Doc- 22-513-04 - One or more queued Job in Add paper to the tray
the Document Feeder DADH Tray during IIT ument Glass, remove the system is being held due being used to clear
Input Tray or close the Standby and Document Han- documents in the Doc- to lack of resources queued job
Document Feeder. dler Cover is open. ument Feeder Input 22-557-00 Configuration Parameter Serial number sync failure, Go to dC132, check
Tray. error. power on failed the serial number is
To use the Document correct. Enter dC131
Feeder to scan your NVM ID 616-003,
documents, lower the check machine config-
Document Feeder. If uration.
the fault remains, per- Perform 03-397-00
form the 05-300-00 RAP, 03-398-00, 03-
DADH Open RAP 399-00 RAP, 22-352-
22-505-17 - Machine is in a non customer Enter customer mode 00 RAP
mode. Enter dC131 Read/ 22-558-00 - An HFSI item has reached or Reset ‘Actual’ count to
Write and check that exceeded its threshold zero or reset the
NVM ID 425-001 = 0, threshold
425-003 = 0 and 616-
22-566-00 - Fax service cannot register Perform 22-371-00,
14 = 4 22-372-00 RAP
22-506-17 Auto configuration is dis- Machine is in a non customer Enter customer mode 22-567-00 - Fax service cannot un-regis- Perform 22-371-00,
abled mode. Enter dC131 Read/
ter 22-372-00 RAP
Write and check that
22-568-00 - Status requiring POPO -
NVM ID 425-001 = 0,
425-003 = 0 and 616- detected & Auto-Reset Count
less than 2.
14 = 4
22-570-00 - DC1001 command to IME Cleaning Unit life
22-507-05 The document size was Document larger than Try one of the follow-
reports successful entry into extended. No user
different than expected. expected ing:
The job has been deleted. Select Mixed Size snooze mode intervention is
required. Print and
Originals and reload
Copy services are
into the Document
Feeder available, but Image
quality may be
OR
affected.
Make sure the origi-
nals are not creased
or folded and retry
from the Document
Glass. Perform 05- Table 14 Chain 70 to 78 Status codes
257-00 RAP Status
22-508-04 Scanning will be delayed Scan start up delayed whilst No user intervention is Code UI Message Reason for Message Reference / Action
awaiting resources required. Job will 70-111-00 Jam in area 1b. Jam in lower feeder vertical Clear the media jam.
begin when system is
transport Copying and printing
ready.
are not available.
22-511-04 Paper required for current Paper required for current job Load paper to com-
70-111-01 Jam in area 1b. Jam in lower feeder VT (A4 Slide Tray 5 away from
job is not available is not loaded plete the held job or tray 5 installed) the machine.
cancel job
70-111-02 Jam in area 1b. Jam in lower feeder VT (A3 Slide Tray 5 away from
22-512-04 Auto paper select is not All trays direct select only Enable one tray for
tray 5 installed) the machine.
available auto select

Table 14 Chain 70 to 78 Status codes Table 14 Chain 70 to 78 Status codes
Status Status
70-305-00 Bottom Left Side Door Feeder VT. Lower left door is Copying and printing 71-535-00 Tray 1 is nearly empty. Tray 1 media low Add media. Copying
is open. open are not available. Close Add paper and printing can con-
the door. Refer to RAP tinue from other trays.
70-325-00 Refer to 71A RAP and
70-312-00 Trays 1 to 3 are not Comms failure for Trays 1-3 Perform 70-312-00 WD 7.5.
available. Notify your RAP 71-536-00 - Tray 1 lifting -
System Administrator. 72-102-00 Misfeed in tray 2 Misfeed in tray 2 Clear the media jam.
70-314-00 Tray 1 is not available. Trays 1 - 3 out of service Copying and printing Copying and printing
Notify the system (comms failure) are not available. Per- are not available.
administrator form the 70-312-00 Refer to 72-101-00, 72-
Tray 1 to Tray 3 Com- 106-00, 72-110-00 RAP
munication Failure 72-103-00 Unexpected paper size Media Size Mismatch in Tray 2 Open Tray 2.
RAP. or type detected from (alternate method) Check paper size, ori-
71-102-00 Misfeed in Tray 1 Misfeed in Tray 1 Clear the media jam. Tray 2. entation and type.
Copying and printing 72-300-00 - Tray 2 is open Close tray. Printing can
are not available continue from other
Refer to 71-101-00, 71- trays
106-00 RAP
72-301-00 Tray 2 is open Tray 2 is open Close tray. Printing can
71-103-00 Unexpected paper size Media Size Mismatch in Tray 1 Open Tray 1. continue from other
or type detected from (alternate method) Check paper size, ori- trays.
Tray 1. entation and type. Per- Refer to 72-320-00
form 71B RAP. RAP and WD 7.5.
71-300-00 - Tray 1 is open Close tray. Printing can 72-302-00 Tray 2 is open Tray 2 is open Close Tray. Printing can
continue from other continue from other
trays trays
71-301-00 Tray 1 is open Tray 1 is open Close tray. Printing can 72-313-00 Tray 2 is not available. T2 out of service (mechanical Copying and printing
continue from other Notify the system failure) are not available. Per-
trays. administrator form the 72-215-00
Refer to WD 7.5. Tray 2 Elevate Up Fail-
71-302-00 Tray 1 is open Tray 1 is open Close Tray. Printing can ure RAP.
continue from other 72-530-00 Tray 2 is empty. Add Tray 2 is out of media Add media. Copying
trays. paper and printing can con-
Refer to WD 7.5. tinue from other trays.
71-313-00 Tray 1 is not available. Tray 1 mechanical failure Copying and printing Refer to 72A RAP
Notify the system are not available. Per- 72-535-00 Tray 2 is nearly empty. Tray 2 media low Add media. Copying
administrator form the 71-215-00 Add paper and printing can con-
Tray 1 Elevate Up Fail- tinue from other trays
ure RAP.
72-536-00 - Tray 2 lifting -
71-530-00 Tray 1 is empty. Add Tray 1 is out of media Add media. Copying
73-102-00 Misfeed in tray 3 Misfeed in tray 3 Clear the media jam.
paper and printing can con-
Copying and printing
tinue from other trays. are not available.
Refer to 71A RAP and
Refer to 73-101-00, 73-
WD 7.5.
106-00, 73-110-00 RAP

Status Status
73-103-00 Unexpected paper size Media Size Mismatch in Tray 3 Open Tray 3. 74-120-00 - Tray 4 guides move in run Reload paper in tray 4.
or type detected from (alternate method) Check paper size, ori- Printing can continue
Tray 3. entation and type. from other trays
73-111-00 Jam in Paper Trans- Jam in tray 3 horizontal trans- Clear the media jam. 74-313-00 Tray 4 (Bypass) is not Tray 4 mechanical failure Copying and printing
port. port Copying and printing available. Notify your are not available. Refer
are not available. Refer System Administrator. to the following, 74-
to 73-101-00, 73-106- 101-00 Bypass Tray
00, 73-110-00 RAP. Mis-Feed RAP, 74-120-
73-300-00 - Tray 3 is open Close Tray. Printing can 00 Bypass Tray Guides
continue from other Move in Run RAP and
trays 74-214-00 Bypass Tray
73-301-00 Tray 3 is open Tray 3 is open Close Tray. Printing can Nudger Failure RAP.
continue from other
trays. Perform 73-320- 74-530-00 - Tray 4 is out of media Add media. Copying
00 RAP and printing can con-
73-302-00 Tray 3 is open Tray 3 is open Close Tray. Printing can tinue from other trays
continue from other 75-102-00 Misfeed in tray 5 Misfeed in tray 5 Clear the media jam.
trays. Perform 73-320- Copying and printing
00 RAP. are not available.
73-305-00 Paper Transport is Feeder HT drawer is open Copying and printing Refer to 75-101-00
RAP
open. are not available
75-102-01 Misfeed in Tray 5. Misfeed in Tray 5: A3 Remove the misfed
73-313-00 Tray 3 is not available. T3 out of service (mechanical Copying and printing
sheet. Refer to 75-101-
Notify the system failure) are not available. Refer
administrator to the following, 72- 00 RAP
215-00 Tray 2 Elevate 75-103-00 Unexpected paper size Media Size Mismatch in Tray 5 Open Tray 5.
Up Failure RAP and 72- or type detected from (alternate method) Check paper size, ori-
320-00 Tray 2 Open in Tray 5. entation and type.
Run RAP. 75-103-01 Unexpected paper size Media Size Mismatch in Tray 5 Lower Tray 5 using the
73-530-00 Tray 3 is empty. Add Tray 3 is out of media Add media. Copying or type detected from (alternate method) button indicated.
paper and printing can con- Tray 5. Check paper size, ori-
tinue from other trays. entation and type.
Perform 73A RAP 75-110-00 Jam in tray 5 docking Jam in tray 5 docking area Clear the misfeed.
73-535-00 Tray 3 is nearly empty. Tray 3 media low Add media. Copying area Copying and printing
Add paper and printing can con- are not available. Refer
tinue from other trays to 75-101-00 RAP.
73-536-00 - Tray 3 lifting - 75-110-01 Jam in Tray 5 docking Jam in Tray 5 docking area Slide Tray 5 away from
74-102-00 Misfeed in Tray 4 Misfeed in tray 4 Clear the media jam. area. the machine. Refer to
75-101-00 RAP.
(Bypass). Copying and printing
are not available. 75-300-00 - Tray 5 is open Close Tray. Printing can
Refer to 74-101-00 continue from other
RAP trays. Refer to 75A
RAP.
74-103-00 Unexpected paper size Media Size Mismatch in Tray 4 Open Tray 4.
or type detected from (alternate method) Check paper size, ori- 75-301-00 Tray 5 is open Tray 5 is open Close Tray. Printing can
Tray 4 (Bypass). entation and type. continue from other
Refer to WD 8.3 trays. Refer to 75A
RAP.

Table 14 Chain 70 to 78 Status codes
Status
Table 15 Chain 82 to 89 Status codes
Status
75-305-00 Tray 5 is undocked Tray 5 is undocked Printing can continue
from other trays. Refer
to 75-325-00 RAP. 82-100-00 Paper jam in area 1A IME jam at zone 1A (middle Open middle left door,
75-305-01 Tray 5 is undocked. Tray 5 is undocked Slide Tray 5 up to vertical) clear the paper jam.
machine. Refer to 75- (Tray 5 not installed) Refer to 82-110-00 to
325-00 RAP. 82-114-00, 82-152-00,
82-157-00 to 82-159-
75-312-00 Tray 5 is not available. Tray 5 comms failure Check cabling connec-
Notify your System tions. Copying and 00, 82-164-00 to 82-
166-00 RAP. Copying
Administrator. printing are not avail-
and printing are not
able. Refer to 75-312-
00 RAP. available
75-313-00 Tray 5 is not available. Tray 5 mechanical failure Copying and printing 82-100-01 Paper jam in area 1A IME jam at zone 1A (middle Open middle left door,
vertical) clear the paper jam.
Notify the system are not available. Per-
(Tray 5 not installed) Refer to 82-110-00 to
administrator form the following; 75-
212-00, 75-215-00 Tray 82-114-00, 82-152-00,
82-157-00 to 82-159-
5 Elevate Up Failure
00, 82-164-00 to 82-
RAP and 75-213-00,
75-216-00 Tray 5 Ele- 166-00 RAP. Copying
vate Down Failure RAP.
available
75-525-00 Tray 5 is overloaded Tray 5 is overloaded Remove some media.
82-100-02 Paper jam in Area 1a. Jam at Zone 1A (Middle Verti- Slide Tray 5 away from
remove some paper Copying and printing
can continue from other cal) the machine, clear the
paper jam. Refer to
trays. Perform 75-212-
82-110-00 to 82-114-
00, 75-215-00 RAP.
00, 82-152-00, 82-
75-530-00 Tray 5 is empty. Add Tray 5 is out of media Add media. Copying 157-00 to 82-159-00,
82-164-00 to 82-166-
tinue from other trays.
00 RAP
Perform 75B RAP
82-101-00 Paper jam in area 2 IME jam at zone 2 (upper verti- Open upper left door,
75-535-00 Tray 5 is nearly empty. Tray 5 media low Add media. Copying cal) clear the paper jam.
Add paper and printing can con-
Refer to 82-125-00 to
82-133-00, 82-153-00,
Perform 75B RAP. 82-155-00, 82-160-00,
75-536-00 - Tray 5 lifting - 82-162-00, 82-163-00
75-537-00 - Tray 5 lowering - RAP, 82-132-00, 82-
78-103-00 Unknown paper size or Media Size Mismatch in Tray 6 Open Tray 6. 155-00 RAP, 82-133-
type detected on tray 6 Check paper size, ori- 00 RAP, 82-134-00
(inverter). entation and type. RAP. Copying and
printing are not avail-
able
82-103-00 - Sensor 16 LE time out that Slide Tray 5 away from
originated from the A4 tray 5. the machine. Refer to
82-133-00 RAP. Open
the top and middle left
side door to clear jam.

Status Status
82-103-01 - Sensor 16 LE time out that Slide Tray 5 away from 91-606-00 - Head to drum measurement is Head to Drum spacing
originated from the A3 tray 5. the machine. Refer to started. check in Progress.
82-133-00 RAP. Open Please wait, this may
the top and middle left take up to ten minutes
side door to clear jam. to complete.
88-510-00 Please wait... Pre- IME preheater cleaning Please wait until clean- 91-609-00 - Waste Tray removal detected, The waste tray is cur-
heater cleaning in ing is completed. Print- when the Waste Tray is locked. rently in use, please
progress. ing is temporarily re-insert the waste
unavailable. tray.
88-511-00 Please wait… Print Media is exhausted during the Please wait, cooling in 91-632-00 - Print Head 1 has changed -
Engine cooling in cooling phase of Clean for Ink progress... since last boot.
progress. Smears. 91-633-00 - Print Head 2 has changed -
89-525-00 - IME clam shell open - since last boot.
89-560-00 Registration in progress IME registration calibration Please wait. Printing 91-634-00 - Print Head 3 has changed -
will be delayed since last boot.
89-561-00 - NVM entries for RALPH media Refer to OF 17 Service 91-635-00 - Print Head 4 has changed -
Registration Calibration got Code RAP since last boot.
corrupted or reset. 91-636-00 - IOD tool have tried repeatedly Perform 91-636-00
to run and have failed enough RAP
to exceed our disabled limita-
tion... OR Some user (from
Table 16 Chain 91 to 94 Status codes front panel diagnostics) has
Status manually disabled the running
of a tool. Therefore IOD cannot
improve print quality.
91-584-00 Waste Tray not Waste ink tray is not detected Install a waste ink tray,
91-637-00 - IOD Y Run out NVRAM param- Perform 91-637-00
detected (Missing). or missing. PL 91.10 Item 15. If
eters are reset. RAP
Insert the Waste Tray. necessary refer to WD
9.4. and 91-832-00 91-638-00 - IOD Chronic Jets Detected. Perform 91-638-00
RAP
RAP
91-639-00 - Sent once per cold purge. Sent No service action
91-589-00 - IME waste ink tray is locked in The waste ink tray
when the overall purge, which required
place to allow to cool needs emptying but is
locked while it cools. might request multiple heads to
be purge, is requested.
are not available
A cold purge is performed at
91-590-00 - IME waste tray is almost full The tray will need to be power up. That is, the ink in the
emptied soon. Printing
system is cold, we warm it up,
and copying can con-
and then perform a purge.
tinue
91-591-00 Waste Tray is full. IME waste tray is full Empty the tray. Copy-
Please empty the ing and printing are not
Waste Tray. available. If necessary
refer to WD 9.4.

Status Status
91-640-00 - Sent once per warm purge. No service action 91-653-00 - Head 4 freeze off - has com- No service action
Sent when the overall purge, required pleted required
which might request multiple 91-654-00 Please wait... Print Head Purge in Progress No service action
heads to be purge, is Engine Maintenance - required.
requested. Head Purge in
Progress.
A warm purge is performed
91-659-00 Please wait... Auto- Auto Maintenance routines in No service action
during the lifetime of a power mated Print Engine progress required.
on session. The ink is already
Maintenance in
up to temp, and we purge the
progress.
print heads.
91-668-00 Please wait... Print IME Print Quality Maintenance No service action
91-641-00 - A freeze off means that we No service action Quality Maintenance in in Progress required.
would let 1, or more, print required
progress.
heads cool down so that the
91-840-00 - IME in jet substitution and sin- No service action
ink is in a solid state. This
would then be followed by a gle sided print mode. Intention required.
is for A/F counter to be incrimi-
cold purge. The freeze off
nated by 1.
would be communicated by the
freeze off DCStatusUpdates, 91-841-00 - IME in jet substitution and sin- No service action
and the cold purges that would gle sided print mode. Intention required.
follow would be communicated is for A/F counter to be incrimi-
by the cold purge DCStatusUp- nated by 2.
dates. 92-530-00 Paper Tray communi- IME comms problem with Switch the machine
91-642-00 - Sent when a cold purge for No service action cation fault. Please call paper tray. Paper trays 1 to 3 off, then switch the
head1 has completed. required for assistance. not available. machine on GP 14.
Check connection on
91-643-00 - Sent when a cold purge for No service action
head2 has completed. required 3trays module. If prob-
lem persists, perform
91-644-00 - Sent when a cold purge for No service action
the 70-312-00 Tray 1
head3 has completed. required
to Tray 3 Communica-
91-645-00 - Sent when a cold purge for No service action tion Failure RAP.
head4 has completed. required Copying and printing
91-646-00 - Sent when a warm purge for No service action are not available.
head1 has completed. required 92-531-00 Paper tray communica- 3TM Communications prob- -
91-647-00 - Sent when a warm purge for No service action tion fault. Please call for lems (TtmSerialLinkSafety)
head2 has completed. required assistance.
91-648-00 - Sent when a warm purge for No service action 92-535-00 Paper Feeder commu- IME comms problem with Switch the machine
head 3 has completed. required nication fault. Call for paper feeder platform. High off, then switch the
91-649-00 - Sent when a warm purge for No service action assistance. capacity paper tray not avail- machine on GP 14.
head 4 has completed. required able Check connection to
91-650-00 - Head 1 freeze off - has com- No service action printer. If problem per-
sists, perform the 75-
pleted required
312-00 IME to Tray 5
91-651-00 - Head 2 freeze off - has com- No service action
Communication Fail-
pleted required ure RAP. Copying and
91-652-00 - Head 3 freeze off - has com- No service action printing are not avail-
pleted required able.

Status Status
92-536-00 Tray 5 is unavailable. Tray 5 communications prob- Perform 92-535-00, 93-505-00 Magenta Ink is empty. IME magenta ink is empty Load more magenta
Please call for assis- lems (tray 5 SerialLinkSafety) 92-536-00 RAP. Load Xerox ColorQube solid ink. Copying and
tance. Magenta Ink. printing are not avail-
92-572-00 System fault. Call for IME. An unrecoverable fault Switch the machine able. Check the ink low
assistance has occurred off, then switch the sensor and harness.
machine on GP 14. Refer to WD 9.18
Copying and printing 93-506-00 Magenta ink stick is Ink stick loaded sensor actu- Clear the ink loader
are not available. jammed. Call for assis- ated. Ink stick transport motor jam. Copying and
92-573-00 - Warming Up - tance operated. Ink stick not detected printing are not avail-
by ink out sensor. able
92-574-00 - Mechanical Initialization -
93-510-00 Cyan Ink is empty. Load IME cyan ink is empty Load more cyan solid
92-576-00 - IME frame buffer borrow busy Print engine adjust-
Xerox ColorQube Cyan ink. Copying and print-
ments in progress.
Copying and printing Ink. ing are not available.
Check the ink low sen-
are temporarily
sor and harness. Refer
unavailable
to WD 9.18
92-577-00 - Recovery in progress -
93-511-00 Cyan ink stick is Ink stick loaded sensor actu- Clear the ink loader
92-578-00 Print Engine in Non- IME in non-thermal mode. Print Enter diagnostics jammed. Call for assis- ated. Ink stick transport motor jam. Copying and
thermal Mode. engine is operating in non-ther- dC335 and select a
tance operated. Ink stick not detected printing are not avail-
mal manufacturing mode. Print heater routine. Run the
and copy service disabled. routine and then exit
diagnostics. The 93-515-00 Yellow Ink is empty. IME yellow ink is empty Load more yellow solid
Load Xerox ColorQube ink. Copying and print-
machine warms up.
Yellow Ink. ing are not available.
Enter dC131 Read/
Write and check that Check the ink low sen-
sor and harness. Refer
NVM ID 425-003 = 0
to WD 9.18
Select exit and reboot.
93-516-00 Yellow ink stick is Ink stick loaded sensor actu- Clear the ink loader
92-582-00 Please wait... Warming IME Cold Boot in progress
up from extremely low jammed. Call for assis- ated. Ink stick transport motor jam. Copying and
ambient temperature.
92-802-00 - PEST Warnings Exist Review dC123 PEST
93-821-00 - Black ink loader is low Load more black solid
Fault History log
ink. Copying and print-
93-500-00 Black Ink is empty. IME black ink is empty Load more black solid ing can continue. If the
Load Xerox ColorQube ink. Copying and print-
ink stick cannot be
Black Ink. ing are not available.
loaded, go to OF 11.
Check the ink low sen-
sor and harness. Refer 93-822-00 - Magenta ink loader is low Load more magenta
solid ink. Copying and
to WD 9.18.
printing can continue.
93-501-00 Black ink stick is Ink stick loaded sensor actu- Clear the ink loader
If the ink stick cannot
jammed. Call for assis- ated. Ink stick transport motor jam. Copying and be loaded, go to OF
11.
93-823-00 - Cyan ink loader is low Load more cyan solid
ink. Copying and print-
ing can continue. If the
ink stick cannot be
loaded, go to OF 11.

Status Status
93-824-00 - Yellow ink loader is low Load more yellow solid 93-878-00 - This status is raised when the Incompatible Magenta
ink. Copying and print- detected ink stick is different Ink detected. Refer to
ing can continue. If the from the expected one (as per GP 34. Notify the Sys-
ink stick cannot be the billing type). tem Administrator. All
loaded, go to OF 11. machine services are
93-825-00 - Black ink low threshold has Load more black solid available. Can be
been reached. ink sticks. Print and cleared by switching
other machine ser- off, then switching on
vices are unaffected. If the machine, GP 14.
the ink stick cannot be 93-879-00 - This status is raised when the Incompatible Cyan Ink
loaded, go to OF 11. detected ink stick is different detected. Refer to GP
93-826-00 - Magenta ink low threshold has Load more magenta from the expected one (as per 34. Notify the System
been reached. solid ink sticks. Print the billing type). Administrator. All
and other machine ser- machine services are
vices are unaffected. If available. Can be
the ink stick cannot be cleared by switching
loaded, go to OF 11. off, then switching on
93-827-00 - Cyan ink low threshold has Load more cyan solid the machine, GP 14.
been reached. ink sticks. Print and 93-880-00 - This status is raised when the Incompatible Yellow
other machine ser- detected ink stick is different Ink detected. Refer to
vices are unaffected. If from the expected one (as per GP 34. Notify the Sys-
the ink stick cannot be the billing type). tem Administrator. All
loaded, go to OF 11. machine services are
available. Can be
93-828-00 - Yellow ink low threshold has Load more yellow solid
off, then switching on
other machine ser-
the machine, GP 14.
vices are unaffected. If
the ink stick cannot be 93-881-00 - This status is raised when the Incompatible Black Ink
loaded, go to OF 11. detected ink stick is different detected. Refer to GP
from the expected one (as per 34. Notify the System
93-876-00 Ink Loader Main Cover Ink loader door is open. Close Close the ink loader
the billing type). Administrator. All
Open the door all machine services door.
are available. Refer to WD 8.2. machine services are
available.
Check the ink loader
switch (S93-025), PL 93-882-00 Incompatible Magenta Magenta sold ink stick Check machine on cor-
93.10 Item 19. ink stick detected, expected, metered was rect contract - Print
93-877-00 - This status is raised when the Incompatible Black Ink please contact the sys- detected config page, General
tem administrator. set up, service plan.
detected ink stick is different detected. Refer to GP
Check ink loaded is as
from the expected one (as per 34. Notify the System
the billing type). Administrator. All per the customers con-
tract GP 34.
Check the ink load
available. Can be
cleared by switching sensors dC330 - 93-
026 to 93-041
the machine, GP 14.

Status Status
93-883-00 Incompatible Cyan ink Cyan sold ink stick expected, Check machine on cor- 93-887-00 Incompatible cyan ink Cyan metered ink stick Check machine on cor-
stick detected, please metered was detected. rect contract - Print stick detected. Notify expected, DMO was detected. rect contract - Print
contact the system config page, General your System Adminis- config page, General
administrator. set up, service plan. trator. set up, service plan.
Check ink loaded is as Check ink loaded is as
per the customers con- per the customers con-
tract GP 34. tract GP 34.
Check the ink load Check the ink load
sensors dC330 - 93- sensors dC330 - 93-
026 to 93-041 026 to 93-041
93-884-00 Incompatible Yellow ink Yellow sold ink stick expected, Check machine on cor- 93-888-00 Incompatible yellow ink Yellow DMO ink stick expected, Check machine on cor-
stick detected, please metered was detected rect contract - Print stick detected. Notify metered was detected. rect contract - Print
contact the system config page, General your System Adminis- config page, General
administrator. set up, service plan. trator. set up, service plan.
Check ink loaded is as Check ink loaded is as
per the customers con- per the customers con-
tract GP 34. tract GP 34.
Check the ink load Check the ink load
sensors dC330 - 93- sensors dC330 - 93-
026 to 93-041 026 to 93-041
93-885-00 Incompatible Black ink Black sold ink stick expected, Check machine on cor- 93-889-00 - In a recovery sequence or cold Please close the Ink
stick detected. Notify DMO was detected. rect contract - Print power start, when ink stick Loader Main Cover.
your System Adminis- config page, General door is open.
trator. set up, service plan. 93-890-00 Incompatible black ink Black metered ink stick Check machine on cor-
Check ink loaded is as stick detected. Notify expected, DMO was detected rect contract - Print
per the customers con- your system administra- config page, General
tract GP 34. tor. set up, service plan.
Check the ink load Check ink loaded is as
sensors dC330 - 93- per the customers con-
026 to 93-041 tract GP 34.
93-886-00 Incompatible magenta Magenta DMO ink stick Check machine on cor- Check the ink load
ink stick detected. expected, sold was detected. rect contract - Print sensors dC330 - 93-
Notify your System config page, General 026 to 93-041
Administrator. set up, service plan. 93-891-00 Incompatible black ink Black DMO ink stick expected, Check machine on cor-
Check ink loaded is as stick detected. Notify metered was detected rect contract - Print
per the customers con- your system administra- config page, General
tract GP 34. tor. set up, service plan.
Check the ink load Check ink loaded is as
sensors dC330 - 93- per the customers con-
026 to 93-041 tract GP 34.
Check the ink load
sensors dC330 - 93-
026 to 93-041

Status Status
93-892-00 Incompatible black ink Black DMO ink stick expected, Check machine on cor- 93-925-00 Black ink stick jam. Add Black Ink Stick jam Black ink stick jam
stick detected. Notify sold was detected rect contract - Print black ink to aid jam detected.
your system administra- config page, General recovery. Load a Black Ink stick
tor. set up, service plan. to aid jam recovery.
Check ink loaded is as 93-926-00 Magenta ink stick jam. Magenta Ink Stick jam Magenta ink stick jam
per the customers con- Add magenta ink to aid detected.
tract GP 34. jam recovery. Load a Magenta Ink
Check the ink load stick to aid jam recov-
sensors dC330 - 93- ery.
026 to 93-041 Switch the machine
93-893-00 - This is raised while the IME is This is raised while the off, then switch the
attempting to clear a potentially IME is attempting to machine on, GP 14.
jammed ink stick. clear a potentially 93-927-00 Cyan ink stick jam. Add Cyan Ink Stick jam Cyan ink stick jam
jammed ink stick. cyan ink to aid jam detected.
93-894-00 - This is raised while the IME is - recovery. Load a Cyan Ink stick
attempting to clear a potentially to aid jam recovery.
jammed ink stick. 93-928-00 Yellow ink stick jam. Yellow Ink Stick jam Yellow ink stick jam
93-895-00 - This is raised while the IME is - Add yellow ink to aid detected.
attempting to clear a potentially jam recovery. Load a Yellow Ink stick
jammed ink stick. to aid jam recovery.
93-896-00 - This is raised while the IME is - 93-941-00 - This status is raised when the Incompatible Magenta
attempting to clear a potentially detected ink stick is different Ink detected. Refer to
jammed ink stick. from the expected one (as per GP 34. Notify the Sys-
93-905-00 - It is raised when the IME rec- - the billing type). tem Administrator. All
ognizes that the cyan ink stick machine services are
is consumed. available.
93-942-00 - This status is raised when the Incompatible Cyan Ink
This means it went past the ink detected ink stick is different detected. Refer to GP
low flag (it's past the point it from the expected one (as per 34. Notify the System
can be removed from the sys- the billing type). Administrator. All
tem and will be consumed). It's machine services are
critical for supplies replenish- available.
ment so we can estimate the 93-943-00 - This status is raised when the Incompatible Yellow
rate at which ink sticks are detected ink stick is different Ink detected. Refer to
being used. from the expected one (as per GP 34. Notify the Sys-
ognizes that the magenta ink machine services are
stick is consumed. available.
93-907-00 - It is raised when the IME rec- - 93-944-00 - This status is raised when the Incompatible Magenta
ognizes that the yellow ink stick detected ink stick is different Ink detected. Refer to
is consumed. from the expected one (as per GP 34. Notify the Sys-
ognizes that the black ink stick machine services are
is consumed. available.

Status Status
93-945-00 - This status is raised when the Incompatible Cyan Ink 93-952-00 - This status is raised when the Incompatible Cyan Ink
detected ink stick is different detected. Refer to GP detected ink stick is not a sup- detected. Refer to GP
from the expected one (as per 34. Notify the System ported type. 34. Notify the System
the billing type). Administrator. All Administrator. All
machine services are machine services are
available. available.
93-946-00 - This status is raised when the Incompatible Yellow 93-953-00 - This status is raised when the Incompatible Yellow
detected ink stick is different Ink detected. Refer to detected ink stick is not a sup- Ink detected. Refer to
from the expected one (as per GP 34. Notify the Sys- ported type. GP 34. Notify the Sys-
the billing type). tem Administrator. All tem Administrator. All
93-947-00 - This status is raised when the Incompatible Magenta 93-954-00 - This status is raised when the Incompatible Magenta
detected ink stick is different Ink detected. Refer to detected ink stick is different Ink detected. Refer to
from the expected one (as per GP 34. Notify the Sys- from the expected one (as per GP 34. Notify the Sys-
the billing type). tem Administrator. All the billing type). tem Administrator. All
93-948-00 - This status is raised when the Incompatible Cyan Ink 93-955-00 - This status is raised when the Incompatible Cyan Ink
detected ink stick is different detected. Refer to GP detected ink stick is different detected. Refer to GP
from the expected one (as per 34. Notify the System from the expected one (as per 34. Notify the System
the billing type). Administrator. All the billing type). Administrator. All
93-949-00 - This status is raised when the Incompatible Yellow 93-956-00 - This status is raised when the Incompatible Yellow
detected ink stick is different Ink detected. Refer to detected ink stick is different Ink detected. Refer to
from the expected one (as per GP 34. Notify the Sys- from the expected one (as per GP 34. Notify the Sys-
the billing type). tem Administrator. All the billing type). tem Administrator. All
93-950-00 - This status is raised when the Incompatible Black Ink 94-500-00 Cleaning unit will need Cleaning unit is near end of Re-order cleaning unit,
detected ink stick is not a sup- detected. Refer to GP replacing soon. Reor- life. PL 94.10 Item 21, but
ported type. 34. Notify the System der now, DO NOT do not load unit. Copy-
Administrator. All replace until requested. ing and printing can
machine services are continue
available. 94-501-00 Cleaning unit needs to Cleaning unit is empty of oil Install a new cleaning
93-951-00 - This status is raised when the Incompatible Magenta be replaced. Replace and needs replacing. unit, PL 94.10 Item 21.
detected ink stick is not a sup- Ink detected. Refer to cleaning unit now.
ported type. GP 34. Notify the Sys- 94-502-00 Cleaning unit is not Cleaning unit not present or not Install cleaning unit PL
tem Administrator. All detected. Please insert detected. 94.10 Item 21. Refer to
machine services are cleaning unit. the 94-568-00, 94-570-
available. 00, 94-572-00, 94-573-
00Cleaning Unit I/O
Error RAP. Copying
available

Table 16 Chain 91 to 94 Status codes OF 4b Status Messages in Alphabetical Order
Status Status Message Tables
The status message tables contain all the messages to which a status code can be attributed.
94-503-00 Cleaning Unit will need This status is raised while we -
• Table 1 Status Messages - to F
replacing soon. Re- are in the last 3000 impres-
order now. DO NOT sions. • Table 2 Status Messages G to N.
replace until requested. • Table 3 Status Messages O to R.
94-547-00 - Y - axis belt ratio error. Imaging Install new drum belt, • Table 4 Status Messages S to Y.
drum belt is worn PL 94.20 Item 2.
Refer to OF 17 Service Table 1 Status messages - to F
Code RAP Status
94-600-00 Load 8.5 x 11" Paper in Letter/A4 chase media needed Load the required UI Message Code Reason for Message Reference / Action
any tray to enable Auto- to clean drum media. Refer to GP 20. - 02-517-00 PagePack Grace Period Active -
Drum cleaning. Copying and printing
- 02-518-00 PagePack Grace Period -
are not available
Expired
94-601-00 Load SRA3 (320 x 450 SRA3 paper needed to clean Load the required
- 02-521-00 XEIP Browser is dead or not Perform the 02-321-
mm) Paper in any tray drum media. Refer to GP 20.
to enable Auto-Drum Copying and printing responding 00 XEIP Browser
Dead RAP.
cleaning. are not available
- 03-504-00 Unknown Switch the machine
94-602-00 Load 12 x 18" Paper in 12”x18” chase media needed Load the required
off, then switch the
any tray to enable auto- to clean drum media. Refer to GP 20.
Drum cleaning. Copying and printing machine on GP 14.
are not available - 03-538-00 Machine Active Registration -
has been disabled via the
94-603-00 - Chase Sheet being Fed -
DC_715 diagnostic Routine.
94-604-00 Load A4 paper into any A4 Chase Media Needed to Load any tray with
- 03-555-00 Machine has entered intrusive Go to dC301. Per-
tray to enable auto- Clean Drum paper of the following
cleaning to proceed. size to continue clean- customer tools mode. form a Copier NVM
Initialization and NVM
ing: A4. Refer to GP
data select All.
20.
After Initialization per-
94-613-00 Cleaning Unit fault. Call Cleaning Unit failure A fault has occurred in form routines dC977
for assistance quoting the Cleaning Unit,
and dC978.
error code 94-613-00. install new cleaning
- 03-558-00 Not Defined -
unit PL 94.10 Item 21.
94-614-00 - It is raised when the IME rec- -
ognizes that the DMU has - 03-558-02 Not Defined -
changed. - 03-558-03 Not Defined -
- 05-525-00 Document feeder tray empty Perform 05B DADH
Document Sensor
Failure RAP.
- 05-535-00 Document feeder tray loaded -
- 05-547-00 DADH feed roll assembly near Re-order feed roll
end of life assembly PL 5.15
Item 1.
- 10-536-00 Transfix Calibration NVRAM Refer to OF 17 Ser-
parameters are reset. vice Code RAP

Xerox® ColorQube® 9203 Family 2-615 OF 4a, OF 4b
Table 1 Status messages - to F Table 1 Status messages - to F
Status Status
UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action
- 12-410-00 PTU selected whilst marking Pressing the Pause to - 20-545-00 Fax job could not be sent at this Fax job could not be
job is running Unload button will time. Please try again sent at this time.
cancel this request. Please try again
- 12-643-01 Booklet Maker Staples Empty - - 20-546-00 Not enough memory to use fax -
- 12-741-00 Machine is paused for unload- Follow the instruc- service
ing. Need to press button on tions. If necessary, - 20-547-00 Fax memory is low -
pop up screen perform 12H-171 - 22-502-00 An active message has been Go to the Status
- 12-740-00 Tray ready for unloading Follow the instructions produced. screen and select the
to unload the tray. Faults tab. Press the
- 12-742-00 Pause To Unload Time-out Follow the instruc- Active Messages
Warning tions. button and perform
the action appropriate
to the message.
- 12-755-00 The finisher has detected a 50 Install 100 sheet sta-
sheet staple. 100 sheet staple ple cartridge - 22-505-17 Machine is in a non customer Enter customer mode
cartridge should be used mode. Enter dC131 Read/
Write and check that
- 17-510-00 Duplicate IPv6 address -
NVM ID 425-001 = 0,
detected
425-003 = 0 and 616-
- 17-551-00 Server Fax Service cannot - 14 = 4
Register
- 22-513-04 One or more queued Job in the Add paper to the tray
- 17-553-00 Internet Fax Service cannot -
system is being held due to being used to clear
Register
lack of resources queued job
- 17-554-00 Email Service cannot Register. -
- 22-558-00 An HFSI item has reached or Reset ‘Actual’ count to
- 17-556-00 Server Fax Service cannot Un- - exceeded its threshold zero or reset the
Register threshold
- 17-557-00 Internet Fax Service cannot - - 22-566-00 Fax service cannot register Perform 22-371-00,
Un-Register 22-372-00 RAP
- 17-558-00 Email Service cannot Un-Reg- - - 22-567-00 Fax service cannot un-register Perform 22-371-00,
ister. 22-372-00 RAP
- 17-559-00 Network Scanning Service can- - - 22-568-00 Status requiring POPO -
not Register. detected & Auto-Reset Count
- 17-560-00 Network Scanning Service can- - less than 2.
not Un-Register. - 22-570-00 DC1001 command to IME Cleaning Unit life
- 17-561-00 Reprint Saved Jobs Service - reports successful entry into extended. No user
cannot Un-Register. snooze mode intervention is
- 17-562-00 Registration with edge server - required. Print and
fails Copy services are
available, but Image
- 17-563-00 Communication with edge -
server fails quality may be
affected.
- 17-570-00 Communication with NNTP -
- 71-300-00 Tray 1 is open Close tray. Printing
server failed
can continue from
- 20-544-00 Please wait.....The fax service Please wait.....The fax
other trays
is initializing service is initializing
- 71-536-00 Tray 1 lifting -

OF 4b 2-616 Xerox® ColorQube® 9203 Family
Status Status
- 72-300-00 Tray 2 is open Close tray. Printing - 91-606-00 Head to drum measurement is Head to Drum spacing
can continue from started. check in Progress.
other trays Please wait, this may
- 72-536-00 Tray 2 lifting - take up to ten minutes
- 73-300-00 Tray 3 is open Close Tray. Printing to complete.
can continue from - 91-609-00 Waste Tray removal detected, The waste tray is cur-
other trays when the Waste Tray is locked. rently in use, please
re-insert the waste
- 73-536-00 Tray 3 lifting -
tray.
- 74-120-00 Tray 4 guides move in run Reload paper in tray
4. Printing can con- - 91-632-00 Print Head 1 has changed -
since last boot.
tinue from other trays
- 91-633-00 Print Head 2 has changed -
- 74-530-00 Tray 4 is out of media Add media. Copying
since last boot.
and printing can con-
tinue from other trays - 91-634-00 Print Head 3 has changed -
- 75-300-00 Tray 5 is open Close Tray. Printing since last boot.
can continue from - 91-635-00 Print Head 4 has changed -
other trays. Refer to since last boot.
75A RAP. - 91-636-00 IOD tool have tried repeatedly Perform 91-636-00
- 75-536-00 Tray 5 lifting - to run and have failed enough RAP
- 75-537-00 Tray 5 lowering - to exceed our disabled limita-
tion... OR Some user (from
- 82-103-00 Sensor 16 LE time out that orig- Slide Tray 5 away
front panel diagnostics) has
inated from the A4 tray 5. from the machine.
manually disabled the running
Refer to 82-133-00 of a tool. Therefore IOD cannot
RAP. Open the top
improve print quality.
and middle left side
- 91-637-00 IOD Y Run out NVRAM param- Perform 91-637-00
door to clear jam.
eters are reset. RAP
- 82-103-01 Sensor 16 LE time out that orig- Slide Tray 5 away
inated from the A3 tray 5. from the machine. - 91-638-00 IOD Chronic Jets Detected. Perform 91-638-00
RAP
Refer to 82-133-00
RAP. Open the top - 91-639-00 Sent once per cold purge. Sent No service action
and middle left side when the overall purge, which required
door to clear jam. might request multiple heads to
be purge, is requested.
- 89-525-00 IME clam shell open -
- 89-561-00 NVM entries for RALPH media Refer to OF 17 Ser-
A cold purge is performed at
Registration Calibration got cor- vice Code RAP power up. That is, the ink in the
rupted or reset.
system is cold, we warm it up,
- 91-589-00 IME waste ink tray is locked in The waste ink tray and then perform a purge.
place to allow to cool needs emptying but is
locked while it cools.
are not available
- 91-590-00 IME waste tray is almost full The tray will need to
be emptied soon.
Printing and copying
can continue

Xerox® ColorQube® 9203 Family 2-617 OF 4b
Status Status
- 91-640-00 Sent once per warm purge. No service action - 91-653-00 Head 4 freeze off - has com- No service action
Sent when the overall purge, required pleted required
which might request multiple - 91-840-00 IME in jet substitution and sin- No service action
heads to be purge, is gle sided print mode. Intention required.
requested. is for A/F counter to be incrimi-
nated by 1.
A warm purge is performed dur-
- 91-841-00 IME in jet substitution and sin- No service action
ing the lifetime of a power on gle sided print mode. Intention required.
session. The ink is already up
is for A/F counter to be incrimi-
to temp, and we purge the print
nated by 2.
heads.
- 92-573-00 Warming Up -
- 91-641-00 A freeze off means that we No service action
would let 1, or more, print required - 92-574-00 Mechanical Initialization -
heads cool down so that the ink - 92-576-00 IME frame buffer borrow busy Print engine adjust-
is in a solid state. This would ments in progress.
then be followed by a cold Copying and printing
purge. The freeze off would be are temporarily
communicated by the freeze off unavailable
DCStatusUpdates, and the cold - 92-577-00 Recovery in progress -
purges that would follow would - 92-802-00 PEST Warnings Exist Review dC123 PEST
be communicated by the cold Fault History log
purge DCStatusUpdates.
- 92-820-00 PEST Warnings Exist -
- 91-642-00 Sent when a cold purge for No service action
- 93-821-00 Black ink loader is low Load more black solid
ink. Copying and
- 91-643-00 Sent when a cold purge for No service action printing can continue.
head2 has completed. required If the ink stick cannot
- 91-644-00 Sent when a cold purge for No service action be loaded, go to OF
head3 has completed. required 11.
- 91-645-00 Sent when a cold purge for No service action - 93-822-00 Magenta ink loader is low Load more magenta
head4 has completed. required solid ink. Copying and
- 91-646-00 Sent when a warm purge for No service action printing can continue.
head1 has completed. required If the ink stick cannot
be loaded, go to OF
- 91-647-00 Sent when a warm purge for No service action
head2 has completed. required 11.
- 91-648-00 Sent when a warm purge for No service action - 93-823-00 Cyan ink loader is low Load more cyan solid
ink. Copying and
printing can continue.
- 91-649-00 Sent when a warm purge for No service action
If the ink stick cannot
head 4 has completed. required be loaded, go to OF
- 91-650-00 Head 1 freeze off - has com- No service action 11.
pleted required
- 93-824-00 Yellow ink loader is low Load more yellow
- 91-651-00 Head 2 freeze off - has com- No service action solid ink. Copying and
pleted required printing can continue.
- 91-652-00 Head 3 freeze off - has com- No service action If the ink stick cannot
pleted required be loaded, go to OF
11.

Status Status
- 93-825-00 Black ink low threshold has Load more black solid - 93-879-00 This status is raised when the Incompatible Cyan Ink
been reached. ink sticks. Print and detected ink stick is different detected. Refer to GP
other machine ser- from the expected one (as per 34. Notify the System
vices are unaffected. the billing type). Administrator. All
If the ink stick cannot machine services are
be loaded, go to OF available. Can be
11. cleared by switching
- 93-826-00 Magenta ink low threshold has Load more magenta off, then switching on
been reached. solid ink sticks. Print the machine, GP 14.
and other machine - 93-880-00 This status is raised when the Incompatible Yellow
services are unaf- detected ink stick is different Ink detected. Refer to
fected. If the ink stick from the expected one (as per GP 34. Notify the Sys-
cannot be loaded, go the billing type). tem Administrator. All
to OF 11. machine services are
- 93-827-00 Cyan ink low threshold has Load more cyan solid available. Can be
other machine ser- off, then switching on
vices are unaffected. the machine, GP 14.
If the ink stick cannot - 93-881-00 This status is raised when the Incompatible Black
be loaded, go to OF detected ink stick is different Ink detected. Refer to
11. from the expected one (as per GP 34. Notify the Sys-
- 93-828-00 Yellow ink low threshold has Load more yellow the billing type). tem Administrator. All
been reached. solid ink sticks. Print machine services are
and other machine available.
services are unaf- - 93-889-00 In a recovery sequence or cold Please close the Ink
fected. If the ink stick power start, when ink stick door Loader Main Cover.
cannot be loaded, go is open.
to OF 11. - 93-893-00 This is raised while the IME is This is raised while
- 93-877-00 This status is raised when the Incompatible Black attempting to clear a poten- the IME is attempting
detected ink stick is different Ink detected. Refer to tially jammed ink stick. to clear a potentially
from the expected one (as per GP 34. Notify the Sys- jammed ink stick.
the billing type). tem Administrator. All - 93-894-00 This is raised while the IME is -
machine services are attempting to clear a poten-
available. Can be tially jammed ink stick.
cleared by switching
- 93-895-00 This is raised while the IME is -
off, then switching on attempting to clear a poten-
the machine, GP 14.
tially jammed ink stick.
- 93-878-00 This status is raised when the Incompatible Magenta
- 93-896-00 This is raised while the IME is -
detected ink stick is different Ink detected. Refer to
attempting to clear a poten-
from the expected one (as per GP 34. Notify the Sys- tially jammed ink stick.
the billing type). tem Administrator. All
available. Can be
cleared by switching
the machine, GP 14.

Status Status
- 93-905-00 It is raised when the IME recog- - - 93-945-00 This status is raised when the Incompatible Cyan Ink
nizes that the cyan ink stick is detected ink stick is different detected. Refer to GP
consumed. from the expected one (as per 34. Notify the System
the billing type). Administrator. All
This means it went past the ink machine services are
low flag (it's past the point it can available.
be removed from the system - 93-946-00 This status is raised when the Incompatible Yellow
and will be consumed). It's criti- detected ink stick is different Ink detected. Refer to
cal for supplies replenishment from the expected one (as per GP 34. Notify the Sys-
so we can estimate the rate at the billing type). tem Administrator. All
which ink sticks are being used. machine services are
- 93-906-00 It is raised when the IME recog- - available.
nizes that the magenta ink stick - 93-947-00 This status is raised when the Incompatible Magenta
is consumed. detected ink stick is different Ink detected. Refer to
- 93-907-00 It is raised when the IME recog- - from the expected one (as per GP 34. Notify the Sys-
nizes that the yellow ink stick is the billing type). tem Administrator. All
consumed. machine services are
- 93-908-00 It is raised when the IME recog- - available.
nizes that the black ink stick is - 93-948-00 This status is raised when the Incompatible Cyan Ink
consumed. detected ink stick is different detected. Refer to GP
- 93-941-00 This status is raised when the Incompatible Magenta from the expected one (as per 34. Notify the System
detected ink stick is different Ink detected. Refer to the billing type). Administrator. All
from the expected one (as per GP 34. Notify the Sys- machine services are
the billing type). tem Administrator. All available.
machine services are - 93-949-00 This status is raised when the Incompatible Yellow
available. detected ink stick is different Ink detected. Refer to
- 93-942-00 This status is raised when the Incompatible Cyan Ink from the expected one (as per GP 34. Notify the Sys-
detected ink stick is different detected. Refer to GP the billing type). tem Administrator. All
from the expected one (as per 34. Notify the System machine services are
the billing type). Administrator. All available.
machine services are - 93-950-00 This status is raised when the Incompatible Black
available. detected ink stick is not a sup- Ink detected. Refer to
- 93-943-00 This status is raised when the Incompatible Yellow ported type. GP 34. Notify the Sys-
detected ink stick is different Ink detected. Refer to tem Administrator. All
machine services are - 93-951-00 This status is raised when the Incompatible Magenta
available. detected ink stick is not a sup- Ink detected. Refer to
- 93-944-00 This status is raised when the Incompatible Magenta ported type. GP 34. Notify the Sys-
detected ink stick is different Ink detected. Refer to tem Administrator. All
available.

Status Status
- 93-952-00 This status is raised when the Incompatible Cyan Ink A fax memory error 20-559-00 Fax memory error Switch the machine
detected ink stick is not a sup- detected. Refer to GP has occurred. Notify off, then switch the
ported type. 34. Notify the System the system adminis- machine on GP 14.
Administrator. All trator. Printing can continue
machine services are A fax memory error 20-570-00 Fax memory error Switch the machine
available. has occurred. Notify off, then switch the
- 93-953-00 This status is raised when the Incompatible Yellow the system adminis- machine on GP 14.
detected ink stick is not a sup- Ink detected. Refer to trator. Printing can continue
ported type. GP 34. Notify the Sys- A fax memory error 20-571-00 Fax memory error Switch the machine
tem Administrator. All has occurred. Notify off, then switch the
machine services are the system adminis- machine on GP 14.
available. trator. Printing can continue
- 93-954-00 This status is raised when the Incompatible Magenta A Fax Service error 03-547-00 Basic fax card failure detected Switch the machine
detected ink stick is different Ink detected. Refer to has occurred. Call for off, then switch the
from the expected one (as per GP 34. Notify the Sys- assistance. machine on GP 14. If
the billing type). tem Administrator. All the problem persists,
machine services are perform the 20-331-
available. 00, 20-338-00, 20-
- 93-955-00 This status is raised when the Incompatible Cyan Ink 339-00, 20-341-00
detected ink stick is different detected. Refer to GP Fax Network Line 1
from the expected one (as per 34. Notify the System Fault RAP.
the billing type). Administrator. All A Fax Service error 03-550-00 The fax card was not detected Switch the machine
machine services are has occurred. Call for off, then switch the
available. assistance. machine on GP 14. If
- 93-956-00 This status is raised when the Incompatible Yellow the problem persists,
detected ink stick is different Ink detected. Refer to perform the 20-331-
from the expected one (as per GP 34. Notify the Sys- 00, 20-338-00, 20-
the billing type). tem Administrator. All 339-00, 20-341-00
machine services are Fax Network Line 1
available. Fault RAP.
- 94-547-00 Y - axis belt ratio error. Imaging Install new drum belt, A Fax Service error 03-551-00 The fax service is unavailable Switch the machine
drum belt is worn PL 94.20 Item 2. has occurred. Call for off, then switch the
Refer to OF 17 Ser- assistance. machine on GP 14. If
vice Code RAP the problem persists,
- 94-603-00 Chase Sheet being fed - perform the 20-331-
00, 20-338-00, 20-
- 94-614-00 It is raised when the IME recog- -
nizes that the DMU has 339-00, 20-341-00
Fax Network Line 1
changed.
Fault RAP.
A fax memory error 20-556-00 Fax service error. Reset fax Switch the machine
Accounting out of 16-551-00 Network controller - accounting Accounting Adminis-
has occurred. Notify service off, then switch the
the System Adminis- machine on GP 14. memory. Please notify log is full or a hard disk full trator needs to
machine administrator state exists retrieve accounting
trator Printing can continue
data log from the sys-
A fax memory error 20-558-00 Fax memory error Switch the machine
tem
has occurred. Notify off, then switch the
the system adminis- machine on GP 14.
trator. Printing can continue

Status Status
Additional memory is 16-553-00 Network controller - not enough Hardware must be Black ink stick is 93-501-00 Ink stick loaded sensor actu- Clear the ink loader
required to support physical memory is configured added or replaced. jammed. Call for ated. Ink stick transport motor jam. Copying and
Scan to File. Notify on the platform to support scan assistance operated. Ink stick not detected printing are not avail-
the System Adminis- to file by ink out sensor. able
trator Booklet maker staple 12-643-00 BM staples empty The booklet maker
All output trays are 12-909-00 Punch head home sensor not Clear the paper jam. cartridge is empty. staple cartridge is
unavailable. Check for made Switch off the empty. Follow the
obstructions in the fin- machine then switch instructions at the
isher on the machine, GP printer to load a new
14. Perform 12-462- staple cartridge, PL
00-110 RAP for LCSS 12.185 Item 8. Print-
All incomplete jobs 19-514-00 Video job integrity fault Resubmit the job ing can continue, but
have been deleted. detected. stapled booklet mak-
ing is unavailable
All incomplete jobs 22-503-04 System error. Jobs have been No user intervention is
have been deleted. lost and must be resubmitted required. Machine is Booklet Maker sta- 12-642-00 BM staples low The booklet maker
temporarily unavail- ples low. Re-order staple cartridge sup-
able Booklet Staple Car- plies are low. Re-
tridge. order staple cartridge,
Auto configuration is 22-506-17 Machine is in a non customer Enter customer mode
disabled mode. Enter dC131 Read/ PL 12.185 Item 8.
Write and check that Booklet Maker Staple 12-644-00 Booklet Maker Staples Empty The Booklet Maker
NVM ID 425-001 = 0, Cartridge is empty. and HVF Finisher front door Staple Cartridge is
425-003 = 0 and 616- Replace now. open. empty. User interven-
14 = 4 tion is required to
install a new Booklet
Auto paper select is 22-512-04 All trays direct select only Enable one tray for
Maker Staple Car-
not available auto select
tridge, PL 12.185 Item
Autonet functions are 16-508-00 Autonet is not available. Switch the machine 8. Printing and Copy-
not available. Notify off, then switch the
ing can continue with-
your System Adminis- machine on GP 14. If
out stapled booklet
trator the problem persists, making.
perform the 16-780-00
Booklet Making and 12-943-00 Booklet making or tri-folding Check for obstructions
to 16-789-47 Other
Tri-folding are unavail- capability degraded in the HVF BM and
Network Faults 3 RAP.
Printing can continue able. Check for the tri-folder. Check
obstructions that the HVF BM and
if other network proto-
tri-folder interlocks are
cols are used.
made. Switch the
Black Ink is empty. 93-500-00 IME black ink is empty Load more black solid machine OFF and
Load Xerox Col- ink. Copying and
ON, GP 14. Check the
orQube Black Ink. printing are not avail-
current fault codes list
able. Check the ink for HVF BM or tri-
low sensor and har-
folder faults and per-
ness. Refer to WD
form the appropriate
9.18. RAP.
Black ink stick jam. 93-925-00 Black Ink Stick jam Black ink stick jam
Add black ink to aid detected.
jam recovery. Load a Black Ink stick
to aid jam recovery.

Status Status
Booklet Making avail- 12-945-00 All trays have degraded capa- Check for obstructions Cleaning unit is not 94-502-00 Cleaning unit not present or not Install cleaning unit PL
able. All other output bility, except booklet maker in the buffer, stacker detected. Please detected. 94.10 Item 21. Refer
trays unavailable and top tray areas. insert cleaning unit. to the 94-568-00, 94-
Switch the machine 570-00, 94-572-00,
OFF and ON, GP 14. 94-573-00Cleaning
Check the current Unit I/O Error RAP.
fault codes list for Copying and printing
faults in the buffer, are not available
stacker and top tray Cleaning unit needs to 94-501-00 Cleaning unit is empty of oil Install a new cleaning
areas and perform the be replaced. Replace and needs replacing. unit, PL 94.10 Item
appropriate RAP. cleaning unit now. 21.
Booklet making is 12-913-00 Back stop motor fails to move Clear the paper jam. Cleaning unit will 94-500-00 Cleaning unit is near end of life. Re-order cleaning
unavailable. Check for or not home Switch off the need replacing soon. unit, PL 94.10 Item
obstructions in the BM machine then switch Reorder now, DO 21, but do not load
on the machine, GP NOT replace until unit. Copying and
14. requested. printing can continue
Booklet Stapler not 12-743-00 Booklet Making & Tri-folding Booklet Making and Cleaning Unit will 94-503-00 This status is raised while we -
available. Power off unavailable. Tri-folding is unavail- need replacing soon. are in the last 3000 impres-
then on. If problem able. Switch the Re-order now. DO sions.
persists, call for ser- machine off and on, NOT replace until
vice. GP 14. Check the cur- requested.
rent fault code list for Close the Finisher Top 12-601-00 Finisher Top Cover Open Close the top cover
HVF BM or tri-fold
Tray. (Cover over output tray)
faults and go to appro-
Close Finisher Top 12-602-00 Top Cover Open Close the Finisher Top
priate RAP. Printing
can continue to all Cover. Cover.
available output tray Close Finisher Top 12-606-00 Inserter Top Cover open Close the inserter top
Cover. cover
Booklet Stapler not 12-726-00 Failure of the booklet maker Perform 12-063-00-
available. Power off stapling functions. 171, 12-411-00-171 Close Finisher 12-609-00 Inserter Left Cover open (HVF Close inserter left
then on. If problem RAP for staple unit 1, Inserter Left Side without Tri-folder) cover
persists, call for ser- and 12-403-00-171, Door.
vice. 12-413-00-171, 12- Close the Finisher 12-608-00 The Tri-Folder Unit Front Door Close the tri-folder
414-00-171 RAP for Folder Front Door. is open front door
staple unit 2 Close the Finisher 12-607-00 Tri-folder top cover open Close the tri-folder top
Bottom Left Side Door 70-305-00 Feeder VT lower left door is Copying and printing Folder Top Cover. cover
is open. open are not available. Configurable services 02-590-00 Configurable services not sta- Switch the machine
Close the door. Refer error ble at power on. off, then switch the
to RAP 70-325-00 machine on GP 14. If
Cleaning Unit fault. 94-613-00 Cleaning Unit failure A fault has occurred in the problem persists,
Call for assistance the Cleaning Unit, perform the 02-390-00
quoting error code install new cleaning Configurable Ser-
94.613. unit PL 94.10 Item 21. vices RAP.

Status Status
Configuration mis- 19-550-00 The copy controller / single Switch the machine DHCPv6 services are 17-512-00 DHCPv6 Failure status -
match board controller cannot access off, then switch the not available. Notify
the EPC memory or the image machine on, GP 14. your System Adminis-
disk. For machines W/O trator.
TAG 006. Install a Document Feeder - 05-539-00 DADH feed head CRU None
new EPC memory Feed Roller has been replaced. Message automati-
module, PL 3.10 Item replaced. cally cleared half a second after
28. Install a new hard setting
disk drive, PL 3.10
Do not switch the 01-500-00 IME power switch is moved to Print jobs sent to the
Item 2. Install a new
power on again while the off position device will not print
copy control PWB, PL powering down is in and may be lost.
3.10 Item 17.
progress
For machines W/TAG
Duplicate IPv6 17-513-00 Duplicate IPv6 address Reconfigure with a
006. Install a new
EPC memory mod- address detected. detected. unique address.
Switch off, then switch
ule, PL 3.11 Item 21.
on the machine, GP
Install a new hard disk
drive, PL 3.11 Item 2. 14.
Install a new single Enter your access 03-559-02 Walk Up Code Entered FDI. Your Job cannot be
board control PWB, code or the current job Not Defined completed due to
PL 3.11 Item 13. may be deleted. insufficient funds.
Configuration Param- 22-557-00 Serial number sync failure, Go to dC132, check
Please enter access
eter error. power on failed the serial number is
code on the external
correct. Enter dC131
NVM ID 616-003, accounting device to
continue your job.
check machine config-
uration. Empty chad bin 12-549-00 Hole punch chad bin is full and Empty chad bin
Perform 03-397-00 needs emptying
RAP, 03-398-00, 03- Fax job limit has been 20-565-00 All jobs IDs allocated cannot Switch the machine
399-00 RAP, 22-352- reached. Notify the create any more off, then switch the
00 RAP system administrator. machine on GP 14.
Cyan Ink is empty. 93-510-00 IME cyan ink is empty Load more cyan solid Cleared when fax job
Load Xerox Col- ink. Copying and IDs become available
orQube Cyan Ink. printing are not avail- Fax line 1 is unavail- 20-562-00 No communication on fax line 1 Fax is available using
able. Check the ink able. Check line con- fax line 2
low sensor and har- nection Or notify your
ness. Refer to WD System Administrator.
9.18. Fax line 2 is unavail- 03-548-00 Extended fax not detected/con- Check fax line con-
Cyan ink stick jam. 93-927-00 Cyan Ink Stick jam Cyan ink stick jam able. Notify your Sys- firmed nection
Add cyan ink to aid detected. tem Administrator.
jam recovery. Load a Cyan Ink stick Fax line 2 is unavail- 20-550-00 Extended card failure detected Fax is available using
to aid jam recovery. able. Notify your Sys- fax line 1
Cyan ink stick is 93-511-00 Ink stick loaded sensor actu- Clear the ink loader tem Administrator.
jammed. Call for ated. Ink stick transport motor jam. Copying and Fax line 2 is unavail- 20-563-00 No communication on fax line 2 Fax is available using
assistance operated. Ink stick not detected printing are not available. Check line con- fax line 1
by ink out sensor. able nection Or notify your
System Administrator.

Status Status
Fax line 2 is unavail- 20-572-00 Fax service error Fax line 1 is still avail- Finisher Main Tray is 12-665-00 Bin status message received Perform 12-151-00-
able. Fax line 1 is still able. out of service. from the finisher indicating bin 110, 12-152-00-110
available. 1 out of service (LCSS) RAP
Fax memory error. 03-549-00 Fax POST failure status. Switch the machine Finisher Main Tray is 12-734-00 Stacker Tray Bin Nearly Full
off, then switch the nearly full.
machine on GP 14. Finisher Main Tray out 12-902-00 Finisher is in degraded mode, Switch the machine
Fax service is unavail- 20-580-00 See if the NVM values supplied Fax service is unavail- of service. Check for top tray is out of service. off and on, GP 14.
able by the Fax are invalid able obstructions in the Check for obstructions
Finisher Front Door 12-564-01 Finisher front door open (HVF) Close the finisher Main Tray. in the tray.
Open front door Finisher Main Tray out 12-906-00 Right center tray out of service, Switch the machine
Finisher Front Door 12-564-02 Finisher front door open Close the finisher of service. Check for tray home fault off and on, GP 14.
Open (HVF with tri-folder) front door obstructions in the Check for obstructions
Main Tray. in the tray.
Finisher Front Door 12-564-00 Finisher front door open Close the finisher
Open (LCSS) front door Finisher Top Tray and 12-745-00 Top tray and Stacker unavail- Check for obstructions
Finisher is not 12-600-00 The finisher unit (LCSS) is not Dock the output mod- Main Tray are not able (Only Booklet Maker Tray in the HVF BM and
available. available) the tri-folder. Check
docked. Re-dock fin- correctly docked. Printing has ule. Perform 12-310-
that the HVF BM and
isher now. stopped. 00-110, 12-312-00-
110, 12-313-00-110 tri-folder interlocks are
made. Switch the
RAP
machine OFF and
Finisher is not 12-600-01 The finisher unit (HVF without Dock the output mod-
ON, GP 14. Check the
docked. Re-dock fin- tri-folder) is not correctly ule. Perform 12-310- current fault codes list
isher now. docked. Printing has stopped. 00-171, 12-312-00-
for HVF BM or tri-
171, 12-313-00-171
folder faults and per-
RAP form the appropriate
Finisher is not 12-600-02 The finisher unit (HVF with tri- Dock the output mod- RAP.
docked. Re-dock fin- folder) is not correctly docked. ule. Perform 12-310-
Finisher Top Tray is 12-729-00 The top output bin is nearly full The top output bin is
isher now. Printing has stopped. 00-171, 12-312-00-
nearly full. nearly full. This out-
171, 12-313-00-171 put bin may need to
RAP
be unloaded soon.
Finisher Main Tray is 12-730-00 The stacker tray is full The middle output bin Printing can continue.
full. (LCSS and HVF) is full. This output bin
Finisher Top Tray is 12-692-00 Top tray is full Empty top tray
needs to be unloaded. full. Empty Top Tray.
Front door is open. 01-510-00 The front door is open. Copying and printing
bin is disabled.
are not available. Per-
Perform 12-462-00-
110 RAP or 12-460- form the 01-510-00
Front Door Open RAP.
00-171 to 12-462-00-
171 RAP
Finisher Main Tray is 12-730-01 The stacker tray is full The middle output bin
full. (HVF) is full. This output bin
needs to be unloaded.
bin is disabled.
Perform 12-460-00-
171 to 12-462-00-171
RAP

Table 2 Status messages G to N
Status
Table 2 Status messages G to N
UI Message Code Reason for Message Reference / Action
Status
Incompatible or 12-765-00 The IME interface indicates that Switch the machine
UI Message Code Reason for Message Reference / Action
unknown finisher the finisher is incompatible / off then on, GP 14.
The Hole Punch Waste 12-649-00 Hole punch chad bin is full and Hole punch waste detected. Check fin- unknown. Check the finisher
Container is full. Empty needs emptying. (LCSS) container is full, jobs isher compatibility communication lead.
Hole Punch Waste Con- requesting hole If the problem per-
tainer. punching will be held. sists, perform 12-762-
Empty chad bin 00-110, 12-764-00-
The Hole Punch Waste 12-649-01 Hole punch chad bin is full and Hole punch waste 110, 12-765-00-110
Container is full. Empty needs emptying. (HVF) container is full, jobs RAP for LCSS. 12-
Hole Punch Waste Con- requesting hole 762-00-171, 12-764-
tainer. punching will be held. 00-171, 12-765-00-
Empty chad bin 171 RAP for HVF.
Hole Punching not avail- 12-579-00 Hole punching is not available Check that the hole Image Disk is offline. 19-512-00 The image disk cannot read or The system is unable
able. Power machine punch unit is correctly Call for assistance. write and must be serviced. PO to read from the
Off then On. If problem installed. Switch off / PO will temporarily alleviate image disk. Printing
persists, call for assis- the machine then the problem. has stopped. Perform
tance. switch on the the 19-300-00 to 19-
machine, GP 14. Per- 310-00 Image Disk
form 12-043-00-110, (HDD 1) Failure RAP.
12-046-00-110 RAP Image disk is offline. 19-511-00 Image disk unavailable. Perfor- The system is unable
for LCSS, 12-044-00- Job(s) may take longer mance is degraded. Service is to read from the
171 to 12-047-00-171 than normal. Notify the required. image disk. Jobs may
RAP for HVF System Administrator take longer than nor-
Hole Punch not 12-640-00 Finisher punch unit is missing Make sure that the mal. Perform the 19-
detected (Missing). or incorrectly installed. punch unit is correctly 300-00 to 19-310-00
Please insert the Hole installed. Image Disk (HDD 1)
Punch. Perform 12-043-00- Failure RAP.
110, 12-046-00-110 Image Overwrite is in 17-590-00 Image Overwrite (ODIO) is in -
RAP progress… the machine Progress
Hole punching is 12-908-00 Punch head motor fails Clear the paper jam. is Offline.
unavailable. Check for Switch off the Image rotation is not 03-564-00 Image rotation is not available Image rotation is not
obstructions in the hole machine then switch available. Call for assis- available.
puncher on the machine, GP tance
14. Perform 12-043- Immediate job over- 19-506-00 Immediate job overwrite failed. Perform an on
00-110, 12-046-00- write failed. Notify the demand overwrite
110 RAP for LCSS System Administrator immediately
Immediate Job Over- 16-535-00 Immediate Job Overwrite failed Immediate Job Over-
write failed. Please per- write failed. Please
form and On Demand perform and On
Overwrite immediately Demand Overwrite
immediately

Table 2 Status messages G to N Table 2 Status messages G to N
Status Status
Incompatible FAX Soft- 03-546-00 Incompatible fax software The embedded fax Incompatible black ink 93-892-00 Black DMO ink stick expected, Check machine on
ware Detected detect at power on software version is stick detected. Notify sold was detected correct contract - Print
(Upgrade Required) incompatible with the your system administra- config page, General
system. A software tor. set up, service plan.
upgrade should be Check ink loaded is as
performed per the customers
Refer to 03-417-00 contract GP 34.
RAP. Check the ink load
Incompatible Black ink 93-885-00 Black sold ink stick expected, Check machine on sensors dC330 - 93-
stick detected. Notify DMO was detected. correct contract - Print 026 to 93-041
your System Adminis- config page, General Incompatible cyan ink 93-887-00 Cyan metered ink stick Check machine on
trator. set up, service plan. stick detected. Notify expected, DMO was detected. correct contract - Print
Check ink loaded is as your System Adminis- config page, General
per the customers trator. set up, service plan.
contract GP 34. Check ink loaded is as
Check the ink load per the customers
sensors dC330 - 93- contract GP 34.
026 to 93-041 Check the ink load
Incompatible black ink 93-890-00 Black metered ink stick Check machine on sensors dC330 - 93-
stick detected. Notify expected, DMO was detected correct contract - Print 026 to 93-041
your system administra- config page, General Incompatible Cyan ink 93-883-00 Cyan sold ink stick expected, Check machine on
tor. set up, service plan. stick detected, please metered was detected. correct contract - Print
Check ink loaded is as contact the system config page, General
per the customers administrator. set up, service plan.
Incompatible black ink 93-891-00 Black DMO ink stick expected, Check machine on sensors dC330 - 93-
stick detected. Notify metered was detected correct contract - Print 026 to 93-041
your system administra- config page, General Incompatible magenta 93-886-00 Magenta DMO ink stick Check machine on
tor. set up, service plan. ink stick detected. Notify expected, sold was detected. correct contract - Print
Check ink loaded is as your System Adminis- config page, General
per the customers trator. set up, service plan.
sensors dC330 - 93-
026 to 93-041

Status Status
Incompatible Magenta 93-882-00 Magenta sold ink stick Check machine on Incomplete system 16-586-00 The network controller agent -
ink stick detected, expected, metered was correct contract - Print information. Notify the process has stopped
please contact the sys- detected config page, General System Administrator
tem administrator. set up, service plan. Incomplete system 16-580-00 The network controller ESS Switch the machine
Check ink loaded is as information. Please configuration utility process has off, then switch the
per the customers notify the System stopped machine on GP 14.
contract GP 34. Administrator Printing and scanning
Check the ink load can continue
sensors dC330 - 93-
Ink Loader Main Cover 93-876-00 Ink loader door is open. Close Close the ink loader
026 to 93-041
Open the door all machine services door.
Incompatible yellow ink 93-888-00 Yellow DMO ink stick expected, Check machine on are available. Refer to WD 8.2.
stick detected. Notify metered was detected. correct contract - Print Check ink loader door
your System Adminis- config page, General switch (S93-025), PL
trator. set up, service plan. 93.10 Item 19.
Check ink loaded is as Insert sheet sent to a 12-749-00 An insert sheet has not arrived See the message text.
per the customers
different tray to the rest at its intended output destina- If necessary, perform
contract GP 34.
of the job. tion 12-191-00-171, 12-
Check the ink load 193-00-171, 12-194-
sensors dC330 - 93-
00-171, 12-196-00-
026 to 93-041
171 RAP and 12-125-
Incompatible Yellow ink 93-884-00 Yellow sold ink stick expected, Check machine on 00-171, 12-126-00-
stick detected, please metered was detected correct contract - Print 171 RAP
contact the system config page, General
Insufficient memory for 16-555-00 Network controller - not enough Additional memory
administrator. set up, service plan.
Fax job. Notify your Sys- physical memory is configured required to support
Check ink loaded is as tem Administrator. on the platform to support Lan fax. The Fax service is
per the customers
Fax not available
contract GP 34.
Jam in area 1b. 70-111-01 Jam in lower feeder VT (A4 tray Slide Tray 5 away
Check the ink load
sensors dC330 - 93- 5 installed) from the machine.
026 to 93-041 Jam in area 1b. 70-111-02 Jam in lower feeder VT (A3 tray Slide Tray 5 away
5 installed) from the machine.
Incomplete system 16-578-00 The network controller ESS Switch the machine
information. Notify the fault log service process has off, then switch the Jam in area 1b. 70-111-00 Jam in lower feeder vertical Clear the media jam.
System Administrator stopped machine on GP 14. transport Copying and printing
Printing and scanning are not available
can continue Jam in Paper Transport. 73-111-00 Jam in tray 3 horizontal trans- Clear the media jam.
Incomplete system 16-583-00 The network controller ESS Switch the machine port Copying and printing
information. Notify the counters utility process has off, then switch the are not available.
System Administrator stopped machine on GP 14. Refer to 73-101-00,
Printing and scanning 73-106-00, 73-110-00
can continue RAP.
Incomplete system 16-585-00 The network controller ESS Switch the machine Jam in tray 5 docking 75-110-00 Jam in tray 5 docking area Clear the misfeed.
information. Notify the configuration synchronization off, then switch the area Copying and printing
System Administrator process has stopped machine on GP 14. are not available.
Printing and scanning Refer to 75-101-00
can continue RAP.

Status Status
Jam in Tray 5 docking 75-110-01 Jam in Tray 5 docking area Slide Tray 5 away Magenta ink stick is 93-506-00 Ink stick loaded sensor actu- Clear the ink loader
area. from the machine. jammed. Call for assis- ated. Ink stick transport motor jam. Copying and
Refer to 75-101-00 tance operated. Ink stick not detected printing are not avail-
RAP. by ink out sensor. able
Job status information 16-579-00 The network controller ESS Switch the machine Middle left side door is 01-505-00 The IME middle left door (below Copying and printing
not available. Notify the completed job log service has off, then switch the open Bypass tray) is open are not available. Per-
System Administrator stopped machine on GP 14. (without Tray 5 installed) form the 01-505-00
Printing and scanning Middle Left Door
can continue Open RAP.
Load SRA3 (320 x 450 94-601-00 SRA3 paper needed to clean Load the required Middle left side door is 01-505-01 The IME middle left door (below Copying and printing
mm) Paper in any tray drum media. Refer to GP open Bypass tray) is open are not available. Per-
to enable Auto-Drum 20. Copying and print- (with Tray 5 installed) form the 01-505-00
cleaning. ing are not available Middle Left Door
Load 8.5 x 11" Paper in 94-600-00 Letter / A4 chase media Load the required Open RAP.
any tray to enable Auto- needed to clean drum media. Refer to GP Misfeed in Tray 1 71-102-00 Misfeed in Tray 1 Clear the media jam.
Drum cleaning. 20. Copying and print- Copying and printing
ing are not available are not available
Load A4 paper into any 94-604-00 A4 Chase Media Needed to Load any tray with Refer to 71-101-00,
tray to enable auto- Clean Drum paper of the following 71-106-00 RAP
cleaning to proceed. size to continue clean- Misfeed in tray 2 72-102-00 Misfeed in tray 2 Clear the media jam.
ing: A4. Refer to GP Copying and printing
20. are not available.
Machine is in a non cus- 22-504-16 Non customer mode. Auto con- Enter customer mode Refer to 72-101-00,
tomer mode. figuration is disabled. Wait for Enter dC131 Read/ 72-106-00, 72-110-00
machine to exit Diagnostics Write and check that RAP
mode. The machine is unavail- NVM ID 425-001 = 0, Misfeed in tray 3 73-102-00 Misfeed in tray 3 Clear the media jam.
able 425-003 = 0 and 616- Copying and printing
14 = 4 are not available.
Magenta Ink is empty. 93-505-00 IME magenta ink is empty Load more magenta Refer to 73-101-00,
Load Xerox ColorQube solid ink. Copying and 73-106-00, 73-110-00
Magenta Ink. printing are not avail- RAP
able. Check the ink Misfeed in Tray 4 74-102-00 Misfeed in tray 4 Clear the media jam.
low sensor and har- (Bypass). Copying and printing
ness. Refer to WD are not available.
9.18. Refer to 74-101-00
Magenta ink stick jam. 93-926-00 Magenta Ink Stick jam Magenta ink stick jam RAP
Add magenta ink to aid detected. Misfeed in tray 5 75-102-00 Misfeed in tray 5 Clear the media jam.
jam recovery. Load a Magenta Ink Copying and printing
stick to aid jam recov- are not available.
ery. Refer to 75-101-00
Switch the machine RAP
off, then switch the Misfeed in Tray 5. 75-102-01 Misfeed in Tray 5: A3 Remove the misfed
machine on, GP 14. sheet. Refer to 75-
101-00 RAP
Network Cable 16-544-00 Ethernet cable is unplugged Ensure cables are
unplugged properly connected

Status Status
Network connectivity 16-590-00 The network controller CCS Switch the machine Network scanning hard- 16-554-00 Network controller - Hardware Hardware must be
configuration server not process has failed off, then switch the ware must be added or must be added or replaced added or replaced.
available. Notify the machine on GP 14. replaced. Notify the
System Administrator Printing and scanning System Administrator
can continue Network services involv- 16-565-00 Network controller - the Post- Switch the machine
Network controller com- 03-518-00 Network controller not avail- Switch the machine ing Apple Talk are not script connectivity process has off, then switch the
munication error able. off, then switch the available. Notify the failed machine on GP 14.
machine on GP 14. If System Administrator Printing can continue
the fault remains, rein- if other submission
stall software, GP 4. methods are used
Network controller con- 16-575-00 The network controller ESS Automatic network Network Services 16-589-00 The network controller serial Switch the machine
nection is about to be registration service process has controller reset involving a Serial Port port connectivity has failed off, then switch the
reset stopped are not available. Notify machine on GP 14.
Network controller con- 16-576-00 The network controller ESS Automatic network your System Adminis- Printing can continue
nection is about to be event notification service pro- controller reset trator.
reset cess has stopped Network services involv- 16-510-00 Scan to E-mail process failed Switch the machine
Network controller con- 16-577-00 The network controller ESS Automatic network ing Scan to E-mail are off, then switch the
nection is about to be platform manager service pro- controller reset. not available. Notify the machine on GP 14. If
reset cess has stopped Machine is unavail- System Administrator the problem persists
able check network con-
nections
Network controller con- 16-584-00 The network controller docu- Automatic network
nection is about to be ment manager agent process controller reset. Network Services 16-514-00 Post office protocol (POP3) (for Switch the machine
reset has stopped Machine is unavail- involving Scan to E-mail inbound IFAX messages) pro- off, then switch the
able are not available. cess failed machine on GP 14.
Please notify the Sys-
Network controller error. 16-536-00 The ESS XSA service is Switch the machine
tem Administrator
Some network services unavailable. Network controller off, then switch the
not available Please error machine on GP 14. Network Services 16-517-00 SMTP process failed Switch the machine
contact the system involving Scan to E-mail off, then switch the
administrator. are not available. machine on GP 14.
Please notify the Sys-
Network printing dis- 16-571-00 Network controller - print ser- Switch the machine
abled. Notify the System vice has failed off, then switch the tem Administrator
Administrator machine on GP 14. Network Services with 16-599-00 Raw TCP/IP printing (port Switch the machine
Printing cannot con- Port 9100 Process are 9100) process has failed. off, then switch the
tinue not available. Notify machine on GP 14.
Network printing dis- 16-572-00 Network controller - print ser- Switch the machine your System Adminis- Other printing and can
trator. continue
abled. Notify the System vice has failed off, then switch the
Administrator machine on GP 14. Network services 16-511-00 Internet fax process failed Switch the machine
Printing cannot con- related to Internet Fax off, then switch the
tinue are not available. machine on GP 14. If
Please notify the Sys- the problem persists
Network Printing dis- 16-573-00 Network controller - ESS print Switch the machine
tem Administrator check network con-
abled. Notify your Sys- service has failed off, then switch the
tem Administrator. machine on GP 14. nections
Printing cannot con-
tinue

Status Status
Network Services using 16-559-00 Network controller - BOOTP ini- Check the BOOTP Network Services with 16-529-00 The network controller’s Scan Some Network Ser-
BOOTP initialization not tialization failure Server and its network Scan Compressor are Compressor service process vice are not available.
available. Notify the connection. Switch not available. Please has stopped. The Network Control-
System Administrator the machine off, then notify the System ler connection is
switch the machine on Administrator about to be reset
GP 14. No message 03-563-00 Network service are being Please wait, the Net-
Network Services using 16-557-00 Network controller - DC plat- Switch the machine established, print jobs maybe work Controller is ini-
DC Platform recovery form failed off, then switch the delayed tializing. No user
not available. Notify the machine on GP 14. intervention is
System Administrator required. Printing is
Network Services using 16-558-00 Network controller - DC com- Switch the machine currently unavailable
DC Platform recovery munications failed off, then switch the Refer to 03-331-00,
not available. Notify the machine on GP 14. 03-332-00 RAP
System Administrator No tray is configured 22-504-04 No paper tray is configured to Job must be deleted.
Network Services using 16-518-00 Web Services Edge Client Switch the machine with the required paper run the stock size required for Paper tray must be
WS Edge Client are not interface does not work off, then switch the size. this job. configured to run the
available. Please notify machine on GP 14. If stock size.
the System Administra- the problem persists Notify your System 03-597-00 The Document Feeder is not Perform 05-250-00,
tor check network con- Administrator or call for available. Use the Document 05-251-00 RAP
nections assistance. Glass.
Network Services using 16-519-00 Web Services Client controller Switch the machine Notify your System 05-538-00 DADH not available. A document feeder
WS Edge Client are not does not work off, then switch the Administrator or call for fault has occurred,
available. Please notify machine on GP 14. If assistance. copy jobs can only be
the System Administra- the problem persists made from the docu-
tor check network con- ment glass. Printing
nections can continue.
Network Services using 16-520-00 Web Services Server controller Switch the machine Notify your System 05-542-00 DADH document transport Perform 05A RAP
WS Edge Client are not interface does not work. off, then switch the Administrator or call for needs service
available. Please notify machine on GP 14. If assistance.
the System Administra- the problem persists
tor check network con-
nections
Network Services using 16-528-00 The network controller’s WS Some Network Ser- Table 3 Status messages O to R
WS Scan Temp are not Scan Temp service process vice are not available.
Status
available. Please notify has stopped. The Network Control- UI Message Code Reason for Message Reference / Action
the System Administra- ler connection is
tor about to be reset Offsetting is not avail- 12-701-00 OCT offset failure occurred Perform 12-701-00-65
able at the Output Tray. RAP
Network services with 16-501-00 Job Based Accounting not Not enough CCM
Job Based Accounting enough DC memory. Some memory to run the Only a partial list is 16-574-00 ESS queue utility has failed Switch the machine
not available. Please Network Controller services are Network Accounting available for display off, then switch the
notify the machine not available feature machine on GP 14.
administrator Original size not 22-504-05 Invalid Mixed Size Original Pair Make sure the origi-
detected detected. It will be treated as nals are not creased
the next largest standard size. or folded
Perform 05-257-00
RAP

Table 3 Status messages O to R Table 3 Status messages O to R
Status Status
Paper jam in area 1A 82-100-00 IME jam at zone 1A (middle Open middle left door, Paper Jam in Areas 4a 01-103-00 IME jam at zone 4a (exit) and Clear the paper jam in
vertical) clear the paper jam. and 4b. 4b (horizontal), open front door. area 4a and 4b. Print
(Tray 5 not installed) Refer to 82-110-00 to and copy services are
82-114-00, 82-152-00, disabled.
82-157-00 to 82-159- Refer to 10-110-00 to
00, 82-164-00 to 82- 10-113-00, 10-125-00
166-00 RAP. Copying to 10-128-00, 10-147-
and printing are not 00, 10-148-00 RAP,
available 10-140-00 to 10-146-
Paper jam in area 1A 82-100-01 IME jam at zone 1A (middle Open middle left door, 00, 10-149-00 to 10-
vertical) clear the paper jam. 151-00 RAP, 83-110-
(Tray 5 installed) Refer to 82-110-00 to 00, 83-111-00, 83-
82-114-00, 82-152-00, 113-00, 83-114-00,
82-157-00 to 82-159- 83-118-00 RAP
00, 82-164-00 to 82- Paper Jam in Area 3a 01-108-00 IME jam at zone 3a (registra- Clear the paper jam in
166-00 RAP. Copying tion / preheat), open front door. area 3a. Print and
and printing are not copy services are dis-
available abled.
Paper jam in Area 1a. 82-100-02 Jam at Zone 1A (Middle Verti- Slide Tray 5 away Refer to 89-110-00 to
cal) from the machine, 89-113-00, 89-129-00
clear the paper jam. RAP, 89-125-00 to 89-
Refer to 82-110-00 to 128-00, 89-130-00
82-114-00, 82-152-00, RAP
82-157-00 to 82-159- Paper Jam in Areas 3a 01-112-00 IME jam at zone 3a (registra- Clear the paper jam in
00, 82-164-00 to 82- and 3b. tion) and 3b (post transfix), area 3a and 3b. Print
166-00 RAP open front door. and copy services are
Paper jam in area 2 82-101-00 IME jam at zone 2 (upper verti- Open upper left door, disabled.
cal) clear the paper jam. Refer to 10-110-00 to
Refer to 82-125-00 to 10-113-00, 10-125-00
82-133-00, 82-153- to 10-128-00, 10-147-
00, 82-155-00, 82- 00, 10-148-00 RAP,
160-00, 82-162-00, 10-140-00 to 10-146-
82-163-00 RAP, 82- 00, 10-149-00 to 10-
132-00, 82-155-00 151-00 RAP, 83-110-
RAP, 82-133-00 RAP, 00, 83-111-00, 83-
82-134-00 RAP. 113-00, 83-114-00,
Copying and printing 83-118-00 RAP
are not available

Status Status
Paper Jam in Areas 3a, 01-114-00 IME jam at zone 3a (registra- Clear the paper jam in Paper Jam in Area 3a 01-110-00 IME jam at zone 3a (registra- Clear the paper jam in
3b and 4a. tion), 3b (post transfix) and 4a area 3a, 3b and 4a. and 4a. tion) and 4a (exit), open front area 3a and 4a. Print
(exit), open front door. Print and copy ser- door. and copy services are
vices are disabled. disabled.
Refer to 10-110-00 to Refer to 89-110-00 to
10-113-00, 10-125-00 89-113-00, 89-129-00
to 10-128-00, 10-147- RAP, 89-125-00 to 89-
00, 10-148-00 RAP, 128-00, 89-130-00
10-140-00 to 10-146- RAP
00, 10-149-00 to 10- Paper Jam in Areas 3a, 01-111-00 IME jam at zone 3a (registra- Clear the paper jam in
151-00 RAP, 83-110- 4a and 4b. tion), 4a (exit) and 4b (horizon- area 3a, 4a and 4b.
00, 83-111-00, 83- tal), open front door. Print and copy ser-
113-00, 83-114-00, vices are disabled.
83-118-00 RAP Refer to 10-110-00 to
Paper Jam in Areas 3a, 01-113-00 IME jam at zone 3a (registra- Clear the paper jam in 10-113-00, 10-125-00
3b and 4b. tion), 3b (post transfix) and 4b area 3a, 3b and 4b. to 10-128-00, 10-147-
(horizontal), open front door. Print and copy ser- 00, 10-148-00 RAP,
vices are disabled. 10-140-00 to 10-146-
Refer to 10-110-00 to 00, 10-149-00 to 10-
10-113-00, 10-125-00 151-00 RAP, 83-110-
to 10-128-00, 10-147- 00, 83-111-00, 83-
00, 10-148-00 RAP, 113-00, 83-114-00,
10-140-00 to 10-146- 83-118-00 RAP
00, 10-149-00 to 10- Paper Jam in Areas 3a 01-109-00 IME jam at zone 3a (registra- Clear the paper jam in
151-00 RAP, 83-110- and 4b. tion) and 4b (horizontal), open area 3a and 4b. Print
00, 83-111-00, 83- front door. and copy services are
113-00, 83-114-00, disabled.
83-118-00 RAP Refer to 10-110-00 to
Paper Jam in Areas 3a, 01-115-00 IME jam at zone 3a (registra- Clear the paper jam in 10-113-00, 10-125-00
3b, 4a and 4b. tion), 3b (post transfix), 4a area 3a, 3b, 4a and to 10-128-00, 10-147-
(exit) and 4b (horizontal), open 4b. Print and copy 00, 10-148-00 RAP,
front door. services are disabled. 10-140-00 to 10-146-
Refer to 10-110-00 to 00, 10-149-00 to 10-
10-113-00, 10-125-00 151-00 RAP, 83-110-
to 10-128-00, 10-147- 00, 83-111-00, 83-
00, 10-148-00 RAP, 113-00, 83-114-00,
10-140-00 to 10-146- 83-118-00 RAP
00, 10-149-00 to 10- Paper Jam in Area 3b. 01-104-00 IME jam at zone 3b (post trans- Clear the paper jam in
151-00 RAP, 83-110- fix), open front door. area 3b. Print and
00, 83-111-00, 83- copy services are dis-
113-00, 83-114-00, abled.
83-118-00 RAP

Status Status
Paper Jam in Areas 3b 01-106-00 IME jam at zone 3b (post trans- Clear the paper jam in Paper Jam in Area 4b. 01-101-00 IME jam at zone 4b (horizon- Clear the paper jam in
and 4a. fix) and 4a (exit), open front area 3b and 4a. Print tal), open front door. area 4b. Print and
door. and copy services are copy services are dis-
disabled. abled.
Refer to 10-110-00 to Refer to 82-145-00,
10-113-00, 10-125-00 82-146-00, 82-150-
to 10-128-00, 10-147- 00, 82-151-00, 82-
00, 10-148-00 RAP, 156-00 RAP,
10-140-00 to 10-146- 82-145-00, 82-146-
00, 10-149-00 to 10- 00, 82-150-00, 82-
151-00 RAP, 83-110- 151-00, 82-156-00
00, 83-111-00, 83- RAP, 82-149-00 RAP
113-00, 83-114-00, Paper jam in the Docu- 05-520-00 Post feed and takeaway roll Remove the sheet.
83-118-00 RAP ment Feeder jam Perform 05-330-00,
Paper Jam in Areas 3b, 01-107-00 IME jam at zone 3b (post trans- Clear the paper jam in 05-331-00 Feed Sen-
4a and 4b. fix), 4a (exit) and 4b (horizon- area 3b, 4a and 4b. sor Failure RAP
tal), open front door. Print and copy ser- Paper jam in the Docu- 05-522-00 Sheet left over DADH CVT sen- Remove sheet. Per-
vices are disabled. ment Feeder sor after jam. form 05-350-00, 05-
Refer to 10-110-00 to DADH post feed sensor or TAR 352-00 RAP
10-113-00, 10-125-00 sensor
to 10-128-00, 10-147- Paper jam in the Docu- 05-526-00 DADH - sheet left over DADH Reset when DADH
00, 10-148-00 RAP,
ment Feeder document present sensor after top cover closed after
10-140-00 to 10-146-
jam. 05-330 fault is raised jam cleared. Perform
00, 10-149-00 to 10- 05-330-00, 05-331-00
151-00 RAP, 83-110-
RAP
00, 83-111-00, 83-
Paper jam in the docu- 05-570-00 DADH jam. Remove, then re-load
113-00, 83-114-00,
83-118-00 RAP ment feeder. all document in the
DADH.
Paper Jam in Area 3b 01-105-00 IME jam at zone 3b (post trans- Clear the paper jam in
Paper Jam in the Fin- 12-732-00 Sheet detected near the PPI Clear the sheet. If
and 4b. fix) and 4b (horizontal), open area 3b and 4b. Print
isher. pickup sensor necessary, perform
front door. and copy services are
disabled. 12-191-00-171, 12-
193-00-171, 12-194-
Paper Jam in Area 4a. 01-102-00 IME jam at zone 4a (exit), open Clear the paper jam in
00-171, 12-196-00-
front door. area 4a. Print and
171 RAP
copy services are dis-
abled. Paper Jam in the Fin- 12-733-00 Sheet detected near the PPI Check the paper. If
isher. tab standby sensor necessary, perform
Refer to 10-110-00 to
12-191-00-171, 12-
10-113-00, 10-125-00
to 10-128-00, 10-147- 193-00-171, 12-194-
00-171, 12-196-00-
00, 10-148-00 RAP,
171 RAP
10-140-00 to 10-146-
00, 10-149-00 to 10- Paper jam in the Fin- 12-627-01 Page over exit HVF into BM Open the Finisher
151-00 RAP, 83-110- isher. Sensor (Sensor in Area 6a) Front Door.
00, 83-111-00, 83- Cleared via area 6a
113-00, 83-114-00, Paper jam in the Fin- 12-627-02 Page over exit HVF into BM Open the Finisher
83-118-00 RAP isher. Sensor (Sensor in Area 6a) Front Door.
Cleared via area 6a

Status Status
Paper jam in the Fin- 12-735-00 Sheet detected near the buffer Clear the sheet. If Paper Jam in the Fin- 12-618-00 Paper is detected over the top Clear the paper jam.
isher sensor necessary, perform isher tray exit sensor at power-up, Perform 12-171-00-
12-157-00-171, 12- interlock status change or after 110, 12-172-00-110
158-00-171 RAP and shutdown. (LCSS) RAP
12-141-00-171, 12- Paper Jam in the Fin- 12-618-01 Paper is detected over the top Clear the paper jam.
142-00-171 RAP isher tray exit sensor at power-up, Perform 12-125-00-
Paper jam in the Fin- 12-736-01 Sheet detected near Exit HVF Clear the sheet. If interlock status change or after 171, 12-126-00-171
isher to BM entry sensor. necessary, perform shutdown. (HVF) RAP
(without tri-folder) 12-113-00-171, 12- Paper Jam in the Fin- 12-619-00 Paper jam near the output to Clear the paper jam.
114-00-171, 12-190- isher the top tray. (LCSS) Perform 12-171-00-
00-171, 12-192-00- 110, 12-172-00-110
171 RAP RAP
Paper jam in the Fin- 12-736-02 Sheet detected near Exit HVF Clear the sheet. If Paper Jam in the Fin- 12-619-01 Paper jam near the output to Clear the paper jam.
isher to BM entry sensor. necessary, perform isher the top tray. (HVF) Perform 12-171-00-
(with tri-folder) 12-113-00-171, 12- 171, 12-172-00-171
114-00-171, 12-190- RAP
00-171, 12-192-00-
Paper Jam in the Fin- 12-620-00 Paper is detected over the Clear the paper jam.
171 RAP
isher stacker exit sensor at power- Perform 12-151-00-
Paper jam in the Fin- 12-752-00 Page over Buffer Path Sensor Clear the area or per- up, interlock status change or 110, 12-152-00-110
isher form 12-198-00-171, after shutdown. (LCSS) RAP
12-199-00-171 RAP
Paper Jam in the Fin- 12-620-01 Paper jam near the output to Clear the paper jam.
Paper jam in the Fin- 12-753-00 Page near Buffer Path Sensor Clear the area or per- isher the stacker tray. Sheet over 2nd Perform 12-151-171,
isher form 12-198-00-171, top exit sensor 12-152-171 RAP
12-199-00-171 RAP Paper Jam in the Fin- 12-621-00 If Entry sensor made to the Clear the paper jam.
Paper Jam in the Fin- 12-610-00 Paper is detected over the Clear the paper jam. isher Stacker Bin Exit sensor made Perform 12-171-00-
isher entry sensor (LCSS) Perform 12-199-00- exceeds 1600 ms (A4 LEF 1st 110, 12-172-00-110
110 RAP page/A3 SEF all pages) or RAP
Paper Jam in the Fin- 12-610-01 Paper is detected over the Clear the paper jam. 1100 ms (A4 LEF mid set page)
isher entry sensor (HVF) Perform 12-125-00- or 900 ms (A4 LEF last page of
171, 12-126-00-171 set). (LCSS)
RAP Paper Jam in the Fin- 12-621-01 Paper jam near the output to Clear the paper jam.
Paper Jam in the Fin- 12-611-00 After receiving the Paper at IOT Clear the paper jam. isher the stacker tray. Sheet over 2nd Perform 12-151-171,
isher Exit sensor Command the Perform 12-199-00- top exit sensor 12-152-171 RAP
Entry sensor is not made within 110 RAP Paper Jam in the Fin- 12-624-00 Sheet over the inserter pickup Clear the area or per-
1000 ms. (LCSS). Paper jam isher sensor form 12-479-00-171
near the entry to the finisher RAP
unit.
Paper Jam in the Fin- 12-625-00 Sheet over the inserter tab Clear the area or per-
Paper Jam in the Fin- 12-611-01 Paper jam near the entry to the Clear the paper jam. isher standby sensor form 12-191-00-171,
isher finisher unit (HVF without tri- Perform 12-125-00- 12-193-00-171, 12-
folder) 171, 12-126-00-171 194-00-171, 12-196-
RAP 00-171 RAP
Paper Jam in the Fin- 12-612-00 Paper is detected over the hole Clear the paper jam. Paper Jam in the Fin- 12-626-00 Sheet over the buffer position Clear the area or per-
isher punch position sensor at Perform 12-043-00- isher sensor form 12-198-00-171,
power-up, interlock status 110, 12-046-00-110 12-199-00-171 RAP
change or after shutdown. RAP
(LCSS)

Status Status
Paper Jam in the Fin- 12-627-00 Sheet over the HVF exit into Clear the area or per- Paper Jam in Finisher 12-718-00 Sheet over tri- folder assist Clear the paper jam.
isher BM sensor form 12-198-00-171, Folder Unit. sensor Perform 12-185-00-
12-199-00-171 RAP 171 to 12-187-00-171
Paper Jam in the Fin- 12-628-00 Sheet over the stacker bin exit Clear the area or per- RAP
isher sensor form 12-151-171, 12- Paper Jam in Finisher 12-719-00 Sheet over tri- folder exit sen- Clear the paper jam.
152-171 Folder Unit. sor Perform 12-185-00-
Paper Jam in the Fin- 12-629-00 Sheet over the tri-folder entry Clear the area or per- 171 to 12-187-00-171
isher sensor form 12-183-00-171, RAP
12-184-00-171 RAP Paper removed or 01-540-01 Check the settings for tray 1. Confirm tray 1 set-
Paper Jam in the Fin- 12-630-01 Sheet over the booklet maker Clear the area or per- added to tray 1 tings.
isher entry sensor (without tri-folder) form 12-183-00-171, Paper removed or 01-540-02 Check the settings for tray 2. Confirm tray 2 set-
12-184-00-171 RAP added to tray 2 tings.
Paper Jam in the Fin- 12-630-02 Sheet over the booklet maker Clear the area or per- Paper removed or 01-540-03 Check the settings for tray 3. Confirm tray 3 set-
isher entry sensor (with tri-folder) form 12-183-00-171, added to tray 3 tings.
12-184-00-171 RAP Paper removed or 01-540-04 Check the settings for the Confirm tray 4 set-
Paper Jam in the Fin- 12-636-01 Sheet over the booklet maker Open and close the added to tray 4 bypass tray. tings.
isher exit sensor. (without tri-folder) finisher front door, Paper removed or 01-540-05 Check the settings for tray 5. Confirm tray 5 set-
clear the area or per- added to tray 5 tings.
form 12-181-00-171, Paper removed or 01-540-06 Check the settings for tray 6. Confirm tray 6 set-
12-182-00-171 RAP
added to tray 6 tings.
Paper Jam in the Fin- 12-636-02 Sheet over the booklet maker Open and close the
Paper required for cur- 22-511-04 Paper required for current job is Load paper to com-
isher exit sensor. (with tri-folder) finisher front door,
rent job is not available not loaded plete the held job or
clear the area or per- cancel job
form 12-181-00-171,
Paper Transport is 73-305-00 Feeder HT drawer is open Copying and printing
12-182-00-171 RAP
open. are not available
Paper jam in the Fin- 12-746-00 Sheet detected near the tri-fold Clear the sheet. If
Paper tray communica- 92-531-00 3TM Communications prob- -
isher. entry sensor necessary, perform
12-183-00-171, 12- tion fault. Please call for lems (TtmSerialLinkSafety)
assistance.
184-00-171 RAP
Paper Tray communica- 92-530-00 IME comms problem with paper Switch the machine
tion fault. Please call for tray. Paper trays 1 to 3 not off, then switch the
isher. exit sensor necessary, perform
12-185-00-171 to 12- assistance. available. machine on GP 14.
Check connection on
187-00-171
3trays module. If
problem persists, per-
isher. assist sensor necessary, perform form the 70-312-00
12-185-00-171 to 12-
Tray 1 to Tray 3 Com-
187-00-171 RAP
munication Failure
Paper Jam in the Fin- 12-717-01 Sheet over HVF BM compiler Clear the HFV BM RAP. Copying and
isher. paper present sensor (without paper present sensor printing are not avail-
tri-folder) area. Perform 12-166- able.
00-171 RAP
Please wait... Auto- 91-659-00 Auto Maintenance routines in No service action
Paper Jam in the Fin- 12-717-02 Sheet over HVF BM compiler Clear the HFV BM mated Print Engine progress required.
isher. paper present sensor (with tri- paper present sensor Maintenance in
folder) area. Perform 12-166- progress.
00-171 RAP

Status Status
Please Wait… Disk 17-580-00 Disk Encryption is in progress - Print Engine in Non- 92-578-00 IME in non-thermal mode. Print Enter diagnostics
encryption operation in thermal Mode. engine is operating in non-ther- dC335 and select a
progress. mal manufacturing mode. Print heater routine. Run
Please wait… Print 88-511-00 Media is exhausted during the Please wait, cooling in and copy service disabled. the routine and then
Engine cooling in cooling phase of Clean for Ink progress... exit diagnostics. The
progress. Smears. machine warms up.
Enter dC131 Read/
Please wait... Print 91-654-00 Head Purge in Progress No service action
Engine Maintenance - required. Write and check that
NVM ID 425-003 = 0
Head Purge in
Progress. Print Engine Mainte- 91-564-00 Head Purge in Progress No service action
nance - Head Purge in required.
Please wait... Print 91-668-00 IME Print Quality Maintenance No service action
Quality Maintenance in in Progress required. Progress….Please
Wait.
progress.
Provide payment or the 03-559-00 Generic FDI. Unable to com- Your Job cannot be
Please wait… The 03-556-00 Power on while the IIT is being -
current job may be plete the current job. completed due to
scanner is initializing. initialized
deleted. insufficient funds.
Please wait.... the sys- 19-510-00 Please wait.... the system is Please wait.... the
tem is attempting to attempting to recover. system is attempting
Please complete all
recover. to recover.
steps required by the
Please wait...... The 19-513-00 The image disk is full The printer has external accounting
image disk is full. detected either an device to continue
image disk read / write your job.
problem or has
Provide payment or the 03-559-05 Walk Up FDI. Unable to com- Your Job cannot be
received bad data current job may be plete the current job - FDI Inac- completed due to
from the image disk.
deleted. tivity Timer Enabled insufficient funds.
Printing has stopped.
Please wait, freeing 19-502-00 Out of memory resources. The Current job has been Please insert card into
memory machine has run out of image terminated and moved the external account-
processing memory for the cur- to the job log. ing device to continue
rent job. your job.
Please wait... the sys- 03-561-00 The system is recovering Wait until the system
tem is attempting to recovers To immediately delete
recover this job, select the
Please wait... Warming 92-582-00 IME Cold Boot in progress - Close button, then the
up from extremely low Job Status button
ambient temperature. located on the control
panel and then your
Please wait... Pre- 88-510-00 IME preheater cleaning Please wait until
heater cleaning in cleaning is completed. job.If no action is
taken, the job will be
progress. Printing is temporarily
deleted in the follow-
unavailable
ing number of min-
utes:

Status Status
Provide payment or the 03-559-06 Walk Up Coin Entered FDI. Not Your Job cannot be Provide payment. 03-559-03 Walk Up Coin Entered FDI. Not Your Job cannot be
current job may be Defined - FDI Inactivity Timer completed due to Defined completed due to
deleted. Disabled insufficient funds. insufficient funds.
Please insert money
Please insert money into the external
into the external accounting device to
accounting device to continue your job.
continue your job. To cancel this job,
press the hard-panel
To immediately delete Job Status button,
this job, select the select the job and
Close button, then the then the Delete but-
Job Status button ton.
located on the control Provide payment or the 03-559-04 Walk Up Key Entered FDI. Not Your Job cannot be
panel and then your current job may be Defined completed due to
job. deleted. insufficient funds.
If no action is taken, Please insert Key

the job will be deleted Counter into the exter-
in the following num- nal accounting device
ber of minutes: to continue your job.
Provide payment. 03-559-01 Walk Up FDI. Unable to com- Your Job cannot be Registration in progress 89-560-00 IME registration calibration Please wait. Printing
plete the current job. completed due to will be delayed
insufficient funds. Reload originals or 05-546-00 On pre-feed the DADH fails to Reload originals or
select original size and recognize the size of the docu- select size. Perform
Please insert card into
press Start ment 05-257-00 RAP
the external account-
ing device to continue Reload sheets in Docu- 05-527-00 Document in the DADH at Remove the sheets
ment Feeder. power on or exit from power from the Original Input
your job.
save Tray.
To cancel this job, Remove documents 22-505-02 Documents Sensed in the To scan from the Doc-
press the hard-panel from the Document DADH Tray during IIT Standby ument Glass, remove
Job Status button, Feeder Input Tray or and Document Handler Cover documents in the Doc-
select the job and close the Document is open. ument Feeder Input
then the Delete but- Feeder. Tray.
ton. To use the Document
Feeder to scan your
documents, lower the
Document Feeder. If
the fault remains, per-
form the 05-300-00
DADH Open RAP and
the 05B DADH Docu-
ment Sensor Failure
RAP.

Table 3 Status messages O to R Table 4 Status messages S to Y
Status Status
Remove the document. 05-560-00 Document too short for DADH, Remove document Service limit exceeded. 16-533-00 Unknown Service limit
It is too short to be fed use document glass. Fault 05- from DADH during New services will not be exceeded. New ser-
by Document Feeder. 310 raised jam clearance, Per- available until some services will not be avail-
form 05-310-00 RAP vices are removed able until some
Reorder but do not 05-578-00 DADH roller feeds reaches Order new DADH services are removed
replace Document Han- near end of life. Do not replace feed roll assembly, PL Some jobs may have 03-562-00 - Removed upon user
dler Feed Roller until prompted. 5.15 Item 1. been deleted intervention
Replace the Document 05-579-00 DADH roller feeds reaches end Install new DADH Some jobs may have 19-505-00 Compressor DVMA time-out. Confirm that UI mes-
Feed Roller. of life feed roll assembly, PL been deleted. Current job has been deleted sage has been seen.
5.15 Item 1. Rescan the job.
Some Network Services 16-560-00 Some processes on the net- Switch the machine
are not available due to work controller have failed off, then switch the
a process error. Notify machine on GP 14.
Table 4 Status messages S to Y your System Administra-
tor.
Status
UI Message Code Reason for Message Reference / Action Some Network Account- 16-596-00 ACCOUNTING_DEATH_STAT Network Accounting
ing Services are not US. error. User interven-
Scanner Fault. Call for 14-517-00 Scanner fault. Switch the machine
available. Notify your tion is required to
assistance. off, then switch the System Administrator. Power Off/On the
machine on GP 14.
machine. Print and
Scan to Distribution Ser- 16-525-00 The network controller’s Scan Some Network Ser- other machine ser-
vices are not available. to Distribution service process vice are not available. vices are unaffected.
Please notify the System has stopped The Network Control- Some network authenti- 16-582-00 The network controller ESS Switch the machine
Administrator ler connection is
cation services unavail- authentication SPI process has off, then switch the
about to be reset
able. Notify the System stopped machine on GP 14.
Scan to File Services are 16-561-00 Network controller - Scan to Switch the machine Administrator Printing cannot con-
not available. Notify the File processes have failed off, then switch the tinue
System Administrator machine on GP 14.
Some Network Control- 16-521-00 The network controller’s CPI Some Network Ser-
Scanning will be delayed 22-508-04 Scan start up delayed whilst No user intervention is ler services involving service process has stopped vice are not available.
awaiting resources required. Job will CPI are not available. The Network Control-
begin when system is Please notify the System ler connection is
ready. Administrator about to be reset
Select Confirm if the 05-585-00 When Status 05-579 is active Select Confirm if the Some network diagnos- 16-581-00 The network controller ESS Switch the machine
Document Feeder - and the DADH Top cover is Document Feeder - tic services unavailable. diagnostic service process has off, then switch the
Feed Roller was opened (status 05-502) Feed Roller was Notify the System stopped machine on GP 14.
replaced. replaced. Administrator Printing and scanning
Software error 02-520-00 Software error has occurred. Switch the machine can continue
off, then switch the Some network services 16-504-00 DDNS error. Some network The DDNS address
machine on GP 14. involving DDNS are not controller services are not resolution process
Some Lan Fax Services 16-595-00 The network controller Lan-Fax Switch the machine available. Notify your available has failed. Switch the
are not available. Notify service has failed off, then switch the System Administrator machine off, then
your System Administra- machine on GP 14. switch the machine on
tor. GP 14. If the problem
persists check the
DDNS server’s net-
work connections

Table 4 Status messages S to Y Table 4 Status messages S to Y
Status Status
Some Network Services 16-593-00 Network controller - DHCP Check DHCP server Some network services 16-563-00 Network controller - the Novell Switch the machine
involving DHCP are not address resolution has failed network connection. involving Novell are not Netware connectivity process off, then switch the
available. Notify your Switch the machine available. Notify the Sys- has failed machine on GP 14.
System Administrator. off, then switch the tem Administrator Printing can continue
machine on GP 14. if other submission
Other network print- methods are used
ing can continue Some network services 16-569-00 Network controller - Parallel Switch the machine
Some Network Services 16-591-00 Network controller Ethernet Check Ethernet con- involving Parallel Port Ports are not available off, then switch the
involving Ethernet are process has failed nection. Switch the are not available. Notify machine on GP 14.
not available. Notify your machine off, then the System Administra-
System Administrator. switch the machine on tor
GP 14. Local printing Some network services 16-568-00 Network controller - a PCL Switch the machine
can continue involving PCL are not interpreter error has occurred, off, then switch the
Some network services 16-570-00 Network controller - an HTTP Switch the machine available. Notify the Sys- causing the process to fail machine on GP 14, to
involving HTTP are not interpreter error has occurred, off, then switch the tem Administrator enable PCL printing.
available. Notify the Sys- causing the process to fail machine on GP 14. Printing can continue
tem Administrator Printing can continue if other job format
if other submission methods are used
methods are used Some Network Services 16-594-00 Network controller - RARP Check RARP server
Some network services 16-509-00 Insufficient memory for internet Switch the machine involving RARP are not address resolution has failed network connection.
involving Internet Fax fax off, then switch the available. Notify your Switch the machine
are not available. Notify machine on GP 14. System Administrator. off, then switch the
the System Administra- Printing can continue machine on GP 14.
tor if other network proto- Other network print-
cols are used ing can continue
Some Network Services 16-522-00 The network controller’s Job Some Network Ser- Some network services 16-567-00 Network controller - a Post- Switch the machine
involving Job Log are not Log service process has vice are not available. involving Postscript are script interpreter error has off, then switch the
available. Please notify stopped The Network Control- not available. Notify the occur, causing the process to machine on GP 14.
the System Administra- ler connection is System Administrator fail Printing can continue
tor about to be reset if other submission
Some network services 16-562-00 Network controller - the Line Switch the machine methods are used
involving LPD are not Printer Deamon (LPD) process off, then switch the Some network services 16-505-00 Insufficient memory for E-mail Switch the machine
available. Notify the Sys- has failed machine on GP 14. involving Scan to E-mail off, then switch the
tem Administrator Printing can continue are not available. Notify machine on GP 14. If
if other submission your System Administra- the problem persists
methods are used tor check the network
Some network services 16-564-00 Network controller - the Net- Switch the machine connections
involving NetBios are not BIOS connectivity process has off, then switch the Some network services 16-507-00 SLP process stopped. Some Switch the machine
available. Notify the Sys- failed machine on GP 14. involving SLP are not network controller services are off, then switch the
tem Administrator Printing can continue available. Notify your not be available machine on GP 14.
if other submission System Administrator
methods are used Some Network Services 16-526-00 The network controller’s SMB Some Network Ser-
involving SMB are not service process has stopped. vice are not available.
available. Please notify The Network Control-
the System Administra- ler connection is
tor about to be reset

Status Status
Some network services 16-513-00 Simple service discovery proto- Switch the machine Staple Cartridge sup- 12-716-00 LCSS and HVF staples low The finisher's main
involving SSDP are not col (SSDP) failed off, then switch the plies are low. staple cartridge sup-
available. Please notify machine on GP 14. plies are low. Re-
the System Administra- order staple cartridge.
tor Printing can continue.
Some Network Services 16-527-00 The network controller’s TCP/ Some Network Ser- LCSS PL 12.55 Item
involving TCP/IP are not IP service process has vice are not available. 7, HVF PL 12.110
available. Please notify stopped. The Network Control- Item 31. HVFBM PL
the System Administra- ler connection is 12.185 Item 8.
tor about to be reset Stapling not available. 12-921-00 The stapler position sensor Close the BM stapler
Some Network Services 16-598-00 Network controller - TCP / IP Another IP address Call for assistance. indicates the stapler module is module. If necessary,
involving TCP/IP are not address is already in use on the needs to be used. not closed in initialisation perform 12-063-00-
available. Notify your network Switch the machine 171, 12-411-00-171
System Administrator. off, then switch the RAP for staple unit 1,
machine on GP 14. and 12-403-00-171,
12-413-00-171, 12-
Some Network Services 16-597-00 The network controller TIFF Switch the machine
414-00-171 RAP for
involving TIFF are not interpreter has failed off, then switch the
available. Notify your machine on GP 14. staple unit 2
System Administrator. Other network print- Stapling not available. 12-653-00 Stapling disabled, out of ser- Perform 12-371-00-
ing can continue Please call for assis- vice. (LCSS) 110, 12-372-00-110,
tance 12-378-00-110 RAP
Some Network Services 16-523-00 The network controller’s Job Some Network Ser-
with Job Tracker are not Tracker service process has vice are not available. Stapling not available. 12-721-00 Stapler not in position -
available. Please notify stopped The Network Control- Call for assistance.
the System Administra- ler connection is System fault. Call for 03-505-00 A system fault has occurred Perform 03-325-00
tor about to be reset assistance RAP and 03-355-00
Some Network Services 16-524-00 The network controller’s Ker- Some Network Ser- RAP
with Kerberos are not beros service process has vice are not available. System fault. Call for 16-503-00 Incomplete system information Switch the machine
available. Please notify stopped The Network Control- assistance off, then switch the
the System Administra- ler connection is machine on GP 14.
tor about to be reset System fault. Call for 92-572-00 IME. An unrecoverable fault Xerox service
Staple Cartridge is 12-715-00 The finisher's main staple car- Install new staple car- assistance has occurred required. Copying and
empty. Replace now. tridge is empty. Follow the tridge, PL 12.55 Item printing are not avail-
instructions at the printer to 7. able
load a new staple cartridge. System fault. Notify your 03-565-00 System fault System fault. Notify
Non-staple printing can con- system administrator your system adminis-
tinue. (LCSS) trator
Staple Cartridge is 12-715-01 HVF staple cartridge empty Install a new staple System fault. Notify your 04-565-00 IME controller communication System fault. Switch
empty. Replace now. cartridge. Perform 12- system administrator failure the machine off, then
369-00-171 to 12-377- switch the machine on
00-171 RAP GP 14.
Load 12 x 18" Paper in 94-602-00 12”x18” chase media needed to Load the required
any tray to enable auto- clean drum media. Refer to GP
Drum cleaning. 20. Copying and print-
ing are not available

Status Status
The Booklet Maker Tray 12-728-00 Booklet maker output tray is full Empty the tray. If nec- The Booklet Tray in the 12-727-00 Booklet Maker Output Tray The Booklet Maker
in the Finisher is full. essary, perform 12C- Finisher is Nearly full Nearly Full output tray is nearly
Empty the Tray. 171 RAP full. Printing can con-
The machine is in power 01-550-00 Machine is in power saver - tinue, but this tray will
saver mode. mode. need emptying soon.
The machine is in sleep 01-551-00 Machine is in sleep mode. - The current job exceeds 12-411-00 Copy Job will exceed the out- Empty the tray
mode the tray capacity, you will put destinations capacity
be prompted to empty
The network controller is 16-502-00 Status active when ever the Cleared when the net-
about to be reset network controller detects that work controller reset the tray.
a platform reset is about to is initiated The document handler is 05-501-00 DADH is open. Close the DADH. If
occur raised the fault remains, per-
form the 05-300-00
The number of originals 22-503-05 Insufficient originals detected in Re-sort and reload all
was less than the num- the DADH. originals. DADH Open RAP.
ber originally scanned The document handler 05-502-00 DADH top cover open. Close the DADH top
top cover is open cover. If the fault
The output tray is almost 04-569-00 The OCT detects that it is 90% The Tray is almost full.
remains, perform the
full full Empty the tray when it
is full. Copy and print 05-258-00, 05-307-00
DADH Cover Inter-
services available.
lock Open RAP.
Scan service is avail-
able. The document size was 05-546-00 On pre-feed the DADH fails to Reload originals or
Booklet Stapler not avail- 12-720-00 Failure of any BM or TF func- Check for obstructions different than expected. recognize the size of the docu- select size. Perform
The job has been ment 05-257-00 RAP
able. Power off then on. tion. in the HVF BM and
deleted.
If problem persists, call The Booklet Maker and Tri- the tri-folder. Check
for service. folder are currently unavailable that the HVF BM and The document size was 22-507-05 Document larger than expected Try one of the follow-
tri-folder interlocks are different than expected. ing:
made. Switch the The job has been Select Mixed Size
machine OFF and deleted. Originals and reload
ON, GP 14. Check into the Document
the current fault codes Feeder
list for HVF BM or tri- OR
folder faults and per- Make sure the origi-
form the appropriate nals are not creased
RAP. or folded and retry
The Booklet Maker Tray 12-727-00 Booklet Maker Output Tray The Booklet Maker from the Document
Glass. Perform 05-
in the Finisher is nearly Nearly Full Tray is near full. User
257-00 RAP
full. intervention will be
required soon to The Extensible Interface 17-565-00 EIP service not responding Switch off, then switch
empty the tray to allow Platform (EIP) browser is on the machine, GP
continued booklet not responding. 14.
making. Print and
Copy services can
continue; other
unaffected.

Status Status
The Finisher is not avail- 12-762-00 Communication failure between Switch the machine Tray 1 is not available. 70-314-00 Trays 1 - 3 out of service Copying and printing
able. Notify your Admin- IME and Finisher off and on, GP 14. Notify the system admin- (comms failure) are not available. Per-
istrator. Check the finisher istrator form the 70-312-00
communication lead. Tray 1 to Tray 3 Com-
If the problem per- munication Failure
sists, perform 12-762- RAP.
00-110, 12-764-00- Tray 1 is not available. 71-313-00 Tray 1 mechanical failure Copying and printing
110, 12-765-00-110 Notify the system admin- are not available. Per-
RAP for LCSS. 12- istrator form the 71-215-00
762-00-171, 12-764- Tray 1 Elevate Up
00-171, 12-765-00- Failure RAP.
171 RAP for HVF.
Tray 1 is open 71-301-00 Tray 1 is open Close tray. Printing
The Finisher is not cor- 12-764-00 The IME cannot detect a fin- Switch the machine can continue from
rectly connected. Notify isher plugged in (including off and on, GP 14. other trays.
your Administrator. catch tray) Check the finisher Refer to WD 7.5.
communication lead.
Tray 1 is open 71-302-00 Tray 1 is open Close Tray. Printing
If the problem per-
can continue from
sists, perform 12-762- other trays.
00-110, 12-764-00-
Refer to WD 7.5.
110, 12-765-00-110
Tray 2 is a dedicated 01-545-02 Tray 2 is a dedicated paper Reload required paper
RAP for LCSS. 12-
762-00-171, 12-764- paper tray. and correctly adjust
the paper guides.
00-171, 12-765-00-
171 RAP for HVF. Tray 2 is empty. Add 72-530-00 Tray 2 is out of media Add media. Copying
The Hole Punch Waste 12-641-00 The chad bin has been Reinstall the chad bin.
Container is not removed from the finisher Perform 12-043-00- tinue from other trays.
Refer to 72A RAP
detected. Please re- 110, 12-046-00-110
insert. RAP Tray 2 is nearly empty. 72-535-00 Tray 2 media low Add media. Copying
The output tray is full 04-568-00 The OCT is full. Empty the OCT.
tinue from other trays
Top left side door is open 01-506-00 The IME upper left door Copying and printing
(Bypass tray) is open are not available. Per- Tray 2 is not available. 72-313-00 T2 out of service (mechanical Copying and printing
Notify the system admin- failure) are not available. Per-
form the 01-506-00
istrator form the 72-215-00
Upper Left Door Open
RAP. Tray 2 Elevate Up
Failure RAP.
Tray 1 is a dedicated 01-545-01 Tray 1 is a dedicated paper Reload required paper
Tray 2 is open 72-301-00 Tray 2 is open Close tray. Printing
paper tray. and correctly adjust
can continue from
the paper guides.
other trays.
Tray 1 is empty. Add 71-530-00 Tray 1 is out of media Add media. Copying Refer to 72-320-00
RAP and WD 7.5.
Tray 2 is open 72-302-00 Tray 2 is open Close Tray. Printing
Refer to 71A RAP and
WD 7.5. can continue from
other trays.
Tray 1 is nearly empty. 71-535-00 Tray 1 media low Add media. Copying
Refer to 72-320-00
RAP and WD 7.5.

Status Status
Tray 3 is empty. Add 73-530-00 Tray 3 is out of media Add media. Copying Tray 5 is not available. 75-313-00 Tray 5 mechanical failure Copying and printing
paper and printing can con- Notify the system admin- are not available. Per-
tinue from other trays. istrator form the following; 75-
Perform 73A RAP 212-00, 75-215-00
Tray 3 is nearly empty. 73-535-00 Tray 3 media low Add media. Copying Tray 5 Elevate Up
Add paper and printing can con- Failure RAP and 75-
tinue from other trays 213-00, 75-216-00
Tray 3 is not available. 73-313-00 T3 out of service (mechanical Copying and printing Tray 5 Elevate Down
Failure RAP.
Notify the system admin- failure) are not available.
istrator Refer to the following, Tray 5 is empty. Add 75-530-00 Tray 5 is out of media Add media. Copying
72-215-00 Tray 2 Ele- paper and printing can con-
vate Up Failure RAP tinue from other trays.
and 72-320-00 Tray 2 Perform 75B RAP.
Open in Run RAP. Tray 5 is nearly empty. 75-535-00 Tray 5 media low Add media. Copying
Tray 3 is open 73-301-00 Tray 3 is open Close Tray. Printing Add paper and printing can con-
can continue from tinue from other trays.
other trays. Perform Perform 75B RAP.
73-320-00 RAP. Tray 5 is open 75-301-00 Tray 5 is open Close Tray. Printing
Tray 3 is open 73-302-00 Tray 3 is open Close Tray. Printing can continue from
can continue from other trays. Refer to
other trays. Perform 75A RAP.
73-320-00 RAP. Tray 5 is overloaded 75-525-00 Tray 5 is overloaded Remove some media.
Tray 4 (Bypass) is not 74-313-00 Tray 4 mechanical failure Copying and printing remove some paper Copying and printing
available. Notify your are not available. can continue from
System Administrator. Refer to the following, other trays. Perform
74-101-00 Bypass 75-212-00, 75-215-00
Tray Mis-Feed RAP, RAP.
74-120-00 Bypass Tray 5 is unavailable. 92-536-00 Tray 5 communications prob- Perform 92-535-00,
Tray Guides Move in Please call for assis- lems (PfpSerialLinkSafety) 92-536-00 RAP.
Run RAP and 74-214- tance.
00 Bypass Tray Tray 5 is undocked 75-305-00 Tray 5 is undocked Printing can continue
Nudger Failure RAP. from other trays.
Refer to 75-325-00
Tray 5 is not available. 75-312-00 Tray 5 comms failure Check cabling con- RAP.
Notify your System nections. Copying and Tray 5 is undocked. 75-305-01 Tray 5 is undocked Slide Tray 5 up to
Administrator. printing are not avail- machine. Refer to 75-
able. Refer to 75-312- 325-00 RAP.
00 RAP. Tray 6 (Inserter) is 12-617-00 Tray 6 (Inserter) detects no Add paper to tray 6.
empty. Add paper paper present Perform 12J-171 RAP.

Status Status
Tray 6 (Inserter) is 12-744-00 Inserter Unavailable The Post Process Unexpected paper size 75-301-01 Media Size Mismatch in Tray 5 Lower Tray 5 using
unavailable. Check for Inserter is not avail- or type detected from (alternate method) the button indi-
obstructions. Power off able. Switch the Tray 5. cated.Check paper
then on. machine off and on, size, orientation and
GP 14. Check the cur- type.
rent fault code list for Unexpected paper size 12-750-00 A shorter than expected sheet Follow the message
inserter faults and go or type detected from the has been fed from the inserter text. Check the size of
to appropriate RAP. Tray 6 (Inserter) the paper in the
Tray 6 (Inserter) is 12-731-00 Post Process Inserter Tray (tray Load more paper. If inserter. Refer to 12J-
empty. Load more media 6) is empty. Jobs will be held if necessary, perform 171 RAP
for Insertion. inserts are required. 12J-171 RAP Unknown paper size or 78-103-00 Media Size Mismatch in Tray 6 Open Tray 6.
Tray 6 (Inserter) is 12-944-00 Inserter capability degraded Check for obstructions type detected on tray 6 Check paper size, ori-
unavailable. Check for in the inserter. If nec- (inverter). entation and type.
obstructions in the essary, perform 12- Waste Tray is full. 91-591-00 IME waste tray is full Empty the tray. Copy-
Inserter. 191-00-171, 12-193- Please empty the Waste ing and printing are
00-171, 12-194-00- Tray. not available. If nec-
171, 12-196-00-171 essary refer to WD
RAP and 12J-171 9.4.
RAP Waste Tray not detected 91-584-00 Waste Tray is not detected or Install a waste ink
Trays 1 to 3 are not 70-312-00 Comms failure for Trays 1-3 Perform 70-312-00 (Missing). Insert the missing. tray, PL 91.10 Item
available. Notify your RAP Waste Tray. 15. If necessary refer
System Administrator. to WD 9.4 and 91-
Unable to staple. Check 12-901-00 Finisher is in degraded mode, Switch the machine 832-00 RAP.
for obstructions in the unable to staple. off and on, GP 14. If Yellow Ink is empty. 93-515-00 IME yellow ink is empty Load more yellow
output trays. the problem persists, Load Xerox ColorQube solid ink. Copying and
perform the 12-369- Yellow Ink. printing are not avail-
00-171 to 12-377-00- able. Check the ink
171 RAP, then the low sensor and har-
12F-171 RAP. ness. Refer to WD
Unexpected paper size 71-103-00 Media Size Mismatch in Tray 1 Open Tray 1. 9.18.
or type detected from (alternate method) Check paper size, ori- Yellow ink stick jam. Add 93-928-00 Yellow Ink Stick jam Yellow ink stick jam
Tray 1. entation and type. yellow ink to aid jam detected.
Perform 71B RAP. recovery. Load a Yellow Ink
Unexpected paper size 72-103-00 Media Size Mismatch in Tray 2 Open Tray 2. stick to aid jam recov-
or type detected from (alternate method) Check paper size, ori- ery.
Tray 2. entation and type. Yellow ink stick is 93-516-00 Ink stick loaded sensor actu- Clear the ink loader
Unexpected paper size 73-103-00 Media Size Mismatch in Tray 3 Open Tray 3. jammed. Call for assis- ated. Ink stick transport motor jam. Copying and
or type detected from (alternate method) Check paper size, ori- tance operated. Ink stick not detected printing are not avail-
Tray 3. entation and type. by ink out sensor. able
Unexpected paper size 74-103-00 Media Size Mismatch in Tray 4 Open Tray 4. Your Administrator is 16-506-00 Your Administrator is reconfig- The system adminis-
or type detected from (alternate method) Check paper size, ori- reconfiguring the sys- uring the system trator is saving the
Tray 4 (Bypass). entation and type. tem. Services will not be Machine Configura-
Refer to WD 8.3. available tion to a remote sta-
Unexpected paper size 75-103-00 Media Size Mismatch in Tray 5 Open Tray 5.Check tion.
or type detected from (alternate method) paper size, orienta-
Tray 5. tion and type.

OF 5 Boot Up Failure RAP Procedure
Use this RAP if the UI displays ‘The machine is not available’ or ‘Copying and printing not Perform the following:
available’ or the machine does not come to a ‘Ready to scan your job’ state. Also, use this RAP 1. Disconnect the DADH communication / power cable (PJ188 / PJ851), PL 5.10 Item 6 from
if the software loading procedure fails. the image processing module.
2. If an LCSS or HVF is installed, disconnect the communication cable and the power cord.
Initial Actions Install a finisher bypass connector, PL 26.10 Item 3.
3. If a fax is installed, remove the embedded fax PWB, PL 20.05 Item 4.
WARNING
The machine boots up.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform the following:
• Go to the relevant procedure and check the UI:
– OF 2 UI Touch Screen Failure RAP (W/O TAG 006).
• Check the IME POST LED’s for a POST error code, OF 16.
– OF 18 UI Touch Screen Failure RAP (W/TAG 006).
• Pull out the image processing PWB module. Check that both heat sink assembly fans, PL
• For machines W/O TAG 006:
3.10 Item 10 and the chassis fan assembly, PL 3.10 Item 6 are running. Install new
assemblies as necessary. – Check the state of the LEDs on the copy controller PWB, Figure 2. Refer to
Table 1 and perform the relevant service actions.
• If the boot up failure occurs after new components are installed, make sure the new com-
ponents are compatible with the machine and all PJs correctly seated. Check that no pins – Check the state of the LEDs on the network controller PWB, Figure 3. Refer to
are damaged. Table 2 and perform the relevant service actions.
• For machines W/O TAG 006. Check that the following components are seated correctly: NOTE: The non-fault state of the LEDs is shown in Figure 2 and Figure 3.
– DIMM module, PL 3.10 Item 5.
• For machines W/TAG 006. Check the state of the LEDs on the single board control-
NOTE: Due to board flex, the DIMM module may not make good contact in the cen- ler PWB, Figure 1. Refer to Table 3 and perform the relevant service actions.
NOTE: The non-fault state of the LEDs is shown in Figure 1.
• Re-install the original embedded fax PWB. Connect the DADH communication /
– Software module, PL 3.10 Item 9.
power cable. Connect the output device communication cable and power cord.
– NVM PWB, PL 3.10 Item 21.
– EPC memory PWB, PL 3.10 Item 28. Connect the DADH communication / power cable (PJ188 / PJ851). Switch on the machine, GP
14. The machine boots up.
Y N
20 seconds.
• For machines W/O TAG 007. Scanner PWB, PL 62.16 Item 8.
– Check that all the PJs are seated correctly on the copy controller PWB. • For machines W/TAG 007. Scanner PWB, PL 62.17 Item 1.
– Check that all the PJs to HDD1 copy controller and HDD2 network controller are fully
seated, PL 3.10 Item 2. NOTE: Ensure the correct output device for the machine is installed. WorkCentre LCSS and
• For machines W/TAG 006. Check that the following components are seated correctly: HVF output devices look similar but internally have different components to the ColorQube
– System memory module, PL 3.11 Item 4. 9203 family. If a WorkCentre product is install accidentally the machine will fail to Boot Up.
– Software module, PL 3.11 Item 7. The following output device serial number prefixes are for the ColorQube 9203 family:
– NVM PWB, PL 3.11 Item 17. • JF2A, for the LCSS
– EPC memory PWB, PL 3.11 Item 21. • BHY, for the HVF
– Check that all the PJs are seated correctly on the single board controller PWB. • BKA, for the HVF BM
– Check that all the PJs to the HDD single board controller are fully seated, PL 3.11 Connect the output device communication cable and power cord. Switch on the machine, GP
Item 2. 14. The machine boots up.
Y N
The output device is a HVF with a booklet maker.
A
A
Y N Table 1 Copy controller LEDs
Fault
• OCT, PL 12.00 Item 1. LED No. State Service Actions
30 Off NOTE: This LED flashes when the software is running.
Install a new software module, PL 3.10 Item 9 then perform an Alt-
Disconnect the booklet maker PWB. The machine boots up. boot 8, refer to GP 4 Machine Software. If the fault remains, install a
Y N new copy controller PWB, PL 3.10 Item 17.
Install a new HVF PWB, PL 12.140 Item 2. 35 On Indicates a circuit clock error. Perform an Altboot 8, refer to GP 4
Machine Software. If the fault remains, install a new copy controller
Install a new BM PWB, PL 12.175 Item 10. PWB, PL 3.10 Item 17.
36 On Indicates failed data transfer from the software module to the FPGA.
If necessary, reload the software. Refer to GP 4 Machine Software. Reseat all connectors on copy controller PWB. If necessary, install a
new software module, PL 3.10 Item 9.
Table 1 Copy controller LEDs
37 or 38 N/A NOTE: These LEDs are not relevant.
Fault 39 Off NOTE: This LED flashes briefly when the SIM card is accessed. If
LED No. State Service Actions the LED does not flash during SIM card access, this can indicate a
13, 14 Off NOTE: If LED No. 36 is on, LEDs 13 and 14 will be off. fault.
Indicates +5V failure or that the software is not fully loaded. Perform Check that the SIM card serial number and the machine chassis
an Altboot 8, refer to GP 4 Machine Software. If the hard drive is numbers match. Install a new SIM card of the same type, PL 3.11
spinning and the Altboot 8 did not solve the problem, install a new Item 22, refer to GP 19. If the fault persists, install a new single
power distribution PWB, PL 3.10 Item 1. board controller PWB, PL 3.11 Item 13.
15 Not NOTE: Normal operation is indicated by the LED flashing during 40 On The SIM card is corrupt or does not contain the correct serial num-
flash- hard drive access. If the LED does not flash during hard drive ber. Install a new SIM card of the same type, PL 3.11 Item 22, refer
ing. See access, this can indicate a fault. to GP 19.
Note
Check the SATA power and data harnesses, PL 3.10 Item 3. Install
new components as necessary. Perform an Altboot 8, refer to GP 4
Machine Software. If persistent then try changing SATA data har-
Table 2 Network controller LEDs
ness and / or SATA drive and Altboot 8.
Fault
16, 17,19 On Indicates a voltage supply or regulation fault. Install a new copy con-
LED No. State Service Actions
troller PWB, PL 3.10 Item 17.
18 Off Indicates a voltage supply or regulation fault. Install a new copy con- 10 Not NOTE: Normal operation is indicated by the LED flashing during
troller PWB, PL 3.10 Item 17. flash- hard drive access. If the LED does not flash during hard drive
21 On Indicates a CPU crash. Perform an Altboot 8, refer to GP 4 Machine ing. See access, this can indicate a fault.
Note
Software. If the fault remains, install a new copy controller PWB, PL Check the SATA data and power harness, PL 3.10 Item 3. Install
3.10 Item 17. new components as necessary. Perform an Altboot 8, refer to GP 4
22 On Indicates that the FPGA is not programmed. Install a new copy con- Machine Software. If persistent then try changing the SATA data har-
troller PWB, PL 3.10 Item 17. ness and / or SATA drive. Perform Altboot 8 after a hard drive
23 Off Indicates +3.3V failure. Install a new copy controller PWB, PL 3.10 replacement.
Item 17. 12, 14, 16 All off Check the network connection to the machine. If the connection is
24 Off Indicates +3.3V failure. Switch off the machine, GP 14. Disconnect and 18 good, install a new network controller PWB, PL 3.10 Item 4.
PJ104 from the Network Controller PWB and PJ8 from the Power 19 Off Indicates +3.3V failure. Refer to WD 1.7. Check the PDB to network
Distribution PWB. Switch on the machine, GP 14. If the machine controller PWB harness, PL 3.10 Item 13. If necessary, install a new
boots up, install a new network controller PWB, PL 3.10 Item 4. If power distribution PWB, PL 3.10 Item 1.
the machine fails to boot up, install as necessary a new power distri- 20 On Indicates the FPGA in not programmed. Install a new network con-
bution PWB, PL 3.10 Item 1 and a copy controller PWB, PL 3.10 troller PWB, PL 3.10 Item 4.
Item 17.
21, 25 or 26 N/A NOTE: These LEDs are not relevant.

Table 2 Network controller LEDs Table 3 Single Board controller LEDs
Fault Fault
LED No. State Service Actions LED No. State Service Actions
29, 30 Off Indicates that +5V is not available at the USB ports. Refer to WD 35 Off Indicates a circuit clock error. Power off and power on the machine.
1.7. Check for +5V on PJ104 pin 8 on the Network Controller PWB. Perform an Altboot 8, refer to GP 4 Machine Software. If the fault
If necessary, install a new power distribution PWB, PL 3.10 Item 1. If persists, install a new single board controller PWB, PL 3.11 Item 13.
+5V is available on PJ104 pin 8 install a new network controller 37 or 38 N/A NOTE: These LEDs are not used.
PWB, PL 3.10 Item 4, then perform an Altboot 8, refer to GP 4 39 Off NOTE: This LED flashes briefly when the SIM card is accessed. If
Machine Software.
the LED does not flash during SIM card access, this can indicate a
A Off NOTE: This LED should be on or flashing during data transfer. fault.
Check the ethernet cable. Check that the SIM card serial number and the machine chassis
B Off Check the ethernet cable. If necessary, install a new network con- numbers match. Install a new SIM card of the same type, PL 3.11
troller PWB, PL 3.10 Item 4. Item 22, refer to GP 19. If the fault persists, install a new single
board controller PWB, PL 3.11 Item 13.
40 On The SIM card is corrupt or does not contain the correct serial num-
ber. Install a new SIM card of the same type, PL 3.11 Item 22, refer
Table 3 Single Board controller LEDs to GP 19.
Fault 45 Off NOTE: This LED flashes when the hard drive is accessed. If the
LED No. State Service Actions LED does not flash during hard drive access, this can indicate a
fault.
1, 2 Off NOTE: These LEDs flash when the software is running correctly.
Check the harnesses to the single board controller PWB hard drive,
Install a new software module, PL 3.11 Item 7 and perform an Alt- PL 3.11 Item 3. Install new components as necessary. Perform an
boot 8. If the fault persists, install a new single board controller
Altboot 8, refer to GP 4 Machine Software.
6, 7, 8, 9, 10, N/A NOTE: These LEDs are not used.
3 Off Indicates failed data transfer from the software module to the FPGA.
11, 12, 15,
Reseat all connectors on single board controller PWB. If necessary, 16, 17, 31,
install a new software module, PL 3.11 Item 7.
32, 37, 38,
4, 13, 14 Off Indicates +5V failure or that the software is not fully loaded. Perform 46, 47, 48, 49
an Altboot 8, refer to GP 4 Machine Software. If the fault remains,
A Off NOTE: This LED should be on or flashing during data transfer.
install as necessary a new software module, PL 3.11 Item 7, power
distribution PWB, PL 3.11 Item 1. Check the ethernet cable.
5, 18, 20, 25, Off Indicates a voltage supply or regulation fault. Install a new single B Off Check the ethernet cable. If necessary, install a new single board
26, 43 board controller PWB, PL 3.11 Item 13. controller PWB, PL 3.11 Item 13.
21 On Indicates a CPU crash. Power off and power on the machine. Per-
form an Altboot 8, refer to GP 4 Machine Software. If the fault
remains, install a new single board controller PWB, PL 3.11 Item 13.
22 On Indicates that the FPGA is not programmed. Install a new single
board controller PWB, PL 3.11 Item 13.
23 Off Indicates +3.3V failure. Install a new single board controller PWB,
PL 3.11 Item 13.
24 Off Indicates +3.3V failure. Check harnesses and install as necessary a
new power distribution PWB, PL 3.11 Item 1 and a single board con-
troller PWB, PL 3.11 Item 13.
30 Off NOTE: This LED flashes when the software is running.
Install a new software module, PL 3.11 Item 7 then perform an Alt-

boot 8, refer to GP 4 Machine Software. If the fault remains, install a
new single board controller PWB, PL 3.11 Item 13.

Figure 1 Single board controller LEDs Figure 2 Copy controller LEDs

OF 6 Fans and Air Systems RAP
Use this RAP to diagnose faulty machine fans. Faulty fans can cause smells or overheating.
Procedure
WARNING
NOTE: Bear in mind that not all fans operate all of the time that the machine is switched on.
Identify the suspect fan. From Table 1, check that the fan operates and in the correct direction.
Refer to the following:
• The indicated PJ.

• The indicated PWB that supplies the fan.
• GP 10 How to Check a motor.
As necessary, install a new fan, or the assembly containing the fan, referring to the indicated
parts list reference.
In Table 1, the direction ‘In to out’ indicates that the air is drawn from inside the machine and is
exhausted to the outside. In the case of the power supply unit, it indicates that air is drawn out
from inside the unit.
Table 1 Fan information

Name WD No. PWB PJ Direction PL reference
Chassis fan WD 1.7 Power distribution PJ7 On to PWBs PL 3.10 Item 6
W/O TAG 006 PWB
Chassis fan WD 1.9 Power distribution PJ7 On to PWBs PL 3.11 Item 5
W/TAG 006 PWB
Drum cooling fan WD 9.1 Drum driver PWB PJ501 In to out PL 94.20 Item 4
Figure 3 Network controller LEDs Marking unit fan WD 9.4 Drum driver PWB PJ901 In to out PL 1.15 Item 23
Abatement fan WD 9.4 Drum driver PWB PJ901 In to out PL 94.20 Item 11
Enclosure fan WD 9.4 Drum driver PWB PJ901 In to out PL 1.15 Item 6
Power supply fan - Power supply unit - In to out PL 1.15 Item 2

OF 7 Sleep Mode RAP • Analogue Power Gauge 24V. Refer to wiring diagrams WD 1.4 and WD 9.4.
Use this RAP when the machine has problems entering or leaving the sleep (energy saving) mode. – Source - Power Supply Unit, PJDC2, pin 31.
– Destination - Drum Driver PWB, PJ902, pin 31.
Initial Actions – Action - This signal informs the drum driver PWB that the +24V power used is within
the expected range.
– Analogue power gauge 24V signal level - This is an analogue signal between 0V and
WARNING +3.3V. When this signal is below +2.11 volts, the power used is within the expected
Ensure that the electricity to the machine is switched off while performing tasks that do range.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Analogue Power Gauge 50V. Refer to wiring diagrams WD 1.4 and WD 9.4.
– Source - Power Supply Unit, PJDC2, pin 29.
In sleep mode, check that the machine is running very quietly and check that only the green
LED on top of the power supply unit, PL 1.15 Item 2 is lit. In this mode the sleep mode button at
the right end of the UI keyboard, is illuminated with a green lamp. In run mode, all three power – Action - This signal informs the drum driver PWB that the +50V supply power used is
supply LEDs are lit. within the expected range.
– Analogue power gauge 50V signal level - This is an analogue signal between 0V and
Procedure +3.3V. When this signal is below +2.11 volts, the power used is within the expected
range.
The following signals are used to control and monitor the active state of the machine:
The above signals are carried on a ribbon cable and are therefore difficult to measure. Check
• Active 24V. Refer to WD 1.4 and WD 9.4. that the cable is in good condition and is securely and correctly connected. Install new compo-
– Source - Power Supply Unit, PJDC2, pin 24. nents as required:
• Drum driver power supply interface cable, PL 1.15 Item 10.
– Action - This signal informs the drum driver PWB that the +24V supply is switched
on. When this supply is on, it also enables the +5V, +12V and -12V supplies. • Drum driver PWB, PL 1.15 Item 4.
– Active 24V signal level - This is +3.3V when the machine is in the normal mode and • Power supply unit, PL 1.15 Item 2.
0V in sleep mode. Check the power supplies during normal or sleep mode as follows:
• Active 50V. Refer to wiring diagrams WD 1.4 and WD 9.4.
• +3.3V ESTAR. Refer to WD 1.3. This supply is switched on both in normal and sleep
– Source - Power Supply Unit, PJDC2, pin 26.
modes. If necessary, go to 01B +3.3V ESTAR Distribution RAP.
• +3.3V. Refer to WD 1.6. This supply is switched on both in normal and sleep modes. If
– Action - This signal informs the drum driver PWB that the +50V supply is switched on. necessary, go to 01C +3.3V Distribution RAP.
– Active 50V signal level - This is +3.3V when the machine is in the normal mode and • +5V. Refer to WD 1.3. This supply is switched on during normal mode and is switched off
0V in sleep mode. during sleep mode. If necessary, go to 01D +5V Distribution RAP.
• Energy Star 24V. Refer to wiring diagrams WD 9.4 and WD 1.4. • +12V. Refer to WD 1.3. This supply is switched on during normal mode and is switched off
– Source - Drum Driver PWB, PJ902, pin 27. during sleep mode. If necessary, go to 01E +12V Distribution RAP.
– Destination - Power Supply Unit, PJDC2, pin 27. • -12V. Refer to WD 1.3. This supply is switched on during normal mode and is switched off
– Action - This signal reports back to the power supply unit that the +24V supply was during sleep mode. If necessary, go to 01F -12V Distribution RAP.
switched off when the machine entered sleep mode, and Energy Star became • +17V. Refer to WD 1.5. This supply changes voltage according to the machine mode.
active. Switching this supply off, also switched off the +5V, +12V and -12V supplies. When the machine is switched on, the machine enters Print Engine Self Test (PEST) and
– Energy Star 24V signal level - This is +3.3V when the machine is in the normal mode this supply is measured at about +17V. When the machine enters normal running mode,
and is 0V in sleep mode. this supply rises to +24V. When the machine enters sleep mode, this supply returns to
• Energy Star 50V. Refer to wiring diagrams WD 9.4 and WD 1.4. about +17V. It is used to generate the +3.3V for the IIT. If necessary, go to 01G +17V Dis-
tribution RAP.
– Refer to wiring diagrams WD 9.4 and WD 1.4.
• +24V. Refer to WD 1.3. This supply is switched on during normal mode and is switched off
– Source - Drum Driver PWB, PJ902, pin 28.
during sleep mode. If necessary, go to 01H +24V Distribution RAP.
– Destination - Power Supply Unit, PJDC2, pin 28.
• +50V. Refer to WD 1.3. This supply is switched on during normal mode and is switched off
– Action - This signal reports back to the power supply unit that the +50V supply was during sleep mode. If necessary, go to 01J +50V Distribution RAP.
switched off when the machine entered sleep mode, and Energy Star became active.
• -50V. Refer to WD 1.3. This supply is switched on during normal mode and is switched off
– Energy Star 50V signal level - This is +3.3V when the machine is in the normal mode during sleep mode. If necessary, go to 01K -50V Distribution RAP.
and is 0V in sleep mode.

OF 8 Multi-feed RAP Tray 5
To solve several sheet multi-feeds or extra blank sheet output problems.
1. The tray moves down when the door is opened, and moves up when the door is closed.
Initial Actions a. Check the tray 5 paper feed assembly. REP 81.7.
b. Check the tray 5 paper feed rollers, PL 81.45 Item 2.
c. Install new components as necessary, PL 75.68, PL 75.70.
WARNING Bypass Tray
Ensure that the electricity to the machine is switched off while performing tasks that do Perform the following:
1. Ensure that the customer is not filling the tray above the max fill line.
2. Clean the feed roll and retard pad with a damp cloth with water.
• Check the condition of the paper. Do not use incorrectly cut paper, damp paper, paper
with rough edges, badly drilled paper, paper with wrapper wax or glue contamination. 3. Check that the clutch, PL 74.10 Item 5 has a torque resistance and does not rotate freely.
Refer to IQ 1 Image Quality Entry RAP. 4. Install a new clutch, feed roll, nudger and retard roll, PL 74.10.
• Check the paper specification, GP 20.
• Multi-feed from the bypass tray, go to 74A By-pass Tray RAP
Procedure
When checking for multi-feeds always use a new ream of paper. If a new ream can not be
used, then perform the following:
1. Fan the paper.

2. Turn the paper round or turn the paper over.
3. Remove four or five sheets from the top of the stack.
4. When loading multi-reams of paper into tray 3. Remove the top and bottom sheet from
each ream. This will prevent ream interface multi-feeds.
Tray 1 and Tray 2
1. Check that the paper tray side guides are set to the correct paper size.
2. The paper tray drops down when the tray is pulled out and the tray elevates up when
pushed in.
a. Check the paper feed assembly, REP 81.1.
b. Check the paper feed rolls, REP 81.4.
c. Check that the clutch assembly, tray 1, PL 81.25 Item 4 or tray 2, PL 81.26 Item 4,
has a torque resistance and does not rotate freely.
d. Install new components as necessary, Tray 1, PL 81.25, Tray 2, PL 81.26.
3. The paper trays for worn, broken or missing components.
a. Install new components as necessary, PL 70.10 Item 1.
Tray 3
1. The tray moves down when the tray is pulled out, and moves up when the tray is closed.
a. Check tray 3 paper feed assembly, REP 81.2.
b. Check that the clutch assembly, PL 81.30 Item 4 has a torque resistance and does
not rotate freely.
c. Install new components as necessary, PL 81.30 Item 1.
2. The paper tray for worn, broken or missing components. Install new components as nec-
essary, PL 73.15.

OF 9 Ink Stick Count Mismatch OF 10 Intermittent Failure RAP
Use this RAP when the number of ink sticks in the ink loader does not correspond with the per- Use this RAP to locate failures when no specific cause can be found, i.e. if the machine resets
cent values shown on the UI display. to ‘Ready to scan your job’ or ‘Please wait’ during a print / copy run, or a fault code occurs
which cannot easily be repeated.
The NVRAM value is read by the software and processed internally. It is actually the approxi-
mate number of micrograms of ink left in the ink loader and is not a percentage. The percent- Initial Actions
age is computed by the software and updated by the IME software to the UI.
Procedure WARNING
Only perform this procedure when: Ensure that the electricity to the machine is switched off while performing tasks that do
• There is more than one ink stick difference between the number of ink sticks in the ink death or injury. Moving parts can cause injury.
loader and the indicated value on the UI.
• If the NVM values have been corrupted.
Perform the following: WARNING
1. Remove the rear cover, PL 81.10 Item 1. Perform the following to gather additional information about the fault:
2. Remove the ink loader access cover rear, PL 81.10 Item 7. • Ask the customer if there are any specific print / copier functions that cause the fault to
3. Check the number of ink sticks in the loader. occur; e.g. using the input or output module, or making reduced images.
4. Enter Service mode, GP 1. • Enter Machine Status and check the active messages and the event log. If a fault code is
5. Select Adjustments. raised when the failure occurs, then go to the appropriate RAP.
6. Select dC131 NVM Read / Write. • Make copies and observe where the paper stops and which components are switched ON
7. Enter the NVM ID from the list below: or OFF when the failure occurs.
• Cyan NVM ID 420-001. • Check if there is a repeating pattern to the failure.
• Magenta NVM ID 420-002.
• Yellow NVM ID 420-003.
Procedure
• Black NVM ID 420-004. Go to the relevant checkout:
8. Select Read. The NVM description and value will be displayed. • Customer Power Supply Checkout
9. To calculate the new values which are nominal mass and measured in micrograms: • External Electrical Equipment Checkout
Black ink stick has a mass value = 204000000 micrograms. • Common Causes Checkout
Colour ink stick has a mass value = 189000000 micrograms • Connectors and Wiring Checkout
Count the number of complete ink sticks and estimate the size of the ink stick in the melt • Power Supply Checkout
plate assembly. Make the calculation using the mass values for each ink colour. Enter the • EPROMs Checkout
values in the NVM for each colour. • Electric Motors Checkout
10. To modify the ink level value: • Solenoids and Clutches Checkout
a. Select the NVM ID for the ink stick to be changed. • Switches and Sensors Checkout
b. Select Read. • Electrostatic Discharge Checkout
c. Select +/- in the Value of ink level box. • Paper Trays 1 to 5 Checkout
d. Enter the new value using the key pad. If the wrong value is entered, press C to back • Output Device Checkout
space.
e. Select Write to enter the new value in the NVM.
f. Select Call Closeout, Exit and Reboot.
11. Switch the machine off, then switch the machine on, GP 14.
12. Check that the number of ink sticks in the ink loader correlates with the ink level indicator
on the user interface.

Customer Power Supply Checkout • To check for wire breaks inside insulation, gently pull the relevant connector and wire
while measuring continuity.
• Check that all the PWB and in-line connections are good; refer to PJ Locations.
WARNING • Check the continuity of the ground connections to the input and output modules.
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. • Check that all the input and output module static eliminators are connected correctly and
in good condition; refer to the relevant input or output module RAP.
CAUTION Power Supply Checkout

If you suspect that the customer AC power is incorrect, DO NOT try to correct the customer Check the power cord for continuity.
power. DO NOT reconnect the printer. Inform the customer and your manager.
• Measure the customer power voltage at the power outlet and check that the customer EPROMs Checkout
power is within specification. Refer to GP 22 Electrical Power Requirements. Check that the DIMM and software modules are located correctly. Check that the NVM PWB
• Check that the customer power does not drop below the specification when the copier is and EPC memory PWB are installed correctly. If necessary, reseat or install new components,
making copies; use a digital meter and select “Peak Hold”. Refer to GP 22 Electrical PL 3.10 (W/O TAG006) and PL 3.11 (W/TAG006).
Power Requirements.
NOTE: dC640 can be used to isolate a defective EPC memory PWB. In the case of a defective
External Electrical Equipment Checkout EPC PWB the procedure will stop at 99% of completion then the system will hang. With a good
EPC memory PWB the dC640 procedure will complete within 20 seconds.
WARNING Electric Motors Checkout

Take care when measuring AC mains (line) voltage. Electricity causes death or injury. Refer to GP 10 How to Check a Motor and perform the following:
• Disconnect each motor in turn to locate the motor that is causing the fault. When the
faulty motor has been located, install a new motor.
CAUTION
• If the fault still exists, locate the PWB that drives the motor and install a new PWB.
If you suspect that the customer power is incorrect, DO NOT try to correct the customer power.
DO NOT reconnect the machine. Inform the customer and your manager. Solenoids and Clutches Checkout
Perform the following: Refer to GP 12 How to Check a Solenoid or Clutch and perform the following:
• Ask the customer if there is any electrical equipment, which uses a large amount of cur- • Check that the components are installed correctly.
rent, that is connected to the same supply circuit as the machine. • Check that there is no mechanical binding, slipping or interference.
• With the customer's assistance, check if the failure occurs when electrical equipment near • Enter the relevant output codes and check that the energizing of the components is reli-
to the machine is switched ON or OFF. able. Check if the fault is caused when the components de-energize.
• If possible, connect the machine to a different supply circuit from the equipment that is • If it is suspected that a clutch or solenoid is faulty, install a new component as necessary.
causing the problem. • If the fault still exists, locate the PWB that drives the component and install a new PWB.
Common Causes Checkout Switches and Sensors Checkout
Make the following checks of common causes of intermittent failures: Refer to GP 11 How to Check a Sensor and GP 13 How to Check a Switch and perform the fol-
• Check for intermittent connections in the wiring to the LED exposure lamp. lowing:
• Check that the front door interlock switch is fully actuated by the front door interlock actu- • Check that the components are clean and installed correctly. Ensure that the wiring to the
ator. If the fault is eliminated when an interlock cheater is installed, check that the inter- components is connected correctly.
lock actuator is not damaged. Install new parts as necessary. • Enter the relevant input codes and check that the sensing of the components is reliable.
Connectors and Wiring Checkout Check if the fault is caused when the components are actuated.
Refer to REP 1.1 for details of wiring harness repair. • If it is suspected that a switch or sensor is faulty, install a new component as necessary.
• If the fault still exists, locate the PWB that controls the component and install a new PWB.
Electrostatic Discharge Checkout
• Visible signs of damage to the wiring and the ribbon cables. Especially check wiring to
Refer to GP 7 System Grounding Verification and perform the following:
components that move.
• If the fault only occurs when feeding from a specific paper tray, go to Paper Trays 1 to 5
• Check for pinched wires near moving parts.
Checkout.
• The DADH module harness for broken wiring and ensure that the earth terminals are
• Check that all EPROMs and the NVM are seated correctly and that the connectors are not
secure.
damaged.

Paper Trays 1 to 5 Checkout OF 11 Unable to Load Ink Sticks
• Check that the paper tray size detection sensors match the size of paper in the trays. When the machine powers off the key plate is moved to prevent the customer from loading ink
Check that the control panel indicators display the correct size of paper. sticks with the power off. This is to ensure that the ink sticks count will be correct.
• Perform the Electrostatic Discharge Checkout.
Initial Actions
• Refer to the appropriate RAPs to check the operations of sensors, feed components and
associated harnessing.
– 71-101-00, 71-106-00 Tray 1 Misfeed RAP WARNING
– 72-101-00, 72-106-00, 72-110-00 Tray 2 Misfeed RAP
– 73-101-00, 73-106-00, 73-110-00 Tray 3 Misfeed RAP not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
– 75-101-00 Tray 5 Misfeed RAP death or injury. Moving parts can cause injury.
– 74-101-00 Bypass Tray Misfeed RAP • Check that the machine is on the correct service plan, GP 34.
Output Device Checkout • Check that the correct ink sticks are being used for the service plan, GP 34.
To run the machine without the output device connected, use a finisher bypass harness, PL
Procedure
26.10 Item 7. If the problem is cleared, then go to the appropriate output device.
• LCSS. Check the following: CAUTION

– Ground connection on the power cord, PL 12.75. The ink key motor can overheat if run repeatedly. Allow 2 minutes between each run of the ink
– Static eliminator on bin 0 entry, PL 12.60 Item 7. key motor.
– Static eliminator on the tamper assembly, PL 12.45 Item 5. To observe the operation of the key plate when in diagnostics. Open the ink loader access
– Static eliminator on the bin 1 entry, PL 12.65 Item 7. cover, PL 81.10 Item 5. Use a magnet to cheat the ink loader cover switch, PL 93.10 Item 19.
– Check that all of the connectors on the LCSS PWB are pushed fully home. Ensure Enter dC330 code 93-051 or 052 or 053, to run the ink key plate motor, MOT93-051, PL 93.10
that all of the ground wires are connect to the frame. Item 14. MOT93-051 runs.
– Check all the harnesses for damage and short circuit to ground. Y N
• HVF. Check the following:
Refer to:
– Ground connection to the power supply unit, PL 12.140 Item 4.
– Static eliminator on BM entry. PL 12.150 Item 26.
– Exit brush on HVF upper exit guide, PL 12.125 Item 8.
– Static eliminator on BM exit, PL 12.185 Item 16.
– Exit brush on the Tri folder right hand frame, PL 12.215 Item 13.
– Ground wire on the BM compiler motor, PL 12.175 Item 1. Install new components as necessary:
– Ground wire on the BM back stop motor, PL 12.160 Item 4. • Ink key plate motor, PL 93.10 Item 14.
– Ground wires to HVF buffer motor and transport motor 2, PL 12.120 Item 1. • Ink loader upper assembly, PL 93.10 Item 1.
– Ground wires to HVF transport motor 1 and bypass feed motor, PL 12.120 Item 2. • Media path driver PWB, PL 1.15 Item 5.
– Ground wire between the BM flapper bracket, PL 12.150 Item 24 and the crease
blade assembly, PL 12.170 Item 13. The key plate moves when the motor runs.
Y N
– Ground wire between the crease blade assembly, PL 12.170 Item 13 and the BM
Perform a dC361 NVM Save and Restore. Perform a dC301 NVM Initialization to re-cali-
tamper bracket, PL 12.155 Item 12.
brate the machine. The key plate moves to the correct position
– Ground wire between the base of the HVF and the BM. Y N
– Check that all of the connectors on the HVF PWB, and BM PWB are pushed fully Perform a NVM restore the original NVM values. Perform a software load GP 4.
home. Ensure that all of the ground wires are connected to the frame. If the problem is still present, install a new ink loader upper assembly, PL 93.10 Item 1.
– Where the Tri Folder PWB and the Inserter PWB options are installed check that the
PWB connectors are pushed fully home. Ensure that all of the ground wires are con- Refer to dC301 and perform the actions required to re-calibrate the machine.
nected to the frame
– Ground wire on the Inserter PWB, PL 12.310 Item 9. The fault may be intermittent, check the wiring to the ink key plate motor. Clean the ink loading
– Inserter docking PJ and connector. area to ensure that the ink key plate moves smoothly. If necessary, install a new ink loader
upper assembly, PL 93.10 Item 1.
– Check all the harnesses for damage and short circuit to ground.

OF 12 Not Used OF 13 Convenience Stapler RAP
To identify problems with the convenience stapler.
Procedure
WARNING
WARNING
CAUTION
Incorrect voltage may damage the convenience stapler. The convenience stapler must not be
connected to the power outlet if the voltage is incorrect.
NOTE: There are no serviceable components in the convenience stapler.
Figure 1 shows the convenience stapler.

Check that the power lead is correctly connected to the convenience stapler PL 25.10 Item 1.
Check the AC mains (line) voltage at the customer power outlet. The voltage measured is
within the power requirements, GP 22.
Y N
If the voltages are incorrect or the wiring of the main supply is found to be defective,
inform your technical manager and the customer. Do not attempt to repair or adjust the
customer supply.
Install a new convenience stapler, PL 25.10 Item 1.
Convenience stapler

OF 14 Extensible Interface Platform RAP OF 15 Xerox Secure Access RAP
Use this RAP when experiencing faults with the Xerox Extensible Interface Platform. Overview
Xerox Secure Access uses an external device, such as a card reader or biometric device, to
Procedure authorize access to the machine. The reader then passes the information to the controller,
which handles the authentication process, including which GUI screens are displayed, accept-
ing GUI responses that defines their content and order. The controller can pass user identities
WARNING and passwords directly to the machine after gathering the data from an external server. All
Ensure that the electricity to the machine is switched off while performing tasks that do communication is via a secure network link, Figure 1 Network Diagram.
death or injury. Moving parts can cause injury. Xerox Secure Access is controlled via the CentreWare Web GUI. The active status is displayed
1. For machines W/O TAG 006. in tools within Access Control. If communications cannot be established with the Xerox Secure
Access Server, the service may be temporarily disabled by touching the now enabled Off but-
Refer to WD 3.1. Check the communications cable between PJ905 on the UI PWB to
ton within the Xerox Secure Access tools window. Once communication is re-established the
PJ19 on the copy controller PWB. If necessary, repair the wiring, REP 1.1, or install a new
stored Xerox Secure Access setting are restored.
harness, PL 2.10 Item 7. Check that the copy controller PWB is correctly and securely
connected to the network controller PWB.
• Network controller PWB, PL 3.10 Item 4. Card reader or
biometric device Server
• UI PWB, PL 2.10 Item 2.
For machines W/TAG 006.
Refer to WD 3.4. Check the communications cable between PJ905 on the UI PWB to Client PC
PJ19 on the single board controller PWB. If necessary, repair the wiring, REP 1.1, or Machine
install a new harness, PL 2.10 Item 7.
• Single board controller PWB, PL 3.11 Item 13. Ethernet - secure link
• UI PWB, PL 2.10 Item 2.
2. Go to 02-321-00 XEIP Browser Dead RAP.
Ethernet
Authentication device
Controller
Figure 1 Network Diagram
Initial Actions
WARNING
Before working on the Xerox Secure Access, test the machine in the service mode to ensure
no faults are displayed and that the machine is functioning properly. If it is not, repair any prob-
lems before proceeding with diagnosing the Secure Access Accessory. Diagnostics can be
entered to test copier functionality when Secure Access is installed.

Perform the steps that follow: • Disconnect the small power cord from the Secure Access Authentication Device. Check
• Check the connection between the Card Reader and the Secure Access Authentication there is +5V at the connector that plugs into the Secure Access Authentication Device. If
Device. there is no +5V, install a new the power supply.
• Check which LED’s are on or blinking on the Secure Access Authentication Device. If the • There is a ‘Keyed’ switch on the end of the Secure Access Authentication Device. Obtain
LEDs on the Secure Access Authentication Device are not operating, go to Secure the key from the customer. Insert the key into the ‘keyed’ switch and cycle the switch 1
Access Authentication Device Failure. quarter turn clockwise and then back to its start position. Observe the LEDs and listen for
an audible tone.
• Check for the LED’s are on or blinking on the Card Reader. If the LEDs on the Card
Reader are not operating, go to Card Reader Failure. • If the LEDs on the Secure Access Authentication Device “Uplink” and “Downlink” Ethernet
• If customers have problems of install / setting up, or any other problems related to their ports do not cycle on and off as the controller goes through its boot-up process, or if the
audible tone is not heard. Install a new Secure Access Authentication Device.
Secure Access Administrator, they should refer to the Installation / Administration Guide
or contact Xerox Technical Support. NOTE: A new device will require the Secure Access Administrator to reconfigure the
Secure Access Authentication Device Failure server with the new MAC address of the new part. Be sure to inform the Secure Access
Administrator of the MAC address of the device being removed and the MAC address of
The primary failure modes are power problems or failed hardware components. The symptom
the new device
of these failures can be detected by observing the LEDs on the Secure Access Authentication
Device, Figure 2. Card Reader Failure
The primary failure modes are power problems or failed hardware components. The symptom
of these failures can be detected by observing the LED on the Card Reader. Table 1.
• The Green LED on the Card Reader is On

• The Green LED on the Card Reader Flashes Rapidly
• The Red LED on the Card Reader is On
• The Red LED on Card Reader Flashes Slowly
• The Red LED on Card Reader Flashes Rapidly
• The Card Reader LED’s are not On or Blinking
Table 1 LED identification

When the LED on the
card reader is Meaning
Red The authentication device is in idle mode; there is no active
Down link port session.
Card reader
Power supply connection Green The authentication device is in ready mode; a session is active.
Up link port
connection Slow flashing red The authentication device has no connection to the server.
Slow flashing green The authentication device is communicating to the server.
Fast flashing red Invalid card / password; access denied
Figure 2 Authentication device

The Green LED on the Card Reader is On
Check the power to the Secure Access Authentication Device. • This indicates an active Secure Access Session and the Card Read correctly corre-
• Check the power supply at the wall socket. If there is no power at the wall socket, have sponds to a valid Secure Access Account.
the customer restore power and continue when confirmed. • If the UI on the machine is locked, check with the customer for a second PIN number for
• Disconnect the power cord from the wall socket and the power supply. Check the power additional security. This PIN number will need to be entered via the soft keys on the UI.
cord for continuity and damage. If necessary install a new power cord. • Ensure that the card corresponds to a valid Secure Access Account.
Disconnect the power cord from the power supply and plug the power cord into the wall The Green LED on the Card Reader Flashes Rapidly
outlet. Using a multimeter, check for line voltage at the end of the power cord discon- • This indicates a valid card swipe and in the process of authentication on the server.
nected from the power supply. If there is power at the wall but not at the end of the power • If the UI on the machine is locked, check with the customer for a second PIN number for
cord. Install a new power cord. additional security. This PIN number will need to be entered via the soft keys on the UI.

• If the UI on the machine is locked and no secondary PIN is required. Check that the Xerox OF 16 POST Error RAP
Secure Access is installed correctly, and ask customer to check the configuration at the
Power on Self Test (POST) occurs each time the machine is powered on. POST verifies the
server.
functionality of key subsystems before passing control to Print Engine Self Test (PEST).
The Red LED on the Card Reader is On
• This indicates the Card Reader is in an idle state. If the red LED remains on, and the UI • Use this RAP when the UI has stalled and shows the splash-logo screen, or the system
remains locked after a card is swiped, re-orient the card and re-swipe. appears to have power but the UI is blank.
• Try a known good card in the reader. If the other card is working on the problem Card • POST begins when power is switched on before higher level machine functions (such as
Reader. Ask customer to make sure the card corresponds to a valid Secure Access the user interface) are operational.
Account.
• POST is performed by the IME controller PWB and the copy controller PWB / single board
• Try the card in a known good reader. If the card is working on a known good Card Reader, controller PWB.
it may be a problem with the Secure Access Authentication Device. Check to see is the • The IME POST results are displayed using the LED’s on the front of the IME controller
LEDs on the Secure Access Authentication Device are on.
PWB, Figure 1, and two LED’s at the rear on the media path driver PWB, Figure 2.
The Red LED on Card Reader Flashes Slowly
LED’s on the front of the IME controller PWB, Figure 1.
• This indicates the reader is connected to the controller but the controller is not connected
– ENG OK (green, DS302) - Displays IME firmware status.
to the server. Check the Ethernet green LED on the Authentication Device.
– ENG error (red, DS301) - Displays IME firmware error blink codes, the first digit is 3
• If the Ethernet green LED on the Authentication Device is off, make sure the connectors
or 4.
of the LAN connections are working properly. If the connections are working, this indi-
cates the network may not work properly. Ask customer to check with Network Adminis- – Cable error (red, DS604) - Displays status of major cables in the IME and -12V
needed for the printhead PWBs.
trator.
– CPU error (red, DS605) - Displays IME operating system status and error blink
• If the Ethernet green LED on the Authentication Device is either on or flashing, contact
codes, the first digit is 2.
the Secure Access Administrator.
• The 2 media path driver PWB LED’s on the back of the machine display the same pat-
The Red LED on Card Reader Flashes Rapidly
terns codes as the 2 engine status LED’s on the front IME. If there is a loss of communi-
• This indicates a valid card but does not correspond to a valid Secure Access Account at cation with the media path drive PWB, at PJ 408, only the front LED’s will blink.
the server, test with a known valid user’s card.
LED’s on the Media path driver PWB, Figure 2.
• If all cards react the same way, this indicates the Server Configuration may not be correct.
– IME OK (green, DS801) - Displays IME firmware status.
Ask customer to check the Server Configuration.
– IME error (red, DS802) - Displays IME firmware error blink codes.
• If all the card react this way, this indicates the cards are not valid. Ask customer to check
the Server Configuration
The Card Reader LED’s are not On or Blinking
• Check to see is the Secure Access is correctly installed.
• If there is still no LED on the Card Reader, install a new the Card Reader.
NOTE: if there is another working Card Reader available, the readers can be changed
over to confirm failure.
• If the Card Reader is not functioning, the web page of the machine has a setting that will
enable UI keypad access. If the users know their card access number, they can use the
machine by manually entering their number. The process is as follows:
1. Go to the machine web page under properties and then security and check the box
that says “Allow local user interface initiation”.
2. Enable the keypad and test with valid credentials. This will validate the rest of the
secure access function.
3. Leave it in this mode until the new card reader can be installed.

Green LED, (ENG OK)
Red LED, (IME error)

Red LED, (ENG error) blink blink code.
code Visible with the rear
cover removed.
Red LED, (CABLE error)
Green LED, (IME OK)

Red LED, (CPU error) blink code
Figure 1 POST LED front location Figure 2 POST LED rear location
Procedure
WARNING
Interpreting POST messages
POST error codes consist of three digits, each digit may be a number from 1 to 9.
1. Watch the front red (ENG error) and red (CPU error) or the rear red (IME error) LEDs for a
rapid flutter. This indicates that the next blinks will communicate POST error information.
The sequence loops continuously so each set of blinks does not need to be read consec-
utively.
2. After the flutter count the number of blinks to determine the hundreds digit. At the end of
the first digit there will be a pause.
3. After the pause count the number of blinks to determine the tens digit. At the end of the
second digit there will be a second pause.

4. After the second pause count the number of blinks to determine the ones digit. Table 1 POST Hard Fault Codes
5. Refer to Table 1 for a list of POST blink codes and definitions. Error Code Service action
• IME POST Engine errors are blink codes 4XX. POST_BLACKHEART_LOAD_FAILURE 223 Switch the machine off, then switch the
• IME POST Communication errors are blink codes 3XX. machine on, GP 14. Install a new IME
• IME POST CPU errors are blink codes 2XX. controller PWB, PL 92.10 Item 1.
6. Check the wiring and all connectors on the relevant PWB as indicated by the error code. POST_BLACKHEART_MAPPING_FAILURE 224 Switch the machine off, then switch the
Perform the service actions shown in Table 1. machine on, GP 14. Install a new IME
NOTE: After completing the service actions to clear the fault the print engine should boot
POST_BLACKHEART_ID_READ_FAILURE 225 Switch the machine off, then switch the
up normally, but then display a fault code relating to the fault just cleared. Switch the
machine on, GP 14. Install a new IME
machine off, then switch the machine on, GP 14 to clear the fault code.
7. If the fault remains or no blink codes are communicated, go to Additional LED Checks. POST_BLACKHEART_ID_MISMATCH 226 Switch the machine off, then switch the
Table 1 POST Hard Fault Codes machine on, GP 14. Install a new IME
Error Code Service action
POST_BLACKHEART_WRITE_MISMATCH 227 Switch the machine off, then switch the
POST_BAD_ERROR_CODE 211 Switch the machine off, then switch the machine on, GP 14. Install a new IME
machine on, GP 14. Install a new IME controller PWB, PL 92.10 Item 1.
controller PWB, PL 92.10 Item 1. POST_BLACKHEART_ACCESS_FAIL 228 Switch the machine off, then switch the
POST_PROG_MACHINE_CHECK 212 Switch the machine off, then switch the machine on, GP 14. Install a new IME
controller PWB, PL 92.10 Item 1. POST_BLACKHEART_INTERRUPT_FAIL 229 Switch the machine off, then switch the
POST_PROG_SYS_PANIC 213 Switch the machine off, then switch the machine on, GP 14. Install a new IME
controller PWB, PL 92.10 Item 1. POST_NVRAM_ACCESS_FAILURE 231 Switch the machine off, then switch the
POST_CPU_EXCEPTION_ERROR 214 Switch the machine off, then switch the machine on, GP 14. Install a new IME
POST_CALLISTO_LOAD_FAILURE 215 Switch the machine off, then switch the
POST_CALLISTO_MAPPING_FAILURE 216 Switch the machine off, then switch the
POST_CALLISTO_ID_READ_FAILURE 217 Switch the machine off, then switch the
POST_CALLISTO_ID_MISMATCH 218 Switch the machine off, then switch the
POST_CALLISTO_WRITE_MISMATCH 219 Switch the machine off, then switch the
POST_CALLISTO_ACCESS_FAIL 221 Switch the machine off, then switch the
POST_CALLISTO_INTERRUPT_FAIL 222 Switch the machine off, then switch the

Table 1 POST Hard Fault Codes Table 1 POST Hard Fault Codes
Error Code Service action Error Code Service action
ENG_SC_CONNECT_FAULT 321 Perform the following: ENG_ADC_FAILED 416 ADC timer failed to indicate micro code
1. Check the ribbon cable connector load failure. Switch the machine off,
PJ20 on the W/OTAG 006 copy then switch the machine on, GP 14.
controller PWB, PL 3.10 Item 17, Install a new IME controller PWB, PL
or on the W/TAG 006 single board 92.10 Item 1.
controller PWB, PL 3.11 Item 13. ENG_PS_LINE_CROSS_FAILED 417 Switch the machine off, then switch the
2. Check the ribbon cable connector machine on, GP 14. Install a new power
PJ402 on the media path driver supply unit, PL 1.15 Item 2.
PWB, PL 1.15 Item 5. Ensure that ENG_CALLISTO_ACCESS_ERROR 418 Callisto is part of the IME controller.
the ribbon cable is installed with Switch the machine off, then switch the
the red stripe towards the rear of machine on, GP 14. Install a new IME
the machine. controller PWB, PL 92.10 Item 1.
3. Check the ribbon cable between ENG_MU_VER_MISMATCH 419 Firmware on marking unit driver PWB,
PJ20 and PJ402. If necessary PL 92.10 Item 4.
install a new WO/TAG 006 drawer ENG_MUID_VER_MISMATCH 421 Firmware version mismatch on marking
service loop harness PL 3.10 Item unit driver PWB, PL 92.10 Item 4.
20 or a W/TAG 006 SBC drawer
ENG_DD_VER_MISMATCH 422 Firmware on drum driver PWB, PL 1.15
service loop harness PL 3.11 Item
Item 4.
16.
ENG_PS_VER_MISMATCH 423 Firmware in power supply, PL 1.15 Item
4. Refer to 01D +5V Distribution 2.
RAP. Check for 5V supply to the
ENG_MP_VER_MISMATCH 424 Firmware on media path PWB, PL 1.15
copy controller PWB, (W/O TAG
Item 5.
006) / single board controller PWB
(W/TAG 006). ENG_TTM_VER_MISMATCH 425 Firmware on 3TM PWB, PL 73.16 Item
4.
5. Refer to the OF 5 Boot Up Failure
RAP. Check the condition of the ENG_PFP_VER_MISMATCH 426 Firmware in tray 5 module, PL 75.68
LEDs on the copy controller PWB Item 8.
and the network controller PWB, ENG_CALLISTO_VER_MISMATCH 427 Install a new IME controller PWB PL
W/O TAG 006 or single board con- 92.10 Item 1.
troller PWB, W/TAG 006. Perform ENG_INIT_FAILED 428 Install a new IME controller PWB PL
any relevant service actions. 92.10 Item 1.
6. If the fault still occurs, perform an ENG_BLACKHEART_VER_MISMATCH 429 Install a new IME controller PWB PL
Altboot procedure, GP 4. 92.10 Item 1.
ENG_TEST4 411 This code is not for field use. ENG_INT_STORM 431 Switch the machine off, then switch the
ENG_PWR_NO_HEATER_REQ 412 Heater requests not being received. machine on, GP 14. Install a new IME
Install a new IME controller PWB, PL controller PWB, PL 92.10 Item 1.
92.10 Item 1. ENG_SW_FAULT 432 Unknown software condition. Switch the
ENG_SAFETY_TIMEOUT_LNK 413 Software failed to reset. Switch the machine off, then switch the machine
machine off, then switch the machine on, GP 14. Install a new IME controller
on, GP 14. Install a new IME controller PWB, PL 92.10 Item 1.
PWB, PL 92.10 Item 1. ENG_24V_FAIL 433 Perform the 01-540-00, 01-544-00
ENG_SYS_TIMER 414 This code is not for field use. +24V, +/-12V, +5V Failure RAP. If the
fault remains, perform the 01H +24V
ENG_PCI_ACCESS_ERROR 415 Switch the machine off, then switch the
Distribution RAP.

Table 1 POST Hard Fault Codes Table 1 POST Hard Fault Codes
Error Code Service action Error Code Service action
ENG_DD_LINK_DOWN 434 Check for: ENG_MP_INT_STORM 443 Go to the 92-546-00, 92-547-00 MP
• Poor connection on PJ403 on IME Interrupt Storm Faults RAP.
controller PWB and / or PJ603 on ENG_IMD_INT_STORM 444 Go to the 92-546-00, 92-547-00 MP
Drum Driver PWB. Interrupt Storm Faults RAP.
• Screen display; Please wait --Sys- ENG_TTM_INT_STORM 445 Go to the 92-548-00 TTM Interrupt
tem Power Up. Green splash Storm Fault RAP.
screen with Energy star logo--non ENG_PFP_INT_STORM 446 Go to the 92-549-00 PFP Interrupt
responsive. Storm Fault RAP.
• When cable connection secured, ENG_CIS_INT_STORM 447 Go to the 92-551-00 CIS Interrupt
machine may boot up with 92-515 Storm Fault RAP.
code which goes away with a ENG_SBC_INT_STORM 448 Go to the 92-552-00 SBC Interrupt
POPO. Storm Fault RAP
• Install a new Drum driver PWB PL POST_24V_FAIL 449 Perform the 01-540-00, 01-544-00
1.15 Item 4. +24V, +/-12V, +5V Failure RAP. If the
ENG_MP_LINK_DOWN 435 Check for: fault remains, perform the 01H +24V
• Poor connection on PJ402 on IME Distribution RAP.
controller PWB and / or PJ408 on
Media Path PWB.
Additional LED Checks
If the LED’s remain on or dim then refer to the Table 2 for the possible patterns. Perform the
• Screen display; Please wait --Sys-
relevant service actions. If the fault remains, go to the OF 3 Unresponsive Machine RAP.
tem Power Up. Green splash
screen with Energy star logo--non
Table 2 LED status
responsive.
• When cable connection secured, CPU error Cable error Engine error Engine OK
machine may boot up with 92-525 UI Screen Red LED Red LED Red LED Green Service action
code which goes away with a Dark - - - - Go to OF 3 RAP
POPO.
Splash On dim - - - Perform IME Blink Condi-
• Install a new Media path driver tion A
PWB PL 1.15 Item 5. Splash Off On dim On dim On dim Perform IME Blink Condi-
ENG_PS_LINK_DOWN 436 • Install a new power supply unit, PL tion A
1.15 Item 2.
Splash Off - On bright On bright Perform IME Blink Condi-
• Install a new IME controller PWB, tion A
PL 92.10 Item 1.
Splash Off - Slow blink Fast blink Perform IME Blink Condi-
• Instal a new drum driver PWB, PL tion B
1.15 Item 4.
Splash Slow blink On dim On dim On dim Perform IME Blink Condi-
ENG_ADC_INT_STORM 437 Go to the 92-541-00, 92-570-00 Inter- tion C
rupt Storm Fault RAP.
Splash Off On bright Off Blink Check all communication
ENG_PS_INT_STORM 438 Go to the 92-542-00 PS Interrupt Storm PJs on the IME controller
Fault RAP. PWB and the links to the
ENG_MU_INT_STORM 439 Go to the 92-543-00, 92-544-00 MU printhead PWB.
Interrupt Storm Faults RAP. Splash On dim On dim On dim On dim Install a new 8 pin
ENG_MUID_INT_STORM 441 Go to the 92-543-00, 92-544-00 MU NVRAM, PL 92.10 Item
Interrupt Storm Faults RAP. 11.
ENG_DD_INT_STORM 442 Go to the 92-545-00 DD Interrupt Storm
Fault RAP.

IME Blink Condition A OF 17 Service Code RAP
This indicates a power failure or CPU fault. Where a fault occurs on the machine but the machine is still able to run the status is displayed
in the machine service code.
1. Check 3.3V on the IME controller PWB at PJ701. Refer to WD 9.6. If the voltage is not
present, go to 01B +3.3V ESTAR Distribution RAP.
Procedure
2. Check memory module is seated correctly, PL 92.10 Item 16.
To find out the service code status of the machine select the machine status key. The service
3. Check that there is no link between the two pins on J805 (boot) and J806 (mode) on the code is displayed on the bottom left of the screen on the Machine Information tab, Figure 1.
IME controller PWB.
4. Install a new IME controller PWB, PL 92.10 Item 1.
IME Blink Condition B
3
The operating system is OK but engine did not start. Machine information tab.
1. Check that there is no link between the pins on J806 (mode) on IME controller PWB.
2. Install a new IME Controller PWB, PL 92.10 Item 1.
IME Blink Condition C
A RAM error has been detected.
1. Check memory module is seated correctly, PL 92.10 Item 16.

2. Check 3.3V on the IME controller PWB at J701. Refer to WD 9.6. If the voltage is not
present, go to 01B +3.3V ESTAR Distribution RAP.
3. Install new memory module, PL 92.10 Item 16.
4. Install a new IME controller PWB, PL 92.10 Item 1.
1 2
Select machine status Service code number.
key.
Figure 1 Service mode screen
1. Identify the service code in the bottom left corner of the UI, Figure 1.
• The service codes are listed in Table 1, the action needed is marked as 1.
• The service actions required to correct the faults are listed in Table 2.
2. If there is more than one fault to the service code, ensure all actions are completed before
moving onto the next stage.
Once the fault is fixed the service code on the UI will refresh to 0 when service mode is closed.

NOTE: A number other than 0 indicates a fault. Table 1 Service code table
Drum IOD IOD Y Run Reg / Transfix
Table 1 Service code table Drive PEST Chronic out IOD in Preheat Calibration
Drum IOD IOD Y Run Reg / Transfix Service Belt Warning Jets NVRAM Degraded Calibrated NVRAM
Code Error Exist Detected Reset Mode Required Reset
Drive PEST Chronic out IOD in Preheat Calibration
Service Belt Warning Jets NVRAM Degraded Calibrated NVRAM 37 0 1 0 0 1 0 1
Code Error Exist Detected Reset Mode Required Reset 38 0 1 0 0 1 1 0
0 0 0 0 0 0 0 0 39 0 1 0 0 1 1 1
1 0 0 0 0 0 0 1 40 0 1 0 1 0 0 0
2 0 0 0 0 0 1 0 41 0 1 0 1 0 0 1
3 0 0 0 0 0 1 1 42 0 1 0 1 0 1 0
4 0 0 0 0 1 0 0 43 0 1 0 1 0 1 1
5 0 0 0 0 1 0 1 44 0 1 0 1 1 0 0
6 0 0 0 0 1 1 0 45 0 1 0 1 1 0 1
7 0 0 0 0 1 1 1 46 0 1 0 1 1 1 0
8 0 0 0 1 0 0 0 47 0 1 0 1 1 1 1
9 0 0 0 1 0 0 1 48 0 1 1 0 0 0 0
10 0 0 0 1 0 1 0 49 0 1 1 0 0 0 1
11 0 0 0 1 0 1 1 50 0 1 1 0 0 1 0
12 0 0 0 1 1 0 0 51 0 1 1 0 0 1 1
13 0 0 0 1 1 0 1 52 0 1 1 0 1 0 0
14 0 0 0 1 1 1 0 53 0 1 1 0 1 0 1
15 0 0 0 1 1 1 1 54 0 1 1 0 1 1 0
16 0 0 1 0 0 0 0 55 0 1 1 0 1 1 1
17 0 0 1 0 0 0 1 56 0 1 1 1 0 0 0
18 0 0 1 0 0 1 0 57 0 1 1 1 0 0 1
19 0 0 1 0 0 1 1 58 0 1 1 1 0 1 0
20 0 0 1 0 1 0 0 59 0 1 1 1 0 1 1
21 0 0 1 0 1 0 1 60 0 1 1 1 1 0 0
22 0 0 1 0 1 1 0 61 0 1 1 1 1 0 1
23 0 0 1 0 1 1 1 62 0 1 1 1 1 1 0
24 0 0 1 1 0 0 0 63 0 1 1 1 1 1 1
25 0 0 1 1 0 0 1 64 1 0 0 0 0 0 0
26 0 0 1 1 0 1 0 65 1 0 0 0 0 0 1
27 0 0 1 1 0 1 1 66 1 0 0 0 0 1 0
28 0 0 1 1 1 0 0 67 1 0 0 0 0 1 1
29 0 0 1 1 1 0 1 68 1 0 0 0 1 0 0
30 0 0 1 1 1 1 0 69 1 0 0 0 1 0 1
31 0 0 1 1 1 1 1 70 1 0 0 0 1 1 0
32 0 1 0 0 0 0 0 71 1 0 0 0 1 1 1
33 0 1 0 0 0 0 1 72 1 0 0 1 0 0 0
34 0 1 0 0 0 1 0 73 1 0 0 1 0 0 1
35 0 1 0 0 0 1 1 74 1 0 0 1 0 1 0
36 0 1 0 0 1 0 0 75 1 0 0 1 0 1 1

Table 1 Service code table Table 1 Service code table
Drum IOD IOD Y Run Reg / Transfix Drum IOD IOD Y Run Reg / Transfix
Drive PEST Chronic out IOD in Preheat Calibration Drive PEST Chronic out IOD in Preheat Calibration
Service Belt Warning Jets NVRAM Degraded Calibrated NVRAM Service Belt Warning Jets NVRAM Degraded Calibrated NVRAM
Code Error Exist Detected Reset Mode Required Reset Code Error Exist Detected Reset Mode Required Reset
76 1 0 0 1 1 0 0 115 1 1 1 0 0 1 1
77 1 0 0 1 1 0 1 116 1 1 1 0 1 0 0
78 1 0 0 1 1 1 0 117 1 1 1 0 1 0 1
79 1 0 0 1 1 1 1 118 1 1 1 0 1 1 0
80 1 0 1 0 0 0 0 119 1 1 1 0 1 1 1
81 1 0 1 0 0 0 1 120 1 1 1 1 0 0 0
82 1 0 1 0 0 1 0 121 1 1 1 1 0 0 1
83 1 0 1 0 0 1 1 122 1 1 1 1 0 1 0
84 1 0 1 0 1 0 0 123 1 1 1 1 0 1 1
85 1 0 1 0 1 0 1 124 1 1 1 1 1 0 0
86 1 0 1 0 1 1 0 125 1 1 1 1 1 0 1
87 1 0 1 0 1 1 1 126 1 1 1 1 1 1 0
88 1 0 1 1 0 0 0 127 1 1 1 1 1 1 1
89 1 0 1 1 0 0 1
90 1 0 1 1 0 1 0
91 1 0 1 1 0 1 1 Table 2 Service Actions
92 1 0 1 1 1 0 0 Fault Description Actions Required
93 1 0 1 1 1 0 1 Drum drive belt error Drum drive belt is worn or dam- Go to 94-547-00, 94-555-00 Y-axis
94 1 0 1 1 1 1 0 aged. Belt Ratio Error RAP
95 1 0 1 1 1 1 1 PEST Warnings Check dC123 PEST Fault History Go to the appropriate RAP
96 1 1 0 0 0 0 0 Exist for PEST chain link errors.
97 1 1 0 0 0 0 1 Chronic jets detected Chronic jets are detected on one Go to 91-638-00 IOD Detects
98 1 1 0 0 0 1 0 or more printheads. Chronic Jet Error RAP
99 1 1 0 0 0 1 1 Y run out NVM reset The NVRAM has been corrupted Perform dC977 Drum Run out Cali-
100 1 1 0 0 1 0 0 and was reset to default.or dC301 bration.
with Domain = Copier, NVM Data
101 1 1 0 0 1 0 1
= System or All, was done reset-
102 1 1 0 0 1 1 0 ting the NVRAM
103 1 1 0 0 1 1 1 IOD in degraded Print quality is suboptimal. Go to 91-636-00 IOD in Degraded
104 1 1 0 1 0 0 0 mode Mode RAP.
105 1 1 0 1 0 0 1
106 1 1 0 1 0 1 0 Registration / Pre- The NVRAM has been corrupted Perform dC625 Registration / Pre-
107 1 1 0 1 0 1 1 heat Calibration is and was reset to default or dC301 heat Calibration
108 1 1 0 1 1 0 0 required with Domain = Copier, NVM Data
= System or All, was done reset-
109 1 1 0 1 1 0 1
ting the NVRAM
110 1 1 0 1 1 1 0
Transfix Calibration The NVRAM has been corrupted The transfix calibration values need
111 1 1 0 1 1 1 1
NVRAM Reset and was reset to default or dC301 to be entered from the labels on the
112 1 1 1 0 0 0 0 with Domain = Copier, NVM Data engine frame. Enter dC978 Transfix
113 1 1 1 0 0 0 1 = System or All, was done reset- Calibration Values.
114 1 1 1 0 0 1 0 ting the NVRAM

OF 18 UI Touch Screen Failure RAP (W/TAG 006)
Use this RAP to solve user interface touch screen problems when the machine has power but
either the display is missing, is too dark or the user interface touch screen responds incorrectly
or does not refresh.
Initial Actions
WARNING
• If the UI is blank. Check that the software module, PL 3.11 Item 7 is seated correctly.
• Refer to GP 1 to access the user interface diagnostics.
• Press the Machine Status key. Select the Tools tab. Select Device Settings, then Display
Brightness. Adjust the brightness level.
• Refer to REP 2.1 to access the user interface assembly.
• Check and re-seat the PJ’s on the user interface control PWB.
• If the UI fails to boot, observe the progress icon on the screen to determine the failure.
– Yellow progress block = XUI code booting up.
– Non moving green block = Code loaded but not communicating.
– Moving green block = ESS is operational and XUI is trying to communicate with IME
and CCS.
• If the problem occurs while entering or exiting sleep mode, go to the OF 7 Sleep Mode RAP.
Procedure
Refer to WD 3.4. Check the +3.3V from PJ19 on the single board controller PWB to PJ900 on
the user interface control PWB. +3.3V is measured.
Y N
Check the wiring and harness between the single board controller PWB and the user
interface control PWB. Repair the wiring as necessary, REP 1.2, or install a new harness,
PL 2.10 Item 7. If the wiring is good, go to 01C +3.3V Distribution RAP.
Refer to WD 3.5. Check the +12V from PJ19, pin 17 on the single board controller PWB to
PJ901, pin 5 on the user interface control PWB. +12V is measured.
Y N
Check the wiring and harness between the single board controller PWB and the user
interface control PWB. Repair the wiring as necessary, REP 1.2, or install a new user
interface harness, PL 2.10 Item 7. If the wiring is good, go to 01E +12V Distribution RAP.
Reload the machine software, GP 4. The fault remains.
Y N
Check that the ribbon cables between the user interface control PWB and the touch screen are
in good condition and are securely and correctly connected. Check the wiring and ribbon
cables on the touch screen assembly. As necessary, install new components:
• LCD to PWB harness, (40-way ribbon cable), PL 2.10 Item 11.
• User interface touch screen assembly, PL 2.10 Item 3.

3 Image Quality
Image Quality RAPs TP 23 Drum Run Out and Y-Stitch Test Pages............................................................... 3-97
IQ 1 Image Quality Entry RAP......................................................................................... 3-3 TP 24 Registration Calibration Page ............................................................................... 3-97
IQ 2 Copy or Print Damage RAP..................................................................................... 3-20 TP 25 IME Test Print ....................................................................................................... 3-98
IQ 3 Blurred Image on Copies RAP ................................................................................ 3-23 TP 26 Printhead Uniformity / Colour Bands Test Page ................................................... 3-100
IQ 4 Wrong Copied Colours RAP.................................................................................... 3-24
IQ 5 Jagged or Blurry Lines or Text RAP ........................................................................ 3-25
Image Quality Specifications
IQ 6 Missing Ink or Grainy Output RAP........................................................................... 3-31 IQS 1 Registration and Skew .......................................................................................... 3-101
IQS 2 Image Area............................................................................................................ 3-102
IQ 7 Metering Blade Timing RAP .................................................................................... 3-32
IQS 3 Y-Dot Position ....................................................................................................... 3-103
IQ 8 Cross Process Ink Artifacts (Smudge) RAP ............................................................ 3-33
IQ 9 Deletions in the Process Direction RAP .................................................................. 3-35 IQS 4 Y-Stitch.................................................................................................................. 3-103
IQS 5 X-Stitch.................................................................................................................. 3-104
IQ 10 Incorrect Margin, Misregistration or Skew RAP..................................................... 3-42
IQS 6 Blurry Text............................................................................................................. 3-104
IQ 11 Smudges, Debris, Smears in the Process Direction, or Paper Stack Marks RAP. 3-44
IQ 12 Missing or Partial Image RAP................................................................................ 3-47 IQS 7 Curl........................................................................................................................ 3-105
IQS 8 Uniformity in the Process Direction ....................................................................... 3-105
IQ 13 All Colours Uneven RAP ....................................................................................... 3-49
IQ 14 Some Colours Uneven RAP .................................................................................. 3-54
IQ 15 Wrong Colour RAP ................................................................................................ 3-59
IQ 16 Scratches or Gloss Marks in the Process Direction RAP ...................................... 3-63
IQ 17 Gloss Marks in the Cross-Process Direction RAP................................................. 3-64
IQ 18 Irregular Duplex Gloss Differences RAP ............................................................... 3-65
IQ 19 Image Ghosting RAP............................................................................................. 3-66
IQ 20 Wavy or Stringy Lines RAP ................................................................................... 3-68
IQ 21 Oil on Output RAP ................................................................................................. 3-69
IQ 22 Repeating Spot Deletions RAP ............................................................................. 3-72
IQ 23 Residual Ink From Previous Print RAP.................................................................. 3-73
IQ 24 Wrinkling RAP ....................................................................................................... 3-74
IQ 25 Random Spots RAP .............................................................................................. 3-76
IQ 26 Poor Ink Adhesion RAP......................................................................................... 3-78
IQ 27 Unacceptable Received Fax Image Quality RAP .................................................. 3-80
IQ 28 Showthrough on Copies RAP................................................................................ 3-80
IQ 29 DADH, Document Glass and Scanner RAP .......................................................... 3-81
IQ 30 Blocking RAP......................................................................................................... 3-82
Image Quality Test Prints

TP 1 Initial Test Print Pages............................................................................................ 3-83
TP 2 to TP 10 Solid Fill Test Pages ................................................................................ 3-84
TP 11 Colour Bands and Dithers Test Pages ................................................................. 3-85
TP 12 Chase Page .......................................................................................................... 3-85
TP 13 Text Test Pages.................................................................................................... 3-86
TP 14 Drum Stripper Blade Test Page............................................................................ 3-86
TP 15 Media Path Test Pages ........................................................................................ 3-87
TP 16 Stitch Identification Test Pages ............................................................................ 3-89
TP 17 Service Usage Profile ........................................................................................... 3-89
TP 18 TRC Generation Test Pages ................................................................................ 3-90
TP 19 Y-Dot Position Correction Test Page.................................................................... 3-91
TP 20 Oil Bar Chase and Metering Blade Timing Test Pages ........................................ 3-91
TP 21 Jet Test Pages...................................................................................................... 3-92
TP 22 Cleaning Pages .................................................................................................... 3-96
October 2014 Image Quality

Image Quality October 2014
IQ 1 Image Quality Entry RAP Procedure
Use this RAP to determine the source of an image quality problem. NOTE: If possible, use the customer job to recreate the image quality defect.
Symptom descriptions use terminology listed in Table 1. Refer to the example illustrations in Print TP 1 Initial Test Print Pages. The test pages are good.
each RAP for a representation of the symptom. Y N
Refer to Table 1. Go to the relevant image quality RAP.
Test patterns are listed in Table 2.
Check the test pages for damage. The test pages are undamaged.
Initial Actions Y N
Go to IQ 2 Copy or Print Damage RAP.
NOTE: To aid in troubleshooting image quality issues, use media from an unopened ream
acclimatized to room temperature. Print a duplex copy of TP 11 Colour Bands and Dithers Test Pages. The test pages are good.
Y N
NOTE: Chase sheets are printed to the top tray during jam clearance. These must not be con-
fused with blank or partial images.
• Check the error logs, GP 2 and service code, OF 17 for errors related to the imaging If a fax is installed, send a test fax to the machine. The test fax image quality is good.
defect. Y N
• Do not use cleaning pages (TP 22) to evaluate image quality. Compare the fax print with the initial test pages. The fax print and initial test pages
have the same defect.
• If possible, run a customer print job using default settings.
Y N
• Use approved media within specifications, GP 20. Check media in the tray is clean and Go to IQ 27 Unacceptable Received Fax Image Quality RAP.
there are no loose particles which can cause ink blisters where ink adheres to the debris,
not the media. If necessary, turn over the media in the tray. Refer to Table 1. Go to the relevant image quality RAP.
• Check the operating environment is within specifications, GP 23.
• Make sure the machine is positioned to allow adequate airflow at all vents. Refer to GP 21 Make 3 copies of the colour bands test page, TP 26 from the document glass. The copies are
Installation Space Requirements. good.
• Make sure the interior of the machine is clean. Refer to GP 27 Machine Cleaning Proce- Y N
Check the image quality defect. The defect on the copies is identical.
dure.
Y N
• Check that the paper tray guides are set to the correct paper size.
• Check that the fixed paper tray guides are set to the correct paper size, ADJ 73.1 Tray 3
Paper Tray Guide Setting, ADJ 75.1 Tray 5 Paper Tray Guide Setting. Go to the IQ 29 DADH, Document Glass and Scanner RAP.
• Check the document guides on the DADH.
• Check that the image adjustment and print mode settings are correct for the image being Use the DADH to make copies of the initial test pages, TP 1. The copies are good.
printed/copied. Y N
• Check the settings for the media size and type are correct for each tray. Go to IQ 29 DADH, Document Glass and Scanner RAP.
NOTE: Always load A4 or 8.5 x 11 inch media as appropriate to your market region in If possible, use the customer document to make a copy from the document glass or DADH, at
Tray 4 before printing internal test prints. Failure to do this may result in the test prints 100% magnification. Make another copy at a different magnification setting. Compare the cop-
printing the wrong size / location on the media and giving false results. ies. The defect is on the same part of the image.
Y N
• Check the machine for Mod/TAG 022. Refer to critical service bulletin C8090-05-07.
• If possible, check that the customer is not attempting to copy poor quality originals. If the
original is too damaged to successfully feed through the DADH, suggest scanning directly Perform the Optics Cleaning Procedure:
from the document glass. • For machines W/O TAG 007. Perform ADJ 62.1 Optics Cleaning Procedure.
• For machines W/TAG 007. Perform ADJ 62.5 Optics Cleaning Procedure.

Xerox® ColorQube® 9203 Family 3-3 IQ 1
Image Quality Symptoms
Table 1 Image Quality Symptoms

Term Description IQ RAP Test Pattern
Adhesion Ink flakes can easily be brushed off from the paper. Ink may have a raised spotty texture. IQ 20, IQ 26 TP 1
Background on copies Undesirable ink dots on the copy. Uniform darkening across all the non-copied (white) areas. The ink deposits are IQ 29 TP 9 (TP 2 to TP
localized or may cover the entire copy. Depending on background density, background is referred to as low, 10)
medium, high, or very high. Background may occur in all colors, single colors, or any combination of single colors.
Characters on a copy are good but the white areas have a coloured background.
Banding in process direction A light to dark relative variation in print density within a (near) uniform color across the print. May occur as a wide IQ 13, IQ 14 TP 11
band or localized band in the process direction.
• If the defect matches any in Figure 1 or Figure 2, go to the IQ 13 All Colours Uneven RAP.
• If the defect matches any in Figure 3 or Figure 4, go to the IQ 14 Some Colours Uneven RAP.
Black print A print that is completely black or grey all over, but has no visible image of the original document. See digital - TP 1
defects.
Blank print See partial images/missing images. - -
Blocking Blocking can occur where ink from one print is deposited on the back of another when prints are allowed to accu- IQ 30 -
mulate in a stack in the output tray. The combination of pressure from the weight of the media and ambient heat
may cause partial transfer of the image to the next print in the stack. Blocking is aggravated by abrasion, vibration,
or storage under a large stack of prints (compression). See also residual image.
Blurred image on copies Image on copies is blurred. IQ 3 TP 1
Blurred image on print See jagged lines, jagged text or digital defects.
Blurry lines See jagged lines. - -
Blurry text See jagged text. - -
Contamination See debris. - -
Copy damage Creases, curls, cuts, folds, wrinkles, or embossed marks on the print. Also see wrinkling. IQ 2, IQ 24 N/A
Debris Ink or other fragments easily wiped from the print which are not adhered to the paper. IQ 11 TP 9 (TP 2 to TP
10)
Deletions Areas of the image missing from the print in the form of: IQ 9, IQ 22, IQ 6 TP 1, TP 9 (TP 2 to
• Process direction deletions. If the defect matches any in Figure 5 or Figure 6, go to the IQ 9 Line Deletions in TP 10)
the Process Direction RAP.
• Spot deletions. If the defect matches Figure 7, go to the IQ 22 Repeating Spot Deletions RAP.
• White spots or a grainy appearance. If the defect matches Figure 8, go to the IQ 6 Missing Ink or Grainy Out-
put RAP.
• White spots are areas of missing ink caused by poor ink adhesion, see adhesion.
Digital defects Image is stretched, geometrically relocated, progressively distorted, scrambled, precisely blurred, or colors are N/A N/A
geometrically displaced or switched. Go to the 92-581-00 Image Transfer Error RAP.
Displaced or Fragmented Image Distorted images. Displaced images. See digital defects. - -
Dropout Areas of missing ink pixels usually in mid-scale density areas. Image may look grainy. IQ 6 TP 11 Duplex
Ghosting Faint image which shows as a gloss differential from the previous print or previous area repeated onto a subse- IQ 19 TP 4 (TP 2 to TP
quent print. 10)
Gloss bands (process or cross pro- Lines or bands of irregular gloss, most noticeable in solid areas, in process or cross process direction. IQ 16, IQ 17 TP 5 (TP 2 to TP
cess direction) 10)
Gloss irregularities Random changes in gloss level causing an irregular, uneven gloss or matted appearance, most noticeable in solid IQ 18 TP 5 (TP 2 to TP
areas. 10)

IQ 1 3-4 Xerox® ColorQube® 9203 Family
Grainy Speckled or sand-like appearance in what is meant to be a smooth area. IQ 6 TP 11
Ink discolouration Color shift noted on the print relative to other prints of the same image. May be localized in process direction wide IQ 14, IQ 15, IQ 13 TP 10 (TP 2 to TP
bands: 10)
• If the defect is across some of the printheads and matches any in Figure 3, go to the IQ 14 Some Colours
Uneven RAP.
• If the wrong colours are printed, Figure 9, go to the IQ 15 Wrong Colour RAP.
• If the defect is across all colours and matches any in Figure 1, go to the IQ 13 All Colours Uneven RAP.
Ink transfer See residual image. - -
Irregular line See jagged lines. - -
Irregular process direction streak See banding. - -
Irregular text See jagged text. - -
Jagged line Lines meant to be straight in the cross process direction are blurry, jagged or have relative misalignments. May be IQ 5 TP 1
localized at the 3 boundaries between printheads. Pixel position may be slightly incorrect in the process direction.
Jagged text Text meant to be correctly formed in the cross process direction is blurry, jagged or has relative misalignments. IQ 5 TP 1
May be localized at the 3 boundaries between printheads. Pixel position may be slightly incorrect in the process
direction.
Lead edge smear See smudges, smears -
Light image The image is visible on the print, but with insufficient overall density: IQ 13, IQ 14 TP 1
• If the defect is across all colours, go to the IQ 13 All Colours Uneven RAP.
• If the defect is across some of the colours, go to the IQ 14 Some Colours Uneven RAP.
Light lines in the cross process Image dependent increasingly faint localized bands in the cross process direction, Figure 10. IQ 13 TP 1
direction
Lines Lines of missing ink - see deletions. - -
Lines of extra ink - see smudges, smears.
Marks See spots of ink. - -
See smudges, smears.
Missing colours See deletions. - -
Missing images See partial images. - -
Non uniformity See banding. - -
See dropout.
See light Image.
Offsetting See residual image. - -
Oil on output Spots or splatter of oil on the output. IQ 21 TP 1
Partial images Either the complete or portions of the image are missing. IQ 12 TP 1
Print damage Creases, curls, cuts, folds, wrinkles, or embossed marks on the print. Also see wrinkling. IQ 2 N/A
Repeat images • Gloss - see ghosting - -
• Ink/density - see residual images
Residual image Ink from a previous print is deposited onto subsequent print. See also blocking. IQ 23 TP 10 (TP 2 to TP
10)
Rotated image The image on the printed document has turned 90 degrees to the image printed on the original document. Go to N/A N/A
the 62A Scanning Document Size RAP (W/O TAG 007) or 62C Scanning Document Size RAP (W/TAG 007).
Scratch A very thin gloss band or area of removed ink from the image in the process direction caused by obstructions IQ 16 TP 5 (TP 2 to TP
present in the paper path 10)

Skew A difference in angular alignment between printed image and the media edge IQ 10 TP 1
Smudges, smears Darker irregular streaks of ink in the process or cross process direction, in either the image or non-image areas: IQ 11, IQ 8, IQ 16 TP 1
• If the defect matches any in Figure 11, go to the IQ 11 Smudges, Smears in the Process Direction or Stack
Marks RAP.
• If the image has extra ink in localized areas in the cross process direction, go the IQ 8 Cross Process Ink Arti-
facts (Smudge) RAP.
• If the image has scratches or marks in the process direction, go to the IQ 16 Scratches or Gloss Marks in the
Process Direction RAP.
Spots of ink A deposit of ink in an undesired area on the print (usually circular in shape). IQ 25 TP 1
Spots of missing ink See deletions. - -
Stitch Alignment is incorrect in either the process or cross process direction at the 3 printhead boundaries causing local- IQ 5, IQ 9 TP 1
ized blurry or jagged appearance of the linear elements of the image.
• If the defect matches any in Figure 12 or Figure 13, go to the IQ 5 Jagged Lines or Text RAP.
• If the defect matches any in Figure 5 go to the IQ 9 Line Deletions in the Process Direction RAP.
Streaks See banding. - -
Stretched or distorted Image See digital defects. - -
Trail edge image distortion If copies have distortion approximately 7mm in from the trail edge, go to the IQ 29 DADH Document Glass and IQ 29 -
Scanner RAP
Uneven density See banding. - -
Wavy or stringy lines Images have wavy or stringy lines of ink, or have a blistered appearance. IQ 20 TP 1
Wrinkled image Areas which have distinctive physical distortions in the paper. IQ 24 TP 2 (TP 2 to TP
10)
Wrong copied colour The colour of the copy does not match the colour of the original. IQ 4 TP 1
Wrong printed colour See ink discoloration. -
See banding.

Figure 1 IQ defects 1












Test Patterns NOTE: These test patterns are designed to enhance subtle defects. Defects revealed by these
prints may not occur in the course of ordinary printing. In servicing the system, you should min-
Test patterns aid in the identification of print quality problems. Table 2 lists test patterns avail-
imize the defects shown by the prints but not necessarily eliminate them. Refer to IQS 1 Image
able from diagnostics, provides a short description, and indicates where the pattern is
accessed. Test patterns are described in detail in Test Patterns. Quality Specifications.
Table 2 Embedded Test Patterns

Number Test Pattern Description Media size Simplex or Duplex Print From
TP 1 Initial test prints Multiple pattern on three sheets consisting of black text, cross process lines and A4 (8.5x11) Simplex or duplex dC612
colour bands
TP 2 (TP 2 to TP 10) Cyan solid fill Cyan solid fill - 100% coverage within printable margins, primary only All Simplex or duplex dC612
TP 3 (TP 2 to TP 10) Magenta solid fill Magenta solid fill - 100% coverage within printable margins, primary only All Simplex or duplex dC612
TP 4 (TP 2 to TP 10) Yellow solid fill Yellow solid fill - 100% coverage within printable margins, primary only All Simplex or duplex dC612
TP 5 (TP 2 to TP 10) Black solid fill Black solid fill - 100% coverage within printable margins, primary only All Simplex or duplex dC612, dC959
TP 6 (TP 2 to TP 10) Red solid fill Red solid fill - 100% coverage within printable margins All Simplex or duplex dC612
TP 7 (TP 2 to TP 10) Green solid fill Green solid fill - 100% coverage within printable margins All Simplex or duplex dC612
TP 8 (TP 2 to TP 10) Blue solid fill Blue solid fill - 100% coverage within printable margins All Simplex or duplex dC612
TP 9 (TP 2 to TP 10) White solid fill Produces a blank page All Simplex or duplex dC612
TP 10 (TP 2 to TP 10) CMYKRGB solid fill Prints all solid fill pages All Simplex or duplex dC612
TP 11 Colour bands and dithers Colour bands and dithers A4 (8.5x11) LEF Simplex dC612
TP 12 Chase No ink on page. Does not exercise printheads or use imaging cycles. Used to A4 (8.5x11) Simplex dC612
clean ink from the drum
TP 13 Text pages Portrait and landscape pages of text A4 (8.5x11) LEF Simplex dC612
TP 14 Strip test print A set of prints used for verifying stripper blade actuation A4 (8.5x11) LEF Simplex dC612
TP 15 Media path layout A map of the rollers and media path ribs. Used to identify the cause of scuffs and All Simplex dC612
scratches
TP 16 Stitch Identification print Clearly identifies the region where printheads stitch together A4 (8.5x11) LEF Simplex dC612
TP 17 Full usage profile Machine usage and status information. A4 (8.5x11) Simplex or duplex dC612
TP 18 TRC generation Dithers test pages for TRC calibration A4 (8.5x11) Simplex dC972
(option 4)
TP 19 Y-dot position correction 1 and 5 pixel cross-process lines A4 (8.5x11) Simplex dC972
(option 5)
TP 20 Oil bar chase, metering Check cleaning unit function A4 (8.5x11) Simplex dC959
blade timing pages and
black solid fill
TP 21 Jet test Prints a sequence of 2, 4 or 8 pages. A4 (8.5x11) Simplex dC968, dC977
TP 22 Cleaning pages Printhead purge page A4 (8.5x11) Simplex dC968
TP 23 Drum runout and Y-stitch Two pages of horizontal lines A4 (8.5x11) Simplex dC977
TP 24 Registration calibration Registration target print A4 (8.5x11) Simplex dC625
TP 25 IME Test Print Isolate IME from system controller 8.5x11 only Simplex TP 25
TP 26 Printhead Uniformity/ Seven solid fill bars of colours, yellow, magenta, cyan, black, red, green and A4 (8.5x11) Simplex dC972 (option
Colour Bands Test Page blue. 3)

A B
IQ 2 Copy or Print Damage RAP If the damage or fold is upwards, then check the transfix stripper assembly, PL
10.20 Item 14 and the exit path, PL 10.15.
Use this RAP when the output copies or prints have nicks, tears, creases, folds, or curled
If the damage or fold is downward, then check the drum stripper blade assem-
edges.
bly, PL 10.10 Item 18 and PL 10.10 Item 3.
Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.
Open the stripper gate, GP 31. Carefully clear any paper debris from the area. Check the
stripper blade for damage, PL 10.12 Item 3. The stripper blade is damaged.
Procedure Y N
Press the machine status button on the keypad. Select the Faults tab on the UI, then
Current Messages. If the message ‘Cleaning unit life extended, image quality may
WARNING be impacted’ is displayed, install a new cleaning unit, PL 94.10 Item 21. Or open the
Ensure that the electricity to the machine is switched off while performing tasks that do front door and remove the inner cover. Enter dC959 and run the slow speed exer-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause ciser. While this is running, ensure the cleaning unit blade and roller is making con-
death or injury. Moving parts can cause injury. tact with the drum. Cleaning unit blade and roller is making contact with the
drum.
Y N
WARNING Check the cleaning unit components:
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If • Cam front, PL 94.10 Item 9.
the stripper blade is dirty a new blade must be installed. • Cam rear, PL 94.10 Item 13.
• Drive gear, PL 94.10 Item 23.
• Cleaning unit motor, PL 94.10 Item 24.
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. Print TP 14 Drum Striper Blade Test Print. The test page is good.
Y N
Refer to Figure 1. The stripper blade releases from the drum before the
WARNING MLE line is reached.
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Y N
machine. Do not show the customer how to un-dock the LCSS. Refer to Figure 2. The pattern shown is caused by the stripper blade
Check the paper trays for damaged paper. The paper in the tray is undamaged. bouncing on the drum. The stripper blade releases from the drum at
Y N the intersection of the MLE line.
Load new paper in the trays. Y N
Redefine the image quality defect. Refer to IQ 1 Image Quality Entry
Separate the finisher from the printer. Install a finisher bypass harness, PL 26.10 Item 3. Make RAP.
test prints. The prints are good.
Y N Install a new back latch fork, PL 10.10 Item 12.
Check the lead edge of the paper for damage. The damage is limited to the lead edge
only. Install a new stripper solenoid assembly, PL 10.10 Item 3.
Y N
Print chase pages, TP 12 to identify where the prints are damaged. Check the paper Check that the stripper blade latches correctly at the front and at the rear. The
path, GP 29 Component Locations for the following: stripper blade latches correctly.
• Obstructions. Y N
Check the latch components. Install new components as necessary:
• Damaged guides and rolls. Pay particular attention to the areas that align with
the damaged on the prints. If necessary, print the Media Path Test Pages, TP • Stripper guide latch cam shaft, PL 10.10 Item 18.
15. • Stripper solenoid assembly, PL 10.10 Item 3.
• The edges of the paper path for protruding objects.
Check the transfix blade for damage, PL 10.20 Item 14. The transfix blade is dam-
• Ensure that the paper feed does not skew the paper, go to OF 8 Multi-feed
aged.
RAP.
Y N
• Check the prints for damaged or folded corners (dog ears). Install a new stripper solenoid assembly, PL 10.10 Item 3.
A B A C D
A C D E
Install new transfix stripper assembly, PL 10.20 Item 14. • If heavy-weight paper is used, the paper can stop in the vertical transport and cause
a 10-126 fault. The fault is caused when the vertical transport motor is over loaded.
Install a new stripper blade PL 10.12 Item 3. Check the position of the jam clearance guide 5a, 6a and 5B. Check the vertical
transport rolls and bearings for contamination. If necessary remove and clean the
Remove the finisher bypass connector and dock the finisher to the machine. An LCSS is drive shaft and the bearings. If the problem continues then install a new transport
installed motor.
Y N
Check the alignment of the HVF/HVF BM to the machine, refer to ADJ 12.1-171 Machine Check the alignment of the LCSS to the machine, refer to ADJ 12.2-110 Machine to LCSS
to HVF/HVF BM Alignment. The alignment is good. Alignment. The alignment is good.
Y N Y N
Perform ADJ 12.1-171 Machine to HVF/HVF BM Alignment. Perform ADJ 12.2-110 Machine to LCSS Alignment.
Check the items that follow: Check the items that follow:
• Look for paper fragments in the HVF/HVF BM paper path. Paper fragments can • Look for torn paper in the LCSS paper path. Torn fragments can pass through the IOT and
move through the IOT and HVF/HVF BM paper path without causing a problem until LCSS paper path without causing a problem until they finally wedge themselves at some
they finally wedge themselves at some point. A likely place for a fragment of paper to point. A likely place for a piece of paper to be wedged is at the hole punch assembly,
be wedged is at the hole punch assembly, where the top and bottom guides form the where the top and bottom guides form the narrowest part of the paper path.
narrowest part of the paper path. • Ensure that the shaft diverter assembly, PL 12.60 Item 13, operates correctly and has full
• Ensure that the exit diverter solenoid, SOL 12-225, PL 12.120 Item 4, operates cor- movement.
rectly and has it’s full movement. • Ensure that the hole punches park at the fully open position. If they protrude even slightly,
• Ensure that the hole punches park at the fully open position. If they protrude even a jam will occur in the narrow paper path of the hole punch. If the punch does not park
slightly, a jam will occur in the narrow paper path of the hole punch. If the punch correctly, refer to the 12-043-00-110, 12-046-00-110 Hole Punch Operation Failure RAP.
does not park correctly, refer to the 12-044-00-171 to 12-047-00-171 HVF Punch • Ensure that the jam clearance guide, PL 12.70 Item 6, closes and latches correctly. Check
Head Position RAP. that the magnet at the rear is located and functions correctly. Check the latch, PL 12.70
• Check that all the idler rolls in the HVF/HVF BM paper path are free to rotate, partic- Item 7 at the front is positioned correctly and that the guide engages fully with the latch.
ularly those on the jam clearance guides: • Ensure that all idler rolls in the LCSS paper path are free to rotate, particularly those on
– Top jam clearance guide, PL 12.115 Item 26. the jam clearance guide, PL 12.70 Item 6, where the paper turns through 90 degrees.
– Buffer pocket jam clearance guide, PL 12.125 Item 10. • Ensure that the paper path ribs of the jam clearance guide, PL 12.70 Item 6, and the entry
guide outer cover, PL 12.70 Item 5, are free of “scores” and “nicks”. Check also for con-
– Inserter jam clearance guide, PL 12.125 Item 11.
tamination and glue from label stock. If necessary, install new parts.
– Input jam clearance guide, PL 12.125 Item 12.
• Make sure that the jam clearance guides 5a, 5b and 5d close and latch correctly.
• Check that the paper path ribs of the jam clearance guide 6e, PL 12.150 Item 7 and
the exit path PL 12.185 are free of scores and nicks. Check also for contamination.
• Check that the paper size reported on the user interface corresponds to the actual
paper size loaded in the trays, refer to the 71B Tray 1 Wrong Size Paper RAP or 72B
Tray 2 Wrong Size Paper RAP.
• Make sure that the BM tampers move to the correct paper size, refer to the 12-066-
00-171, 12-384-00-171, 12-419-00-171, 12-420-00-171 HVF BM Tamper Fault RAP.
• Ensure that the BM paper guide, PL 12.150 Item 7, closes and latches correctly.
• If the top sheet of paper is being been torn from booklets, check that the components
in the lower crease roll gear and clutch assembly are correctly installed. Refer to
REP 12.52-171 BM Crease Rolls.
E
Figure 1 TP 14 test print Figure 2 TP 14 test print

IQ 3 Blurred Image on Copies RAP Check that the carriage is fully docked against the drum frame. The carriage is fully docked.
Y N
Use this RAP when copied images are blurred. Refer to Figure 1.
Remove any obstructions. Check the wiring that runs along the umbilicals.
Check that the print heads are securely attached to the carriage. The printheads are
securely attached.
Y N
Y N
Make a copy of the text print (TP 1) from the document glass. Copy quality is good.
Y N
Perform the following
• For machines W/O TAG 007.
– Perform ADJ 62.1 Optics Cleaning Procedure.
– ADJ 62.3 Scan Motor and Scanner Drive Belt.
• For machines W/TAG 007.
– Perform ADJ 62.5 Optics Cleaning Procedure.
If the fault remains, install new components as necessary:
• For machines W/O TAG 007.
– Scan drive belt, PL 62.16 Item 12.
– Carriage motor, PL 62.16 Item 3.
– Scanner module, PL 62.10 Item 1.
For machines W/TAG 007.
– Scan drive belt, PL 62.18 Item 9.
– Carriage motor, PL 62.17 Item 5.
– Scan carriage assembly, PL 62.18 Item 11.
– Scanner module, PL 62.10 Item 1.
Make a copy of the text test (TP 1) from the DADH. Copy quality is good.
Y N
• ADJ 5.2 DADH Height Adjustment.
• ADJ 5.4 DADH Cleaning Procedure.
If the fault remains, install new components as necessary:
Figure 1 Blurred copied image • Feed roll assembly, PL 5.15 Item 1.
• CVT roll kit, PL 5.25 Item 17.
Procedure • Top access cover assembly, PL 5.20 Item 17.
WARNING Re-define the image quality defect, refer to IQ 1 Image Quality Entry RAP.

A B
IQ 4 Wrong Copied Colours RAP • Scanner module, PL 62.10 Item 1.
Use this RAP when the colour of the copy does not match the colour of the original.
For machines W/O TAG 006 and W/O TAG 007, refer to WD 3.1 and WD 3.2. Check the
following wiring:
NOTE: Due to the nature of solid ink printing, some difference in colour reproduction is normal.
• Between PJ15 on the Copy Controller PWB and PJ922 on the Scanner PWB.
Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. • Between PJ16 on the Copy Controller PWB and PJ401 on the IME Controller PWB.
For machines W/TAG 006 and W/TAG 007, refer to WD 3.4. and WD 3.5. Check the fol-
Procedure lowing wiring:
• Between PJ15 on the single board controller PWB and PJ922 on the Scanner PWB.
• Between PJ16 on the single board controller PWB and PJ401 on the IME Controller
WARNING
PWB.
For machines W/O TAG 006 and W/TAG 007, refer to WD 3.1 and WD 3.2. Check the fol-
lowing wiring:
• Between PJ15 on the Copy Controller PWB and PJ922 on the Scanner PWB.
Make copies of the customers document with different original type settings and the auto back-
ground suppression switched on, then off. Colours are reproduced accurately. • Between PJ16 on the Copy Controller PWB and PJ401 on the IME Controller PWB.
Y N
Print the colour bars and dithers test pages, TP 11. Make copies and evaluate the differ- Advise the customer which settings to use. Perform SCP 5 Final Actions.
ences. Colours are reproduced accurately.
Y N
1. For machines W/O TAG 006, refer to WD 3.1. Check that the connector is
securely connected to PJ15 on the Copy Controller PWB.
For machines W/TAG 006, refer to WD 3.4. Check that the connector is
securely connected to PJ15 on the single board controller PWB.
2. Check that the white AGC strip on the CVT glass is at the front and underside
of the glass, refer to REP 62.3.
3. Enter dC131 NVM Read/Write. Make sure the following IIT DADH NVM set-
tings are set to default:
• 801-005.
• 801-010.
• 801-015.
• 801-016.
• 801-017.
• 801-018.
• 801-020.
• 801-021.
• 801-022.
• 801-023.
• 801-025.
• 801-026.
• (W/O TAG 007) Scanner PWB, PL 62.16 Item 8.
• (W/TAG 007) Scanner PWB, PL 62.17 Item 1.
• (W/O TAG 006) Copy controller PWB, PL 3.10 Item 17.
A B
IQ 5 Jagged or Blurry Lines or Text RAP Procedure
Use this RAP to troubleshoot the following defects: 1. Print TP 1 Initial Test Print Pages and TP 16 Stitch Identification Test Pages. Check for
the following defects:
• Jagged lines in the cross process direction • Alignment errors, Figure 1 and Figure 2. Dot placement errors spanning all colours in
• Jagged text in the cross process direction one or more of the printhead stitch zones. If observed, go to the Y-Stitch, Printhead
Roll and Drum Runout Checkout.
• Blurry or out of focus text. This could occur intermittently or only on the first or second
prints after a period of machine inactivity. • Misdirected or weak jets, Figure 3. If observed, go to the Weak Jets with Y-Dot Error
• Irregularly spaced text Checkout.
Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. • Weak intensity and poor Y-dot placement in all colours and all jets of a single print-
head, Figure 4. A pale band across the whole width of a head with misplacement in
the process direction. If observed, go to the Weak Intensity and Y-Dot Error in All
Initial Actions Colours Across a Printhead .
• Y-dot placement defects in the process direction with acceptable jet intensity, Figure
5. A jagged edge in the process direction on lines and colour bands. If observed, go
WARNING
to the Y-Dot Error Checkout.
• Jagged text, Figure 6. Pixel position may be incorrect in the process direction. If
observed, go to the Blurry/Jagged Text Defect Checkout.
2. If the defect does not match any of the above, re-define the image quality defect. Refer to
IQ 1 Image Quality Entry RAP.
WARNING Y-Stitch, Printhead Roll and Drum Runout Checkout
Take care during this procedure. The stripper blade is very sharp and can cause injury. Procedure
Evaluate TP 16 Stitch Identification Test Page, Figure 1 and Figure 2. The severity of the
stitch defect varies in the process direction, Figure 2.
WARNING Y N
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If Perform dC971 Head to Head Alignment Adjustment up to three times. Print TP 16 Stitch
the stripper blade is dirty a new blade must be installed. Identification Test Pages. The severity of the alignment defect is within specification,
refer to IQS 3 Y-Dot Position.
Y N
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. abled and will not operate in dC914. Use the dC330 component control chain 91 to
run these components.
CAUTION Perform dC914 Head to Head Alignment Test and check for obstructions that block
Use care when moving the marking unit into the service position when hot. Ink can spill from head alignment motion. Head alignment motion is free from obstructions.
the ink reservoir located at the back of the unit if opened with too much force. Cross-colour ink Y N
contamination could also occur. Remove obstructions and check printhead stitch and roll motor operation, refer
to:
• 91-504-00, 91-505-00 Printhead Stitch Motor Over Current RAP.
CAUTION
• 91-506-00 to 91-509-00 Roll Motor Over Current RAP.
easily make the printhead unusable.
Check that the printheads are securely attached to the carriage. Printheads are
• Check that the printheads are securely attached to the carriage. Run dC967 Printhead to securely attached.
Drum Spacing. Perform ADJ 91.1 Printhead Attachment Check. Y N
• Check that the printhead carriages are fully docked against the drum frame. If not, check Perform ADJ 91.1 Printhead Attachment Check.
the wiring that runs along the umbilicals. Failure to properly route the upper or lower car-
riage wiring may lead to jagged or blurry lines or text. Perform dC971 Head to Head Alignment Adjustment. Print TP 16 Stitch Identification
• Clean any oil accumulation from the drum position encoder assembly, PL 94.20 Item 8. If Test Pages.
necessary, install a new drum position encoder assembly.
A B
A B
if the severity of the alignment defect exceeds specification, refer to IQS 3 Y-Dot
Position. Perform the following:
• Check for obstructions that block carriage and printhead motion.
• Clean the IOD, refer to GP 27 Cleaning Procedure.
• Clean the drum, refer to GP 27 Cleaning Procedure.
NOTE: Before printing TP 23, ensure that A4 or 8.5 x 11 inch plain paper is loaded long edge
feed into tray 4. Use the best quality media available. Do not use hole punched paper.
Perform dC977 Drum Runout Calibration. Print TP 23 Drum Runout and Y-stitch Test Pages.
Test pages are good.
Y N
Go to 91-637-00 Drum Runout Calibration Needed RAP.
Figure 1 Y-stitch or printhead roll error

Weak Jets with Y-Dot Error Checkout
Refer to Figure 3.
Go to 91-638-00 IOD Detects Chronic Jet Error RAP.
Figure 3 Weak jets with Y-dot error
Figure 2 Drum run-out defect

C D
Weak Intensity and Y-Dot Error in All Colours Across a Printhead Y N
Checkout Install new printheads as necessary, PL 91.20 Item 2 or PL 91.25 Item 2.
Refer to Figure 4.
Re-define the image quality defect, refer to IQ 1 Image Quality Entry RAP.
Figure 4 Weak intensity and poor Y-dot position
Procedure
Print TP 1 Initial Test Print Pages. Test pages are good.
Y N
Evaluate the colour bands test print. If the defect is similar to that shown in Figure 4, Per-
form dC972 Printhead Uniformity, option 1. Print TP 1 Initial Test Print Pages. Test
pages are good.
Y N
Evaluate the text print. Check the Y-dot position, refer to IQS 3 Y-Dot Position. Y-
dot position is acceptable.
Y N
Evaluate the text print, refer to IQS 6 Blurry Text. Blurry text is acceptable.
C D
Y-Dot Error Checkout Procedure
Refer to Figure 5. Perform dC967 Head to Drum Spacing Check. Head to Drum Spacing Check is successful.
Y N
Perform dC972 option 5, Y-dot position correction. Print TP 1 Initial Test Print Pages. Compare
the test pages with IQS 3. Test pages are good.
Y N
• Option 2 Head to Head Alignment Adjust.
• Option 3 Head to Head Uniformity.
• Option 4 TRC Generation.
Print TP 1 Initial Test Print Pages. Compare the test pages with IQS 3 and IQS 6. Test
pages are good.
Y N
Perform dC972 option 5 Y Dot Position Correction. Print TP 1 Initial Test Print
Pages. Compare the test pages with IQS 3 and IQS 6. Test pages are good.
Y N
Figure 5 Abnormal Y-dot position

Blurry/Jagged Text Defect Checkout Procedure
Refer to Figure 6. Check the position of the carriages. The carriages are docked to the drum.
Y N
Y N
Perform dC972 option 5, Y-dot position correction. Print TP 1 Initial Test Print Pages. Evaluate
the text page only and compare with IQS 6. Text page is good.
Y N
Perform dC972 option 1, Printhead Uniformity. Option 1 runs options 1 through 5, before
proceeding to run option 5, Print TP 1 Initial Test Print Pages. Evaluate the text page only
and compare with IQS 6. Text pages are good.
Y N
Perform dC972 option 5, Y-Dot Position Correction. Print TP 1 Initial Test Print
Pages. Evaluate the text page only and compare with IQS 6. Text pages are good.
Y N
Figure 6 Blurry/jagged text

IQ 6 Missing Ink or Grainy Output RAP Initial Actions
Use this RAP when the output has white spots or a grainy appearance, Figure 1.
A grainy appearance can be caused by: WARNING

• Image processing on certain postscript print files that contain transition areas between Ensure that the electricity to the machine is switched off while performing tasks that do
greys and near-greys. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• Inherent graininess in prints.
• Missing pixels (known as dropout). This is most visible in halftone regions and is most
prevalent on duplex prints and / or rough / textured media. WARNING
NOTE: Media containing cotton, linen or parchments can exhibit dropout due to surface tex- Take care during this procedure. The stripper blade is very sharp and can cause injury.
ture. Areas of missing ink on envelopes that outline the seams or flaps is normal. • If the customer is using banner pages, make sure they are printed in the same orientation
NOTE: Opening the paper tray or switching from SEF to LEF prints can cause dropout on the as the job. Printing banner sheets in a different orientation to the job can cause dropout.
next duplex print. Reprinting the job will normally resolve this issue. • Check that the defect occurs when making prints and is not related to copy quality. If the
defect is present on copies only, Go to IQ 29 DADH Document Glass and Scanner RAP.
• If the graininess only appears on postscript prints in transition areas between greys and
near greys, print the job using composite black (selected from the print driver).
NOTE: This change can affect billing black / white / grey pages with greater than 1.5%
coverage. It is therefore not recommended to save composite black as the default setting.
• Fast colour and standard print resolutions can cause more dropout. If graininess is
observed at either of these resolutions, print the job at a higher resolution (enhanced or
high resolution / photo).
• Turn the media over in the tray. Media quality can vary between sides.
• Print the job on smoother media. Inform the customer to use the smoothest, best quality
media available.
• If the pattern of graininess is exactly the same on multiple copies of the same print, use a
higher print resolution. This is an indication that the defect is inherent in the print file. No
other service action is possible. Defect is within specification.
• Enlarging an image may result in a grainy appearance.
• Press the Machine Status button on the keypad, select the Fault tab on the UI, then Cur-
rent Messages. If the message ‘Cleaning unit life extended, image quality may be
impacted’ is displayed, install a new cleaning unit, PL 94.10 Item 21.
• Check the drum page count in dC131 NVM ID 492-070. If a drum has not been replaced
on this machine, this page count will equal the meter total. If a new drum has been
installed, the meter count will be higher than the drum page count (the offset will equal the
page count that a new drum was installed on). If this NVM value has become corrupt or if
the drum page count was not properly reset when a new drum was installed, images may
have a more grainy appearance.
Figure 1 Duplex dropout example

Procedure IQ 7 Metering Blade Timing RAP
Make a duplex print of TP 11 Color Bands and Dithers Test Pages. Look at the last sheet only Use this RAP to diagnose faults with operation of the cleaning unit metering blade.
(black dither print). The image level of graininess is the same on both sides.
Y N Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.
Check that the front and rear thermistors are not misaligned or bent and that they are
making contact with the drum. Check that there is no paper or debris between the ther- Procedure
mistors and the drum. The thermistors are good.
Y N
WARNING
Perform dC335 Heater Monitor and Exerciser. Check the operating temperature of the
drum and registration / preheat assemblies. Temperatures are within the set point NOTE: Before printing TP 20, ensure that A4 or 8.5 x 11 inch plain paper is loaded long edge
range. feed into tray 4. Use the best quality media available. Do not use hole punched paper.
Y N
Check the fault history, GP 2, for a corresponding fault code. Perform the relevant 1. Print TP 20 Oil Bar Chase and Metering Blade Timing Test Pages.
RAP. 2. Evaluate the metering blade timing test page only. If the metering blade engages and dis-
engages within the tolerance zones, the cleaning unit and cleaning unit drive train are
Enter dC978 Transfix Calibration Values. Check the transfix calibration values against working correctly.
those on the drum frame. Calibration values match. 3. If the metering blade is engaging or disengaging outside the tolerance zones, Figure 1
Y N either the cleaning unit or the cleaning unit drive train is defective.
Correct transfix calibration values in NVM, dC131. 4. Refer to 94-520-00 Cleaning Unit Drive Train RAP to determine if the cleaning unit drive
train is defective. If the drive train is operating correctly, replace the cleaning unit PL 94.10
Enter dC962 to test the transfix assembly. Transfix assembly operates normally. Item 21.
Y N
• Transfix roller, PL 10.20 Item 1.
• Flexure encoder, PL 10.20 Item 5.
• Transfix motor, PL 10.20 Item 11.
Open the front door and remove the inner cover. Enter dC959, Cleaning Unit Exerciser,
and run the slow speed exerciser. While this is running ensure the cleaning unit metering
blade and roller are making contact with the drum. Metering blade and roller are mak-
ing contact with the drum.
Y N
Check the cleaning unit front cam, PL 94.10 Item 9, rear cam, PL 94.10 Item 13,
drive gear, PL 94.10 Item 23 and cleaning unit motor, PL 94.10 Item 24. Install new
parts as necessary.
No other service action is possible. Defect is within specification.

Instruct the customer to run the job with extra heavy weight selected as the job media
type regardless of the media type being used. Instruct the customer to change the paper
type back to its original setting when finished. Extra heavy weight media selection affects
stapling and hole punching finish options.
Go to IQ 26 Poor Ink Adhesion.

IQ 6, IQ 7 3-32 Xerox® ColorQube® 9203 Family
IQ 8 Cross Process Ink Artifacts (Smudge) RAP
Use this RAP when the output has extra ink in localised areas in the cross process direction,
Blade engage out of Figure 1.
tolerance zone
Blade disengage out

of tolerance zone
Figure 1 Metering blade timing page (too long)
Figure 1 Cross process ink artifacts

Xerox® ColorQube® 9203 Family 3-33 IQ 7, IQ 8
A B C
Procedure Perform SCP 5 Final Actions.
Print TP 14 Drum Stripper Blade Test Print. The stripper blade releases between 35
WARNING and the 50 mm mark on pitch 1 and between 270 to 291 mm mark for pitch 2.
Y N
Install a new stripper blade solenoid, PL 10.10 Item 3.
Perform dC969 Clean Ink Smears. Print three copies of TP 4 Yellow Solid Fill Test
pages (TP 2 to TP 10). The test pages are good.
Y N
Install a new stripper blade assembly, PL 10.12 Item 3.
WARNING
Take care during this procedure. The stripper blade is very sharp and can cause injury. Perform SCP 5 Final Actions.

WARNING
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If Re-define the image quality defect, refer to IQ 1 Image Quality Entry RAP.
WARNING
Open the stripper gate, GP 31. Inspect the drum stripper blade for ink accumulation.
NOTE: Occasionally, the combination of rough media, a high coverage image, and a long print
job creates a condition where stripper blade ink accumulation is unavoidable. Advise the cus-
tomer to consider changing to smoother media.
Print three copies of TP 4 Yellow Solid Fill Test Pages (TP 2 to TP 10). Test pages are good.
Y N
Press the Machine Status button select the Fault tab on the UI and enter Current Mes-
sages. Check if the message ‘Cleaning unit life extended, image may be impacted’ is dis-
played. A different message is displayed.
Y N
Install a new cleaning unit, PL 94.10 Item 21.
Open the front door and remove the inner cover. Enter dC959 and run the slow speed
exerciser. While this is running, check that the cleaning unit blade and roller are making
contact with the drum. The cleaning unit blade and roller are making contact with
the drum.
Y N
Check the front cam, PL 94.10 Item 9, rear cam, PL 94.10 Item 13, drive gear, PL
94.10 Item 23 and the cleaning unit motor, PL 94.10 Item 24 The components are
good.
Y N
Perform dC969 Clean Ink Smears. Print three copies of TP 4 Yellow Solid Fill
Test Pages (TP 2 to TP 10). Test pages are good.
Y N
Install a new stripper blade assembly PL 10.12 Item 3.
A B C
IQ 9 Deletions in the Process Direction RAP • X - Stitch - Defects along the X-stitch area indicated by the chevrons, Figure 1. X-
stitch generally appears as a set of white stripes in the stitch region. X-stitch can
Use this RAP to troubleshoot the following defects:
also appear as a darker, more dense strip indicating an overlap of ink. An X-stitch
• Deletions in the process direction. defect is seen in all colours but it may appear more severe in some colours (espe-
• Scraped ink in the process direction. cially black. If observed, go to the X-Stitch Defect Checkout.
• Scratches in the process direction.
NOTE: Chevrons on the print indicate the X-stitch region between each printhead.
• X-stitch defects. X-stitch defects occur along this narrow area of the print.
• Light lines in the process direction.
• Missing or weak jet - Deletions of a single primary colour that run consistently in the
• Roving missing jets.
process direction, Figure 2. If observed, go to the Missing or Weak Jet Checkout.
• Scraped Ink - A line of missing ink in the process direction, Figure 7. Edges of the
defect are rough or jagged. Ink may appear in the margin or the trailing edge. Dis-
Procedure tinct from multiple missing jets by the irregular edges of the deletion. If observed, go
to the Scraping Checkout.
• A broad line of missing ink of a single primary colour in the process direction with
WARNING straight edges, Figure 8. Distinct from scraping by the uniform edges of the deletion.
Ensure that the electricity to the machine is switched off while performing tasks that do If observed, go to the Multiple Missing Jets Checkout.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause • Multiple deletions and blobs of ink on the print, Figure 9. If observed, go to the Purge
death or injury. Moving parts can cause injury. Line Obstruction Checkout.
• X - Axis defect - High-frequency bands in the process direction, Figure 10. If
observed, go to the X-Axis Defect Checkout.
WARNING
• Missing or discoloured jets caused by a worn wiper blade forcing ink or debris into
Take care during this procedure. The stripper blade is very sharp and can cause injury. the printhead jetstack, Figure 11. If observed, go to the Printhead Maintenance
Checkout.
• Light lines in the process direction indicating missing jets, that clear after a head
WARNING
purge, followed by further missing jets on the same carriage. This is caused by a
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If dirty wiper blade contaminating the printheads and is known as a roving jet. If this
the stripper blade is dirty a new blade must be installed. defect is observed, go to the Printhead Maintenance Checkout.
• Multiple missing lines of a primary colour in the process direction in a single print-
head, Figure 12. The missing lines will also show up in any secondary colours that
WARNING are effected by the primary colour (i.e. missing lines in yellow will also show up in red
Take care during this procedure. Sharp edges may be present that can cause injury. and green). If this is observed go to the Internally Leaking Printhead Checkout.
2. If the defect does not match any of the above re-define the image quality defect, refer to
CAUTION IQ 1 Image Quality Entry RAP.
Use care when moving the marking unit into the service position when hot. Ink can spill from
the ink reservoir located at the back of the unit if opened with too much force. Cross-colour ink
contamination could also occur.
CAUTION
NOTE: Before printing test pages, ensure that A4 or 8.5 x 11 inch plain paper is loaded long
edge feed into tray 4. Use the best quality media available. Do not use hole punched paper.
1. Evaluate the colour bands test page, TP 26. Check for the following defects:

A B
X-Stitch Defect Checkout 1. Enter dC131 NVM read/write NVM ID 490-41 and change value to 4.
Refer to Figure 1. 2. Enter dC971 and start the routine.
Y N
NOTE: If the machine has SMP2 or later software, the stitch and roll motors are
disabled and will not operate in dC914. Use the dC330 component control
chain 91 to run these components.
Perform dC914 Head to Head Alignment Test. Check the motion of the print-
head stitch adjust motors, PL 91.20 Item 4 and PL 91.25 Item 4. The stitch
adjust motors run.
Y N
Check the motion of the printhead X-axis drive motors, PL 91.20 Item 5
and PL 91.25 Item 5.
Go to the 91-504-00, 91-505-00 Printhead Stitch Motor Over Current RAP. The
X-axis drive motors run.
Y N
Go to the 91-510-00, 91-511-00 X Axis Motor Over Current RAP.
Print TP 16. Check the test pages for good alignment following motion testing.
If the defect remains, perform the following:
1. Check for obstructions that block carriage and printhead motion.
2. Check the stitch adjust and roll adjust motor lead screws, PL 91.20 Item
21 or PL 91.25 Item 21 for cracks. Install new components as necessary.
3. Clean the IOD, refer to GP 27 Cleaning Procedure.
4. Clean the drum, refer to GP 27 Cleaning Procedure.

Figure 1 X-stitch defect
Print the colour bands test page, TP 26. The test page is good.
Y N
Procedure Go to the Printhead Maintenance Checkout.
NOTE: If the dC971 routine Head to Head Alignment Adjustment fails to complete refer to ser- If the stitch defect is still present, swap the print heads around to move the artifact to the
vice bulletin T7869-01-12 and ETI 1056514. outside of the page.
Perform dC971 Head to Head Alignment Adjustment up to 3 times. Print TP 16 Stitch Identifi- Perform SCP 5 Final Actions.
cation Test Pages after each adjustment. The test pages are good.
Y N
Manually disable the IOD align calibration:
Y N
Manually re-enable the IOD align calibration:
A B
Missing or Weak Jet Checkout
Refer to Figure 2.
Table 1 Problem jet identification
Jet number
colour label Jet problem
Purple Detected missing jets that have not been labelled as chronic
Red Chronic jet
Green Missing jet for which jet substitution is enabled manually
Black Jetting issue not identified by IOD.
All jets are good.

Y N
Missing jet on dithers only, Figure 3.
Y N
Go to the 91-638-00 IOD Detects Chronic Jet Error RAP.
Perform dC972 Printhead Uniformity, option 4 TRC Generation. Print TP 11 colour bands
and dithers test pages. Test pages are good.
Y N
Perform dC972 Printhead Uniformity, option 6 Reset Head Uniformity Data. Print TP
21 jet test pages. Test pages are good.
Y N
Perform dC972 Printhead Uniformity, option 1 Printhead Replacement Uniformity.
Print 2 copies of TP 11 Colour Bands and Dithers Test Pages. The test pages are good.
Y N
1. dC959 Cleaning Unit Exerciser. If the test fails, install a new cleaning unit, PL 94.10
Figure 2 Missing jet Item 21.
2. Print TP 20 oil bar chase and metering blade timing test pages. Evaluate the oil bar
Procedure chase page only. If necessary, install a new cleaning unit, PL 94.10 Item 21.
Print TP 21 Jet Test Pages and TP 11 Colour Bands and Dithers Test Pages. Identify problem Print 2 copies of TP 11 Colour Bands and Dithers Test Pages. The test pages are good.
jets by referring to Table 1 and Figure 4, Figure 5 and Figure 6. The jet test pages are printed Y N
with no jet interlacing, so masked or missing jets will not generate colour bars. Consider the Go to the 91-638-00 IOD Detects Chronic Jet Error RAP.
points that follow:
• If ink is missing from at least 4 numerically sequential and identically numbered jets in all Perform SCP 5 Final Actions.
4 colours Figure 11, go to the Printhead Maintenance Checkout.
• All jets print their corresponding colour bar on the service jet test page. Perform SCP 5 Final Actions.
• Masked (refer to GP 30) and chronic jets usually will not have a colour bar.
• Jets that begin to work after being masked (intermittent) will have a colour bar even
though their label is green.
• Weak or missing jets that have a black jet number have not been detected by the IOD.
• If the IOD sensor has failed, it could report missing jets incorrectly, causing them to be
mislabeled.

Figure 5 Weak jet 187
Figure 6 Sputtering jet 157

Figure 3 Missing jet on dithers only
Figure 4 Missing jet 157

Scraping Checkout Multiple Missing Jets Checkout
Refer to Figure 7. Refer to Figure 8. Shows multiple missing jets of a single primary colour.
Figure 7 Scraping Figure 8 Multiple missing jets
Procedure Procedure
Check for accumulations of ink or media debris on components that could scrape the drum. Perform the following:
Perform the following: 1. Perform dC968 Head Purge.
1. Clean the following components, GP 27 or install new components as necessary: 2. Print the jet test pages, TP 21.
• Abatement plenum, PL 94.20 Item 12. Analyse the jet test pages. The jet test pages are good.
• IOD shield and sensor, PL 94.15. Y N
2. If necessary, install a new stripper blade assembly, PL 10.12 Item 3. Go to the 91-638-00 IOD Detects Chronic Jet Error RAP.
3. IQ 7 Metering Blade Timing RAP.
Print the colour bands test page, TP 26. The test pages are good.
Y N

C
Purge Line Obstruction Checkout NOTE: Drooling may occur after a purge is completed and the printhead will continue to
‘ooze’ small amounts of ink out of the printhead. Drooling may also occur at initial warm
Refer to Figure 9.
up and effects all four printheads and does not continue after the purge cycle.
This may eventually lead to clogged jets and may stain the face plate.

X-Axis Defect Checkout
Refer to Figure 10.
Figure 10 X-axis defect
Procedure
Figure 9 Purge line obstruction
Go to IQ 13 Uneven in All Colours RAP. Perform the X-Axis Checkout.
Procedure
Check for purge line issues, refer to the 93-549-00 to 93-552-00 and 93-557-00 to 93-560-00
Printheads 1 and 3 Printhead Reservoir Fill Error RAP or the 93-553-00 to 93-556-00 and 93-
561-00 to 93-564-00 Printheads 2 and 4 Printhead Reservoir Fill Error RAP. Purge line errors
are found and corrected.
Y N
Check the printheads for evidence of ink drooling from printhead jetstack area, for exam-
ple: printhead not turning off, ink pouring out of the printhead, ink all over the drum or the
waste tray over filling. If necessary, install a new printhead, PL 91.20 Item 2 or PL 91.25
Item 2.
C
Printhead Maintenance Checkout Procedure
Refer to Figure 11. Print the jet test pages, TP 21. Examine the jet test pages to determine the placement of the
missing jets, Figure 11. The ink is missing from 4 numerically sequential and identically
numbered jets in all 4 colours.
Y N
Go to the Missing or Weak Jet Checkout.
Perform dC965 Printhead Maintenance Cycle Test. Observe wiper motion during the test. Look
for erratic wiper motion that may indicate wiper chatter or motor failure. The wiper moves
smoothly across the printhead jetstack area.
Y N
1. Check the wiper mechanism, refer to the 91-572-00, 91-573-00, 91-575-00 Wiper
Vertical Error RAP.
2. If necessary, install a new HM wiper, PL 91.15 Item 13.
NOTE: Installation of a HM wiper, PL 91.15 Item 13 is recommended if wiper chatter

is observed.
3. dC968 Head Purge.

Print the jet test pages, TP 21. The test pages are good.
Y N
Go to the 91-638-00 IOD Detects Chronic Jet Error RAP.
Go to the Missing or Weak Jet Checkout.
Figure 11 Clogged or contaminated jets

Internally Leaking Printhead Checkout IQ 10 Incorrect Margin, Misregistration or Skew RAP
Procedure Use this RAP to determine the source of margin, misregistration or skew, Figure 1.
Evaluate the colour bands test page, TP 26. Check for the following defect:
NOTE: Since the printhead is leaking internally, no ink will be visible externally on the print
head or on the printer.
If massive amounts of ink is missing in the process direction in one printhead similar to Figure
12, check for a leaky printhead. Note that the missing ink will generally affect a primary colour
and its associated secondary colours. This issue most commonly shows up in black and yellow
meaning the missing ink will also show up in the red and green bars. Purging the printhead to
recover the missing jets will not resolve this issue. Often the missing ink will be noticed on the
colour bands print on TP 26 but not on the jet tests pages printed from dC968. If this defect is
observed then install a new printhead, PL 91.20 Item 2 and PL 91.25 Item 2.
Figure 1 Image skew
Initial Actions
WARNING
Figure 12 Printhead with internal leak • Perform dC608 Document Feeder Registration.
• Perform dC609 Document Glass Registration.

A B C
Procedure Check the operation of the air pumps, refer to 88-508-00 Registration / Preheat Air
Pump Incorrect Current RAP. If the air pumps are working, then install a new regis-
Make 3 prints of TP 2, cyan solid fill test page (TP 2 to TP 10). Check the prints for skew, refer
tration / preheat assembly, PL 88.10 Item 1.
to IQS 1 Registration and Skew. The prints are skewed.
Y N
Make 3 prints of TP 2, cyan k solid fill test page (TP 2 to TP 10). The prints are good.
Make 3, duplex prints of TP 2, cyan solid fill test page (TP 2 to TP 10). Check the prints for
Y N
skew, refer to IQS 1 Registration and Skew. The prints are skewed.
Y N Make five prints from each tray and the bypass tray to identify the source of skew.
Make 3 copies of TP 2 from the document glass. Check the copies for skew. The
copies are skewed. • Check the tray feed rolls and guides for contamination.
Y N • Check the tray feed rolls and transport rolls for wear. Install new components as
Make a copy of TP 2 from the DADH. Check the copies for skew. The copies necessary.
are skewed. • Check that there is no variation in the size or weight of the sheets of paper in
Y N each tray.
No skew is present. Re-define the image quality defect. Refer to IQ 1
• Check the paper path for obstructions. Refer to IQ 2 Copy or Print Damage
Image Quality Entry RAP. RAP.
The skew is originating in the DADH. Go to ADJ 5.3 DADH Skew Adjustment.
There is a skew problem originating in the scanner. Perform the following:
• Check that the scan carriage is parallel to edge of the document glass. If neces-
sary, perform ADJ 62.2 Scan Carriage Assembly.
• Check that the scan cables are wrapped around their drive pulleys, refer to
REP 62.7 Scan Cables.
• If necessary, install a new scanner.
– For machines W/O TAG 007, PL 62.15 Item 1.
– For machines W/TAG 007, PL 62.18 Item 11.
The skew occurs in the duplex paper path. Check the following nip and drive rolls, refer to
GP 29 Component Locations:
• Roller drive J - PL 10.10 Item 1.
• Roller drive L - PL 10.10 Item 2.
• Roller nip P - PL 10.15 Item 6.
• Nip R, C and Q takeaway rolls, PL 82.15 Item 10.
• Transport roller drive 2, D, F - PL 82.10 Item 1.
• Transport roller TAR vertical, E - PL 82.10 Item 2.
Clean the rolls, GP 27 or install new components as necessary.
Perform dC969 Clean Ink Smears. Print 3 copies of TP 2, cyan solid fill test page (TP 2 to TP
10). Check the prints for skew, refer to IQS 1 Registration and Skew. The prints are good.
Y N
Perform dC625 Registration/Preheat Calibration. Registration calibration is good.
Y N
Enter dC330 code 82-007, nip C release solenoid, PL 82.15 Item 4 and 82-008, nip
D release solenoid, PL 70.30 Item 13. The solenoids energise.
Y N
Go to the 82-507-00, 82-508-00 Nip C and Nip D Release Solenoid Over Cur-
rent RAP.
A B C
IQ 11 Smudges, Debris, Smears in the Process Direction, Procedure
or Paper Stack Marks RAP The machine has a finisher fitted.
Y N
Use this RAP to troubleshoot the following defects: Go to Machine Only.
• Faint smudges or smears in the process direction at the edges of the print, Figure 1 and
Separate the finisher from the machine. Install a finisher bypass connector, PL 26.10 Item 3.
Figure 2. Print the initial test pages, TP 1. The prints are good.
• Faint smudges or smears in the process direction in line with text or printed horizontal Y N
lines, Figure 3. Go to Machine Only.
NOTE:
The defect is in the finisher. Dock and connect the finisher. Compare the marks to Figure 1.
• Most roller and rib marks are inherent to the design and cannot be completely eliminated.
The marks are similar to Figure 1, approximately 1mm wide.
• Paper stack marks may only appear on the edge of the stack (but not on the surface of Y N
the print), they should be relatively faint. This type of marking is normal and no permanent The machine has a HVF.
solution is available. To clean, run chase pages, TP 12 to the affected tray until the defect Y N
fades. The benefits of cleaning are temporary. Print three copies of TP 4 Yellow Solid Fill Test Pages (TP 2 to TP 10) to different
output trays to isolate where the marking is taking place. Inspect the media path of
the LCSS. Look for trapped media debris or a build up of ink. Clean any contamina-
tion from the media path.
Initial Actions
The marks are similar to Figure 2.
Y N
WARNING Slight amounts of ink accumulation will show up as marks on the edge of the stack
Ensure that the electricity to the machine is switched off while performing tasks that do (on a large job). As the accumulation of ink increases, it can cause ink marks on the
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause surface of the print from the ink transferring from the ribs onto the media. These
death or injury. Moving parts can cause injury. marks are approximately 1 mm wide and correspond to the rib locations. Clean any
contamination from the media path.
WARNING The booklet maker has additional paper path features which contact the image and create
Take care during this procedure. The stripper blade is very sharp and can cause injury. localised scuff marks. Clean the media path of the booklet maker.
The defect may occur when booklet making with paper above 120 gsm. The ink may
transfer from one sheet to the other sheet it is being folded against. If this occurs then use
WARNING paper of 120 gsm or below.
Print three copies of TP 4 Yellow Solid Fill Test Pages (TP 2 to TP 10) to different output trays
to isolate where the marking is taking place. Inspect the media path of the finisher. Look for a
build up of ink on ribs. Clean any contamination from the media path.
WARNING
CAUTION
If media is found between the drum and IOD sensor, remove the IOD sensor before removing
the media. Pulling media out over the IOD can damage the IOD shield.
• Clear the media path. Check the area surrounding the drum, IOD, cleaning unit, abate-
ment plenum, transfix roller, and drum stripper blade for ink debris or for full or partial
sheets of media.
• Check the pre-heater for ink debris.

A
Machine Only Y N
Procedure
1. Check the stripper solenoid SOL10-021, PL 10.10 Item 3. Refer to 10-570-00
Check that the front drum thermistor, PL 94.20 Item 9 and the rear drum thermistor, PL 94.20
Stripper Solenoid Over Current RAP. If necessary, install a new stripper sole-
Item 10 are not bent or misaligned. Check for paper debris between the thermistors and the
noid assembly, PL 10.10 Item 3.
drum and ensure that the thermistors are making good contact with the drum. Thermistors
are good. 2. Remove the cleaning unit, refer to REP 94.1. Make sure the cleaning unit has
sufficient oil. If necessary, cleaning unit, PL 94.10 Item 21.
Y N
Install new components as necessary 3. Inspect the cleaning unit camshaft assembly, PL 94.10 Item 4 for obstructions
that would prevent it from moving freely. Remove the camshaft assembly.
Check the bushings, PL 94.10 Item 8 and PL 94.10 Item 14 for wear or dam-
• Rear drum thermistor, PL 94.20 Item 10. age. If necessary, install a new camshaft assembly, PL 94.10 Item 4.
4. If necessary, install a new drum stripper blade, PL 10.12 Item 3.
Perform dC335 Heater Monitor and Exerciser. Check the drum operating temperature. Drum
temperature is good.
Y N Print TP 15 Media Path Test Pages, to determine where in the paper path the marking is
occurring. Refer to GP 27 Cleaning Procedure to clean the media path.
Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-00,
If the problem persists, check the following areas for accumulation of ink or media debris.
94-633-00 Drum Heat Error RAP.
Clean as necessary:
Perform dC335 Heater Monitor and Exerciser. Check the preheat operating temperature. Pre- • Cleaning unit metering blade, refer to IQ 21.
heat temperature is good. • Abatement plenum, PL 94.20 Item 12.
Y N • IOD shield and sensor, PL 94.15 Item 1.
Go to 88-500-00 to 88-502-00 Preheat Thermal Error RAP.
• Roller nip N, PL 10.15 Item 1 and roller nip P PL 10.15 Item 6.
Refer to 88-508-00 Registration / Preheat Air Pump Incorrect Current RAP. The Registration • Paper path ribs and guides.
/ Preheat air pump is good.
Y N
Install a new registration / preheat air pump, PL 88.10 Item 5.
Press the Machine Status button select the fault tab on the UI and enter Current Messages.
Check if the message ‘Cleaning unit life extended, image may be impacted’ is displayed. A
different message is displayed.
Y N
Open the front door and remove the inner cover. Enter dC959 and run the slow speed exer-
ciser. While this is running, check that the cleaning unit blade and roller are making contact
with the drum. The cleaning unit blade and roller are making contact with the drum.
Y N
Check the front cam, PL 94.10 Item 9, rear cam, PL 94.10 Item 13, drive gear, PL 94.10
Item 23 and the cleaning unit motor, PL 94.10 Item 24 The components are good.
Y N
Enter dC969 and run Clean Print Smears. Print three copies of TP 4 Yellow Solid Fill Test
Pages (TP 2 to TP 10). Test prints are good.
Y N
Open the stripper gate, GP 31. Check the drum stripper blade for accumulations of ink or
other debris. The stripper blade is clean.
A
Figure 1 Finisher rib marking example Figure 2 HVF BM ejector marking example

IQ 12 Missing or Partial Image RAP
Use this RAP to troubleshoot wide deletions in the process direction that affect a complete
printhead or a when a single colour is missing from a single printhead.
The problem is usually caused by a communication or power error in the marking unit and
causes the substantial or complete loss of a single printhead, Figure 1 and may be seen in one
or all colours. The problem may be an ink supply problem if only a part of the printhead is miss-
ing.
NOTE: Blank sheets accompanying multi-feeds or chase pages following a jam are normal.
Figure 1 Printhead 2 failure
Figure 3 Streaking from IOT

A B C D E
Initial Actions Y N
Install a new IME controller PWB, PL 92.10 Item 1. Print the ini-
tial test pages, TP 1. The test pages are good.
WARNING Y N
Install a new printhead, PL 91.20 Item 2 or PL 91.25 Item
2.
CAUTION Perform SCP 5 Final Actions.

Install new ribbon cables on the printhead that now shows the defect, PL
92.10 Item 7 and PL 92.10 Item 8.
CAUTION
Printhead ribbon cables are interchangeable. Damage to the IME controller PWB is likely if the Perform SCP 5 Final Actions.
cables are installed incorrectly.
CAUTION Perform the relevant RAP.

• Check for media or debris around the printhead and drum. Clean as necessary, refer to
GP 27 Cleaning Procedure.
Procedure
Switch off, then switch on the machine, GP 14. Check the PEST fault history, dC123. New
faults are listed in the PEST history.
Y N
Print the initial test pages, TP 1. Test pages are good.
Y N
NOTE: Before printing TP 26, ensure that A4 or 8.5 x 11 inch plain paper is loaded
long edge feed into tray 4. Use the best quality media available. Do not use hole
punched paper.
Perform dC968 Head Purge on the affected printhead. Print TP 26 Printhead Unifor-
mity / Colour Bands Test Page. Test prints are good.
Y N
Reseat the two ribbon cables, PL 92.10 Item 7 and PL 92.10 Item 8, attached to
the affected printhead. Print the initial test pages, TP 1. The prints are good.
Y N
Switch off the machine, GP 14. Swap the two ribbon cables on the
affected printhead with the two ribbon cables on the working printhead on
the same carriage. Switch on the machine, GP 14. Print the initial test
pages, TP 1. The defect moves to a new location.
Y N
Install a new quad waveamp PWB, PL 92.10 Item 3. Print the initial
test pages, TP 1. The test pages are good.
A B C D E
IQ 13 All Colours Uneven RAP X-Axis Checkout
Use this RAP to troubleshoot uneven colours in all four primary colours (cyan, magenta, yellow Refer to Figure 1.
and black).
Initial Actions
• Enter the customer administration tools, GP 5. On the Tools tab select Troubleshooting
then Automatic Light Lines Fix. Set Quick Fix to On. Set Full Fix to Eco Fix.
restored to the original settings when the image quality defect has been corrected.
• Try running the customers image in a higher print resolution.
Procedure
WARNING
CAUTION
Figure 1 X-axis motion error
CAUTION
If carriage motion is obstructed to the point of producing stringy lines of ink, it is likely that
CAUTION
strings of ink are scattered throughout the machine’s interior. Check the printheads, abatement
Do not touch the exposed face of the printheads. Surface contamination or minor damage can plenum, exit module, and transfix roller for ink residue, clean as necessary, GP 27. Refer to IQ
easily make the printhead unusable. 20 Wavy or Stringy Lines of Ink/Blistering RAP.
1. Evaluate the colour bands test page, TP 26. Check for the following defects. Procedure
• High frequency lines of missing ink, dark lines or both, in the process direction, Fig-
Print the stitch identification test pages, TP 16. The prints are good.
ure 1. The lines are across the width of a printhead. If observed, go to X-Axis Check-
Y N
out.
• Dark or light bands in the process direction, across the width of a printhead, Figure
1. Check for restrictions to printhead motion:
2. The defect might be more noticeable in single colours, Figure 3. If observed, go to
Uniformity Checkout. a. Wrong harness routing, refer to GP 28 Marking Unit Assembly Wiring Har-
nesses.
• Faded lines in the process direction with indistinct edges, Figure 4. The defect is
noticeable in all colours but may be more apparent in some, Figure 5. If observed, go b. Umbilical routing, PL 91.20 Item 10 and PL 91.25 Item 10. Check for obstruc-
to Uniformity Checkout. tions or damage.
• Faded lines in the cross process direction, Figure 6. Ringing seen between horizon- c. Contamination of the front and rear bearing shafts on the upper and lower
tal lines. If observed, go to Ringing Checkout. SFWA frames.
• If the defect is not apparent in all four primary colours, go to the IQ 14 Uneven in d. Check that the orange shipping restraint clips are removed from the carriages.
Some Colours RAP. If the colours are spatially uniform but incorrect, go to the IQ 15 2. Check the condition of the x-axis motors, PL 91.20 Item 5 and PL 91.25 Item 5:
Wrong Colour RAP. • Check for disconnected or damaged wiring harnesses. Repair as necessary,
REP 1.1.
A
A
• Check the X-axis drive motor lead screw, and cone nut. Check that the anti- Uniformity Checkout
rotation stop is engaged. Refer to REP 91.9 X Axis Drive Motor.
Refer to Figure 2, Figure 3, Figure 4 and Figure 5.
abled and will not operate in dC914. Use the dC330 component control chain 91 to
run these components.
3. Perform dC914 Head to Head Alignment Test to check carriage motion. After cor-
recting any obstructions, perform dC971 Head to Head Alignment Adjust. Reprint
the stitch identification test print, TP 16.
The prints are good.
Y N
• X-axis motor, PL 91.20 Item 5.
Perform dC971 Head to Head Alignment Adjust to align the printheads.
Figure 2 Printhead wide non-uniformity

Figure 3 Printhead non-uniformity on dithers Figure 4 Jet to jet non-uniformity

B C
1. Option 6 Reset head uniformity data.
2. Option 2 Head to head alignment adjust.
3. Option 3 Head to head uniformity.
4. Option 4 TRC Generation.
5. Option 5 Y-dot position correction.
Print TP 1. Evaluate the cyan / magenta test page and the red, blue and green
bands on the colour bands test page for distinctive non-uniform bands in the process
direction The prints are good and without non-uniform bands.
Y N
NOTE: The head to head uniformity uses one head as a reference to adjust the
other printheads. Swapping the printheads then changes the reference print-
head, which often results in better uniformity.
Swap printhead 1 with printhead 2 and printhead 3 with print head 4. On a 9201
machine make sure there are no chronic jets on print head 1 or printhead 4
before swapping the heads. If chronic jets are present, then replace the print
head that has a difference appearance than the other printheads. Perform
dC972, Print TP 1 and evaluate the cyan / magenta and the red, blue and green
bands in the colour bands prints for distinctive non-uniform bands in the pro-
cess direction The prints are good and without non-uniform bands.
Y N
Install new print heads as required, PL 91.20 Item 2 or PL 91.25 Item 2.
NOTE: Certain colours (such as darker shades of blue, red and green) are
more prone to show process direction banding. If banding is not seen on the
test prints but the issue is with a particular shade of a colour as opposed to all
or many shades of a colour, no other adjustments or repairs actions are possi-
ble.
Figure 5 Jet to jet non-uniformity on dithers
Advise the customer to print the image in another print resolution or colour cor-
rection may result in a more satisfactory image. Changing the colour in the cus-
Procedure tomers application may result in a more satisfactory image.
NOTE: Before printing the test pages, ensure that A4 or 8.5 x 11 inch plain paper is loaded Perform SCP 5 Final actions.
long edge feed into tray 4. Use the best quality media available. Do not use hole punched
paper. NOTE: Certain colours (such as darker shades of blue, red and green) are more
prone to show process direction banding. If banding is not seen on the test prints but
Evaluate the cyan / magenta test page and the red, blue and green bands in the colour bands the issue is with a particular shade of a colour as opposed to all or many shades of a
print (TP 1). Check for distinctive non-uniform bands in the process direction. The prints are colour, no other adjustments or repairs actions are possible.
good and without non-uniform bands.
Advise the customer to print the image in another print resolution or colour correction
Y N
may result in a more satisfactory image. Changing the colour in the customers appli-
Perform the following dC972 Print Head Uniformity routines:
cation may result in a more satisfactory image.
1. Option 3 Head to head uniformity.
2. Option 4 TRC Generation. Perform SCP 5 Final actions.
3. Option 5 Y-dot position correction.
Print TP 1. Evaluate the cyan / magenta test page and the red, blue and green bands on
the colour bands test page for distinctive non-uniform bands in the process direction.
The prints are good and without non-uniform bands.
Y N
B C B
B
NOTE: Certain colours (such as darker shades of blue, red and green) are more prone to
show process direction banding. If banding is not seen on the test prints but the issue is
with a particular shade of a colour as opposed to all or many shades of a colour, no other
adjustments or repairs actions are possible.
Advise the customer to print the image in another print resolution or colour correction may
result in a more satisfactory image. Changing the colour in the customers application may
result in a more satisfactory image.

NOTE: Certain colours (such as darker shades of blue, red and green) are more prone to show
process direction banding. If banding is not seen on the test prints but the issue is with a partic-
ular shade of a colour as opposed to all or many shades of a colour, no other adjustments or
repairs actions are possible.
Ringing Checkout
Refer to Figure 6. This example is LEF in the process direction. Ringing is both pattern and
image orientation dependent.
Figure 6 Ringing defect
Procedure
If printing on A4 or 8.5 x 11 inch paper, change the media orientation in the tray. Reprint the
customer job. The print is good.
Y N
The printer may be printing within specification. The defect is consistent printhead to
printhead.
Y N
No service action required. The defect is within specification.

IQ 14 Some Colours Uneven RAP • Dark discolouration in wide bands across a whole printhead in the process direction, Fig-
ure 3. Uniform dark discolouration across a whole printhead. If observed, go to Ink Mixing
Use this RAP to troubleshoot the following defects:
in the Printhead or in the Ink Melt Reservoir Checkout.
• Discolouration across the whole page, Figure 4. Uniform discolouration in a single colour
• Light lines in the process direction
across the whole page. If observed, go to Ink Mixing in the Printhead or in the Ink Melt
• Dark lines in the process direction Reservoir Checkout.
• Light discolouration in wide bands across a whole printhead in the process direction • Light discolouration in wide bands across a whole printhead in the process direction, Fig-
• Dark discolouration in wide bands across a whole printhead in the process direction ure 4. Uniform light discolouration across a whole printhead. If observed, go to Ink Mixing
• Discolouration in a single colour primary across the whole page in the Printhead or in the Ink Melt Reservoir Checkout.
• Banding in the process direction • Banding in the process direction. Faded bands in the process direction across all colours,
Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Figure 5 or visible as coloured bands on single colour dithers, Figure 6. If observed, go to
the Banding Checkout.
Initial Actions • If the defect is apparent in all four primary colours, go to the IQ 13 Uneven in All Colours
• Enter the customer administration tools, GP 5. On the Tools tab select Troubleshooting RAP. If the colours are spatially uniform but incorrect, go to the IQ 15 Wrong Colour RAP.
then Automatic Light Lines Fix. Set Quick Fix to On. Set Full Fix to Eco Fix.
restored to the original settings when the image quality defect has been corrected.
• Check the machine for Mod/TAG 022, refer to critical service bulletin C8090-05-07.
Procedure
WARNING
CAUTION
CAUTION
Evaluate the colour bands test page, TP 26. Check for the following defects:
• Light lines in the process direction in a primary colour with corresponding light lines in
secondary colours, Figure 1. Distinct parallel lines, often in groups of six lines, within a
single primary colour and the corresponding secondary colours. If observed, go to the
Missing Jet Checkout.
• Dark lines in the process direction in a primary colour with corresponding dark lines in
secondary colours, Figure 2. Distinct parallel lines, often in groups of six lines, within a
single primary colour and the corresponding secondary colours. If observed, go to the Ink
Mixing at the Printhead Faceplate Checkout.

Missing Jet Checkout Ink Mixing at the Printhead Faceplate Checkout
Missing jets usually occur on a single printhead. Figure 1 shows examples of missing jets on Figure 2 is an example of ink mixing at the surface of the printhead faceplate, showing the
multiple printheads to indicate various combinations of colours. The illustration shows a cyan defect clearing up over a series of prints. This symptom appears as yellow ink looking black. To
missing jet on printhead 1, a magenta missing jet on printhead 2, a yellow missing jet on print- a lesser degree, cyan and magenta may look darker. Black is generally not affected.
head 3, and a black missing jet on printhead 4. The defect is the width of a single jet. The
defect could involve more than one jet of one or more colours.
NOTE:
• Missing cyan jets affect green and blue
• Missing magenta jets affect red and blue
• Missing yellow jets affect red and green
• Missing black jets affect dark shades of all colours
Figure 2 Ink mixing clearing with repeated prints
Procedure
Perform dC965 Printhead Maintenance Test. Check carriage and wiper motion. The wiper
contacts and moves smoothly across the printhead faceplate area.
Y N
Wiper chatter is observed.
Y N
Figure 1 Missing jet example Go to the 91-572-00, 91-573-00, 91-575-00 Wiper Vertical Error RAP.
Procedure Install a new wiper blade, PL 91.15 Item 13.

Go to 91-638-00, IOD Detects Chronic Jet Error RAP.
Print 3 sets of cleaning pages, TP 22. Print the Initial Test Print Pages, TP 1. If ink mixing is still
present, the defect is not caused by printhead faceplate mixing. Re-define the image quality
defect, refer to IQ 1 Image Quality Entry RAP.

Ink Mixing in the Printhead or in the Ink Melt Reservoir Checkout
Ink mixing may occur in the printhead or in the ink melt reservoir. Ink mixing in the printhead
appears as a band across the image, Figure 3. Ink mixing in the ink melt reservoir appears as
discolouration in all four printheads, Figure 4.
Figure 4 Ink mixing in the ink melt reservoir
Procedure
Check for evidence of overfilling of the reservoir, PL 93.10 Item 10. The reservoir is filled to
the correct level.
Figure 3 Ink mixing in printhead 4 Y N
Go to 93-901-00 to 93-904-00 Ink Melt Reservoir Fill Failure RAP.
Check for evidence of cross contamination of the ink melt reservoir. The reservoir is clear of
cross contamination.
Y N
1. Install a new reservoir, PL 93.10 Item 10.
2. dC968 Head Purge 3 times.
Check for leaks in the umbilical connections. The umbilical connections are good.
Y N
Go to 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP.
A
A
Print the colour bands test page, TP 26. Evaluate the test page. All colours are good except
cyan (cyan is mixed with green).
Y N
Ink discolouration is across all 4 printheads.
Y N
Perform dC968 Head Purge 3 times. Purge all 4 printheads. The discolouration
has increased and affects all four heads.
Y N
Check the service log for previous instances of ink mixing. Ink mixing is a
new fault.
Y N
Perform dC968 Head Purge 3 times. Record which printhead had ink discolou-
ration in the service log. Enter GP 5 Customer Administration Tools. Check if
Intelligent Ready power save mode is on. If necessary, advise the customer
that using Intelligent Ready power save mode may avoid future ink discoloura-
tion.
NOTE: Do not change the customer settings.
Install a new reservoir, PL 93.10 Item 10. Perform dC968 Head Purge 3 times.
Install a new reservoir, PL 93.10 Item 10. Perform dC968 Head Purge 3 times.
Perform dC968 Head Purge 3 times. Enter GP 5 Customer Administration Tools. Check if Intel-
ligent Ready power save mode is on. If necessary, advise the customer that using Intelligent
Ready power save mode may avoid future ink discolouration.
NOTE: Do not change the customer settings. Figure 5 Banding on colour bands
Banding Checkout
Refer to Figure 5 and Figure 6.

B
3. Option 5 Y-dot position correction
Print TP 1. Evaluate the cyan / magenta test page and the red, blue and green bands on
the colour bands test page for non-uniform bands in the process direction. The prints
are good and without non-uniform bands.
Y N
1. Option 6 Reset head uniformity data
2. Option 2 Head to head alignment adjust
3. Option 3 Head to head uniformity
4. Option 4 TRC Generation
5. Option 5 Y-dot position correction
Print TP 1. Evaluate the cyan / magenta test page and the red, blue and green
bands on the colour bands test page for non-uniform bands in the process direction.
The prints are good and without non-uniform bands.
Y N
NOTE: The head to head uniformity uses one head as a reference to adjust the
other printheads. Swapping the printheads then changes the reference print-
head, which often results in better uniformity.
Swap printhead 1 with printhead 2 and printhead 3 with print head 4. On a 9201
machine make sure there are no chronic jets on printhead 1 or printhead 4
before swapping the heads. If chronic jets are present, then replace the print
head that has a difference appearance than the other printheads. Perform
dC972, Print TP 1 and evaluate the cyan / magenta and the red, blue and green
bands in the colour bands prints for a distinctive non-uniform bands in the pro-
cess direction. The prints are good and without non-uniform bands.
Y N
Install new printheads as required, PL 91.20 Item 2 or PL 91.25 Item 2.
Figure 6 Banding in dithers Perform SCP 5 Final actions.
NOTE: Certain colours (such as darker shades of blue, red and green) are
Procedure more prone to show process direction banding. If banding is not seen on the
test prints but the issue is with a particular shade of a colour as opposed to all
CAUTION or many shades of a colour, no other adjustments or repairs actions are possi-
ble.
Ink mixing and ink discolouration must be corrected first. If not, printer calibration is performed
with the wrong colour ink, and will require a future service call. Advise the customer to print the image in another print resolution or colour cor-
rection may result in a more satisfactory image. Changing the colour in the cus-
Try running the customers image in a higher print resolution.
tomers application may result in a more satisfactory image.
NOTE: Before printing the test pages, ensure that A4 or 8.5 x 11 inch plain paper is loaded
paper. NOTE: Certain colours (such as darker shades of blue, red and green) are more
prone to show process direction banding. If banding is not seen on the test prints but
Evaluate the cyan / magenta test page and the red, blue and green bands in the colour bands
the issue is with a particular shade of a colour as opposed to all or many shades of a
print (TP 1). Check for non-uniform bands in the process direction. The prints are good and
colour, no other adjustments or repairs actions are possible.
without non-uniform bands.
Y N Advise the customer to print the image in another print resolution or colour correction
Perform the following dC972 Print Head Uniformity routines: may result in a more satisfactory image. Changing the colour in the customers appli-
1. Option 3 Head to head uniformity cation may result in a more satisfactory image.
2. Option 4 TRC Generation Perform SCP 5 Final actions.
B B
B
NOTE: Certain colours (such as darker shades of blue, red and green) are more prone to IQ 15 Wrong Colour RAP
show process direction banding. If banding is not seen on the test prints but the issue is
Use this RAP when the colours on the image are wrong. Refer to Figure 1, Figure 2, Figure 3
with a particular shade of a colour as opposed to all or many shades of a colour, no other
and Figure 4 to compare the defect to the colour band service test pattern, Figure 5.
adjustments or repairs actions are possible.
Advise the customer to print the image in another print resolution or colour correction may Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.
Initial Actions
NOTE: Certain colours (such as darker shades of blue, red and green) are more prone to show
WARNING
process direction banding. If banding is not seen on the test prints but the issue is with a partic-
ular shade of a colour as opposed to all or many shades of a colour, no other adjustments or Ensure that the electricity to the machine is switched off while performing tasks that do
repairs actions are possible. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
WARNING
Do not touch the ink reservoir while it is hot.
CAUTION
• Enter GP 5 Customer Administration Tools. Check if Intelligent Ready power save mode
is on. If necessary, advise the customer that using Intelligent Ready power save mode
may avoid future ink discolouration.
NOTE: Do not change the customer settings.
• Ensure that all inks are loaded in their correct channel in the ink loader. If necessary, rub
the ink sticks on a clean sheet of white paper to determine the stick colour.
Procedure
The colour band service test pattern (XTP 798.000), PL 26.11 Item 15 is used to determine if
there are large differences in colour. No action should be taken to correct minor differences in
colour that may occur between print and test pattern. Magenta is a colour that may look darker
on the test target, but this is normal.
Print the colour bands test page, TP 26. Compare the print with Figure 1, Figure 2, Figure 3
and Figure 4. Wrong colours are seen across the entire print.
Y N
Go to the IQ 14 Uneven in Some Colours RAP.
Check for ink leakage around the umbilical connections. The umbilical connections are
good.
Y N
Go to the 93-937-00 to 93-940-00 Ink Melt Reservoir Leak Error RAP.
A
A
Print the colour bands and dithers test pages, TP 11. The colours are correct compared to
the service target.
Y N
Switch off, then switch on the machine, GP 14, to clear any corrupt data. Print the colour
bands and dithers test pages, TP 11. The colours are correct compared to the service
target.
Y N
Perform dC968 Head Purge 3 times. Print 3 sets of cleaning pages, TP 22. Print the
colour bands and dithers test pages, TP 11. The colours are correct compared to
the service target.
Y N
Install a new ink reservoir PL 93.10 Item 10. Perform dC968 Head Purge 3
times to prime the ink delivery system. Print the colour bands and dithers test
pages, TP 11. The colours are correct compared to the service target.
Y N
Reseat all connections on the IME Controller PWB. If necessary, install a
new IME controller PWB, PL 92.10 Item 1.
If TP 11 is good but the customer’s print jobs are incorrect, advise the customer to check the
print driver settings.
Figure 1 Ink discolouration

Figure 2 Ink mixing (cyan into yellow) Figure 3 Incorrectly loaded ink black into cyan

Figure 4 Corrupt image data Figure 5 Service test pattern

A
IQ 16 Scratches or Gloss Marks in the Process Direction Separate the finisher from the printer. Install a finisher bypass connector, PL 26.10 Item 3. Print
a duplex copy of TP 6 Red Solid Fill Test Page (TP 2 to TP 10). Evaluate both sides of the test
RAP page for process direction gloss streaks. Test page is good.
Use this RAP when the output displays scratches or gloss marks in the process direction. Y N
Open the stripper gate, GP 31. Check the stripper blade for accumulations of ink or media
Scratches or marks typically result from contact with transport components rollers and ribs or debris. The stripper blade is clean.
debris in the media path. Y N
This defect may be accompanied with ink that is smudging in the non-imaged area of the
media in line with the rollers or ribs. Roller marks usually have a well defined width of 10 to 15 Print TP 15 Media Path Test Pages to isolate where the marking is taking place. Inspect,
mm, and run in the process direction, and are evenly spaced across the print. Rib marks are clean, or install new rollers as necessary.
faint, narrow (up to 2 mm) burnish marks evenly spaced in the process direction. These typi- If the problem persists perform the following:
cally come from the finishers. The HVF finisher and booklet maker have features which contact • Check the following components for accumulations of ink or media debris.
the image and can create localized scuff marks.
– Abatement plenum, PL 94.20 Item 12.
– IOD shield and sensor, PL 94.15.
• Inspect the drum for scratches, if necessary install a new drum, PL 94.20 Item 1.
Procedure • Install a new cleaning unit, PL 94.10 Item 21. Print 3 duplex copies of TP 5 Black
Solid Fill Test Pages (TP 2 to TP 10) and evaluate the prints for scratches or gloss
marks
WARNING Scratches or gloss marks are present.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform SCP 5 Final Actions.
Re-install the original cleaning unit. The problem is not in the cleaning unit. Re-define the
image quality defect, refer to IQ 1 Image Quality Entry RAP.
WARNING
The defect is located in the finisher. Dock and connect the finisher. Isolate the location where
Take care during this procedure. The stripper blade is very sharp and can cause injury. the marking is taking place by print one copy of TP 6 Red Solid Fills Test Page (TP 2 to TP 10)
to each output tray. Inspect the media path of the finisher. Look for a build up of ink on ribs and
rollers. Clean any contamination from the media path. Check for dislodged rollers, install new
WARNING components as necessary.
WARNING
NOTE: There are usually no corrective actions for the defect. Some ribs can be cleaned, refer
to GP 27. Printing up to 50 TP 12 Chase pages can clean the ribs temporarily. Advise the cus-
tomer that simplex jobs on light weight media cause fewer problems than duplex jobs on heavy
weight media.
Check the cleaning unit metering blade for paper debris or damage.
NOTE: Ink pixel build up on the metering blade is normal and should not be cleaned off.
The metering blade is good.

Y N
Clean the metering blade of debris. If necessary, install a new cleaning unit PL 94.10 Item
21.
A
IQ 17 Gloss Marks in the Cross-Process Direction RAP Y N
Enter dC959 Cleaning Unit Exerciser. Run the cleaning unit self test. Cleaning unit self
Use this RAP when the output has gloss marks in the cross process direction.
test completes successfully.
Y N
Typical defects include: Install new cleaning unit, PL 94.10 Item 21.
• Chatter, refer to Figure 1. The cleaning unit metering blade is vibrating as it spreads oil
Check the cleaning unit metering blade for paper debris or damage.
onto the drum. Trace amounts of chatter on duplex is normal.
• Insufficient oil. Insufficient oil causes the inked sheet to appear glossier than normal and NOTE: Ink pixel build up on the metering blade is normal and should not be cleaned off.
may also have cross-process cracking marks. This defect can also be caused by high
drum temperature.
Y N
• Jagged streaks, refer to Figure 1. The metering blade is leaving excess oil on the drum. Clean the metering blade of debris. If necessary, install a new cleaning unit PL 94.10
• When the registration/preheat assembly is too hot, on a duplex print, the side that is face Item 21.
up in the output tray can have significantly lower gloss than the side that is face down.
• Gloss band. Some print sequences may result in a gloss band, usually 2-3 inches wide, Enter dC959 Cleaning Unit Exerciser and run the slow speed exerciser. slow speed
that may be visible under some lighting conditions. This is normal. exerciser completes successfully.
• Duplex gloss marks may appear for the first several duplex sheets following a simplex Y N
Go to 94-520-00 Cleaning Unit Drive Error RAP.
print job. Gloss marks will likely diminish after several prints. This is normal.
Open the front door and remove the inner cover. Enter dC959, Cleaning Unit Exerciser,
and run the slow speed exerciser. While this is running ensure the cleaning unit metering
Initial Actions blade and roller are making contact with the drum. Metering blade and roller are mak-
ing contact with the drum.
Y N
WARNING Check the cleaning unit cams mechanism PL 94.10 Item 9, PL 94.10 Item 13 and
Ensure that the electricity to the machine is switched off while performing tasks that do the cleaning unit drive gear and motor PL 94.10 Item 23, PL 94.10 Item 24. Install
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause new parts as necessary.
Check that the front drum thermistor, PL 94.20 Item 9 and the rear drum thermistor, PL
94.20 Item 10 are not bent or misaligned. Check for paper debris between the thermistors
WARNING and the drum and ensure that the thermistors are making good contact with the drum.
Thermistors are good.
Y N
• Front drum thermistor, PL 94.20 Item 9
WARNING • Rear drum thermistor, PL 94.20 Item 10
Perform dC335 Heater Monitor and Exerciser. Check the drum operating temperature.
Press the Machine Status button on the keypad, select the Fault tab on the UI, then Current
Drum temperature is good.
Messages. If the message ‘Cleaning unit life extended, image quality may be impacted’ is dis-
Y N
played, install a new cleaning unit, PL 94.10 Item 21.
Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-
00, 94-633-00 Drum Heat Error RAP.
Procedure
Print 3 simplex copies of TP 6 Red Solid Fill Test Pages (TP 2 to TP 10). Inspect the final test The machine is operating within specification. Perform SCP 5 Final Actions.
page only for metering blade chatter, refer to Figure 1. Test pages are good.
Y N Re-define the image quality defect, refer to IQ 1 Image Quality Entry RAP.
Install new cleaning unit, PL 94.10 Item 21.
Print 5 duplex copies of TP 6 Red Solid Fill Test Pages (TP 2 to TP 10). Inspect the final test
page only for metering blade chatter, refer to Figure 1. Test pages are good.

IQ 18 Irregular Duplex Gloss Differences RAP
Use this RAP when the output displays gloss variations visible on large areas of high ink cover-
age.
Irregular gloss defects can be in any direction, Figure 1.
Initial Actions
WARNING
• Check the media type. Smoother media will provide a more uniform gloss finish.
• Check that the gloss defect is found only on the second printed side of a duplex print and
has an irregular shape.
If the gloss defect is present on simplex prints and runs in either the process or cross pro-
cess direction, go to:
– IQ 16 Scratches or Gloss Marks in the Process Direction RAP
– IQ 17 Gloss Marks in the Cross-Process Direction RAP
– IQ 19 Image Ghosting RAP
Feed direction
Procedure
Metering blade chatter Jagged streaks
Perform dC959 Cleaning Unit Exerciser. The cleaning unit self test is successful.
Y N
Figure 1 Cross-process gloss defects
NOTE: When printing TP 5 from dC959, ensure that A4 or 8.5 x 11 inch plain paper is loaded
paper.
Print four duplex copies of TP 5 Black Solid Fill Test Pages (TP 2 to TP 10). Evaluate the final
prints for irregular gloss defects.
NOTE: It is normal for the second printed side (page 1) to be glossier than the first printed side
(page 2).
Check that page 1 shows uniform gloss across the page and that no gloss defects are visible.
Page 1 is good.
Y N
Run dC335 Heater Monitor and Exerciser Check the registration / preheat assembly tem-
perature. Select RaLPH in the component list. The registration / preheat temperature
is good.
Y N
Go to 88-500-00 to 88-502-00 Preheat Thermal Error RAP.
Check the registration/preheat air pump, refer to 88-508-00 Registration/Preheat Air

Pump Incorrect Current RAP. The registration/preheat air pump is good.
A
A
Y N IQ 19 Image Ghosting RAP
Install a new registration/preheat air pump, PL 88.10 Item 5.
Use this RAP to fix image ghosting problems. Two types of ghosting are possible, simplex and
duplex. Examples of each type are shown in Figure 1 and Figure 2.
The printer is operating within specifications. Refer to IQ 19 Image Ghosting RAP for
additional fixes.
NOTE: Blocking, where ink from one print is deposited on the back of another print, can occur
when prints stack in the output tray. The combination of pressure from the weight of the media
and ambient heat may cause partial transfer of the image to adjacent prints.
Initial Actions
WARNING
• Duplex ghosting may be caused by oil from the first side of the print transferring to the
second side via the transfix roller. Some amount of transfix roller ghosting is normal. This
type of ghosting is most pronounced on the first 2-sided print. Ghosting should fade on
subsequent prints. When duplex ghosting is evident run multiple 2-sided prints to attempt
to clear the defect and inform the customer.
• Attempt to repeat the customer's job using their print sequence and media.
• Press the Machine Status button on the keypad, select the Fault tab on the UI, then Cur-
impacted’ is displayed, install a new cleaning unit, PL 94.10 Item 21.
Procedure
NOTE: Before printing TP 5 or TP 20, ensure that A4 or 8.5 x 11 inch plain paper is loaded long
Print TP 13, followed by four prints of TP 5 Black Solid Fill Test Pages (TP 2 to TP 10). Evalu-
ate the third and fourth prints for evidence of text in the black solid fills, visible as a gloss differ-
ence. The prints are good.
Y N
Figure 1 Irregular gloss print defect The defect is simplex ghosting. Enter dC959 and run the Cleaning Unit Self Test. Self-
test is successful.
Y N
Remove the cleaning unit and inspect for paper debris on the cleaning unit metering
blade.
Y N
Remove paper debris from the cleaning unit metering blade.
Perform dC959 Cleaning Unit Exerciser. Self-test completes successfully.
A
A
Y N
Print TP 20 Oil Bar Chase and Metering Blade Timing Test Pages. Evaluate the meter-
ing blade timing test page only. Test pages are good.
Y N
Go to IQ 7 Metering Blade Timing RAP.
94.20 Item 10 are not bent or misaligned. Check for paper debris between the thermistors
and the drum and ensure that the thermistors are making good contact with the drum.
Y N
Y N
Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-
The defect is duplex ghosting which is inherent to the product. To reduce the defect, inform the
customer to:
• Reprint the job.
• Print multiple, 2-sided sheets with heavy ink coverage (solid fill), then reprint the job.
• If possible, use different media.
Figure 1 Example of simplex ghosting
• Print jobs that exhibit this defect simplex only.

IQ 20 Wavy or Stringy Lines RAP
Use this RAP to fix images that have wavy or stringy lines of ink, or have a blistered appear-
ance.
• Obstruction of the carriage drive causes lines of ink to be deposited on the drum, Figure
1. When this ink gets transfixed onto the media, it will have an embossed texture and
appears wavy. This defect is usually found on individual carriages.
• Excessive oil on the drum can result in a similar artifact with ink having a raised or blis-
tered appearance where the ink can be rubbed off. Refer to IQ 26.
NOTE: Another defect (not shown on the illustration) may occur on a single printhead where a
ribbon cable has become unseated. This defect can look like a muddy strip with the stringy
lines along one or both edges of the defect.
CAUTION
If carriage motion is obstructed to the point of producing stringy lines of ink, it is likely strings of
ink are scattered throughout the machine’s interior. Check the area surrounding the drum pay-
ing particular attention to the abatement plenum, IOD sensor, transfix roller, and exit module.
Printhead jetting may also be affected.
Procedure
WARNING
Figure 2 Duplex transfix roller ghosting The defect is across the entire process direction of the print.
Y N
Check that the printhead ribbon cables are correctly seated. The ribbon cables are
seated correctly.
Y N
Reseat the ribbon cables.
Go to IQ 13 All Colours Uneven RAP. Perform the X-Axis Checkout.
Remove the cleaning unit. Inspect the cleaning unit metering blade for paper debris.

Y N
Remove paper debris from the cleaning unit metering blade.
Perform dC959 Cleaning Unit Exerciser. Self-test completes successfully.

Y N
A
A
Open the front door and remove the inner cover. Enter dC959, Cleaning Unit Exerciser, and IQ 21 Oil on Output RAP
run the slow speed exerciser. While this is running ensure the cleaning unit metering blade and
Use this RAP when prints are contaminated with cleaning unit oil.
roller are making contact with the drum. Metering blade and roller are making contact with
the drum.
Y N Oil can transfer to prints in the form of spots, streaks, or cross-process lines from the metering
blade or drum stripper blade. The oily stain may appear clear or have traces of colour when
Check the cleaning unit cams mechanism PL 94.10 Item 9, PL 94.10 Item 13 and the
held up to light. Refer to Figure 1.
cleaning unit drive gear and motor PL 94.10 Item 23, PL 94.10 Item 24. Install new parts
as necessary.
Cotton, carbonless, parchment, linen or rough media are prone to poor ink transfer, causing gel
to build up in the cleaning unit which may be transferred to the print.
Oil stains may appear at the leading corners following the printing of several sheets where the
leading edge is narrower than the following job, for example short edge feed A4 (8.5 x 11) fol-
lowed by long edge feed A4 (8.5 x 11). This is expected behavior and will stop after a few
prints.
Oil spots may appear after clearing paper jams. The oil spots should stop after several prints.
This is expected behavior and will stop after a few prints.
Figure 1 Wavy or stringy lines defect

Initial Actions
Chronic spots or streaks • Check that the media is free of defects. Media defects can resemble oil spots.
of oil. May indicate a fault • Press the Machine Status button on the keypad, select the Fault tab on the UI, then Cur-
with the cleaning unit.
rent Messages. If the message ‘Cleaning unit life extended. Image quality may be
impacted’ is displayed, install a new cleaning unit, PL 94.10 Item 21. Inspect the area
around the drum for splattered oil. Clean as necessary, GP 27.
Procedure
WARNING
WARNING
WARNING
WARNING
Check the machine for oil spillage and clean as necessary GP 27. Machine oil spillage indi-
cates that the cleaning unit has failed.
NOTE: A thin film of oil on the chassis pan below the cleaning unit is normal.
Oil spillage is indicated.

Y N
Remove the cleaning unit PL 94.10 Item 21. Remove any paper debris from the metering
blade and roller area. Do not wipe the metering blade. Ink pixel build up on the metering
blade is normal. Print TP 20 Oil Bar Chase and Metering Blade Timing test pages. Evalu-
ate the oil bar chase page only.
NOTE: A thin line of oil approximately 35mm below the horizontal line and no more than
Oil stains at corners after switching from Oil stain due to gel build up in the cleaning 1mm wide is acceptable.
short edge feed to long edge feed. unit. Indicates that a new cleaning unit should
Should stop after several prints. be installed. The test page is good.
Y N
The oil bar chase page has an oil spot similar to Figure 2.
Figure 1 Examples of oil contamination
A B
A B
Y N
If the oil spots are randomly scattered on most prints, install a new cleaning
unit, PL 94.10 Item 21. Print TP 20 oil bar chase and metering blade timing test
pages. Evaluate the oil bar chase page only. The random oil spots are still
present.
Y N
Inspect the area around the drum for splattered oil. Clean as necessary,
GP 27.
Evaluate the metering blade timing test page. The test page is good.
Y N

1. Check the drum grounding, GP 7 System Grounding Verification.
2. Inspect the area around the drum for splattered oil. Clean as necessary,
GP 27.
Install a new cleaning unit, PL 94.10 Item 21. Print TP 20 oil bar chase and metering
blade timing test pages. Evaluate the oil bar chase page only. The test page is
good.
Y N
Figure 2 Oil spot

IQ 22 Repeating Spot Deletions RAP Procedure
Use this RAP when the output displays spot deletions, Figure 1. Check the stripper gate transport rollers J and L, PL 10.10 for dirt or debris. The rollers are
clean.
Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Y N
Initial Actions Clean the rollers, GP 27 or install new components as necessary:
• Roller drive J, PL 10.10 Item 1
• Roller drive L, PL 10.10 Item 2
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Print TP 2 to TP 10 Solid Fill Test Pages. Inspect all pages for scratches or marks caused by
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause the drum or the transfix roller, refer to Table 1.
Table 1 Repeating rotational defects
CAUTION Component Defect Spacing

Use care when moving the marking unit into the service position when hot. Ink can spill from Transfix A transfix roller defect appears approximately every 9 inches in the process
the ink reservoir located at the back of the unit if opened with too much force. Cross-colour ink Roller direction and in the same location in the cross-process direction.
contamination could also occur. Drum The drum's circumferential home position varies from print to print, so defect
spacing changes in the process direction. The drum defect remains in the
CAUTION same location in the cross-process direction, Figure 1.
render the printhead inoperative. Test pages are good.
• Check the media path for dust or debris accumulations. Clean as necessary, refer to GP Y N
27 Cleaning Procedure. Inspect the drum and transfix roller for ink, media debris, or cleaning unit residue. The
• Inform the customer that using the best quality, smoothest media available will reduce the drum and transfix roller are clean.
likelihood of encountering spot deletions. Y N
Clean the drum and transfix roller, refer to GP 27 Cleaning Procedure.
NOTE: Media containing cotton, linen or parchments can exhibit deletions due to surface tex-
ture. Carbonless media, especially in large quantities, can also exhibit deletions. Areas of Inspect the drum and transfix roller for damage. Install new components as necessary:
missing ink on envelopes that outline the seams and flaps is normal.
• Drum, PL 94.20 Item 1
• Transfix roller, PL 10.20 Item 1
Figure 1 Drum defect

IQ 23 Residual Ink From Previous Print RAP
Use this RAP when the output has residual ink from a previous image. Refer to Figure 1 and
Figure 2.
NOTE: Image transfer may also occur between media in the output tray. This effect, known as
blocking, may have a similar appearance to residual images from previous prints. Refer to IQ
30 Blocking RAP.
Initial Actions
• Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP.
• The blocking defect may occur when booklet making with paper above 120 gsm. The ink
may transfer from one sheet to the other sheet it is being folded against. If this occurs
then use paper of 120 gsm or below.
• If the customer is using punched media, check that the punched media is loaded correctly
and the tray setting is set to “Punched”.
Procedure
WARNING
Perform dC959 Cleaning Unit Exerciser Self Test. The test was successful.
Y N
Print the solid colour test pages (TP 2 to TP 10). Inspect the lead and trail edge of the test
pages for ink that is not fully transfixed, Figure 1 and for image skew, Figure 2. The test Figure 1 Residual ink due to incomplete transfix
pages are good.
Y N
Perform dC625 Registration/Preheat Calibration. Calibration completes without error.
Y N
Go to the 89-550-00, 89-551-00 Media Registration Error RAP.
Go to the IQ 6 Missing Ink or Grainy Output RAP.

IQ 24 Wrinkling RAP
Use this RAP when the output is wrinkled. Refer to Figure 1 and Figure 2.
NOTE: Some wrinkling of envelope flaps is normal.
Figure 2 Residual ink due to excessive skew
Figure 1 Wrinkles, reduced margins or image skew

Procedure
WARNING
WARNING
WARNING
WARNING
NOTE: Wrinkling can be aggravated by extreme temperature and humidity environments. To

reduce wrinkling, advise the customer to use a heavier weight media, change the feed orienta-
tion from LEF to SEF or increase the size of the image margins.
Print TP 1 Initial Test Print Pages. Check the prints for skew, refer to IQS 1 Registration and
Skew. The prints are skewed.
Y N
Using a fresh ream of paper, print 4, duplex TP 2 cyan solid fill test pages (TP 2 to TP
Figure 2 Wrinkles related to uneven ink coverage 10). The prints are good.
Y N
Perform dC625 Registration/Preheat Calibration. Print 4, duplex Cyan Solid Fill test
pages (TP 2 to TP 10). The prints are good.
Y N
Perform dC962 Transfix Load Test. Transfix loading is within specification.
Y N
Perform dC978 Transfix Calibration Values. Check the stored transfix cali-
bration values against those on the machine frame. If the stored values
are different, correct the transfix values in NVM. If the values are the
same, go to 10-500-00 to 10-540-00 Transfix Error RAP.
Open the stripper gate, GP 31. Check the drum stripper blade for damage,
debris or accumulation of ink. If necessary, install a new stripper blade, PL
10.12 Item 3. Print 4, duplex Cyan Solid Fill test pages (TP 2 to TP 10) The
prints are good.
Y N
Enter dC330 code 82-007, nip C release solenoid, PL 82.15 Item 4 and
82-008, nip D release solenoid, PL 70.30 Item 13. The solenoids ener-
gise.
A B C D
A B C D
Y N IQ 25 Random Spots RAP
Go to the 82-507-00, 82-508-00 Nip C and Nip D Release Solenoid
Use this RAP when the output has random spots. Refer to Figure 1.
Over Current RAP.
If the defect persists, inform the customer to use heavier weight media, a Random spots are usually ink debris from the stripper blade, abatement plenum or printheads.
Spots can appear on the image if the cleaning unit fails to thoroughly clean the drum. Large
different orientation or increase image margins.
spots of primary colours can be caused by a faulty printhead.
Test the customers print job on the newly opened media.

• If the wrinkle defect is on a print job. Enter the Print Setup options / Properties /
Advanced / Image Options and select Paper Compensation.
There is a slight increase in drop out and a small decrease in productivity when this
option is used. Only use when the wrinkle defect is present.
• If the wrinkle defect is on a copy job. Select Image Quality and then Paper Compen-
sation tab on the user interface.
There is a slight increase in drop out and a small decrease in productivity when this
option is used. Only use when the wrinkle defect is present.
• If the defect persists, inform the customer to use heavier weight media, a different
orientation or increase image margins.
Go to IQ 10 Incorrect Margin, Misregistration or Skew RAP.
Figure 1 Random spots from incomplete drum cleaning

A
Initial Actions Perform the self test routine in dC959 Cleaning Unit Exerciser. The cleaning unit self test is
successful.
Y N
WARNING Install a new cleaning unit, PL 94.10 Item 21.
Remove the cleaning unit PL 94.10 Item 21. Check the metering blade and roller area for
paper debris. The metering blade and roller area are free of paper debris.
Y N
Remove the paper debris from the metering blade and roller area. Do not wipe the meter-
ing blade.
WARNING
Take care during this procedure. The stripper blade is very sharp and can cause injury. NOTE: Ink pixel build up on the metering blade is normal and should not be cleaned off
Perform the slow speed exerciser routine in dC959 Cleaning Unit Exerciser. The test is suc-
cessful.
WARNING Y N
Do not clean the stripper blade. The stripper blade is very sharp and can cause injury. If Go to the 94-520-00 Cleaning Unit Drive Error RAP.
Open the front door and remove the inner cover. Enter dC959 and run the slow speed exer-
ciser. While this is running, check that the cleaning unit blade and roller are making contact
WARNING with the drum. The cleaning unit blade and roller are making contact with the drum.
Take care during this procedure. Sharp edges may be present that can cause injury. Y N
Check the front cam, PL 94.10 Item 9, rear cam, PL 94.10 Item 13, drive gear, PL 94.10
Item 23 and the cleaning unit motor, PL 94.10 Item 24
CAUTION Install new components as necessary.
the ink reservoir located at the back of the unit if opened with too much force. Cross-colour ink NOTE: Before printing TP 20, ensure that A4 or 8.5 x 11 inch plain paper is loaded long edge
contamination could also occur. feed into tray 4. Use the best quality media available. Do not use hole punched paper.
Print TP 20 Oil Bar Chase and Metering Blade Timing Test Pages. Evaluate the metering blade
CAUTION timing page only. The metering blade test page is good.
Y N
Go to the IQ 7 Metering Blade Timing RAP.
• Press the Machine Status button on the keypad, select the Fault tab on the UI, then Cur- Check the area surrounding the drum, transfix assembly, and exit module for ink residue or
rent Messages. If the message ‘Cleaning unit life extended. Image quality may be media debris. The areas are clean.
impacted’ is displayed, install a new cleaning unit, PL 94.10 Item 21. Y N
• Check the media. If low grade or recycled media is found, suggest using a better grade of Clean the areas surrounding the drum, transfix assembly, and exit module, refer to GP 27
media. Defects in the media may appear as spots of ink, Figure 2. Cleaning Procedure. Print TP 11 Colour Bands and Dithers Test Pages. The prints are
good.
Procedure Y N
Examine the test pages. The spots are a primary colour, raised, round or
Print TP 14 Drum Stripper Blade Test Print. The stripper blade releases between 35 and
oblong shaped, Figure 2.
the 50 mm mark on pitch 1 and between 270 to 291 mm mark for pitch 2.
Y N
Y N
Perform dC969 Clean Ink Smears. Repeat cleaning until chase sheets are
Install a new stripper blade solenoid, PL 10.10 Item 3.
clean.
Perform dC969 Clean Ink Smears. Print three copies of TP 4 Yellow Solid Fill Test pages
(TP 2 to TP 10). The test pages are good.
The machine has a jetting fault. Go to the IQ 9 Deletions RAP.
Y N
Go to the IQ 6 Missing Ink or Grainy Output RAP.
A
IQ 26 Poor Ink Adhesion RAP
Use this RAP when the ink does not adhere to the media. Refer to Figure 1.
Poor ink adhesion can be caused by overly glossy media coatings, improper oil application, or
errors in drum or preheat temperature regulation.
NOTE: A similar defect, known as x-axis motion error, may be caused by obstruction of the
carriage drive which causes lines of ink to be deposited on the drum. When this is transfixed it
has an embossed texture and appears wavy. Typically x-axis motion error affects individual
carriages. Refer to IQ 20 Wavy or Stringy Lines RAP.
Some customer actions will cause ink to be removed from the image such as scratch or abrad-
ing the surface of the image or applying / removing tape or sticky notes. This is expected
behavior. No further service actions can correct this behavior.
Figure 2 Ink spots
Figure 1 Poor ink adhesion

A B
Initial Actions Perform dC335 Heater Monitor and Exerciser. Check the preheat temperature. Preheat
temperature is good.
Y N
WARNING Go to 88-500-00 to 88-502-00 Preheat Thermal Error RAP.
Enter dC959 Cleaning Unit Exerciser. Run the cleaning unit self test. Cleaning unit self
test completes successfully.
Y N
• Press the Machine Status button on the keypad, select the Fault tab on the UI, then Cur- Install new cleaning unit, PL 94.10 Item 21.
impacted’ is displayed, install a new cleaning unit, PL 94.10 Item 21. Check the cleaning unit metering blade for paper debris or damage.
• If the customer is using glossy or heavyweight media, ensure the correct media type is
selected in the user interface (UI). NOTE: Ink pixel build up on the metering blade is normal and should not be cleaned off.
NOTE: The media type option of light glossy cardstock media will only be available when The metering blade is good.
the bypass tray is selected. Y N
Clean the metering blade of debris. If necessary, install a new cleaning unit, PL
• Ensure the customer is using supported media, refer to GP 20 Paper and Media Size 94.10 Item 21.
Specifications.
Enter dC959 Cleaning Unit Exerciser and run the slow speed exerciser. Slow speed
Procedure exerciser completes successfully.
Y N
WARNING
Enter dC978 Transfix Calibration Values. Check the transfix calibration values against
Ensure that the electricity to the machine is switched off while performing tasks that do those on the drum frame. Calibration values match.
death or injury. Moving parts can cause injury. Correct transfix calibration values in NVM, dC131.
NOTE: When printing TP 5 from dC959, ensure that A4 or 8.5 x 11 inch plain paper is loaded
long edge feed into tray 4. Use the best quality media available. Do not use hole punched Enter dC962 to test the transfix assembly. Transfix assembly operates normally.
paper. Y N
Check the media type and finish, refer to GP 20. If the media appears glossy, load new media. • Transfix roller, PL 10.20 Item 1.
Print TP 5 Solid Black Fill test page (TP 2 to TP 10). The image on the test pattern is good
• Flexure encoder, PL 10.20 Item 5.
with no missing ink.
Y N • Transfix motor, PL 10.20 Item 11.
94.20 Item 10 are not bent or misaligned. Check for paper debris between the thermistors The machine is operating within specification.
and the drum and ensure that the thermistors are making good contact with the drum. Perform SCP 5 Final Actions.
Y N Perform SCP 5 Final Actions.
• Front drum thermistor, PL 94.20 Item 9
• Rear drum thermistor, PL 94.20 Item 10
Y N
Go to 94-536-00, 94-538-00, 94-540-00, 94-542-00, 94-544-00, 94-546-00, 94-632-
A B
IQ 27 Unacceptable Received Fax Image Quality RAP IQ 28 Showthrough on Copies RAP
Use this RAP to identify the causes of poor reception. Use this RAP when copies have show through.
Ensure IQ 1 Image Quality Entry RAP is performed before starting this RAP. Showthrough can be caused by the exposure lamp shining through low weight paper picking
up both sides of a duplex master. This can happen on duplex masters of 60gsm or less.
Initial Actions
WARNING Procedure
Verify the following: Ensure that the electricity to the machine is switched off while performing tasks that do
• This problem occurs only when receiving transmissions. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
• This problem occurs on all receiving transmissions.
Ensure the master is scanned on the document glass with the DADH in the down position.
• Check that the fax country setting, NVM location 200-043, is correct. Refer to Fax Docu-
ment.
Procedure
The condition of the original transmission document is good.
Y N
Generate a new document from the original.
If possible, establish voice contact using the same telecommunication link as used to receive
the document. The line is free of interference sounds and the normal voice can be heard
clearly.
Y N
Go 20H Embedded Fax PWB Voltage Checkout.
Receive the document at a slower receive speed. Set the NVM location 200-089 Line 1 = 11
and location 200-090 Line 2 = 11. Refer to Fax Document. The image quality is acceptable.
Y N
The telecommunication links and harnesses are connected properly and there is
no visible damage.
Y N
Correct the connections. If necessary install new line cable and connectors.
Verify the operation of the machine and the communication link by transmitting between
machines over a known good link. All received documents have an acceptable image
quality.
Y N
Install a new embedded fax PWB, PL 20.05 Item 4.
Go 20H Embedded Fax PWB Voltage Checkout.
Inform the remote user of the required changes to the settings.

IQ 29 DADH, Document Glass and Scanner RAP a. Lower the height of the DADH by half a turn of the setting screws, refer to ADJ 5.2
DADH Height Adjustment. Make copies from the DADH after each adjustment. If the
Use this RAP to identify defects caused by the DADH, document glass or scanner.
fault persists, re-adjust the height of the DADH as necessary.
b. If the fault persists after the height of the DADH has been adjusted, install a new
lower baffle assembly, PL 5.30 Item 14. Re-adjust the height of the DADH to the
default setting, refer to ADJ 5.2 DADH Height Adjustment.
Procedure
Scanner Checkout
• CVT and Document Glass Checkout Perform the following:
• DADH Checkout 1. If the copy of the internal test is fragmented and displaced, check the following:
• Scanner Checkout a. For machines W/O TAG 007 check the harness connections from the full width array
to the Copy Controller PWB, PL 62.15 Item 4.
• Additional Checks
b. Check the following:
CVT and Document Glass Checkout • For machines W/O TAG 006 and W/O TAG 007, check the harness connec-
Perform the following: tions from the Scanner PWB to the Copy Controller PWB, PL 62.16 Item 8 and
1. Clean the top surface of the CVT glass and the document glass, refer to: PL 3.10 Item 17.
• For machines W/O TAG 007. Perform ADJ 62.1 Optics Cleaning Procedure. • For machines W/TAG 006 and W/TAG 007, check the harness connections
• For machines W/TAG 007. Perform ADJ 62.5 Optics Cleaning Procedure. from the Scanner PWB to the single board controller PWB, PL 62.17 Item 1 and
PL 3.11 Item 13.
2. Check the position of the document pad, refer to ADJ 5.6 DADH Document Pad.
• For machines W/O TAG 006 and W/TAG 007, check the harness connections
3. Check that the white AGC strips on the document glass and the CVT glass are at the front
and underside of the glass. from the Scanner PWB to the Copy Controller PWB, PL 62.17 Item 1 and PL
3.10 Item 17.
4. The AGC portion of the CVT glass should be clean and at the front bottom of the CVT
c. If fragmented and displaced images appear in a regular pattern across process
glass, PL 62.10 Item 3. If it is missing, dirty or the glass is not properly installed then this
direction, remove and re-seat all EPC memory PWBs, PL 3.10.
will cause faint, washed out, light copies from the DADH only.
d. If necessary, go to the 62-310-00 Scanner to Copy Controller/Single Board Control-
5. dC609 Document Glass Registration.
ler Communication Fail Entry RAP.
DADH Checkout 2. Raise the DADH. Make a copy from the document glass. If the exposure lamp does not
Perform the following: illuminate or partially illuminates, go to the 62-450-00 to 62-472-00 Calibration Failure
1. Clean the underside of the DADH area around the CVT roll, PL 5.25. RAP.
2. Clean the top surface of the CVT glass and the document glass, refer to: 3. Perform the Optics Cleaning Procedure:
• For machines W/O TAG 007. Perform ADJ 62.1 Optics Cleaning Procedure. • For machines W/O TAG 007. Perform ADJ 62.1 Optics Cleaning Procedure.
• For machines W/TAG 007. Perform ADJ 62.5 Optics Cleaning Procedure. • For machines W/TAG 007. Perform ADJ 62.5 Optics Cleaning Procedure.
3. If the documents are skewed. Check that the document input guides are correctly Additional Checks
adjusted. If the characters on a copy are good, but the white areas have a coloured background, perform
4. Check that the DADH is seated correctly, perform ADJ 5.2 DADH Height Adjustment. the following:
5. Make copies from the DADH. If the copies have a background problem, perform the fol- 1. Enter dC612. Print TP 11.
lowing:
2. If the prints are good, install a new components as necessary:
a. Check the DADH height, Refer to ADJ 5.2 DADH Height Adjustment.
• (W/O TAG 006) Copy controller PWB, PL 3.10 Item 17.
b. If copies have distortion approximately 7mm in from the trail edge, check the mylar
guide strip for damage, PL 5.30 Item 12. If necessary install a new mylar guide strip,
PL 31.11 Item 14.
c. dC608 Document Feeder Registration.
d. Copying thick documents can leave the DADH raised above the document glass.
Raise and lower the DADH five times. If the DADH is still raised, install new counter-
balance, PL 5.10 Item 2 and PL 5.10 Item 4.
6. Make copies from the DADH. If the copies are stretched or smudged, perform the follow-
ing:

IQ 30 Blocking RAP
Use this RAP when the output has ink transfer between images in the output tray stack.
NOTE: A residual image may also occur when ink has been retained on the drum. Ink from an
earlier print then appears on the next sheet. Residual images may have a similar appearance
to blocking. Refer to IQ 23 Residual Ink From Previous Print RAP.
Procedure
Advise the customer that this may be resolved by the use of lighter weight media. Alternatively
emptying the output tray more frequently may help. No other service actions will correct this
issue.

TP 1 Initial Test Print Pages
These A4 (8.5 x 11) pages are a set of diagnostic test prints used to initially diagnose image Cyan / magenta test page
quality issues in IQ 1. TP 1 prints the four test pages shown in Figure 1.
Text print test page
Initial test print pages are printed from dC612. The colour bands test page can also be printed
from dC972, option 3.
NOTE: Test print TP 25 only prints correctly on long edge feed 8.5 x 11 inch plain paper from
tray 3. Use the best quality media available. Do not use hole punched paper.
NOTE: All test prints should be printed on A4 (with the exception of TP 25, see above NOTE)
or 8.5 x 11 inch plain paper and long edge feed. Use the best quality media available. Do not
use hole punched paper.
NOTE: Always load A4 or 8.5 x 11 inch media as appropriate to your market region in Tray 4
before printing internal test prints. Failure to do this may result in the test prints printing the
wrong size / location on the media and giving false results.
Purpose
These test pages are printed as part of an evaluation of image quality performance in IQ 1.
Examine each print for the defect that follow:
• The colour bands print is useful for identifying:

– Jetting defects, refer to IQ 5, IQ 20 and IQ 25.
– Stitching defects, refer to IQ 5, IQ 9 and IQ 13.
– Uniformity defects, refer to IQ 5, IQ 13 and IQ 14.
• The horizontal lines print is useful for identifying:
– Y-dot position defects, refer to IQ 5.
– Y-stitch defects, refer to IQ 5.
– Printhead alignment defects, refer to IQ 5, IQ 9, IQ 12, IQ 13 and IQ 14.
• The text print is useful for identifying:
– Text defects, refer to IQ 5.
– Resolution defects, refer to IQ 5.
• The cyan / magenta print is useful for identifying: Horizontal lines test page
– Uniformity defects, refer to IQ 14.
Colour bands test page
Figure 1 Image quality analysis test pages

Xerox® ColorQube® 9203 Family 3-83 TP 1
TP 2 to TP 10 Solid Fill Test Pages
TP 2 Cyan solid fill
Solid fills are used to purge the jets of contamination or correct cross-colour contaminated jets.
Solid fills are also used to examine media damage, cleaning unit function, skew, and margins.
Solid fill test pages are printed from dC612. TP5 black solid fill can also be printed from dC959. TP 3 Magenta solid fill
NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed.
Use the best quality media available. Do not use hole punched paper. TP 4 Yellow solid fill
NOTE: When printing TP 5 from dC959, ensure that the paper is loaded LEF into tray 4.
TP 5 Black
Purpose solid fill
Figure 1. These single-sided prints provide solid-fills in all eight colours:
• Select TP 2 to print a cyan solid fill.
• Select TP 3 to print a magenta solid fill.
• Select TP 4 to print a yellow solid fill.
• Select TP 5 to print a black solid fill.
• Select TP 6 to print a red solid fill.
• Select TP 7 to print a green solid fill.
• Select TP 8 to print a blue solid fill.
• Select TP 9 to print a white solid fill.
• Select TP 10 to print a set of all eight solid fills (cyan, magenta, yellow, black, red, green,
blue and white).
To solve image quality problems associated with solid fills, refer to IQ 5, IQ 9, IQ 10 and IQ 24.
TP 6 Red solid fill
TP 7 Green solid fill
TP 8 Blue solid fill
TP 9 White solid fill
Figure 1 Solid fill pages

TP 2 to TP 10 3-84 Xerox® ColorQube® 9203 Family
TP 11 Colour Bands and Dithers Test Pages TP 12 Chase Page
These A4 (8.5 x 11 inch) pages are a set of diagnostic test prints used to diagnose image qual- Chase pages are picked from the selected tray and fed through the media path. No image is
ity issues related to colour uniformity. Figure 1 shows the test pages printed. jetted onto the drum.
Colour bands and dithers test pages are printed from dC612. Chase pages are printed from dC612.
NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed. NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed.
Use the best quality media available. Do not use hole punched paper. Use the best quality media available. Do not use hole punched paper.
Purpose Purpose
These pages are used to evaluate print quality problems caused by drifting or mis-adjusted Chase pages are used to clear the drum of any residual image or possible contamination.
printheads. Chase pages are also useful for examining jam conditions and media damage. Use chase
pages to clear the media path, clean light contamination from the registration/preheat assem-
To solve image quality problems associated with colour uniformity, refer to IQ 13. bly, drum, or transfix roller.
Figure 1 colour bands and dithers test pages

Xerox® ColorQube® 9203 Family 3-85 TP 11, TP 12
TP 13 Text Test Pages TP 14 Drum Stripper Blade Test Page
Figure 1 shows the three text test pages used to represent black, text-only printed documents. This page is a diagnostic test print used to diagnose errors related to the drum stripper blade
and stripper drive. The drum stripper blade test page records stripper blade activity during two
Text test pages are printed from dC612. typical drum stripper activation sequences. In addition to blade timing, anomalies in the blade
such as warping, bounce, or edge damage may be visible in the stripped area of the image.
Use the best quality media available. Do not use hole punched paper. The drum stripper blade test page is printed from dC612.
Purpose The test page is designed to print in a particular resolution in order for the scale to be represen-
Text test pages are used to diagnose text quality defects. There are no known imaging prob- tative of millimeters. First, the image is created on the drum. The drum stripper blade is acti-
lems that affect only text and allow all other printed objects, such as fills, dithers, lines, and pic- vated to simulate the stripping of two sheets of media. The area where the stripper blade
tures to be defect-free. Text quality is particularly sensitive to incorrectly placed dots; thus it is contacts the drum is visible on the print as the wiped off region. Figure 1 is an example of two
most dependent on proper printhead operation, mechanical alignment, and motion. The third normal drum stripper blade activation sequences. The test print is followed by two chase
page of landscape text repeats the same characters over and over again across the page to sheets to clean the drum.
aid in detecting spatial variations in dot placement. Look for relative differences between the
quality of the characters across the print. Purpose
To record drum stripper blade action. Refer to Figure 1 showing test page details. Test page
To solve image quality problems associated with text, refer to IQ 5 and IQ 19.
features include a background, a metric scale graduated in millimeters along each edge, a
‘Start’ line that corresponds to the point where the stripper drive solenoid is commanded to
actuate, and a MLE line that corresponds to the point on the drum where the media leading
edge would fall.
During normal operation, the drum stripper blade makes contact in the 10 to 20 mm window of
pitch 1 (left side scale). The drum stripper blade releases from the drum in the 35 to 50 mm
window of pitch 1 (left side scale).
To solve image quality associated with the drum stripper blade, refer to IQ 8 Cross Process Ink
Artifacts (Smudge) RAP.
Figure 1 Text test pages

TP 13, TP 14 3-86 Xerox® ColorQube® 9203 Family
TP 15 Media Path Test Pages
Figure 2 shows the media path test page. Print the media path test page using the same size
media as the affected print. Reconstruct the media path by aligning the test pages vertically.
Jam zone 1a at the top to 4b at the bottom. Compare markings on the affected print to the fea-
tures on the test print to determine the jam zone, nip, or ribs affecting the output. The test
image is cropped according to the media size selected for printing. To see the complete image,
use A3 (11 x 17 inch) media.
Media path test pages are printed from dC612.
Use the best quality media available. Do not use hole punched paper.
Purpose
The media path test page is used to locate the source of scratches, marks, or gloss differences
on the output due to transport components. The page is organized according to the media path
layout shown in Figure 1. Each of the jam areas (1a to 4a) is segregated on the test print with a
horizontal line. Rollers for each nip are identified by letter, and rib locations are indicated by
rectangles or hash marks.
For example, jam zone 1a, located at the top of sheet 1, includes nips H and F and ribs to
guide media up the vertical transport. The roller contact locations, both drive and idler, are
shown along with contact points for the ribs.
To solve image quality associated with scratches, marks, or gloss differences, refer to IQ 16.
Figure 1 Drum stripper blade test page

Figure 1 Media path jam zone and nip layout
Figure 2 Media path test pages

TP 15 3-88 Xerox® ColorQube® 9203 Family
TP 16 Stitch Identification Test Pages TP 17 Service Usage Profile
The printheads work together to stitch the image together. The X-stitch and Y-stitch patterns This series of A4 (8.5 x 11 inch) prints list the information about the machine usage and printer
print when the stitch identification selection is made from dC612. status, Figure 1.
Stitch identification test patterns are printed from dC612. Purpose

The service usage profile tracks printer activity, consumable usage and printer history. This
NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed. data is stored in NVRAM. Service usage profile data includes error logs that retain detail on the
type, date, location and frequency of engine and jam errors. While the service usage profile
Purpose includes data on all aspects of the printer, this section focuses on accessing these error logs to
review printer history.
The X-stitch and Y-stitch patterns indicate the accuracy of printhead alignment. Refer to Figure
1.
The service usage profile list can be printed from dC612.
NOTE: The X-Stitch print is made up of an interference pattern. The degree of an x-stitch issue
is highly exaggerated on this print. The actual x-stitch error will appear less pronounced on a
customer image. If in doubt about the severity of an x-stitch issue print a customer image to
determine if it is visible.
To solve image quality problems associated with stitch errors, refer to IQ 5, IQ 9 and IQ 13.
Figure 1 Stitch identification test pages

TP 18 TRC Generation Test Pages
These four A4 (8.5 x 11 inch) pages have red, green, blue, or black step dithers.
TRC generation test pages are printed from dC972 option 4.
NOTE: Before printing this test page, ensure that A4 or 8.5 x 11 inch plain paper is loaded LEF
into tray 4. Use the best quality media available. Do not use hole punched paper.
Purpose
Figure 1. The TRC Generation Test Pages are a test print suite used to diagnose image quality
issues related to colour uniformity in dithers. This page is part of the printhead uniformity
adjustment sequence used to correct print quality problems related to colour uniformity and dot
position.
To solve image quality problems related to colour uniformity in dithers, refer to IQ 13 and IQ 14.
Figure 1 TRC generation dithers
Figure 1 Service usage profile

TP 19 Y-Dot Position Correction Test Page TP 20 Oil Bar Chase and Metering Blade Timing Test Pages
This A4 (8.5 x 11 inch) print consists of 1 and 5 pixel thick lines in the cross process direction. These test pages are used to check the operation of the cleaning unit.
The colours of the lines are blue, green, red, black, yellow, magenta, and cyan.
The oil bar chase and metering blade timing test pages are printed from dC959 cleaning unit
The Y-dot position correction test page is printed from dC972 option 5. exerciser. Both pages are printed when the oil bar chase test page is selected.
NOTE: Before printing this test page, ensure that A4 or 8.5 x 11 inch plain paper is loaded LEF NOTE: Before printing this test page, ensure that A4 or 8.5 x 11 inch plain paper is loaded long
into tray 4. Use the best quality media available. Do not use hole punched paper. edge feed into tray 4. Use the best quality media available. Do not use hole punched paper.
Purpose Purpose
Figure 1. The Y-Dot Position Correction test page is a diagnostic test print used by service to The oil bar chase test page is used to check that the metering blade leaves no more than a thin
diagnose image quality issues related to dot position errors in the process direction. This page bar of oil on the drum when disengaging. The metering blade timing test page is used to
is part of the printhead uniformity adjustment sequence used to correct print quality problems ensure that the metering blade engages and disengages with the drum at the correct time.
related to colour uniformity and dot position.
1. Oil bar chase, A4 or 8.5 x 11 inch image, Figure 1. A good oil bar chase page will have no
To solve image quality problems associated with dot position in the process direction, refer to oil contamination.
IQ 5.
NOTE: A thin line of oil approximately 35mm below the horizontal line and no more than
1mm wide is acceptable.
Cleaning unit problems that may be indicated by this test page are described in IQ 21 Oil
on Output RAP.
Figure 1 Y-dot position pages Figure 1 Oil bar chase page

2. Metering blade timing test, A4 or 8.5 x 11 inch image, Figure 2. Cleaning unit problems TP 21 Jet Test Pages
that may be indicated by this test page are described in IQ 7.
These A4 (8.5 x 11 inch) pages are a set of diagnostic test prints used to check printhead jet
NOTE: The metering blade may not completely remove all pixels from the drum in the status. There are service jet test pages and customer jet test pages.
wiped area, this is normal behavior.
NOTE: Before printing this test page, ensure that A4 or 8.5 x 11 inch plain paper is loaded long
Tolerance zones are
Blade engage marked by dashed lines Printheads occasionally get clogged jets that require user intervention to restore jet function.
nominal target line on either side of the When a clogged jet occurs, areas of solid colour may show signs of light stripes.
nominal target line
Jet test pages are used to check printhead jet status. Two versions are available, service and
customer. Jet test pages demonstrate effective print quality and provide visual feedback on the
health of printhead jet stack.
Service Jet Test Pages

Service jet test pages are printed from dC968 and dC977.
Blade disengage Tolerance zones are

nominal target line marked by dashed lines
on either side of the
nominal target line
Figure 2 Metering blade timing test page
Figure 1 Jet test pages

The service jet test pages, shown in Figure 1, consists of eight test pattern pages. The first 4 Missing jets may be visible on the jet test pages as white space where the coloured bar
pages show the conditions of printheads 1 and 2. The second 4 pages show the condition of for the jet should be. When a missing jet is detected by the machine, the jet number will
printheads 3 and 4. After completing the jet test pages, a page containing a print quality man- be purple with a purple pointer indication beneath the jet number, Figure 3.
agement status check is produced, Figure 2. This table indicates the status of the each routine,
refer to 91-636-00 IOD in Degraded Mode RAP for the corrective actions.
• The condition of each jet is shown in a bar of ink with the jet number directly beneath.
• The machine is able to detect the condition of jets in some conditions. Detected defective
jets are indicated by a pointer beneath the number. The jet number and pointer for defec-
tive jets are colour coded according to the known condition of the jet.
• The total number of missing, chronic and masked jets per printhead is shown to the side
of the jet indicators.
• JSC[On,On]: indicates jet substitution is enabled (On) for both customer and machine set-
tings. The machine may override the customer setting temporarily if the Quick Light Lines
fix has been selected from the Tools / Fix Image Quality menu. After the next purge or
machine reboot, the settings revert to customer settings. When jet sub is enabled, print
speed slows down only when a jet is missing and is required for the current print. Figure 3 Missing jet number
• PC[On,On]: means the purge configuration is set to purge at night / when idle for both
customer setting and machine setting. Same override rule applies. The purge here is jet • Chronic Jets
fix purge that will only occur if the machine needs to auto recover an intermittent, weak, or Chronic jets may be visible on the jet test pages as white space where the coloured bar
missing jet. for the jet should be. If the machine detects a missing jet but is unable to retrieve it with
• Beneath the data for printhead jet status the test page lists the printhead serial number, maintenance or corrective action the missing jet is designated as chronic. The jet number
page count, current resolution, IME software version and page number. will be red with a red pointer indication beneath the jet number, Figure 4.
To solve image quality problems related to weak, missing or sputtering jets, refer to IQ 9.
Figure 4 Chronic jet number
• Masked Jets (GP 30 How to Mask Jets / Jet Substitution)

Figure 2 Print quality status Masked jets may be visible on the jet test pages as white space where the coloured bar
for the jet should be. Problem jets identified by the customer but not by the machine,
Definitions of Jet Conditions which cannot be revived, can be masked manually. Once masked, the jet number will be
green with a green pointer indication beneath the jet number, Figure 5.
NOTE: Service jet test pages are printed without jet substitution turned on and therefore will
always show the true condition of each jet. The detected machine status may not always match
the true condition of a jet at the time the jet pages are printed. Even if a jet number is purple,
red or green you may see a colour bar over the jet number if the jet has managed to recover on
its own.
There are 3 jet conditions indicated by the jet test pages:
• Missing Jets

Figure 5 Masked jet number
Customer Jet Test Pages

NOTE: Information on the customer jet test pages is included here for completeness. Cus-
tomer jet test pages are not used for fault isolation.
The customer jet test pages, shown in Figure 6, are located in Fix Image Quality and available
for customers to use when diagnosing print quality problems. Figure 7 shows how the cus-
tomer jet test pages includes jet status information for each printhead and the current status of
jet substitution. The customer jet test pages use jet substitution if enabled.
Figure 6 Customer version of the jet test pages
Figure 7 shows the customer version of the jet test page. This version also prints long-edge
feed with the default source being tray 3. The image portion of the print is intended to show the
customer effective print quality with current jet substitution settings. The IOD can miss weak
jets, that is why the customer needs this print to provide a tool when the machine has not self
corrected. If the customer is not happy with these defects the light lines options in Fix Image
Quality window provides tools to do both an align and a purge, which should fix the problems.
This page helps customer service (or a customer) correct issues the machine cannot.

The text at the bottom of the customer version, Figure 7, provides the following:
• Max left / right: Indicates shift position in relation to the drum. Shifting involves all the jets
in the imaging process.
• JSC[On,On]: indicates jet substitution is enabled (On) for both customer and machine set-
tings. The machine may override the customer setting temporarily if the Quick Light Lines
fix has been selected from the Tools / Fix Image Quality menu. After the next purge or
machine reboot, the settings revert to customer settings. When jet sub is enabled, print
speed slows down only when a jet is missing and is required for the current print.
• PC[On,On]: means the purge configuration is set to purge at night / when idle for both
customer setting and machine setting. Same override rule applies. The purge here is jet
fix purge that will only occur if the machine needs to auto recover an intermittent, weak, or
missing jet.
• This information is followed by each print head serial number and the total number of
intermittently weak or missing jets (IWMs) or continuously weak or missing jets (CWMs)
for each print head as defined by the IOD information. Manually masked jets are identified
after chronic jets.
– W (weak) indicates the number of detected missing jets that have not been labelled
as chronic.
– C (chronic) indicates the number of missing jets that have been purged 3 times,
including a cool down / melt cycle (to power the machine off and allow to cool down)
for models 9202 and 9203.
– M (masked) indicates the number of missing jets for which jet substitution is enabled
either manually or by the machine.
For instance, H4:<serial number>; W2;C0;M1 indicates that print head number 4:<serial
number> has 2 weak jets, no chronic jets and one manually masked jet.
Figure 7 Jet status information, customer page

TP 22 Cleaning Pages NOTE: Do not use the cleaning pages to evaluate image quality.
The two-sheet cleaning page, Figure 1, prints following a purge from dC968 to clear the jets of
any ink discolouration. The cleaning page must print long-edge feed on A4 or 8.5 x 11 inch
media. Tray 3 is the default source.
Cleaning pages are printed from dC968.
NOTE: If the machine detects a paper jam when printing cleaning pages, the machine may
automatically recover and purge the sheet. This will result in the cleaning page being printed
on multiple sheets.
Purpose
The cleaning page flushes the jet nozzles of possible contamination or colour contaminated
jets. The first sheet cleans printheads 2 and 4 on the upper carriage. The second sheet cleans
printheads 1 and 3 on the lower carriage. Three sets of prints typically clear any ink mixing or
discolouration associated with printhead maintenance.
To solve image quality problems related to ink discolouration, refer to IQ 14.
Figure 1 Cleaning pages

TP 23 Drum Run Out and Y-Stitch Test Pages TP 24 Registration Calibration Page
Figure 1 shows the drum run out test pages without the defect on the horizontal lines. The two- This print is generated by dC625 to calibrate the registration/preheat assembly. Calibration
page drum run out test print provides visual indication on the success or failure of drum run out procedure requires A4 or 8.5 x 11 inch media.
and Y-stitch calibrations. Two pages of horizontal lines are printed to cover the entire drum.
The print order is marked in the upper left corner (P1 and P2). NOTE: All test prints should be printed on A4 or 8.5 x 11 inch plain paper and long edge feed.
edge feed into tray 4. Use the best quality media available. Do not use hole punched paper. The registration calibration page is printed from dC625.
Drum run out and Y-stitch test pages are printed from dC977. Purpose
Figure 1, serves as a target image for calibration of the registration/preheat assembly. Ten
Purpose sheets are printed for each of the three stances of the registration/preheat assembly. The
To provide a visual indication of drum run out and Y-stitch accuracy. images are fed back through the duplex path and scanned by the registration sensor. Values
for process, cross-process, and skew are calculated and stored in NVM.
To solve image quality problems related to drum run out and y-stitch errors, refer to IQ 5.
To solve image quality problems related to registration calibration, refer to IQ 8 Cross Process
Ink Artifacts (Smudge) RAP and IQ 10 Incorrect Margin, Misregistration or Skew RAP.
Figure 1 Drum run out and Y-stitch pages

TP 25 IME Test Print
This test print isolates the IME from other system issues. The image is a simple pattern of
coloured bars as shown in Figure 1. The image includes primary colour bars printed by all four
printheads. Image size is the width and length of the media less the 4.3 mm (0.017 inch) mar-
gins. The tray selection is from tray 3 only and prints on 8.5 x 11 inch media only.
Figure 1 IME Test Print
The print is printed simplex with a 600x600 resolution. Print orientation (LEF vs. SEF) is deter-
mined by how the selected tray is loaded. The tray is selected automatically based upon the
same priority system used to select a chase source. An error is noted if none of the trays con-
tain valid media. If a finisher is installed, the sheet is sent to the catch tray on the finisher.
Status LEDs
• There are two sets of LEDs, 1 set on the front of the IME controller, Figure 2, and 1 set on
the rear of the media path board, Figure 3.
• The red LED is the IME error LED.
Figure 1 Registration calibration page • The green LED is the IME OK LED.
• The front and rear LEDs give the same information.

Figure 2 Front status LED location Figure 3 Rear status LED location
Procedure
Check that 8.5 x 11 inch size media is loaded into tray 3 tray. Also check that ink and the other
printing prerequisites are met. Print the IME test print using these steps:
NOTE: Test print TP 25 only prints correctly on long edge feed 8.5 x 11 inch plain paper from
tray 3. Use the best quality media available. Do not use hole punched paper.
1. Turn the machine Off.

2. Open the mid left door, PL 70.30 Item 16.
3. Remove the waste tray.
4. Close the front door or insert an interlock cheater.
5. Turn the machine On.
During power-up, the IME checks for the combination of waste tray and left side door sen-
sors that activates test print mode. PEST does not run in this mode.
The red IME error LED begins a repeating series of three blinks with a slight pause
between (111, 111, 111). This sequence indicates IME test print mode is detected.
6. Close the left side door and replace the waste tray.

After closing the left side door and replacing the waste tray, the red IME Error LED turns TP 26 Printhead Uniformity / Colour Bands Test Page
Off and the green IME OK LED begins a sequence of three blinks. This indicates the IME
This A4 (8.5 x 11 inch) page has seven solid fill bars of colours, yellow, magenta, cyan, black,
is in test print mode. The IME generates the print as soon as the thermals come up to
red, green and blue.
temperature and any errors are resolved.
NOTE: The red IME Error LED blinks an error code if the IME determines it is unable to con- The printhead uniformity / colour bands test page is printed from dC972, option 3. The test
tinue (e.g. out of media or ink). After printing the IME test page, the machine reboots to cus- page is also one of the initial test print pages, TP 1.
tomer mode.
Errors and status are reported by blinking the status LEDs (IME OK and IME Error LED).
• In the absence of a fault the green IME OK LED flashes in groups of three to indicate nor-
mal test print mode. Purpose
• During normal test print mode, the red IME error LED is turned Off. The printhead uniformity test page, Figure 1 is used to diagnose image quality issues related to
• When an error is detected, the red IME error LED flashes an error code and the green colour uniformity in solid fills.
IME OK LED remains Off.
To solve image quality problems associated with printhead uniformity, refer to IQ 13, IQ 14 and
For example, an error code of 124 is indicated on the red IME error LED by one flash followed
by a brief pause, followed by two flashes and another brief pause, followed by four flashes fol- IQ 15.
lowed by a longer pause. Between each sequence, the LED flutters to indicate the sequence is
repeating.
Three results may occur:

• 111 indicates to close the door and replace the waste tray to proceed with the test print.
The close cover result is flashed to indicate test print mode is detected. Replace the
waste tray and close the left side door. When these actions are completed, the IME Error
LED turns Off, and the IME OK LED flashes the three short flashes followed by a pause.
• 123 indicates a media resource error. Load the proper media or other needed items (ink,
cleaning unit, etc.). This error can occur during warm-up if the drum is dirty. A resource
error detected during warm-up may require larger than the 8.5 x 11 inch media in order to
clean the drum.
• 124 indicates a test print creation error. Replace the waste tray, close the doors, and
reboot to run PEST (Print Engine Self Test dC123). This error usually indicates insufficient
memory and should not occur normally, but if detected, may indicate a hardware fault.
PEST should indicate any IME issues preventing printing.
Figure 1 Printhead uniformity/colour bands test page

IQS 1 Registration and Skew NOTE: The measurement for skew and margin for Side 1 and Side 2 may not match
Image Registration Margins

Table 1 lists the registration specifications of the DADH, IIT and IOT. Refer to Figure 1. Process direction margin is measured on the leading edge at the center (3).
Cross-process margin is measured on the rear edge near the leading edge corner (4).
Table 1 Registration Specifications
Document
Document Glass Scan DADH Scan
Registration Glass DADH Print IOT IIT IIT
Process direction ± 2.1 mm ± 2.6 mm ± 2.0 mm ± 0.7 mm ± 1.7 mm
Cross-process ± 2.6 mm ± 4.1 mm ± 2.5 mm ± 0.7 mm ± 3.2 mm
Skew
To measure skew use this formula, Figure 1.
Skew (mrads) = Leading edge margin at rear corner (1) minus leading edge margin at front
corner (2) divided by (media width - 8.6 mm) multiplied by 1000.
Refer to Table 2 for the skew specifications in mrads.
Table 2 Skew Specifications (mrads)

Document
Document Glass Scan DADH Scan
Glass DADH Print IOT IIT IIT
Skew specification ± 6.2 mrad ± 9.0 mrad ± 5.4 mrad ± 3.1 mrad ± 7.2 mrad
• Skew for envelopes will exceed the limits stated.

• Skew for A5/8.5 x 5.5 shall be +/- 10 mrads.
Table 3 lists the skew specifications (mm) for the standard paper sizes.
Table 3 Skew Specifications (mm)

Figure 1 Skew and margin measurement
Document
Media Size Document Glass DADH
Media (mm) Glass DADH Print IOT Scan IIT Scan IIT
A4 long edge 297 mm ± 1.79 mm ± 2.6 mm ± 1.56 mm ± 0.89 mm ± 2.8 mm
A4 short edge 210 mm ± 1.25 mm ± 1.81 mm ± 1.09 mm ± 0.62 mm ± 1.45 mm
8.5 x 11 inch 279 mm ± 1.68 mm ± 2.43 mm ± 1.46 mm ± 0.84 mm ± 1.95 mm
long edge
8.5 x 11 inch 216 mm ± 1.29 mm ± 1.87 mm ± 1.12 mm ± 0.64mm ± 1.49 mm
short edge

Xerox® ColorQube® 9203 Family 3-101 IQS 1
IQS 2 Image Area
Image Area
Guaranteed image area is the maximum area over which IQ specifications are valid.
Refer to Table 1 and Figure 1.
Table 1 Image Area Specifications

Characteristic Specification
Maximum image area 448.6 mm (17.6 inches) (process) x 300.3 mm (11.8 inches)
(cross-process)
Minimum image area 210 mm (8.2 inches) (process) x 104 mm (4 inches) (cross-pro-
cess)
Guaranteed image area 448.6 mm (17.6 inches) (process) x 298.648 mm (11.7 inches)
(cross-process)
Resolution/gradation Fast colour: 300 x 300 dpi
Standard:450 x 567 dpi
Enhanced: 600 x 600 dpi (Image processing at 600x2400)
Photo/Hi Res: 525 x 1200 dpi
Figure 1 Maximum image area

IQS 2 3-102 Xerox® ColorQube® 9203 Family
IQS 3 Y-Dot Position IQS 4 Y-Stitch
Specification Specification
Figure 1, shows a level of position error that provides a basis for determining defect severity. If Figure 1 shows a level of y-stitch error that provides a basis for determining defect severity. If
Y-dot position error exceeds Figure 1, corrective action is necessary. Refer to IQ 5. Y-stitch error exceeds Figure 1, corrective action is necessary.
Figure 1 Maximum specified Y-dot misplacement Figure 1 Maximum specified Y-stitch error

Xerox® ColorQube® 9203 Family 3-103 IQS 3, IQS 4
IQS 5 X-Stitch IQS 6 Blurry Text
Specification Specification
Figure 1 shows a level of X-stitch error that provides a basis for determining defect severity. If Figure 1 shows a level of blurry text error that provides a basis for determining defect severity.
X-stitch error exceeds Figure 1, corrective action is necessary. If the capital F in line D2 exceeds Figure 1, corrective action is necessary. Refer to IQ 5.
NOTE: The x-stitch print is made up of an interference pattern. The degree of an x-stitch issue
is highly exaggerated on this print. The actual x-stitch error will appear less pronounced on a
customer image. If in doubt about the severity of an x-stitch issue print a customer image to
determine if it is visible.
Figure 1 Acceptable X-stitch example
Figure 1 Blurry text on TP 12

IQS 5, IQS 6 3-104 Xerox® ColorQube® 9203 Family
IQS 7 Curl IQS 8 Uniformity in the Process Direction
Media Curl Specification
All modules shall handle flat curl of ±12mm in both process and cross process direction in input Figure 1 shows the cyan / magenta and the colour bands print that is printed out in TP 1. No
and output without degradation in performance. Degraded performance (e.g. increased jams, distinct non-uniformity bands in the process direction should be observed on these prints.
reduced tray capacity) can be expected for curl greater than ±12mm. Refer to IQ 13 and IQ 14.
NOTE: Curl is expected to increase above 12mm when printing very high area coverage
(whole page), especially for duplex and paperweights below 80gsm, or when using specific
papers and/or paper batches with internal tension.
Curl is assessed as follows: Run 5 sheets of prints with less than 50% area coverage. Place
the set on a flat surface so that the set curls upwards. Measure the height of each corner after
minimum 15 seconds and maximum 1 minute from the output of the final sheet. No corner
should exceed the 12mm specification in 99.7% of the measurements.
Figure 1 Uniformity test print

Xerox® ColorQube® 9203 Family 3-105 IQS 7, IQS 8
IQS 7, IQS 8 3-106 Xerox® ColorQube® 9203 Family
4 Repairs/Adjustments
REPs 1 - Standby Power REP 5.18 Exit Roll Idler................................................................................................... 4-59
REP 1.1 Wiring Harness Repairs .................................................................................... 4-5 REP 5.19 DADH Removal............................................................................................... 4-60
REP 1.2 Molex SL Connectors........................................................................................ 4-6 REP 5.20 Mylar Guide Strip ............................................................................................ 4-61
REP 1.3 Male Hirose DF1B Connectors ......................................................................... 4-8
REPs 10 - Transfix and Copy/Print Transportation
REP 1.4 AMP EI Connectors .......................................................................................... 4-10
REP 10.1 Transfix Roll .................................................................................................... 4-63
REP 1.5 Hirose DF11 Connectors .................................................................................. 4-13
REP 10.2 Front Transfix Linkage and Gear Kit ............................................................... 4-65
REP 1.6 AMP CT Connectors ......................................................................................... 4-13
REP 10.3 Rear Transfix Linkage and Gear Kit................................................................ 4-68
REP 1.7 Molex Mini-Fit Junior Connectors ..................................................................... 4-14
REP 10.4 Front Transfix Motor........................................................................................ 4-72
REP 1.8 Front Door Interlock Switch............................................................................... 4-16
REP 10.5 Rear Transfix Motor ........................................................................................ 4-73
REP 1.9 Power Supply Unit ............................................................................................ 4-17
REP 10.6 Transfix Blade ................................................................................................. 4-73
REPs 2 - User Interface REP 10.7 Pre Transfix Sensor ........................................................................................ 4-75
REP 2.1 User Interface Assembly................................................................................... 4-21 REP 10.8 M4 Motor and Gearbox ................................................................................... 4-77
REP 2.2 User Interface Touch Screen ............................................................................ 4-23 REP 10.9 Stripper Solenoid Assembly............................................................................ 4-78
REP 2.3 User Interface PWB .......................................................................................... 4-24 REP 10.10 Roller Drive J ................................................................................................ 4-79
REP 10.11 Roller Drive L ................................................................................................ 4-81
REPs 3 - Machine Run Control REP 10.12 Exit / Duplex Solenoid................................................................................... 4-83
REP 3.1 IME Controller PWB.......................................................................................... 4-25 REP 10.13 Diverter Gate................................................................................................. 4-85
REP 3.2 Quad Wave Amp PWB ..................................................................................... 4-26 REP 10.14 Exit Motor (M5) ............................................................................................. 4-87
REP 3.3 Marking Unit Heater PWB................................................................................. 4-27 REP 10.15 Duplex Start Sensor (13) .............................................................................. 4-89
REP 3.4 Marking Unit Driver PWB .................................................................................. 4-28 REP 10.16 Exit Sensor (15) ............................................................................................ 4-90
REP 3.5 Media Path Driver PWB .................................................................................... 4-29 REP 10.17 Roller Nip P................................................................................................... 4-93
REP 3.6 Drum Driver PWB ............................................................................................. 4-30 REP 10.18 Roller Nip N................................................................................................... 4-94
REP 3.7 Copy Controller PWB........................................................................................ 4-32 REP 10.19 Exit illuminator PWB ..................................................................................... 4-95
REP 3.8 HDD Copy Controller Assembly (HDD1) W/O TAG 006................................... 4-33 REP 10.20 Exit Paper Path ............................................................................................. 4-96
REP 3.9 Software Module ............................................................................................... 4-34 REP 10.21 Stripper Blade, Gate and Baffle .................................................................... 4-99
REP 3.10 Single Board Controller PWB (W/TAG 006) ................................................... 4-35 REP 10.22 Upper Baffle .................................................................................................. 4-101
REP 3.11 HDD Single Board Controller Assembly W/TAG 006...................................... 4-36 REP 10.23 Stripper Guide Latch Cam Shaft ................................................................... 4-103
REP 3.12 NVM PWB....................................................................................................... 4-37 REP 10.24 Front and Rear Flexure Encoder .................................................................. 4-104
REP 3.13 8 Pin NVRAM.................................................................................................. 4-37
REPs 12-110 - LCSS
REPs 5 - DADH REP 12.1-110 LCSS Covers ........................................................................................... 4-107
REP 5.1 Top Cover Assembly......................................................................................... 4-39 REP 12.2-110 Input Drive Belt and Paper Entry Transport Motor................................... 4-108
REP 5.2 Top Access Cover Assembly ............................................................................ 4-40 REP 12.3-110 Intermediate Paper Drive Belt.................................................................. 4-109
REP 5.3 Feed Assembly ................................................................................................. 4-41 REP 12.4-110 Paper Output Drive Belt and Transport Motor 2 ...................................... 4-110
REP 5.4 Input Tray Assembly ......................................................................................... 4-42 REP 12.5-110 Bin 1 Drive Belts ...................................................................................... 4-111
REP 5.5 Baffle Assembly ................................................................................................ 4-43 REP 12.6-110 Tamper Assembly.................................................................................... 4-114
REP 5.6 Takeaway Roll Assembly.................................................................................. 4-45 REP 12.7-110 Hole Punch Unit, Motor and Sensors ...................................................... 4-115
REP 5.7 Duplex Solenoid................................................................................................ 4-46 REP 12.8-110 Stapler Traverse Assembly...................................................................... 4-117
REP 5.8 Takeaway and CVT Sensor .............................................................................. 4-48 REP 12.9-110 Staple Head Unit...................................................................................... 4-118
REP 5.9 DADH Tray Size Sensors ................................................................................. 4-49 REP 12.10-110 Ejector Assembly Sensors..................................................................... 4-119
REP 5.10 Registration Sensor ........................................................................................ 4-50 REP 12.11-110 Bin 1 Upper Level Sensor...................................................................... 4-121
REP 5.11 Exit Sensor...................................................................................................... 4-51 REP 12.12-110 Paddle Wheel Shaft Assembly .............................................................. 4-122
REP 5.12 DADH Counterbalance ................................................................................... 4-52 REP 12.13-110 LCSS Un-Docking.................................................................................. 4-125
REP 5.13 Exit Roll Assembly .......................................................................................... 4-53 REP 12.14-110 LCSS PWB ............................................................................................ 4-126
REP 5.14 Feed Roll Assembly ........................................................................................ 4-54 REP 12.15-110 Entry Guide Cover ................................................................................. 4-126
REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt......................................... 4-55 REP 12.16-110 Docking Latch Assembly ....................................................................... 4-128
REP 5.16 Document Width Sensor ................................................................................. 4-57 REP 12.17-110 Ejector Belt ............................................................................................ 4-129
REP 5.17 Input Tray Static Eliminator............................................................................. 4-58 REP 12.18-110 Paddles.................................................................................................. 4-130
October 2014 Repairs/Adjustments

REPs 12-171 - HVF REP 12.52-171 BM Crease Rolls.................................................................................... 4-199
REP 12.1-171 HVF Covers ............................................................................................. 4-131 REP 12.53-171 Compiler Paper Pusher ......................................................................... 4-202
REP 12.2-171 HVF Stapler Assembly ............................................................................ 4-134 REP 12.54-171 Pusher Upper and Lower Sensors ........................................................ 4-203
REP 12.3-171 Top Tray .................................................................................................. 4-136 REP 12.55-171 HVF PSU Assembly .............................................................................. 4-203
REP 12.4-171 Bin 1 Removal ......................................................................................... 4-137 REP 12.56-171 BM Right Hand Cover............................................................................ 4-204
REP 12.5-171 Right Side-Cover Removal ...................................................................... 4-138 REP 12.57-171 HVF Main PWB ..................................................................................... 4-205
REP 12.6-171 HVF Ejector Assembly............................................................................. 4-139 REP 12.58-171 Not Used................................................................................................ 4-206
REP 12.7-171 Pressing Plate Fingers ............................................................................ 4-141 REP 12.59-171 Crease Roll Gate Assembly .................................................................. 4-206
REP 12.8-171 Front and Rear Support Fingers .............................................................. 4-142 REP 12.60-171 BM Paper Guide Assembly ................................................................... 4-209
REP 12.10-171 Stacker Idler Rolls ................................................................................. 4-143 REP 12.61-171 BM Module ............................................................................................ 4-212
REP 12.11-171 Front Tamper Motor Assembly .............................................................. 4-144 REP 12.62-171 BM Slide Assembly................................................................................ 4-217
REP 12.12-171 Bin 1 Elevator Motor Assembly ............................................................. 4-145 REP 12.63-171 Transport Motor 1 .................................................................................. 4-220
REP 12.13-171 HVF/HVF BM Un-Docking ..................................................................... 4-146 REP 12.64-171 Bypass Feed Motor ............................................................................... 4-220
REP 12.14-171 HVF Upper Exit Guide (5c) .................................................................... 4-147 REP 12.65-171 Buffer Motor........................................................................................... 4-221
REP 12.15-171 HVF Rear Tamper Assembly................................................................. 4-148 REP 12.66-171 Transport Motor 2 .................................................................................. 4-221
REP 12.16-171 BM Flapper ............................................................................................ 4-150 REP 12.67-171 Tri Folder Covers................................................................................... 4-222
REP 12.17-171 BM PWB ................................................................................................ 4-151 REP 12.68-171 Tri-Folder Drive Assembly ..................................................................... 4-223
REP 12.18-171 BM Crease Blade Motor ........................................................................ 4-153 REP 12.69-171 Tri Folder Crease Roll Drive Assembly ................................................. 4-226
REP 12.19-171 BM Crease Roll Motor ........................................................................... 4-155 REP 12.70-171 Tri-Folder Feed Roller and Drive Belt .................................................... 4-227
REP 12.20-171 BM Backstop Motor Assembly............................................................... 4-157 REP 12.71-171 TF Assist Gate Solenoid........................................................................ 4-228
REP 12.21-171 BM Backstop Assembly ......................................................................... 4-158 REP 12.72-171 Tri Folder Crease Roll Springs .............................................................. 4-229
REP 12.22-171 BM Entry Roll......................................................................................... 4-160 REP 12.73-171 Tri Folder Top Cover and Idler Assemblies ........................................... 4-229
REP 12.23-171 BM Entry Sensor ................................................................................... 4-161 REP 12.74-171 Tri Folder Roller Assembly and Diverter Solenoid................................. 4-231
REP 12.24-171 BM Crease Roll Gate Motor .................................................................. 4-163 REP 12.75-171 Bin 1 Limit Switches .............................................................................. 4-232
REP 12.25-171 BM Compiler Motor and BM Flapper Motor........................................... 4-163 REP 12.76-171 Bin 1 Upper Level Sensor...................................................................... 4-233
REP 12.26-171 Back Stop Drive Assembly .................................................................... 4-164 REP 12.77-171 Tri Folder Door Interlock Switches and Sensor ..................................... 4-234
REP 12.27-171 BM Staple Heads................................................................................... 4-166 REP 12.78-171 Tri Folder Entry and Assist Gate Sensors ............................................. 4-234
REP 12.28-171 BM Stapler Bracket Assembly ............................................................... 4-168 REP 12.79-171 Tri Folder Exit Sensor............................................................................ 4-235
REP 12.29-171 BM Conveyor Belts ................................................................................ 4-172 REP 12.80-171 Tri Folder PWB ...................................................................................... 4-235
REP 12.30-171 BM Tamper Assembly and Tamper 1 Motor.......................................... 4-174 REP 12.81-171 Tri Folder Main and Bin 2 Tray Harnesses ............................................ 4-236
REP 12.31-171 HVF Buffer Guide Assembly.................................................................. 4-176 REP 12.82-171 Inserter Undocking ................................................................................ 4-237
REP 12.32-171 HVF Input Jam Clearance Guide........................................................... 4-177 REP 12.83-171 Inserter Front and Rear Covers............................................................. 4-238
REP 12.33-171 Buffer Pocket Jam Clearance Guide Assembly..................................... 4-177 REP 12.84-171 Inserter Motor ........................................................................................ 4-239
REP 12.34-171 Inserter Jam Clearance Guide Assembly .............................................. 4-179 REP 12.85-171 Inserter PWB ......................................................................................... 4-239
REP 12.35-171 Diverter Exit Gate .................................................................................. 4-179 REP 12.86-171 Inserter Clutch ....................................................................................... 4-240
REP 12.36-171 Crease Blade Assembly ........................................................................ 4-180 REP 12.87-171 Inserter Top Cover Interlock Switch ...................................................... 4-241
REP 12.37-171 Stacker Driving Shaft Bearings.............................................................. 4-183 REP 12.88-171 Inserter Jam Cover Interlock Switch ...................................................... 4-242
REP 12.38-171 HVF Stacker Driving Belts ..................................................................... 4-184 REP 12.89-171 Main Tray and Paper Length Sensors................................................... 4-243
REP 12.39-171 HVF BM Diverter Gate........................................................................... 4-185 REP 12.90-171 Bottom Tray and Paper Sensors ........................................................... 4-243
REP 12.40-171 HVF Input Roll ....................................................................................... 4-186 REP 12.91-171 Inserter Top Cover and Inserter Pickup Sensor .................................... 4-244
REP 12.41-171 HVF Inserter Guide Roll ........................................................................ 4-187 REP 12.92-171 Lower Jam Cover and Acceleration Sensor .......................................... 4-245
REP 12.42-171 HVF Buffer Pocket Roll.......................................................................... 4-188 REP 12.93-171 Inserter LE and TE Sensors .................................................................. 4-245
REP 12.43-171 HVF Booklet Entrance Roll .................................................................... 4-190 REP 12.94-171 Inserter Bottom Plate Sensor ................................................................ 4-246
REP 12.44-171 HVF Buffer Lower Roll ........................................................................... 4-191 REP 12.95-171 Inserter Pickup Assembly and Reverse Feed Roller ............................. 4-247
REP 12.45-171 HVF Buffer Upper Roll ........................................................................... 4-192 REP 12.96-171 HVF Fixed and Adjustable Casters ....................................................... 4-248
REP 12.46-171 HVF Stacker Exit Feed Roll ................................................................... 4-193 REP 12.97-171 Pause To Unload PWB Assembly ......................................................... 4-250
REP 12.47-171 HVF Top Exit Feed Roll ......................................................................... 4-194 REP 12.98-171 Inserter Idle Roller Assembly................................................................. 4-250
REP 12.48-171 Compiler Paddle Motor Assembly ......................................................... 4-196 REP 12.99-171 Tri-Folder Removal ................................................................................ 4-252
REP 12.49-171 Compiler Paddle Unit............................................................................. 4-197 REP 12.100-171 Ejector Paddle Assembly (W/TAG V-004)........................................... 4-253
REP 12.50-171 BM Exit Sensor...................................................................................... 4-198 REP 12.101-171 Paddle Wheel ...................................................................................... 4-254
REP 12.51-171 Compiler Paper Pusher Motor Assembly .............................................. 4-199 REP 12.102-171 Docking Latch Assembly ..................................................................... 4-255
Repairs/Adjustments October 2014

REPs 16 - Network Controller REP 75.6 Tray 5 Down Limit Switch ............................................................................... 4-313
REP 16.1 Network Controller Software Installation......................................................... 4-259 REP 75.7 Un-docking and Docking Tray 5...................................................................... 4-314
REP 16.2 Network Controller (HDD2) W/O TAG 006 ..................................................... 4-259 REP 75.8 Tray 5 Covers ................................................................................................. 4-317
REP 16.3 Network Controller PWB ................................................................................. 4-260 REP 75.9 Tray 5 Docking Latch ...................................................................................... 4-318
REP 75.10 Tray 5 Elevator Rack Assembly.................................................................... 4-319
REPs 62- Scanner REP 75.11 Tray 5 Elevator Tray Guides ......................................................................... 4-322
REP 62.1 Scanner Module.............................................................................................. 4-261
REP 62.2 Top Cover ....................................................................................................... 4-262 REPs 81 to 89 - Paper Transport
REP 62.3 CVT Glass, CVT Ramp and Document Glass Assembly................................ 4-263 REP 81.1 Tray 1 and Tray 2 Paper Feed Assembly ....................................................... 4-325
REP 62.4 Scan Carriage Home Sensor (W/O TAG 007) ................................................ 4-264 REP 81.2 Tray 3 Paper Feed Assembly ......................................................................... 4-326
REP 62.5 Scan Carriage Assembly (W/O TAG 007) ...................................................... 4-265 REP 81.3 Bypass Module ............................................................................................... 4-327
REP 62.6 Carriage Motor and Mounting (W/O TAG 007) ............................................... 4-266 REP 81.4 Tray 1 and Tray 2 Feed Rolls ......................................................................... 4-329
REP 62.7 Scan Cables (W/O TAG 007).......................................................................... 4-267 REP 81.5 Tray 3 Feed Rolls............................................................................................ 4-331
REP 62.8 Scan Drive Belt (W/O TAG 007) ..................................................................... 4-272 REP 81.6 Bypass Tray Feed Rolls.................................................................................. 4-331
REP 62.9 Input Module Angle Sensor (W/O TAG 007)................................................... 4-273 REP 81.7 Tray 5 Feed Rollers ........................................................................................ 4-332
REP 62.10 LED Exposure Lamps (W/O TAG 007) ......................................................... 4-273 REP 81.8 Tray 1 or Tray 2 Feed Sensor......................................................................... 4-334
REP 62.11 Exposure Lamp Ribbon Harness (W/O TAG 007) ........................................ 4-274 REP 81.9 Tray 3 Feed Sensor ........................................................................................ 4-335
REP 62.12 Scanner PWB (W/O TAG 007) ..................................................................... 4-276 REP 81.10 Bypass Tray Empty Sensor .......................................................................... 4-336
REP 62.13 Scan Carriage Ribbon Cable (W/O TAG 007) .............................................. 4-276 REP 81.11 Tray 5 Feed Sensor ...................................................................................... 4-336
REP 62.14 Document Size Sensor 1 and Document Size Sensor 2 (W/O TAG 007) .... 4-277 REP 81.12 Tray 5 Feed Motor ........................................................................................ 4-338
REP 62.15 Scan Carriage Home Sensor (W/TAG 007).................................................. 4-278 REP 81.13 Nip D Release Solenoid................................................................................ 4-338
REP 62.16 Carriage Motor (W/TAG 007)........................................................................ 4-279 REP 82.1 3 Tray Module Transport Motor ...................................................................... 4-339
REP 62.17 Exposure Lamp Inverter (W/TAG 007) ......................................................... 4-280 REP 82.2 3 Tray Module Transport Drive Belt ................................................................ 4-340
REP 62.18 Exposure Lamp (W/TAG 007)....................................................................... 4-281 REP 82.3 Tray 3 Horizontal Transport Assembly............................................................ 4-340
REP 62.19 Exposure Lamp Ribbon Harness (W/TAG 007)............................................ 4-282 REP 82.4 Tray 3 Horizontal Transport Rolls ................................................................... 4-341
REP 62.20 Input Module Angle Sensor (W/TAG 007) .................................................... 4-283 REP 82.5 Tray 5 Transport motor ................................................................................... 4-342
REP 62.21 Scanner PWB (W/TAG 007) ......................................................................... 4-284 REP 82.6 Tray 5 Transport Drive Belt............................................................................. 4-343
REP 62.22 Document Size Sensor 1 and Document Size Sensor 2 (W/TAG 007) ........ 4-284 REP 82.7 Tray 5 Takeaway Roller .................................................................................. 4-344
REP 62.23 Scan Cables (W/TAG 007) ........................................................................... 4-285 REP 82.8 Confirm Sensor ............................................................................................... 4-346
REP 62.24 Scan Idler Pulley (W/TAG 007)..................................................................... 4-289 REP 82.9 Vertical Transport............................................................................................ 4-347
REP 62.25 Platen Down Sensor (W/TAG 007) ............................................................... 4-290 REP 83.1 Horizontal Paper Path..................................................................................... 4-349
REP 62.26 IIT Video / SBC PWB Harness (W/TAG 007) ............................................... 4-291 REP 83.2 Duplex End Sensor, Nip C Solenoid and HPP Diverter Solenoid ................... 4-350
REP 62.27 Scan Motor and Scan Carriage Drive Belt (W/TAG 007).............................. 4-292 REP 83.3 Duplex Sensor (17) ......................................................................................... 4-352
REP 62.28 Power and Communication Harness (W/TAG 007) ...................................... 4-294 REP 83.4 Horizontal Transport Motor ............................................................................. 4-354
REP 83.5 Horizontal Transport Drive Belts And Takeaway Rolls ................................... 4-355
REPs 70 to 75 - Paper Supply REP 89.1 Registration/Preheat Assembly and Lower Platelet Assembly ....................... 4-357
REP 70.1 3 Tray Module PWB........................................................................................ 4-297 REP 89.2 Registration / Preheat Pumps ......................................................................... 4-360
REP 70.2 Upper Left Hand Door Assembly .................................................................... 4-298 REP 89.3 Registration / Preheat Assembly Nip A Kit...................................................... 4-360
REP 71.1 Tray 1 and Tray 2 Removal ............................................................................ 4-299
REP 71.2 Tray 1 and Tray 2 Paper Guides..................................................................... 4-299 REPs 91 - Marking Unit
REP 71.3 Tray 1 and Tray 2 Lift Gear Assembly ............................................................ 4-301 REP 91.1 Carriage Drive Train........................................................................................ 4-363
REP 73.1 Tray 3 Removal............................................................................................... 4-302 REP 91.2 Vertical Gearbox and Motor ............................................................................ 4-364
REP 73.2 Tray 3 Elevator Motor ..................................................................................... 4-303 REP 91.3 Head Maintenance Wiper ............................................................................... 4-367
REP 73.3 Tray 3 Elevator Cables ................................................................................... 4-304 REP 91.4 Front and Rear Tensioner Base...................................................................... 4-370
REP 73.4 Tray 3 Stack Height Sensor ............................................................................ 4-305 REP 91.5 Head Maintenance Belts and Belt Retainer Clips ........................................... 4-372
REP 73.5 Tray 3 Home Sensor....................................................................................... 4-306 REP 91.6 Head Maintenance Horizontal Motion Motor................................................... 4-374
REP 73.6 Tray 3 Elevator Damper and Gears ................................................................ 4-306 REP 91.7 Marking Unit Upper Carriage .......................................................................... 4-376
REP 75.1 Tray 5 Empty Sensor ...................................................................................... 4-307 REP 91.8 Upper Carriage Drive Shaft, Cranks, Upper Front and Rear Compliant Links 4-379
REP 75.2 Tray 5 Stack Height Sensor ............................................................................ 4-309 REP 91.9 X Axis Drive Motor .......................................................................................... 4-380
REP 75.3 Tray 5 Down Sensor ....................................................................................... 4-310 REP 91.10 Lower Carriage Drive Shaft, Cranks, Lower Front and Rear Compliant Links 4-382
REP 75.4 Tray 5 Elevator Motor Assembly..................................................................... 4-310 REP 91.11 Upper Carriage Ship Restraint Motor............................................................ 4-383
REP 75.5 Tray 5 Upper Limit Switch............................................................................... 4-312 REP 91.12 Purge Line Filter............................................................................................ 4-384

REP 91.13 Stitch / Roll Motor ......................................................................................... 4-386 ADJ 12.6-171 Booklet Compiling Position ...................................................................... 4-460
REP 91.14 Marking Unit Lower Carriage ........................................................................ 4-387 ADJ 12.7-171 Booklet Crease Position........................................................................... 4-463
REP 91.15 Ink Loader Assembly .................................................................................... 4-390 ADJ 12.8-171 Booklet Staple Position ............................................................................ 4-464
REP 91.16 Ink Loader Melt Plate Assembly ................................................................... 4-393 ADJ 12.9-171 Booklet Maker Skew ................................................................................ 4-465
REP 91.17 Ink Load Sensor Assembly ........................................................................... 4-394 ADJ 12.10-171 HVF Motor Drive Belt Tensioning........................................................... 4-466
REP 91.18 Ink Transport Motor and Drive Gear ............................................................. 4-395 ADJ 12.11-171 HVF Idler Drive Belt Tensioning ............................................................. 4-467
REP 91.19 Ink Low Sensor Assembly ............................................................................ 4-397 ADJ 12.12-171 Tri-Folder Fold Adjustment..................................................................... 4-467
REP 91.20 Ink Reservoir Assembly ................................................................................ 4-398
REP 91.21 Reservoir Pump ............................................................................................ 4-402 ADJs 62 - Scanner
REP 91.22 IOD Assembly ............................................................................................... 4-404 ADJ 62.1 Optics Cleaning Procedure (W/O TAG 007) ................................................... 4-469
REP 91.23 Front and Rear Track Guide ......................................................................... 4-406 ADJ 62.2 Scan Carriage Assembly (W/O TAG 007)....................................................... 4-470
REP 91.24 Drum Drive Motor and Belt ........................................................................... 4-408 ADJ 62.3 Carriage Motor and Scanner Drive Belt (W/O TAG 007) ................................ 4-471
REP 91.25 Drum and Front Drum Frame Assembly ....................................................... 4-410 ADJ 62.4 Document Glass Registration Adjustment....................................................... 4-471
REP 91.26 Marking Unit Slide Assembly ........................................................................ 4-414 ADJ 62.5 Optics Cleaning Procedure (W/TAG 007) ....................................................... 4-472
REP 91.27 Cleaning Unit Motor Assembly and Home Sensor ....................................... 4-415 ADJs 73 to 75 - Paper Trays
REP 91.28 Marking Unit Assembly ................................................................................. 4-416 ADJ 73.1 Tray 3 Paper Tray Guide Setting..................................................................... 4-473
REP 91.29 Printhead ...................................................................................................... 4-419
ADJ 75.1 Tray 5 Paper Tray Guide Setting..................................................................... 4-475
REP 91.30 Drum Position Encoder Assembly ................................................................ 4-424
ADJ 75.2 Tray 5 Module to Machine Alignment.............................................................. 4-476
REP 91.31 Umbilical Assembly....................................................................................... 4-425 ADJ 75.3 Tray 5 Module Tray Alignment ........................................................................ 4-476
REP 91.32 Cleaning Unit Cam Shaft Assembly.............................................................. 4-429
REP 91.33 Cleaning Unit Plug Connector ...................................................................... 4-431 ADJs 82 - Paper Transport
REP 91.34 Drum Pulley .................................................................................................. 4-431 ADJ 82.1 Media Registration Calibration ........................................................................ 4-479
REP 91.35 Front and Rear Drum Thermistor.................................................................. 4-433
REP 91.36 Abatement Plenum ....................................................................................... 4-435 ADJs 91 - Marking Unit
REP 91.37 Service Loop................................................................................................. 4-436 ADJ 91.1 Printhead Attachment Check........................................................................... 4-481
REP 91.38 Stitch / Roll Motor Lead Screws.................................................................... 4-438
REPs 94 - Ink Transfer

REP 94.1 Cleaning Unit .................................................................................................. 4-439
ADJs 4 - Machine Lubrication

ADJ 4.1 Machine Lubrication .......................................................................................... 4-441
ADJs 5 - DADH
ADJ 5.1 DADH Drive Belt Adjustment............................................................................. 4-443
ADJ 5.2 DADH Height Adjustment.................................................................................. 4-444
ADJ 5.3 DADH Skew Adjustment ................................................................................... 4-446
ADJ 5.4 DADH Cleaning Procedure ............................................................................... 4-447
ADJ 5.5 DADH Registration Adjustment ......................................................................... 4-448
ADJ 5.6 DADH Document Pad ....................................................................................... 4-448
ADJs 12-110 - LCSS

ADJ 12.1-110 LCSS Bin 1 Level ..................................................................................... 4-449
ADJ 12.2-110 Machine to LCSS Alignment .................................................................... 4-449
ADJ 12.3-110 Hole Punch Position ................................................................................. 4-450
ADJ 12.4-110 Motor Drive Belt Tensioning..................................................................... 4-451
ADJs 12-171 - HVF

ADJ 12.1-171 Machine to HVF / HVF BM, HVF BM to Tri-Folder Alignment.................. 4-453
ADJ 12.2-171 Tri-Folder Paper Settings ......................................................................... 4-454
ADJ 12.3-171 Stapler Anvil Alignment ............................................................................ 4-455
ADJ 12.4-171 Crease Blade Position.............................................................................. 4-458
ADJ 12.5-171 Booklet Tamping ...................................................................................... 4-458

REP 1.1 Wiring Harness Repairs • Power communications cable, PL 12.140 Item 7.
• Bin 2 tray harness, PL 12.205 Item 19.
Purpose
• BM PWB to tri-folder PWB harness, PL 12.205 Item 20.
• Foreign device interface harness, PL 3.10 Item 30.
WARNING • LED lamp ribbon harness, PL 62.15 Item 5.
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord • IIT video/CCB PWB harness, PL 62.16 Item 6.
from the customer supply while performing tasks that do not need electricity. Electricity • DADH/IIT power comms harness, PL 62.16 Item 7.
can cause death or injury. Moving parts can cause injury. • Media path driver PWB to Tray 5 PWB harness, PL 75.68 Item 26.
• Tray 5 elevator harness, PL 75.70 Item 20.
WARNING • Tray 5 elevator motor harness, PL 81.40 Item 16.
• Tray 5 centre reg interface harness, PL 81.40 Item 17.
Do not attempt any repairs to the power cord or safety ground harness/conductor.
• Upper carriage harness, PL 91.20 Item 12.
NOTE: Safety ground connections use green/yellow cables, or green cables with a yellow • Lower carriage harness, PL 91.25 Item 12.
stripe or band.
3. The following connectors can be repaired by removing the faulty terminals and installing
The steps that follow identify the relevant procedures for repairing the various connectors con- new terminals:
tained within the copier. • Molex SL connectors - REP 1.2.
1. If wiring is damaged, use connector splicing blocks to repair damaged wiring. • Male Hirose DF 1B connectors - REP 1.3.
2. The following harness assemblies are not repairable; install new parts: • AMP EI connectors - REP 1.4.
• Any ribbon harness. • Hirose DF11 Connectors - REP 1.5.
• Bypass extension harness, PL 1.15 Item 8. • AMP CT connectors - REP 1.6.
• Drum driver MR sensor harness, PL 1.15 Item 9. • Molex mini-fit junior connectors - REP 1.7.
• Chassis interlock harness, PL 1.15 Item 11.
• AC chassis heater harness, PL 1.15 Item 13.
• Drum driver to front components harness, PL 1.15 Item 14.
• Drum driver / media path power harness, PL 1.15 Item 15.
• Engine fan harness, PL 1.15 Item 16.
• Cleaning unit interface harness, PL 1.15 Item 17.
• Media path exit / horizontal harness, PL 1.15 Item 19.
• Transfix roller harness, PL 1.15 Item 20.
• Media path driver PWB to 3 tray module PWB harness, PL 1.15 Item 21.
• Mid rail front door switch harness, PL 1.15 Item 22.
• User interface harness, PL 2.10 Item 7.
• User interface control PWB to user interface status PWB harness, PL 2.10 Item 9.
• LCD to PWB harness, PL 2.10 Item 11.
• Harness HDD (1)/Copy controller PWB (SATA 300), PL 3.10 Item 3.
• Harness HDD (2)/Network controller PWB (SATA 400), PL 3.10 Item 7.
• PDB to CCB (16 way power) harness, PL 3.10 Item 12.
• PDB to Network Controller PWB (14 way power) harness, PL 3.10 Item 13.
• PDB to CCB (4 way data) harness, PL 3.10 Item 14.
• HDD power harness, PL 3.10 Item 16.
• Drawer service loop harness, PL 3.10 Item 20.
• Communication/power cable, PL 5.10 Item 6.
• Power cord, PL 12.140 Item 4.

Xerox® ColorQube® 9203 Family 4-5 REP 1.1
REP 1.2 Molex SL Connectors 2. Figure 2. Remove the terminal from the connector housing using the Molex extractor tool.
Removal
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
1
from the customer supply while performing tasks that do not need electricity. Electricity
Insert the Molex tool
NOTE: Molex connectors have small black housings in single and double row form with minia-
ture square section pins and sockets. 2
Press the prong flat
1. If the damaged connector is in the centre of a double row housing beneath the latching
clip, the latching prong will not be accessible to release the connector from the housing.
Therefore it will be necessary to disassemble the housing as shown in Figure 1.
1 2
Attach the Molex tool
Hold the wires from both
row connectors
3
Push the terminal out of the
housing using a male terminal
from the repair kit
Figure 2 Removing the terminal.
3. Cut off the damaged terminal, then strip 3mm of insulation from the end of the wire.
3
Bend the housing open
5 4
Pull out the A
Pull out the B row connector
row connector
Figure 1 Disassembling the connector.

REP 1.2 4-6 Xerox® ColorQube® 9203 Family
Replacement 4. Figure 4. Insert the crimped terminal into the appropriate position of the crimp tool and
close the crimp tool, to fasten the insulation of the wire in the outer grip of the terminal.
1. Select the correct replacement terminal, and identify the appropriate crimp positions for
the terminal.
2. Figure 3. Insert a male or female terminal into the appropriate position of the crimp tool
and close the tool just enough to hold the terminal.
Figure 4 Crimping the insulation grip.
Figure 3 Crimping the terminal.
3. Insert the wire fully into the terminal so that the stripped portion of the wire is within the
inner grip of the terminal. Close the crimp tool fully to make the crimp.

5. Figure 5. Check that the crimp is correctly made. REP 1.3 Male Hirose DF1B Connectors
Removal
Correct
WARNING
1. Figure 1. Remove the damaged terminal from the housing.
Incorrect
Loose strands of wire

1
Raise the plastic tab
with a suitable tool, to
release the terminal
Crimp loose
Insulation in the crimp Wire exposed
Figure 5 Inspecting the finished crimp.
6. Insert the replacement terminal into the connector housing.

7. If the repair was carried out on a double row connector that was disassembled, push both 2
connectors into the housing taking care that the “A” connector is fitted on the fastener Remove the terminal
side. from housing
Figure 1 Remove the terminal

REP 1.2, REP 1.3 4-8 Xerox® ColorQube® 9203 Family
Replacement 4. Figure 3. Insert the crimped terminal into the appropriate position of the crimp tool and
close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi-
nal.
CAUTION
There are different terminals for large gauge and small gauge wire. Ensure that the correct
replacement terminal is used.
1. Select the correct replacement terminal and identify the appropriate crimp positions for
the terminal.
NOTE: These connectors can be repaired using either crimp terminals or pre-crimped ter-
minals with flying lead and butt connector, as required.
2. Figure 2. Insert the terminal into the appropriate position of the crimp tool and close the
tool just enough to hold the terminal.
Figure 3 Crimping the insulation grip.
3. Insert the wire fully into the terminal so that the stripped portion of the wire is within the
longer grip of the terminal and the insulation of the wire is within the cable grip of the ter-
minal. Close the crimp tool fully to make the crimp; check that the wire is firmly crimped in
the terminal.

5. Figure 4. Check that the crimp is correctly made. REP 1.4 AMP EI Connectors
Removal
Correct WARNING
NOTE: The male housings contain socket terminals, and the female housings contain pin ter-
minals.
Incorrect
1. Use the extractor tool, to release the terminal from the housing. Refer to Figure 1 to iden-
tify the male housing and terminal type. Refer to Figure 2 to identify the female housing
Wire exposed and the terminal type.
Insulation In the crimp
1
Depress the prong with a small
flat head screw driver to release
crimp loose the terminal
Figure 4 Inspecting the finished crimp.
2
Remove the terminal
from the housing
Figure 1 Terminal removal; male housing.

Replacement
1. Select the correct replacement terminal and identify the appropriate crimp positions for
the terminal.
tool enough to hold the terminal.
2
Remove the terminal from the
housing
1
Insert a paper clip to
release the prong
3. Insert the wire completely into the terminal, so that the stripped portion of the wire is in the
Figure 2 Terminal removal; female housing.
longer grip of the terminal. The insulation of the wire is within the cable grip of the termi-
nal. Close the crimp tool completely to make the crimp. Check that the wire is crimped
firmly in the terminal.

4. Figure 4. Insert the crimped terminal into the appropriate position of the crimp tool and 5. Figure 5. Check that the crimp is correctly made.
close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi-
nal.
Correct
Incorrect
Wire exposed
Insulation in the crimp
Crimp loose
Figure 4 Crimping the insulated grip.

Figure 5 Inspect the finished crimp

REP 1.5 Hirose DF11 Connectors REP 1.6 AMP CT Connectors
Removal Removal
WARNING WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
from the customer supply while performing tasks that do not need electricity. Electricity from the customer supply while performing tasks that do not need electricity. Electricity
can cause death or injury. Moving parts can cause injury. can cause death or injury. Moving parts can cause injury.
NOTE: The male housing contains female terminals that cannot be crimped in the field; if a ter-
minal is damaged, install a new terminal with flying lead. CAUTION
1. Figure 1. Remove the damaged terminal from the connector housing. Amp CT connectors use in-line adaptors to connect housings together. Ensure that the correct
adaptor is used for each in-line connection. Do not attempt to disassemble or repair the in-line
adaptors.
NOTE: There are two types of CT connector: insulation displacement connector (IDC) or crimp
terminal. Repairing crimp terminal CT connectors is performed by installing individual replace-
1 ment terminals with flying leads, connected to the existing wiring with connector splicing blocks
Raise the plastic tab with a suitable tool, to release the (removal steps 2 and 3). Repairing IDC connectors is performed by installing a complete
terminal
replacement housing with wires already fitted, connected to the existing wiring with connector
splicing blocks (removal steps 4 and 5). The replacement procedure is only applicable to crimp
2 terminal connectors.
Remove the terminal from
the housing 1. Identify the terminal type. Go to step 2 for a housing containing crimp terminals, or go to
step 4 for a housing containing insulation displacement (IDC) terminals.
Figure 1 Terminal removed
2. Cut the damaged terminal off the wire.

Replacement
1. Insert the replacement terminal with flying lead into the connector housing.
2. Use a butt connector to connect the flying lead to the original wire.

Xerox® ColorQube® 9203 Family 4-13 REP 1.5, REP 1.6
2. Figure 1. Remove the damaged crimp terminal from the connector housing. REP 1.7 Molex Mini-Fit Junior Connectors
Removal
WARNING
1 Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Raise the plastic tab with a suitable tool, to release the from the customer supply while performing tasks that do not need electricity. Electricity
terminal can cause death or injury. Moving parts can cause injury.
2
Remove the terminal
from the housing
Figure 1 ESD Symbol
Figure 1 Terminal removal.
3. Cut the damaged crimp terminal off of the wire.

4. IDC housings are repaired by installing a complete replacement housing with wires
already fitted, These are connected with connector splicing blocks to the existing wiring.
Select the correct replacement connector.
5. Cut one wire from the faulty connector and then reconnect the wire to the appropriate fly-
ing lead on the replacement connector. Repeat this process for each wire in turn, until the
faulty connector has been fully disconnected and the replacement connector installed in
its place.
Replacement
1. Insert the replacement crimp terminal with flying lead into the connector housing.
2. Use a connector splicing block to connect the flying lead to the original wire.

tool just enough to hold the terminal.
WARNING
1. Figure 2. Remove the terminal from the housing, using the Molex, Mini-Fit extractor tool.
2
Withdraw the terminal
from the connector body
1 Figure 3 Crimping the terminal

Insert the prongs fully down
the sides of the terminal 3. Insert the wire fully into the terminal so that the stripped portion is within the inner grip of
the terminal. Close the crimp tool fully to make the crimp.
4. Figure 4. Insert the crimped terminal into the appropriate position of the crimp tool and
close the crimp tool to fasten the wire insulation in the outer grip of the terminal.
Figure 2 Removing the terminal
Replacement
1. Select the correct terminal type.
Figure 4 Crimping the insulation grip

5. Figure 5. Check that the crimp is correctly made. REP 1.8 Front Door Interlock Switch
Parts List on PL 1.15
Removal
Correct
WARNING
WARNING
Incorrect:
1. Open the front door.
2. Remove the front door interlock switch, Figure 1.
Insulation in the crimp
Wire exposed
Figure 5 Inspecting the finished crimp

2
6. Insert the replacement terminal into the connector housing. Disconnect the wires and
remove the switch
1
Lever out the switch body using a flat
blade screwdriver
Figure 1 Front door interlock removal
Replacement
1. Replacement is the reverse of the removal process.

REP 1.9 Power Supply Unit
Removal 1
Disconnect the
ribbon cable 2
from the drum Disconnect
WARNING driver PWB J6AC
WARNING
4 3
NOTE: Some machines may be fitted with a later type of power supply unit that has a blanking Disconnect Disconnect
cover instead of the sliding cover at the main power cord socket.
1. Remove the rear cover, PL 81.10 Item 1. J5AC

JDC3
2. Remove the main power cord, PL 1.15 Item 1.
J4AC
3. Disconnect the LCSS power cord, PL 12.75 Item 8, if installed, or the HVF power cord. PL
12.140 Item 4 if installed. J8AC JDC1
4. Remove the rear cover, PL 70.25 Item 8
5. Disconnect the harnesses, Figure 1. JDC4
Figure 1 Disconnect harnesses

6. Remove the power supply unit, Figure 2. 2. If a later type of power supply unit is being installed, the blanking cover, PL 70.25 Item 14
(supplied with the new power supply unit) must be installed into the lower rear cover,
Figure 4.
3
Lift and remove the
power supply unit
Blanking cover
2 1
Remove 2 Remove 2
screws screws
Blanking cover not installed Blanking cover installed
Figure 4 Blanking cover location
3. Install the ribbon cable JDC2 and note the location of the support lugs on the rear of the
power supply unit, Figure 5.
Figure 2 Remove the power supply unit
7. Remove the ribbon cable, Figure 3.
1
Connect the ribbon
cable to JDC2
1
Disconnect JDC2 and
remove the ribbon cable
Securing lugs on the back of the power supply

Figure 3 Remove the ribbon cable unit to be located on the frame bracket
Replacement
1. Replacement is the reverse of the removal process. Figure 5 Install the ribbon cable

CAUTION
Ensure that wires are not pinched between the frame and the back of the power supply during
installation
4. Install the power supply unit, Figure 6.
1
Loop the lugs on the rear of the power supply unit over the support brackets
3 2
Install the 4 fixing screws to Rest the power supply
secure the power supply on the supports
Figure 6 Install the power supply unit
5. Re-connect the connectors to the power supply unit and the ribbon cable to the drum
driver PWB, Figure 1.

REP 2.1 User Interface Assembly 2. Prepare to detach the UI control panel, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the user inter-
face assembly. NOTE: The UI control panel has 2
1
NOTE: Detachment of the user interface (UI) control panel will enable the replacement of the Remove 4 screws hooked retainers, located on the
underside at the left and right rear
user interface control PWBA, PL 2.10 Item 2, user interface status PWBA, PL 2.10 Item 4 and
corners.
the user interface touch screen, PL 2.10 Item 3. Only remove the complete user interface
assembly when necessary, e.g reinstallation onto a new scanner assembly.
1. Open the front door. If the complete UI assembly is to be removed, remove the scanner Figure 2 Preparation
module, REP 62.1.

8. Undo the 4 nuts, PL 62.10 Item 8, then remove the left and right brace, PL 62.10 Item 7.
CAUTION 9. Remove the UI base, PL 62.10 Item 19, and the 4 grommets, PL 62.10 Item 6.
Ensure no strain is placed upon the UI harness. Replacement
3. Detach the UI control panel, Figure 3. 1. The replacement is the reverse of the removal procedure.
2. When installing the UI assembly hook the rear retainers into place. Lower the keyboard
fully, then press down and push the UI assembly until it clicks into place. The 4 screws
can then be installed.
3
Bias the control panel counter
clock wise to access the 3
PWB assemblies and the UI
touch screen.
Hooked retainer
4
See Caution
1
Hold the front edge of the UI control panel, then lift
upwards and away from machine.
2
Release the 2 hooked retainers.
Figure 3 Detach the UI control panel
4. Remove the scanner rear cover, refer to REP 62.2.

5. Remove the UI Harness cover, PL 62.10 Item 16.
6. Release the UI Harness clamp, PL 62.10 Item 9.
7. Remove the UI control panel with the UI harness, PL 2.10 Item 7.

REP 2.2 User Interface Touch Screen 3. Remove the user interface touch screen, Figure 2.

Removal 3
Remove retainer
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the user inter- 1
face touch screen. Remove 3 harness 2 3
1. Detach the user interface control panel, REP 2.1. clips Disconnect harnesses Remove 3 screws
2. Place the user interface control panel on a flat surface.
Figure 2 Remove the user interface touch screen
Replacement
1. The replacement is the reverse of the removal procedure.
2. If a problem occurs with the display. Refer to GP 32 User Interface Panel Diagnostics and
check out the functions of the UI.

REP 2.3 User Interface PWB 3. Remove the user interface PWB, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
1 2
CAUTION
Disconnect all 6 harnesses Remove all 8 screws
Ensure that ESD procedures are observed during the removal and installation of the user inter-
face PWB.
1. Detach the user interface control panel, REP 2.1
2. Place the user interface control panel on a flat surface.
Figure 2 Remove the user interface PWB
Replacement
The replacement is the reverse of the removal procedure.

REP 3.1 IME Controller PWB 5. Remove the IME controller PWB, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol 1

Disconnect PJs marked A.
CAUTION 2
Remove screws marked B then remove the
Ensure that ESD procedures are observed during the removal and installation of the IME con- PWB.
troller PWB.
1. Open the front door
2. Remove the inner cover, PL 81.11 Item 2.
3. Pull out the marking unit, GP 6.
Figure 2 IME controller PWB removal
4. Remove the marking unit enclosure cover, PL 91.10 Item 18.
Replacement
1. Replacement is the reversal of the removal process.
2. Carefully transfer the 8 pin NVRAM, PL 92.10 Item 11 from the failed PWB and install
onto the new PWB, prior to power on.
NOTE: If the new IME controller PWB does not have a memory module installed, Figure
2, also transfer the memory module to the new IME controller PWB, prior to power on.
3. Install the new NVRAM onto the failed IME Controller PWB to be returned.
If both IME controller PWB and IME NVRAM chip are replaced at the same time. Then
perform the following:
a. dC977 Drum Runout Calibration.
b. dC625 Registration / Preheat Calibration.
c. The front and rear transfix calibration values need to be entered into dC978. The val-
ues are located on the front of the drum frame.
d. Empty the waste tray, since the NVM tracking purge mass has been lost.
e. Enter dC131 NVM Read / Write at location 492-070 Prints On This Drum and enter
the page count of the machine.

REP 3.2 Quad Wave Amp PWB 2. Remove the quad wave amp PWB, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
1
CAUTION 2 Disconnect PJs marked A.
Ensure that ESD procedures are observed during the removal and installation of the quad Remove screws marked B then
remove the PWB.
wave amp PWB.
1. Remove the IME controller PWB, REP 3.1.
Figure 2 Quad wave amp PWB removal
Replacement
Replacement is the reverse of the removal procedure.

REP 3.3 Marking Unit Heater PWB 6. Remove the marking unit heater PWB, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
1
CAUTION Disconnect PJs marked A.
Ensure that ESD procedures are observed during the removal and installation of the marking
unit heater PWB.
2
Remove screws marked B then the PWB.
3. Pull out the marking unit, REP 91.28.
5. Remove the clamp, PL 92.10 Item 6. Figure 2 Marking unit heater PWB removal
Replacement

REP 3.4 Marking Unit Driver PWB 5. Remove the marking unit driver PWB, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol

1
Disconnect PJs marked A.
CAUTION
2
Remove screws marked B then remove the
unit driver PWB. PWB.
Figure 2 Marking unit driver PWB removal
Replacement

REP 3.5 Media Path Driver PWB 3. Disconnect the PJs, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol

1
Disconnect PJs
marked A.
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the media
path driver PWB.
1. Remove the rear cover, PL 81.10 Item 1.
2. Remove the enclosure fan, PL 1.15 Item 6.
Figure 2 Disconnect PJs

4. Remove the media path driver PWB, Figure 3. REP 3.6 Drum Driver PWB
Removal
WARNING
Figure 1 ESD Symbol

1
Remove screws marked A then remove
PWB assembly.
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the drum
driver PWB.
2. Remove the electronics cooling fan, PL 1.15 Item 6.
Figure 3 Media path driver PWB removal
Replacement

3. Disconnect the PJs, Figure 2. 4. Remove the drum driver PWB, Figure 3.
1 1
Disconnect PJs marked A. Remove screws marked A
then remove the PWB.
Figure 2 Disconnect PJs Figure 3 Drum driver PWB removal
Replacement

REP 3.7 Copy Controller PWB
Parts List on PL 3.10 CAUTION
Lift the copy controller and network controller PWBs. Do not slide the PWBs in the image pro-
Removal
cessing module. The PWBs have components on the underside that can be easily damaged.
NOTE: The copy controller PWB and the network controller PWB are removed as a unit.
WARNING
6. Remove the copy controller PWB and network controller PWB, Figure 2.
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the copy con-
troller PWB.
1. If installed, remove the following components:
• Foreign device interface PWB, PL 3.10 Item 18.
• Fax kit, PL 20.05.
• Fax riser bracket and riser PWB module, PL 3.10.
1 2
2. If a new copy controller PWB is to be installed, remove the following components: Remove 14 screws marked A. Remove locking screws on PJ15 and PJ19.
• DIMM module, PL 3.10 Item 5.
• Software Module, PL 3.10 Item 9. 3
• NVM PWB, PL 3.10 Item 21. Remove the network controller PWB and the copy controller PWB as a unit.
• Product enablement key (SIM), PL 3.10 Item 29.
3. Disconnect all connectors on the rear of the image processing module. Pull out the image Figure 2 Removal
processing module.
4. Disconnect all connectors on the copy controller PWB and the network controller PWB. 7. Separate the network controller PWB from the copy controller PWB.
5. Remove the 2 screws that secure the chassis fan assembly, PL 3.10 Item 6. Release the Replacement
harnesses from the clamps on the fan assembly. Move the fan assembly away from the
1. Join the network controller and copy controller PWBs together before inserting them into
PWBs.
the image processing module.
2. Replacement is the reverse of the removal procedure.
3. Perform an Altboot, refer to GP 4 Machine Software.

REP 3.8 HDD Copy Controller Assembly (HDD1) W/O TAG NOTE: The HDD copy controller assembly is on the right of the image processing module
when viewed from the rear of the machine.
006
Removal
WARNING
WARNING
1. Pull out the image processing module.
2. Remove the HDD from the underside of the image processing module, Figure 1.
2 1
Remove the screw then slide Disconnect 2 harnesses.
out the HDD and bracket.
Figure 1 HDD removal
3. Remove 4 screws to separate the hard drive from the bracket.

Replacement
2. Ensure that the bracket locates into the slots on the drawer
3. When the install is complete perform an AltBoot, GP 4.

REP 3.9 Software Module 2. Remove the software module, Figure 2.
Parts List on PL 3.10, PL 3.11

Removal 1
Release the software
module.
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord 2
from the customer supply while performing tasks that do not need electricity. Electricity Remove the software
module.
WARNING
Figure 2 Removal
Figure 1 ESD Symbol Replacement
CAUTION
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the software
module. Do not use a software module that has previously been in another machine as it will transfer
the machine serial number and speed to the new machine. Destroy used software modules.
The software module contains a small amount of low level code, not machine software. These
modules are extremely reliable and should only be changed as a last resort when all other pos- 1. Install a new software module.
sibilities have been ruled out 2. Make sure the software module is fully seated.
3. At power up a 'configuration parameter' error will appear. The machine does not know
Do not replace the software module before the machine has completed the install wizard. what the serial number is.
4. Enter the serial number from the machines frame serial number plate via dC132. Type
1. Pull out the image processing module. carefully and double check that the entered number is correct.
An incorrect entry can only be rectified with another new software module.
5. The machine will then retrieve the other machine parameters as originally purchased from
the SIM card, machine speed, billing plan and service plan.
6. Check the billing plan and service plan are correct with the customer. If the customer has
changed either since the machine was purchased these will not be reflected.
Use dC103 billing plan and dC136 service plan to correct as necessary.
7. If the data cannot be retrieved from the SIM the machine will default to 9201. Escalate
through the normal channels to have a pre-serialized SIM sent to you.

REP 3.10 Single Board Controller PWB (W/TAG 006)
Lift the single board controller PWB. Do not slide the PWB in the image processing module.
Removal
The PWB have components on the underside that can be easily damaged.
5. Remove the single board controller PWB, Figure 2.
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the copy con-
troller PWB.
1. If installed, remove the following components:
• Foreign device interface PWB, PL 3.11 Item 14.
• Fax kit, PL 20.05.
1 2
• Fax riser bracket and riser PWB module, PL 3.11 Item 9. Remove 10 screws marked A. Remove locking screws on PJ15 and PJ19.
2. If a new copy controller PWB is to be installed, remove the following components:
• System memory, PL 3.11 Item 4. 3
• Software Module, PL 3.11 Item 7. Remove the single board controller PWB.
Figure 2 Removal
• EPC memory PWB, PL 3.11 Item 21.
• Product enablement key (SIM), PL 3.11 Item 22. Replacement
3. Disconnect all connectors on the rear of the image processing module. Pull out the image
processing module.
2. Perform an Altboot, refer to GP 4 Machine Software.
4. Disconnect all connectors on the single board controller PWB.

REP 3.11 HDD Single Board Controller Assembly W/TAG 006 Replacement
Parts List on PL 3.11 1. Replacement is the reverse of the removal procedure.
2. Ensure that the bracket locates into the slots on the drawer
Removal
3. When the install is complete perform an AltBoot, GP 4.
WARNING
WARNING
1. Pull out the image processing module.
2. Remove the HDD from the underside of the image processing module, Figure 1.
NOTE: The HDD single board controller assembly is on the right of the image processing
module when viewed from the rear of the machine.
2 1
out the HDD and bracket.
Figure 1 HDD removal

REP 3.12 NVM PWB REP 3.13 8 Pin NVRAM
Parts List on PL 3.10, PL 3.11 Parts List on PL 92.10
Removal Removal
WARNING WARNING
WARNING
Figure 1 ESD Symbol
CAUTION
Figure 1 ESD Symbol
unit heater PWB.
CAUTION 1. Open the front door.
Ensure that ESD procedures are observed during the removal and installation of the software 2. Remove the inner cover, PL 81.11 Item 2.
module.
The NVM PWB contains the local machine settings. These are retained using battery backed
memory.
5. Remove the 8 pin NVRAM, PL 92.10 Item 11.
NOTE: All customer settings, machine configuration settings, customer copy count, usage and Replacement
fault counters will be lost. Inform back office and follow the local process. 1. Carefully install the new 8 pin NVRAM.
1. Pull out the image processing module. 2. Perform the following:
2. Remove the NVM module. a. dC977 Drum Runout Calibration.
Replacement b. dC625 Registration / Preheat Calibration.
1. Install a new NVM module. c. The front and rear transfix calibration values need to be entered into dC978. The val-
2. Make sure the NVM module is fully seated. ues are located on the front of the drum frame.
3. Open / Close all paper trays and confirm the media in each tray. d. Empty the waste tray, since the NVM tracking purge mass has been lost.
4. Enter dC131 and perform the following: e. Enter dC131 NVM Read / Write at location 492-070 Prints On This Drum. Enter the
• Enter NVM ID 616-001 set the market region. page count of the machine.
• Enter NVM ID 616-052 and set product identifier.
NOTE: . This does not set machine speed, only which product is identified on the
configuration sheet.
• For XE only - Check tray 3 media setting. Enter Service Copy Mode (GP 1). Select:
Machine Info / Tools / Device setting / Paper Management / Tray contents.
5. Perform dC608 Document Feeder Registration
6. Perform dC609 Document Glass Registration.

REP 5.1 Top Cover Assembly
Parts List on PL 5.20 3 4
Remove the 2 latch pins. Remove the top
Removal cover assembly.
WARNING
can cause death or injury. Moving parts can cause injury. Take note of the position of
latch pins.
1. Open the DADH top cover.
2. Remove the DADH top cover assembly, Figure 1.
2
Remove the screw and 1
the plastic bushing (front Disengage the hinges.
and back).
Figure 1 Top cover
Replacement
The replacement is the reverse of the removal procedure. Make sure the latch pins are
installed correctly, refer to Figure 1.

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

torsion spring
2. Remove the DADH rear cover, PL 5.10 Item 1.
3. Remove the DADH top cover assembly, REP 5.1.
4. Remove the DADH top access cover assembly, Figure 1.
2
3 Remove the screw and
the bracket.
Remove the top access
cover assembly.
CVT idler roll torsion

spring
Figure 2 Torsion springs
1
Disconnect PJ191 and
the ground harness.
Figure 1 Top access cover assembly

REP 5.3 Feed Assembly 4. Remove the feed assembly, Figure 1.

Removal
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity Disengage the hinges.
2
WARNING Remove 4 self tapping
Take care during this procedure. Sharp edges may be present that can cause injury. screws marked A.
2. Remove the DADH rear cover, PL 5.10 Item 1.
3. Remove the feed roll assembly, REP 5.14.
7
Remove the feed
assembly.
3 4 5 6
Disconnect PJ183, Disconnect PJ199. Release the Disconnect the ground
PJ184 and PJ187. harness. harness.
Figure 1 Feed assembly
Replacement

REP 5.4 Input Tray Assembly NOTE: To release the tension of the drive belts, refer to ADJ 5.1.
Parts List on PL 5.35 3. Remove the input tray assembly, Figure 1.

Removal
7
Remove 3 1
WARNING self tapping Loosen the
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord screws screw.
marked A.
8
WARNING Remove the
input tray
Take care during this procedure. Sharp edges may be present that can cause injury. assembly.
1. Remove the DADH, REP 5.19.
2. Remove the feed assembly, REP 5.3.
6
Release the
harness. 2
5 Release the
Disconnect 3 tension on the
4 feed motor
PJ190. Disconnect
Release the drive belt.
tension and the ground
disengage the harness.
drive belt.
Figure 1 Input tray assembly
Replacement
2. Perform ADJ 5.1 DADH Drive Belt Adjustment.

REP 5.5 Baffle Assembly 6. Prepare to remove the baffle assembly, Figure 1.

Removal
WARNING
2
WARNING Release the harness.
Take care during this procedure. Sharp edges may be present that can cause injury. 1
Disconnect the link arm.
2. Remove the top access cover assembly, REP 5.2.
3. Remove the feed assembly, REP 5.3. 3
4. Remove the input tray assembly, REP 5.4. Disconnect PJ189.
5. Remove the CVT roll, REP 5.15.
Figure 1 Preparation
CAUTION
When the top access cover assembly, feed assembly, input tray assembly and CVT roll are
removed the DADH structure is weak. Do not lower the DADH in this configuration.
7. Carefully install the DADH frame on the machine. Secure the DADH with the two thumb-
screws.

CAUTION CAUTION
Be careful to prevent damage to the document pad when the document pad is removed from Take care removing the baffle assembly, do not damage the solenoid link arm.
the baffle assembly. 10. Remove the baffle assembly, Figure 3.
8. Move the baffle assembly lower cover to give access, Figure 2.
DADH frame.
2
Disengage the hinge
pin.
3
Slide the tab through
slot in DADH frame.
3 4
Remove the baffle
Disengage the lugs in the
assembly.
lower cover.
1
Feed the harness and
ground harness through the
frame.
Solenoid link arm.
Figure 3 Baffle assembly
2
Remove 2 screws.
4
To help the removal of the
baffle assembly, slide the 1
lower cover approximately Carefully remove the left hand
40mm (1.5 inches) away end of the document pad from the
from the document pad. baffle assembly.
Figure 2 Lower cover movement
9. Disconnect PJ196 from the exit sensor and remove the exit sensor, REP 5.11.

Replacement REP 5.6 Takeaway Roll Assembly
The replacement is the reverse of the removal procedure. Make sure that the torsion springs Parts List on PL 5.35
and harness are in the correct position, Figure 4.
Removal
WARNING
WARNING
Torsion springs.
Route the harness.
Figure 4 Torsion springs and harness

2. Remove the takeaway roll assembly, Figure 1. REP 5.7 Duplex Solenoid
NOTE: To release the tension of the drive belt on the feed motor, refer to ADJ 5.1. Parts List on PL 5.30
Removal
2
Remove 2 E-clips.
WARNING
Small spacers. from the customer supply while performing tasks that do not need electricity. Electricity
Large spacer.
WARNING
3 1. Remove the DADH rear cover, PL 5.10 Item 1.
Slide the bearing forward. 2. Prepare to remove the drive assembly, Figure 1.
1
Disconnect 3 ground
harnesses.
2
Remove 3 self tapping
screws marked A.
1
Release the tension and 3
disengage the drive belt.
Disconnect PJ203 and
PJ204.
4
Remove the takeaway roll
assembly.
4
Release the harnesses.
Figure 1 Takeaway roll assembly
Replacement
The replacement is the reverse of the removal procedure. Make sure the spacers and E-clips Figure 1 Drives assembly
are installed correctly, refer to Figure 1.

NOTE: To release the tension on the drive belts, refer to ADJ 5.1. 4. Remove the duplex solenoid, Figure 3.
3. Remove the drive assembly, Figure 2.

3 2
Disconnect PJ205. Remove the screw.
1
Disconnect the
link arm.
5
1 4 Release the duplex sole-
Release the tension and Disconnect the ground harness. noid from the clips.
disengage the drive
2 belts.
3
Remove the drive assembly. Release the harness.
Figure 3 Duplex solenoid
Figure 2 Drives assembly
Replacement
CAUTION
The screw that attaches the ground harness to the duplex solenoid is shorter than the other
screws. Do not use the incorrect screw.
1. The replacement is the reverse of the removal procedure. Make sure that the wiring is not
caught below the drive assembly.
2. Perform the DADH motor adjustment, ADJ 5.1.

REP 5.8 Takeaway and CVT Sensor Replacement
Parts List on PL 5.20 The replacement is the reverse of the removal procedure. Make sure the spring plate and idler
roll torsion springs are in the correct position. Also make sure that the CVT sensor actuator is
Removal in the correct position below the CVT roll and the idler shaft. Refer to Figure 1 and Figure 2.
Then install the top cover assembly,
WARNING
Takeaway idler roll
torsion spring
WARNING
1. Remove the DADH top cover assembly, REP 5.1.
2. Remove the takeaway or CVT sensor, Figure 1.
2
Disconnect the correct PJ. Remove the
correct sensor.
1
Remove the screw.
Takeaway sensor.
CVT idler roll torsion

spring
CVT
sensor.
Spring plate. Figure 2 Torsion springs
CVT idler roll

shaft.
Figure 1 Takeaway and CVT sensors

REP 5.9 DADH Tray Size Sensors Replacement
Parts List on PL 5.35 The replacement is the reverse of the removal procedure.
Removal
WARNING
1. Remove the input tray assembly, REP 5.4.
CAUTION
Disconnect the ground harness from the static eliminator before the input tray assembly lower
cover is removed, refer to Figure 1.
2. Turn the input tray assembly upside down, then remove the Lower cover right, PL 5.35
Item 9.
3. Remove the relevant sensor, Figure 1.
1
Remove the ground harness
and bracket.
Ground harness.
See CAUTION.
Sensor 2.
2
Sensor 1. Disconnect the correct PJ. Remove
the correct sensor.
Figure 1 Tray size sensors

REP 5.10 Registration Sensor
Removal
WARNING
1. Remove the DADH, top cover assembly, REP 5.1.
2. Remove the registration sensor, Figure 1.
5
Disconnect PJ192. Remove
the registration sensor
4
Remove the sensor assembly.
Torsion spring
location.
Figure 2 Torsion spring location
1
Remove 2 screws. 2 3
Carefully release the Remove the pre-scan
torsion spring. idler roll.
Figure 1 Registration sensor
Replacement
The replacement is the reverse of the removal procedure. Make sure that the torsion spring is
installed correctly, Figure 2.

REP 5.11 Exit Sensor
Removal
WARNING
1. Raise the DADH.
CAUTION
3
Be careful to prevent damage to the document pad when the document pad is removed from Disengage the lugs in the lower
the baffle assembly. cover.
2. Prepare to remove the exit sensor, Figure 1.
2
4 Remove 2
Remove the lower cover. screws.
1
Carefully remove the left hand end of the
document pad from the baffle assembly.

3. Remove the exit sensor, Figure 2. REP 5.12 DADH Counterbalance
Removal
1
Disconnect
PJ196. Remove
WARNING
the exit sensor. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
Do not remove the DADH while the DADH is lowered. In the lowered position the coun-
terbalance springs are compressed and can cause injury when released.
WARNING
2. Put the DADH upside down on a solid flat surface.
NOTE: The counterbalances are different. The removal procedure for the two counterbalances
is same.
3. Remove the relevant counterbalance, right, PL 5.10 Item 2 (4 screws) or left, PL 5.10 Item
4 (4 screws).
Replacement
2. Perform the steps that follow:
• DADH height adjustment, ADJ 5.2.
• DADH registration adjustment, ADJ 5.5.
3. If a new right counterbalance has been installed, perform the DADH skew adjustment,
ADJ 5.3.
Figure 2 Exit sensor removal
Replacement

REP 5.13 Exit Roll Assembly 4. Remove the exit roll assembly, Figure 1.

Removal
Plastic washers.
WARNING
CAUTION
Ground harness.
Disconnect the ground harness from the static eliminator before the input tray assembly lower See CAUTION.
cover left is removed, refer to Figure 1.
3. Turn the input tray assembly upside down. Remove the Lower cover (right), PL 5.35 Item 1
9 and Lower cover (left), PL 5.35 Item 20. lift the exit roll
assembly to
remove.
Retaining clips
Figure 1 Exit roll assembly removal
Replacement
1. Place the exit roll assembly in position, ensure that the plastic washers are located on
either side of the housing, refer to Figure 1.
2. Press the retaining clips into their locating holes, refer to Figure 1.
3. The remainder of the replacement procedure is the reverse of the removal procedure.

REP 5.14 Feed Roll Assembly 2. Remove the DADH feed roll assembly, Figure 1.

Removal
WARNING
1
Completely raise the feed
roll assembly (2 clicks).
2
Raise the feed roll assembly
cover.
3
Remove the feed roll assem-
bly.
NOTE: There are three rollers on the feed roll

cartridge.
If the lower feed roll does not come out with feed
roll assembly, then remove it separately from the
machine.
Figure 1 Feed roll assembly

Replacement REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt
1. The replacement is the reverse of the removal procedure. When the feed rolls are Parts List on PL 5.25
installed, make sure the lowest roll, (retard roll), is positioned as shown in Figure 2.
2. If a new feed roll assembly is installed, reset the DADH feed count to zero. Refer to
Removal
dC135 CRU / HFSI Status.
WARNING
3. Remove the DADH drive assembly, refer to REP 5.7.
4. Remove the duplex gate, Figure 1.
1
Key Retard roll
Lift out the duplex
gate.
Figure 2 Retard roll position
Figure 1 Duplex gate

7. Release the front CVT roll bearing, PL 5.25 Item 4. Remove the CVT roll and CVT motor,
drive belt, Figure 3.
CAUTION
When the top access cover assembly, feed assembly, input tray assembly and CVT roll are
removed the DADH structure is weak. Do not lower the DADH in this configuration
5. Carefully install the DADH frame on the machine. Secure the DADH with the 2 thumb-
screws.
6. Disengage the back CVT roll bearing, Figure 2.
1
Compress the two ends of
the bearing together. 1
Remove the CVT roll.
2
Remove the CVT
motor drive belt.
2 Figure 3 CVT roll

Push the bearing to disengage.
Figure 2 Bearing

Replacement REP 5.16 Document Width Sensor
1. The replacement is the reverse of the removal procedure. Make sure the white washer is Parts List on PL 5.35
installed correctly, Figure 4.
2. Perform the DADH CVT motor adjustment, refer to ADJ 5.1.
Removal
WARNING
CVT roll.
White washer. 2. Remove the input tray assembly, REP 5.4.
CAUTION
cover is removed, refer to Figure 1.
3. Turn the input tray assembly upside down, then remove the Lower cover right, PL 5.35
Item 9 and Lower cover left, PL 5.35 Item 20
Figure 4 Replacement

4. Remove the document width sensor, Figure 1. REP 5.17 Input Tray Static Eliminator
Removal
1
Release the harness.
WARNING
2 from the customer supply while performing tasks that do not need electricity. Electricity
Disconnect PJ193. can cause death or injury. Moving parts can cause injury.
CAUTION
Arm cover is removed, refer to Figure 1
2. Turn the input tray assembly upside down, then remove the Lower cover (right), PL 5.35
3 Item 9 and Lower cover (left), PL 5.35 Item 20.
Remove the document width sensor.
3. Remove the input tray static eliminators, Figure 1.
Ground harness.
Ground harness. 1
Remove the
correct static
eliminator.
Figure 1 Document width sensor
Replacement Figure 1 Static eliminators
The replacement is the reverse of the removal procedure. Make sure the document width sen-
Replacement
sor arm is attached correctly, refer to Figure 1.

REP 5.18 Exit Roll Idler 4. Remove the exit roll idlers, Figure 2.

2
Removal Lift out the exit roll idlers. Bearing
WARNING 3
Remove the 2 bearings.
1. Remove the baffle assembly lower cover, PL 5.30 Item 1.
2. Remove the baffle assembly, REP 5.5.
3. Prepare to remove the exit roll idlers, Figure 1.
1
Release the link arm.
1
Carefully remove the torsion spring
and the document finger.
Bearing
Figure 2 Exit roll idlers
3
Remove the lift bar and
link arm.
2
Raise one end of the exit roll idler shaft, then release
the lift bar.

Replacement REP 5.19 DADH Removal
The replacement is the reverse of the removal procedure. Make sure that the torsion spring Parts List on PL 5.10
and document finger are installed correctly, refer to Figure 3.
Removal
WARNING
WARNING
Do not remove the DADH while the DADH is lowered. In the lowered position the coun-
terbalance springs are compressed and can cause injury when released.
Torsion spring.
WARNING
1. Disconnect the communication/power cable, PL 5.10 Item 6 and the DADH ground har-
Document finger. ness, PL 5.10 Item 11.
2. Raise the DADH.
Figure 3 Torsion spring and document finger

REP 5.20 Mylar Guide Strip
WARNING Parts List on PL 5.30
Use safe handling procedures when removing the module, GP 16. The module is heavy. Removal
NOTE: The DADH weight is 13Kg (29lb.).
3. Remove the DADH from the machine, Figure 1. WARNING

1. Raise the DADH.
2. Open the baffle assembly, PL 5.30 Item 14.
2 3. Remove the old mylar guide strip, PL 5.30 Item 12.
Remove 4. Use cleaning fluid to remove any contamination from the baffle assembly.
the DADH.
Replacement
1. Remove the 3 backing strips from the pressure sensitive adhesive tape on the mylar
guide.
2. Adhere the mylar guide to the baffle assembly, Figure 1.
1
Remove 2 thumbscrews.
1
Bias the corner of the
mylar guide with the edge
of the baffle assembly.
2
Position the centre of the
mylar guide over the cen-
tre rib.
Figure 1 DADH removal
Replacement
2. If a new DADH is installed, perform the steps that follow:
a. Attach the document pad, refer to ADJ 5.6.
b. Reset the DADH feed count to zero. Refer to dC135 CRU / HFSI Status.
c. DADH height adjustment, ADJ 5.2.
d. DADH registration adjustment, ADJ 5.5.
e. DADH skew adjustment, ADJ 5.3.
Figure 1 Mylar guide

REP 10.1 Transfix Roll NOTE: It may be necessary to use a screwdriver to manually rotate the front and rear
transfix motor shafts to move the transfix roll away from the drum.
Removal
location of the front trans-

WARNING fix motor shaft. Rear
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord shaft in similar position at
from the customer supply while performing tasks that do not need electricity. Electricity rear.
WARNING
WARNING
CAUTION
1. Remove the exit paper path, REP 10.20.
2. Remove the cleaning unit, refer to REP 94.1. 1
3. Unlock the stripper gate, GP 31 and fully lower/open the gate. This will lower and cover Remove 3 screws and
ground lead.
the stripper blade with its protective guard.
4. Remove the transfix blade, REP 10.6.
5. Prepare to remove transfix roll, Figure 1.

Replacement
CAUTION 1. Replacement is the reverse of the removal procedure.
Support the weight at the rear of the transfix roll to avoid damage to the drum. 2. Clean the transfix roller and housing with a dry cloth. Remove all grease that is not neces-
sary.
CAUTION NOTE: High pressure bearing grease, PL 26.11 Item 3, is used on the outside diameter of
the transfix roller bearing holder. During normal removal and replacement the existing
Make sure all three screws are moved to the adjacent threaded holes during removal. Leaving
one screw in the original position, while attempting to remove the roller with the other two bearing grease used during manufacture will be sufficient. Only apply grease when both
sides of any bearing surface are being replaced, or if the surfaces have been wiped clean.
screws, can break a tab on the transfix roller. Move the screws back over to the larger, non-
Apply the grease very sparingly.
threaded holes for installation.
6. Remove transfix roll, Figure 2. 3. Ensure that the ground lead between the top transfix roller screw and the front drum
frame is reconnected.
1
Take note of the cautions
above.
2
Install the 3 screws into the
adjacent threaded holes.
Gradually tighten each screw
in sequence to remove the
bearing evenly.
3
Remove the transfix roll from
the front
Figure 2 Transfix roll removal

REP 10.2 Front Transfix Linkage and Gear Kit 3. Prepare to remove the front plate, Figure 1.

Removal
WARNING 2
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Remove 2
from the customer supply while performing tasks that do not need electricity. Electricity long screws
can cause death or injury. Moving parts can cause injury. and washers.
WARNING
CAUTION
1. Remove the transfix roll, REP 10.1.
2. Remove the front drum shroud, PL 94.20 Item 7.
1
Remove 3 T30 screws.

4. Remove the front plate, Figure 2. 5. Prepare to remove transfix linkage and gear, Figure 3.
1
Remove 4 screws
2
Remove 4
screws
3
Remove 2 1
screws. Support the weight of the
transfix linkage and gear.
Refer to note.
4 2
5 Disconnect the front transfix flexure Push the bearing out.
Remove the front plate. encoder harness and remove the cover.
Figure 2 Front plate removal Figure 3 Preparation

NOTE: The transfix linkage and gear is shown in Figure 5. 7. The removed transfix linkage is shown in Figure 5.
6. Remove the transfix linkage and gear, Figure 4.
Figure 5 Transfix linkage
2 1 Replacement
Remove the transfix Remove the retract 1. Replacement is the reverse of the removal procedure.
linkage and gear. spring.
2. Before installing the new transfix linkage, use the transfix roller retaining screws to pre -
tap the three transfix roller retaining holes in the linkage. This will prevent metal shavings
from falling down into the machine during transfix roller installation.
3. Ensure that the arm is in the correct position relative to the gear.
4. Ensure that the spring is re-installed.
Figure 4 Transfix linkage removal 5. Ensure that the ground lead between the top transfix roller screw and the front drum
frame is reconnected.

6. Cross out the old calibration value on the calibration label, Figure 6. REP 10.3 Rear Transfix Linkage and Gear Kit
7. Write the new linkage calibration value on the calibration label, Figure 6.
NOTE: The new front transfix linkage and gear kit should come with documentation stat- Removal
ing the new transfix calibration load values for the parts. If the document is not present
use 2100.
WARNING
Calibration label for front and

rear transfix values
WARNING
CAUTION
Figure 6 Calibration label print quality defects.
1. Remove the drum fan shroud, PL 94.20 Item 5.
8. Perform dC978 Transfix Calibration Values and load the correct values for the new link- 2. Remove the drum drive motor and belt, REP 91.24.
age. 3. Remove the M4 drive and gearbox, REP 10.8.
4. Remove the drum pulley, REP 91.34.
5. Remove the fan assembly mount, Figure 1.
1
Remove 5 screws marked A to
remove the fan assembly
mount
Figure 1 Fan mount removal

6. Disconnect harnesses, Figure 2. 7. Remove 3 gears, Figure 3.
1
Disconnect the ground
lead
2
Remove 2 KL-clips and
2 bushes
3 2
Disconnect 2 PJs from the motor Disconnect 2 PJs
1
Remove 3 KL-clips and 3 gears
Figure 3 Gear removal

CAUTION CAUTION
The bushes might remain in place after the screws are removed. Take care not to drop the The rear compound gear can fall away from the rear plate when the rear outer frame is
bushes when the rear outer frame is removed. removed. Take care not to drop the rear compound gear.
8. Remove 2 screws and 2 bushes, Figure 4. 9. Remove the rear outer frame, Figure 5.
5
Disconnect the
harnesses from
3 both sides of
Remove 1 long screw and 1 the mount
bush
4
Remove the
rear outer
frame from the
machine. Take
care not to drop
the gear
1
Remove 1
screw to
remove the
lever mount
1 2 3
Remove 1 long screw and 1 bush Remove 6 screws marked A Remove 3 screws
marked B
Figure 4 Screw and bush removal Figure 5 Rear outer frame removal

10. Prepare to remove the rear transfix linkage and gear, Figure 6. 11. Remove the rear transfix linkage and gear, Figure 7.
2
1 2 1 Remove the rear transfix linkage
Support the weight of the rear Push the bearing out. Remove the retract spring
transfix linkage and gear.
Figure 6 Preparation Figure 7 Rear transfix linkage removal
Replacement
NOTE: Before tightening the screws, Figure 5, it may be necessary to position the bushes
removed in Figure 4.
2. Ensure that the arm is in the correct position relative to the gear.
3. Ensure that the spring is re-installed.

4. Cross out the old calibration value from the calibration label on the front outer frame, PL REP 10.4 Front Transfix Motor
10.20 Item 19, Figure 8.
Removal
WARNING
Calibration label for front and from the customer supply while performing tasks that do not need electricity. Electricity
rear transfix calibration values can cause death or injury. Moving parts can cause injury.
WARNING
Figure 8 Calibration label 1. Remove the exit paper path, REP 10.20.
2. Remove the front transfix motor, Figure 1.
5. Write the calibration values of the new linkage on the calibration label.
6. Perform dC978 Transfix Calibration Values and load the correct values for the new link-
age.
1
Disconnect 2 harnesses.
2
Remove screws marked A,
then remove the motor.
Figure 1 Front transfix motor removal
Replacement

REP 10.5 Rear Transfix Motor REP 10.6 Transfix Blade
Parts List on PL 10.20 Parts List on PL 10.20
Removal Removal
WARNING WARNING
WARNING WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present that can cause injury.
2. Remove the rear transfix motor, Figure 1. CAUTION
Do not hit the drum. Use care when you are working near the drum. The drum can be damaged
easily, which will cause print quality defects.
1 1. Open the front door.
Disconnect 2 harnesses. 2. Remove the inner cover, PL 81.11 Item 2.
3. Open the stripper gate, GP 31.
2
Remove screws marked
A then remove the motor.
Figure 1 Rear transfix motor removal
Replacement

4. Remove the transfix blade, Figure 1. Replacement
1. Insert the transfix blade into the machine, Figure 2.
1 2
Remove the screw. Remove transfix blade by
pulling it down. 1
Insert the tabs on the transfix
blade into the slots on the
machine frame
Figure 1 Transfix blade removal

Figure 2 Transfix blade replacement
2. Raise the front of the transfix blade until it interfaces with the pins in the front machine
frame.
CAUTION
Be careful when the self tapping screw is installed into a plastic component. Do not over
tighten.
3. Install the screw removed in Figure 1.
4. Close the stripper gate, GP 31.
5. If a new transfix stripper assembly is installed, reset the transfix stripper count to zero.
Refer to dC135 CRU / HFSI Status.

REP 10.7 Pre Transfix Sensor
Removal
WARNING
WARNING
CAUTION
3. Remove the lower platelet assembly, Figure 1.

Horizontal paper path
2
Raise the cover assembly
and heat shield.
1
To release the cover assembly.
Turn the dial to align the hole
on the dial with the arrow as
shown.
3
Remove the screw
through the hole in the
frame.
5
Remove the lower
platelet assembly
Front frame
4
Disconnect the connector.
Figure 1 Remove lower platelet assembly

4. Remove the air pump cover, Figure 2. REP 10.8 M4 Motor and Gearbox
1
Release the clips marked A to Removal
remove the cover.
WARNING
WARNING
Figure 2 Air pump cover removal Take care during this procedure. Sharp edges may be present that can cause injury.
5. Remove the pre transfix sensor, Figure 3. 2. Remove drum fan shroud, PL 94.20 Item 5.
3. Remove the drum motor and drive belt, REP 91.24.
4. Remove the M4 motor (PL 10.10 Item 5) and gearbox (PL 10.10 Item 4), Figure 1.
A
3 2
Disconnect the harness. Use the harness to remove
the sensor through the slot.
A
1
Release the sensor clips.
Figure 3 Sensor removal
Replacement 1 2
Disconnect harness. Remove the screws marked A.
2. If the registration/preheat assembly is removed. Perform the dC625 Registration/Preheat Figure 1 M4 drive and gearbox removal
Calibration.
Replacement

REP 10.9 Stripper Solenoid Assembly 5. Remove stripper solenoid, Figure 1.

Removal A
WARNING
A
WARNING
CAUTION
1. Manually unlock the stripper gate and baffle assembly, refer to GP 31.
2. Open the stripper gate, GP 31. 2 1
3. Remove the rear cover, PL 81.10 Item 1. Disconnect the inline connector, Remove 2 screws marked A.
4. Remove the drum drive motor and belt, REP 91.24. then remove the solenoid assembly.
Figure 1 Stripper solenoid removal
Replacement

REP 10.10 Roller Drive J 4. Remove the 25T gear and bearing, Figure 1.

Removal
WARNING
WARNING
CAUTION
2. Unlock and fully open the stripper gate. GP 31.
3. Remove the M4 motor and gearbox, REP 10.8. 1
Remove the e-clips,
gear and bearing.

5. Lower the upper baffle, Figure 2. 6. Remove roller drive J, Figure 3.
1 2
2 1 Remove roller drive J.
Remove screw Remove the e-clip and
Loosen screw by two
bearing.
turns then lower the baffle.
Figure 2 Lower the upper baffle Figure 3 Roller removal
Replacement

REP 10.11 Roller Drive L 4. Remove the 25T gear and rear bearing, Figure 1.

Removal
WARNING
WARNING
2. Unlock and fully open the stripper gate. GP 31.
3. Remove the M4 motor and gearbox, REP 10.8.
1
Remove the KL-clip,
gear and bearing.
Figure 1 Gear and bearing removal

5. Lower the upper baffle, Figure 2. 6. Remove the roller drive L, Figure 3.
1 1
Remove screw 1 2
Loosen the screw by two
turns then lower the baffle. Remove e-clip and bearing. Remove roller drive L.
Figure 2 Lower the upper baffle Figure 3 Roller removal
Replacement

REP 10.12 Exit / Duplex Solenoid 2. Open the exit transport jam clearance door, Figure 1.

Removal
WARNING
WARNING
1
Open the jam clearance door by
releasing the catch.
Figure 1 Open jam clearance door
3. Remove diverter gate, REP 10.13.

4. Remove the paper guide, Figure 2. 5. Remove the exit/duplex solenoid, Figure 3.
1
With the jam clearance door opened, release the
3 retaining tabs. Then remove the inner paper
guide.
1 2
Remove the screw and ground lead. Disconnect the harness.
Figure 2 Paper guide removal Figure 3 Solenoid removal
Replacement

REP 10.13 Diverter Gate 2. Open the exit transport jam clearance door, Figure 1.

Removal
WARNING
WARNING
1
Open the jam clearance door by

3. Remove the ground lead, Figure 2. 4. Remove the diverter gate from the top exit baffle, Figure 3.
1
Remove the screw and ground
lead.
1 2
Slide to release the guide Carefully release the tab.
Figure 2 Ground screw removal Figure 3 Release the diverter gate

5. Remove the exit / duplex solenoid from the diverter gate assembly, Figure 4. REP 10.14 Exit Motor (M5)
Parts List on PL 10.15 Item 11
Removal
WARNING
WARNING
2. Remove the drive gears, Figure 1.
1
Remove 2 screws release the sole-
noid from the diverter guide.
Figure 4 Remove exit / duplex solenoid
Replacement
1
Remove 2 gears then 2 drive belts.

3. Release the exit motor, Figure 2. 4. Remove the exit motor, Figure 3.
1
Disconnect the harness then
remove the motor.
1
Remove 2 screws.
Figure 2 Motor release Figure 3 Motor removal
Replacement

REP 10.15 Duplex Start Sensor (13) 4. Remove the duplex sensor, Figure 2.

Removal
1
WARNING Remove the sensor then
disconnect the harness.
WARNING
2. Remove the diverter gate, REP 10.13.
3. Remove the paper guide, Figure 1.
1
guide.
Figure 1 Paper guide removal

Replacement REP 10.16 Exit Sensor (15)
1. Replacement is the reverse of the removal procedure. Parts List on PL 10.15
2. Ensure that the lugs on the sensor are located correctly in the sensor holder, Figure 3.
Removal
WARNING
WARNING
Check the lugs secures the sensor in position
Figure 3 Sensor location

2. Open the exit transport jam clearance door, Figure 1. 3. Remove the sensor cover, Figure 2.
NOTE: On some machines, the sensor cover may be secured by screws, not cover
retainers.
1
Release 2 cover retain-
ers. See NOTE.
3
Remove the sensor 2
1 cover. Release 2 cover retainers.
Open the jam clearance door by See NOTE.
Figure 2 Cover removal

4. Remove the exit sensor, Figure 3. Replacement
2. Ensure that the lugs on the sensor are located correctly in the sensor holder, Figure 4.
Check the lugs secure the sensor in position
1 Figure 4 Sensor location

Remove the exit sensor then
disconnect the harness.

REP 10.17 Roller Nip P 3. Remove roller nip P, Figure 2.

Removal
WARNING
WARNING
2. Remove the belt and pulley, Figure 1.
2
Remove the roller nip P.
1
Remove the e-clip and bearing.
Figure 2 Roller nip removal
Replacement
1
Remove the e-clip, gear and drive belt.
Figure 1 Belt and pulley removal

REP 10.18 Roller Nip N NOTE: Carefully remove the roller nip N housing from the exit paper path assembly. The
springs and nip idlers will be ejected.
3. Prepare to remove the roller nip N, Figure 2.
Removal
WARNING
can cause death or injury. Moving parts can cause injury. 1
Remove 2 screws.
WARNING
2. Remove the mounting plate, Figure 1.
2
Loosen screw.
Roller nip N housing.
3
Carefully release the gear
tangs, then remove the gear,
belt and pulley.
4
Remove screw.
1 Belt.
Remove 3 screws then the
mounting plate.
Pulley.
Figure 1 Mounting plate removal 5

6
Remove screw.
Loosen screw.

4. Remove roller nip N, Figure 3. REP 10.19 Exit illuminator PWB
3
Remove the cover Removal
2 and roller nip N.
Remove the screws marked A.
WARNING
A Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
A
A WARNING
2. Remove diverter gate, REP 10.13.
3. Remove the paper guide, Figure 1.
1
guide.
Correct orientation of spring

and nip idler assembly.
Nip idler assembly.
Spring.
Figure 3 Roller nip N removal
Replacement
Figure 1 Paper guide removal

4. Remove the exit illuminator PWB, Figure 2. REP 10.20 Exit Paper Path
Removal
WARNING
WARNING
3. Remove the finisher.
4. Remove the right cover, PL 81.10 Item 3.
5. Remove handle 4a, Figure 1.
2 1
Disconnect the harness. Release the exit illuminator PWB
from the securing tag, then remove
it.
Figure 2 LED PWB removal
Replacement
1
Remove the screw then handle 4a.
Figure 1 Handle 4a removal

6. Remove the ESD antenna from the top of the exit paper guide, Figure 2. 7. Remove the exit paper path, Figure 3.
1
Un-clip the
antenna from the
paper guide
Figure 2 ESD antenna
1
Remove the screws marked A
then the exit paper path.
Figure 3 Exit paper path removal

Replacement 3. Install the exit path, Figure 5.
2. Ensure that the exit module counter balance spring is located in the keeper, Figure 4.
Keeper
3
Install the remaining screws
marked C in any order 2
1 Install screw B
Counter balance spring Install screw A
Figure 5 Securing the exit path
4. Ensure that the ESD antenna is correctly routed and attached to the paper guide, Figure 2.
Figure 4 Correct location (viewed from the rear of the machine)
5. Transfer the finisher docking actuator, PL 12.100 Item 17, if present, from the old exit
paper path assembly to the new exit paper path assembly.

REP 10.21 Stripper Blade, Gate and Baffle
1
Removal Squeeze as indicated to open the
stripper blade retaining tool.
WARNING
2
Position the stripper blade retaining
tool over the stripper blade and
under the cover.
WARNING
Stripper blade retaining
tool
WARNING Stripper blade
CAUTION
END VIEW Cover
3. Open the stripper gate, GP 31.
4. Remove the stripper blade retaining tool from the base of the machine, refer to Figure 4.
5. Use the stripper blade retaining tool to secure the stripper blade in the safe removal posi-
tion, Figure 1.
Stripper blade and

retaining tool
Figure 1 Secure the stripper blade

6. Remove the stripper blade with the stripper blade retaining tool attached, Figure 2. 7. Remove the stripper gate and baffle, Figure 3.
1
Depress the
catch to
release the
stripper
1
Lift tab then withdraw
shaft.
the gate and baffle shaft
from the front.
NOTE: This shaft is
identified by 5 grooves
in the front and is longer
in length than the strip-
per blade shaft.
2
Withdraw the shaft then remove the stripper blade with the retaining tool 2
attached. Remove the stripper gate
and baffle assembly.
Figure 2 Stripper blade removal Figure 3 Strip gate and baffle removal
Replacement
WARNING
Do not leave an old stripper blade at the customers site.
2. The new stripper blade will have a retaining tool already attached.
3. After the stripper blade has been installed, remove the stripper blade retaining tool and
store the tool in the base of the machine, Figure 4.
4. Open and close the stripper baffle several times. Check that the blade guard is correctly
engaged and covering the blade when the baffle is open. If the blade is exposed then
return to Step 4 in the removal process and rectify the problem.
5. The old stripper blade must be returned with the retaining tool attached.
6. Ensure that the old stripper blade is removed from the customers site for safe disposal.

REP 10.22 Upper Baffle
Removal
WARNING
WARNING
WARNING
Install the stripper blade retaining tool in the machine
Figure 4 Stripper blade retaining tool CAUTION


4. Prepare to remove the upper baffle, Figure 1. 6. Remove the upper baffle, Figure 2.
1
Disconnect 3 sensors and LED PWB.
1
Remove 2 screws then
remove the baffle.
Figure 1 Preparation Figure 2 Remove upper baffle
5. Unlock and fully open the stripper gate, GP 31. Replacement

2. If the upper baffle is cleaned, or a new upper baffle is installed, reset the upper JL baffle
count to zero. Refer to dC135 CRU / HFSI Status.

REP 10.23 Stripper Guide Latch Cam Shaft 6. Remove the centre 25T gear, Figure 1.

Removal
WARNING
WARNING
3. Unlock and fully open the stripper gate, GP 31.
5. Remove the M4 motor and gearbox, REP 10.8.
1
Remove
the KL-clip,
gear and
bearing.

7. Remove the stripper guide latch cam shaft, Figure 2. REP 10.24 Front and Rear Flexure Encoder
Removal
2
Unhook the spring and push the latch fork WARNING
away from the shaft. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
3
Remove the e-clip then the shaft.
WARNING
3. Remove the front cover and front flexure encoder, Figure 1.
1
Remove 2 screws
3
Remove the sensor 2
Disconnect the harness
1
Unhook the spring and
push the latch fork away Figure 1 Front flexure encoder
from the shaft.
Figure 2 Shaft removal
Replacement

5. Remove the M4 assembly, Figure 2. Replacement
CAUTION
Take care not to damage or contaminate the flexure encoder.
3
Remove the
assembly
2 1
Disconnect motor harness
Remove 3 screws
Figure 2 Remove M4 assembly
6. Remove the rear flexure encoder, Figure 3.
3
Remove the encoder
2 1
Remove 2 screws Disconnect the harness
Figure 3 Rear flexure encoder

REP 12.1-110 LCSS Covers NOTE: Removing the top cover first will allow easy removal of the front and rear covers.
Parts List on PL 12.10.

Removal 2
Remove the top
cover.
WARNING
1
from the customer supply while performing tasks that do not need electricity. Electricity Remove the rear cover
Open the exit cover,
can cause death or injury. Moving parts can cause injury. remove two screws. assembly.
WARNING
Remove the covers, Figure 1.
5
3 4 Remove two screws.
Open the front door, Remove the front door
remove four screws. cover assembly.
Figure 1 Removing the covers
Replacement
Reverse the removal procedure to replace the covers.

Xerox® ColorQube® 9203 Family 4-107 REP 12.1-110
REP 12.2-110 Input Drive Belt and Paper Entry Transport Replacement
Motor 1. Place the belt around the pulleys.
2. Install the motor screws, but do not tighten.
3. Install the spring
Removal 4. Rotate the shaft by hand to ensure the belt runs smoothly over the pulleys and allow the
spring to tension the belt, ADJ 12.4-110.
5. Tighten the motor screws and re-connect the harness.
WARNING
6. Install the LCSS rear cover, REP 12.1-110.
WARNING
1. Remove the LCSS rear cover, REP 12.1-110.
2. Remove the motor and drive belt, Figure 1.
4
Remove the drive
belt.
3
Remove 2 screws
and motor
2
1 Remove the
Disconnect the spring.
motor harness.
Figure 1 Removing the drive belt

REP 12.2-110 4-108 Xerox® ColorQube® 9203 Family
REP 12.3-110 Intermediate Paper Drive Belt Replacement
Parts List on PL 12.60. 1. Lubricate the belt tensioner, refer to ADJ 4.1.
2. Install the belt over the pulleys, ensuring that the belt is on all five pulleys.
Removal
NOTE: Two of the pulleys are free to slide along the shaft. Ensure the belt is correctly
located on these pulleys.
WARNING
WARNING
1. Remove the LCSS rear cover REP 12.1-110.
2. Remove the intermediate paper drive belt, Figure 1.
1
Disconnect the spring.
4
Remove the drive belt.
2 3
Disconnect PJ307. Disconnect the bulkhead connector.

REP 12.4-110 Paper Output Drive Belt and Transport Motor 2
Parts List on PL 12.60. 4
Remove the
Removal motor and
belt.
WARNING
WARNING
1. Remove the LCSS rear cover, REP 12.1-110. 3
2. Remove the intermediate drive belt, REP 12.3-110. Support the motor
3. Remove the output drive belt and motor, Figure 1. and remove three
screws.
2
Remove the
belt tensioner
1 spring.
Disconnect PJ309.
Replacement
1. Install the belt over the pulleys.
2. Install the motor pivot shouldered screw and fully tighten.
3. Install the two motor mounting bracket securing screws but do not tighten them.
4. Install the belt tensioner spring.
5. Rotate the belt by hand to allow the spring to tension the belt, ADJ 12.4-110. Tighten the
screws.
6. Install the intermediate drive belt, REP 12.3-110.

REP 12.5-110 Bin 1 Drive Belts
Removal
WARNING
WARNING
1. Remove the LCSS front and rear covers, REP 12.1-110.
2. Remove the bin 1 drive belt (rear) Figure 1.

NOTE: Keep all of the components removed as a set. The set of rear frame components
are different from the front frame set.
7
Remove 2 screws
6
Remove 3 screws and
release the lower and middle
8 PWB standoffs, leaving the
Move motor assembly to PWB attached by only the top
the right standoff.
9
Remove 2 screws and
upper pulley.
5
10 Release the tensioner spring.
Disconnect PJ316 and release the belt
from behind the PWB and drive pulley.
11 1 4
Remove screw and Disconnect PJ318. Fully lower bin 1.
remove the belt clamp.
12
Remove 2 screws, lower 3
pulley and drive belt. Remove 3 screws, remove
2 bracket with Bin 1 elevator
Remove E-clip and bearing. motor.
Figure 1 Bin 1 drive belt (rear)

3. Remove the bin 1 drive belt (front) Figure 2. Replacement
NOTE: Ensure the correct set of components are used for each side of the LCSS.
1 1. Reverse the removal procedure to replace the bin 1 drive belts.
If not already lowered,
fully lower bin 1, refer to NOTE: The bin 1 level can critically affect the overall stack registration. Refer to ADJ
figure 1. 12.1-110 if adjustment is necessary.
2. Install the front and rear covers REP 12.1-110.
5
Remove 2 screws, upper
pulley and drive belt.
4
Remove screw and
front belt clamp.
3
Remove two screws
and lower pulley.
2
Release the tensioner spring.
Figure 2 Bin 1 drive belt (front)

REP 12.6-110 Tamper Assembly 3. Figure 2, remove the tamper assembly.

Removal
WARNING
WARNING 1
Remove 2 screws
1. Remove the LCSS covers REP 12.1-110.
2. Prepare to remove the tamper assembly Figure 1.
4 3
Release the harness from the retainer Release the harness 2
next to the paddle motor assembly, PL from all retainers along Lift the tamper
12.25 Item 10. the tamper assembly. assembly upwards
and remove from the
LCSS
A A A A
2 Figure 2 Removing the tamper assembly
Disconnect the tamper
motors harnesses. Replacement
1 NOTE: Ensure that the slots in the tamper assembly locate correctly in the LCSS frame.
Disconnect 4 sensor harnesses marked A and
release the harnesses from the retainers. NOTE: Ensure that the sensors are correctly located in the tamper assembly, they are easily
mis-located when being re-connected to the harnesses.
Figure 1 Preparing the tamper assembly NOTE: Ensure that all connectors in the harness over the tamper assembly are securely con-
nected.
Reverse the removal procedure to replace the tamper assembly.

REP 12.7-110 Hole Punch Unit, Motor and Sensors
Removal
WARNING
WARNING
1. Remove the LCSS covers, REP 12.1-110.
2. Remove and empty the chad bin, PL 12.20 Item 4.
3. Remove the hole punch unit, motor assembly and sensors, Figure 1.

2
Remove 2 screws.
1
Remove the thumb
screw and slide out
the punch unit.
3
Disconnect the
motor harness and
remove the hole
punch motor
assembly.
7
Remove 2 screws,
4 remove sensors
5 and disconnect the
Remove the screw securing the sensor bracket. Discon- Disconnect
nect the harnesses and remove the bracket assembly. harnesses.
the PJ.
Press the tabs together to remove the punch head
home and punch head present sensors.
6
Remove screw and slide out the bracket.
Figure 1 Hole punch unit, motor and sensors
Replacement 2. If necessary, perform ADJ 12.3-110 Hole Punch Position.

1. Reverse the removal procedure to replace the hole punch unit, motor assembly and NOTE: When installing the hole punch motor assembly, ensure that the belt tensioner arm
sensors. does not get trapped behind the motor assembly plate.

REP 12.8-110 Stapler Traverse Assembly 4. Figure 1, Disconnect the harness.

Removal
WARNING
WARNING 1
Take care during this procedure. Sharp edges may be present that can cause injury. Disconnect the group
of 4 connectors.
WARNING 2
Release the harness
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the from the clip.
1. Un-dock the LCSS, REP 12.13-110.
2. Remove the rear cover and front door cover assembly, REP 12.1-110.
3. Manually move the ejector, PL 12.50 Item 1 fully to the right.
NOTE: For clarity the entry
guide cover (PL12.10 item 3)
has been omitted from this
illustration.
Figure 1 Harness disconnection

REP 12.9-110 Staple Head Unit
CAUTION Parts List on PL 12.55.
When removing and replacing the stapler traverse assembly, support the weight of the assem-
Removal
bly underneath the stapler and take care not to damage wiring.
5. Remove the stapler traverse assembly, Figure 2.
WARNING
WARNING
1. Remove the stapler traverse assembly, REP 12.8-110.
2. Place the stapler traverse unit upside-down
2 1
Remove 2 screws. Remove screw at the rear.
SEE CAUTION SEE CAUTION
3
Remove the stapler
traverse assembly.
SEE CAUTION.
Figure 2 Removing the stapler traverse assembly
Replacement
1. Ensure the stapling traverse assembly is engaged on the front and rear locating dowels.
2. Reverse the removal procedure to replace the stapling unit.

REP 12.8-110, REP 12.9-110 4-118 Xerox® ColorQube® 9203 Family
3. Remove the staple head unit from the stapling unit Figure 1. REP 12.10-110 Ejector Assembly Sensors
Removal
A
WARNING
A Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Remove 4 screws
marked A then can cause death or injury. Moving parts can cause injury.
A remove the stapler
cover.
WARNING
WARNING
A machine. Do not show the customer how to un-dock the LCSS.
1. Disconnect the two harnesses between the LCSS and the machine.
2. Un-dock the LCSS, REP 12.13-110 and move it away from the machine.
3. Ensure the stapling unit is at the home position.
4. If necessary, manually move the ejector to the left position.
2
Disconnect the
harnesses.
3
Remove the staple head unit.
Figure 1 Removing the staple head unit
Replacement
Reverse the removal procedure to replace the staple head unit.

Xerox® ColorQube® 9203 Family 4-119 REP 12.9-110, REP 12.10-110
5. Figure 1, remove the ejector assembly. Replacement
CAUTION
When installing the ejector assembly onto the LCSS, ensure that the ejector fingers do not
damage the wiring to the staple head unit.
Reverse the removal procedure to replace the eject assembly or sensors.
Ejector motor encoder
sensor. Remove 2
screws and cover to
access the sensor
3
Lower the ejector
assembly, disengage
the dowels from the
mounting blocks and
remove.
Ejector out sensor

Q12-185
Ejector home sensor

Q12-184
1
Disconnect 2 bulkhead
connectors.
2
Remove 3 screws.
Figure 1 Removing the ejector assembly
6. Remove the appropriate sensor by releasing the sensor tabs and disconnecting the harness.

REP 12.11-110 Bin 1 Upper Level Sensor 2. Remove the bin 1 upper level sensor, Figure 1.

Removal 4
Release the
sensor and
WARNING disconnect
harness.
WARNING
1. Remove the ejector assembly, REP 12.10-110. 3
Remove 2 screws,
remove sensor support
assembly.
2
Disconnect connector.
1
Remove two screws
and harness retainers.
Figure 1 Removal
Replacement
Reverse the removal procedures to replace the bin 1 level sensor.

REP 12.12-110 Paddle Wheel Shaft Assembly 4. Figure 1, remove the paddle motor assembly.

1
Removal Disconnect 2
harnesses
WARNING
WARNING
1. Remove the stapler traverse assembly, REP 12.8-110.
2. Remove the tamper assembly, REP 12.6-110.
3. Remove Bin 1, PL 12.10 Item 10.
2
Release the
harness from
the retainer
3
Remove 2
screws
4
Remove the
motor assembly
Figure 1 Paddle motor assembly

5. Figure 2, prepare the rear components. 6. Figure 3, prepare the front components.
3
Remove the E-clip
and bearing
2
Remove the
gear and flag 2
assembly
Remove 2
screws
1
Remove the E-clip
4
Remove 3 screws
1
Remove E-clip and bearing
Figure 2 Rear preparation Figure 3 Front preparation
7. Ensure that the compiler ejector is in the home position (fully to the left).

8. Figure 4, remove the paddle wheel shaft assembly. Replacement
1. Install the paddle wheel shaft, front bearing and E-clip, refer to Figure 3.
2. Install the output cover, refer to Figure 4.
3. Install the rear bearing and E-clip, refer to Figure 2.
2 4. Install the gear and flag assembly, refer to Figure 2, ensuring that the gear locates onto
Slide shaft assembly the large “D” flat and the flag locates on the small “D” flat.
to the rear 5. Install the flag and E-clip, refer to Figure 2.
6. Figure 5, ensure the paddles and flag are correctly aligned.
1
Align paddles with the output cover
3
Remove the
shaft assembly
1
Move the output
cover to the right 2
Ensure the encoder flag is within the sensor
Figure 5 Paddle alignment
7. Install the motor assembly, refer to Figure 1.

Figure 4 Paddle wheel shaft removal 8. Test the operation of the paddle roll, enter dC330, output code 12-238. When the code is
cancelled the paddles must stop with both rubber blades inside of the output cover. If nec-
essary, check that the gear assembly and flag are correctly located on the “D” flats.

REP 12.13-110 LCSS Un-Docking 3. Figure 1, release the LCSS link bracket assembly.

Removal
WARNING
WARNING
WARNING 1
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Press the latch block forward
machine. Do not show the customer how to un-dock the LCSS. to release both latches.
1. If necessary, disconnect the harnesses between the LCSS and the machine.
2. Open the LCSS front door.
2
Roll the LCSS away from
the machine.
Figure 1 LCSS link bracket assembly
Replacement
Line up the LCSS latches to the machine apertures then push the two units firmly together until
they latch.

REP 12.14-110 LCSS PWB REP 12.15-110 Entry Guide Cover
Parts List on PL 12.75. Parts List on PL 12.70.
Removal Removal
WARNING WARNING
WARNING WARNING
CAUTION WARNING
Do not install a new LCSS PWB until the cause of the damage to the old LCSS PWB has been
determined, go to 12G-110 LCSS PWB Damage RAP.
1. Remove the LCSS top cover, front cover and rear cover, REP 12.1-110.
2. Un-dock the LCSS, REP 12.13-110.
3. Disconnect the harness to the entry sensor, PL 12.70 Item 3, at the rear frame.
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the LCSS
PWB.
1. Remove the LCSS rear cover assembly, REP 12.1-110.
2. Disconnect all harness connectors from the LCSS PWB.
3. Remove the three screws and release the three standoffs securing the LCSS PWB.
Replacement
NOTE: Before replacing the LCSS rear cover assembly, perform 12F-110 LCSS PWB DIP
Switch Settings RAP.
Reverse the removal procedure to replace the LCSS PWB.

4. Figure 1, remove the entry guide cover. Replacement
1. Bias the entry guide cover away from the paper guide when you tighten the screws.
2. The clearance between the entry guide cover and the paper guide must be a minimum of
1 mm. Refer to Figure 2.
NOTE: If the clearance is less than 1 mm, then install a new entry guide cover.
Check for a
minimum
3 clearance of
Remove the entry 1mm
guide cover between the
entry guide
cover and the
paper guide
2
Remove 2 screws
Figure 2 Entry guide cover clearance
3. Run copies through the output device, if possible use heavy weight paper or labels.
Check for marks on the print and for damage to the paper. If there are no marks or dam-
age then install the covers.
1
Remove 2 screws
Figure 1 Entry guide cover removal

REP 12.16-110 Docking Latch Assembly 3. Figure 1, prepare to remove the docking latch assembly.

Removal
WARNING
WARNING
WARNING
1. Remove the front and rear covers, REP 12.1-110.
2
2. Un-dock the LCSS, REP 12.13-110. Remove 2 screws
Flanged hole
1
Disconnect P/J302
Figure 1 Prepare to remove the latch.

4. Figure 2, remove the docking latch assembly. REP 12.17-110 Ejector Belt
Removal
WARNING
Release the har- can cause death or injury. Moving parts can cause injury.
ness retainers
WARNING
2
Disconnect 1. Remove the ejector assembly, refer to REP 12.10-110.
the switch
harness
Flanged
hole
3
Remove 2
screws
4
Remove the latch
assembly
Figure 2 Latch assembly removal.
Replacement
Reverse the removal procedure to replace the docking latch assembly.
CAUTION
Ensure that the front and rear harness are routed through the flanged holes, refer to Figure 1
and Figure 2.

2. Figure 1, remove the ejector belt. REP 12.18-110 Paddles
Removal
WARNING
NOTE: This procedure shows the replacement of the paddles with the paddle wheel shaft
assembly installed. If necessary, remove the paddle wheel shaft assembly before replacing the
paddles. Refer to REP 12.12-110.
1. If necessary, lower bin 1. Enter code dC330 12-242 bin 1 elevator motor cycle. Press stop
1 when the bin has lowered.
Belt grip. Remove the clip.
2. Rotate the paddle until the two rubber blades are visible.
CAUTION
To ensure that the correct home position of the paddle wheel shaft is maintained, install the
new paddle wheels one at a time.
3. Squeeze the two rubber blades together and pull to remove the paddle wheel from the
shaft, Figure 1.
3
Remove the pulley
then the ejector belt.
2
Remove the E-clip.
Figure 1 Remove the ejector belt
Replacement
The replacement is the reverse of the removal procedure. Ensure that the ejector belt is cor-
rectly engaged with the belt grip on the ejector assembly before the clip is reinstalled. Refer to Figure 1 Paddle removal
Figure 1.
Replacement
1. Hold the paddle wheel by the two rubber blades and clip onto the shaft.

REP 12.1-171 HVF Covers
Removal
WARNING
from the customer supply, while performing tasks that do not need electricity. Electricity
WARNING
NOTE: All major HVF covers are dealt with in this procedure, only remove the covers listed for
the procedure that you are performing. 1
Remove the HVF covers as follows: Remove the hinge pin
1. Remove the front door, Figure 1. If required, remove 5 screws to separate the door sup-
port from the front door.
Front cover
Locating tabs
2
Remove the hinge pin (2 places)
3
Remove the front door
Figure 1 Front door removal

2. Remove the top cover, Figure 2. 3. Remove the front cover, Figure 3.
NOTE: In step1 remove the Inserter unit if fitted (See REP 12.82-171), or remove the NOTE: The top cover must be removed before removing the front cover.
Inserter removable cover, PL 12.100 Item 8.
4
Remove 2
screws
3
Lift the top tray to
access 2 screws
1
5 Remove 6
Remove the top cover screws
2 3
Remove the
Remove 2 1
screws
front cover 2
Remove the inserter cover to Lift the cover to disengage the bottom
access 2 screws (see note locating tabs from the frame
Figure 3 Front cover removal

Figure 2 Top cover removal

4. Remove the rear cover, Figure 4.
NOTE: The top cover must be removed before removing the rear cover. 1
Remove 3 screws
at the rear
2
Remove 3 screws
at the front
3
Remove the vent
cover
2
Remove 3
screws
1
Remove 2
screws
3
Lift the rear cover to disengage 4
4 the bottom locating tabs from Remove
Remove the rear cover the frame 3 screws
Figure 4 Rear cover removal
5. Remove the vent cover and foot cover, Figure 5. To provide enough room to remove the
vent cover, undock the HVF, REP 12.13-171.
NOTE: The top front cover and rear cover must be removed before removing the vent
cover and foot cover.
NOTE: The foot cover is not installed if the tri-folder option is installed.
5
Remove the
foot cover
Figure 5 Vent and foot covers removal

Replacement REP 12.2-171 HVF Stapler Assembly
The replacement procedure is the reverse of the removal procedure. Parts List on PL 12.110.
Depending on the installed options and the covers removed, refit covers in the following Removal
sequence:
1. Vent cover, PL 12.100 Item 6. WARNING

2. Foot cover (if no tri-folder installed), PL Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
3. Rear cover, PL 12.100 Item 5. from the customer supply, while performing tasks that do not need electricity. Electricity
4. Front cover, PL 12.100 Item 2.
5. Top cover, PL 12.100 Item 1.
6. Inserter cover (if no inserter installed). PL 12.100 Item 8. WARNING
7. Front door, PL 12.100 Item 3. Take care during this procedure. Sharp edges may be present that can cause injury.
1. Slide the HVF away from the machine.
2. Remove the HVF front door, REP 12.1-171.
3. Remove the HVF top cover, REP 12.1-171.
4. Remove the HVF front cover, REP 12.1-171.
5. Remove the rear cover, REP 12.1-171.

6. Figure 1. At the rear of the HVF, disconnect three connectors and remove one screw 7. Figure 2. With the power cord disconnected, reach behind the stapler and move the ejec-
securing the grounding strap. tor unit to the out position, by turning the encoder of the ejector unit motor, MOT12-236 in
the direction indicated.
1 2
Disconnect three PJs 1 2
Remove grounding
Turn the encoder wheel
strip screw Move stapler to gain
REAR VIEW access
Figure 1 Disconnect PJs and remove screw

Figure 2 Move ejector to the out position

8. Figure 3. Remove the stapler assembly. REP 12.3-171 Top Tray
Removal
WARNING
WARNING
1. If fitted, undock the Inserter, REP 12.82-171.
2. Remove the top and rear covers REP 12.1-171.
3. Prepare to remove the top tray, Figure 1.
1
Remove the screw
2
Pull and slide the stapler
assembly forward
Figure 3 Removing the stapler assembly.
Replacement
NOTE: The ejector unit returns to the home position when the HVF is initialized.
1. Slide the stapler assembly into the tray, taking care not to trap the earth wire at the rear.
2. The remainder of the replacement procedure is the reverse of the removal procedure.
1
Lift the tray and release
the link eyes from the 2
lugs on the tray Remove the pin
and spring

4. Remove the top tray, Figure 2. REP 12.4-171 Bin 1 Removal
5 4
Remove top Remove the E-
Removal
the tray. clip and bearing
WARNING
WARNING
Remove the from the customer supply, while performing tasks that do not need electricity. Electricity
E-clip and
bearing
1. Remove Bin 1. Figure 1
2
Remove the
inner belt idler
puller and inner
pulley.
1
Remove the E-clip
and outer pulley
Figure 2 Top tray removal
Replacement
The replacement procedure is the reverse of the removal procedure.

REP 12.5-171 Right Side-Cover Removal
Removal
WARNING
WARNING
1. With the machine powered on, use the PTU or dC330 code 12-242 to lower Bin 1.
2. Remove Bin 1, REP 12.4-171.
3. If a HVF unit only, remove the middle right side cover, PL 12.105 Item 17.
If a HVF BM unit installed, remove the HVF BM bin 2 assembly, PL 12.190 Item 8.
2
Lift bin 1 to release the
bin from the lifting bar
1
Remove the E-clip
Figure 1 Bin 1 removal
Replacement

4. Remove the right side-cover, Figure 1. REP 12.6-171 HVF Ejector Assembly
Removal
2
Use a small screw-
driver to release the WARNING
2 tabs.
3 WARNING
Remove the right
side cover.
1. Remove Bin 1, REP 12.4-171.
2. Remove the right side-cover REP 12.5-171.
3. Remove the rear cover REP 12.1-171.
4. Remove the front and rear pressing plate finger, REP 12.7-171.
5. Disconnect the connectors, Figure 1.
1
Remove 8
screws.
1
Disconnect 4 harness
connectors to release
the wiring.
Figure 1 Right side cover removal Figure 1 Disconnect the connectors
Replacement

6. Remove the pressing plate and sensor support bracket. Figure 2. 7. Remove the support bracket and ejector assembly, Figure 3.
4 1
Remove the ejector assembly Remove 2 screws
and wiring loom
3 2 1
Remove 1 screw and Remove the pressing plate. Remove 2 screws.
release the sensor and
support bracket.
Figure 2 Pressing plate removal
3 2
Remove the support Remove 2 screws
bracket
Figure 3 Remove the ejector assembly

Replacement REP 12.7-171 Pressing Plate Fingers
1. Set the front and rear support fingers so that their ends are aligned when extended. See Parts List on PL 12.110.
REP 12.8-171.
2. When reinstalling the eject assembly ensure that the tag on the ejector locates into the
Removal
slot in the frame.
3. When refitting the pressing plate, the shaft of the front support finger drive gear must fit in
WARNING
the ejector assembly, see Figure 4. Replace the front pressing plate finger.
WARNING
Front Pressing Plate Finger 1. Remove the right side-cover REP 12.5-171.
2. Remove the screws and lower the fingers through the cover slots, Figure 1.
Move the cover to the front

to locate the shaft end.
End of the gear

shaft
Figure 4 Reinstalling the Pressing Plate

Rear Pressing
Plate Finger
4. The remainder of the replacement procedure is the reverse of the removal procedure. Front Pressing
5. Locate the MOD Tag plate on the metal panel under the HVF docking latch. Ensure that Plate Finger
1
MOD Tag 004 is struck off. Remove 2 screws 2
Remove the fingers
Figure 1 Pressing Plate Fingers
Replacement
Reverse the removal procedures to replace the front and rear pressing plate fingers.

REP 12.8-171 Front and Rear Support Fingers Replacement
Parts List on PL 12.110. Reverse the removal procedure to replace the front or rear support fingers.
Removal NOTE: Set the front and rear support fingers so that their ends are aligned when extended.
See Figure 2.
WARNING With the pressing plate installed, set the front and rear support finger alignment, Figure 2. If the
fingers are not aligned, the compiler output will be uneven and cause exit jams.
WARNING
1. Remove the right side cover REP 12.5-171.
2. Remove the ejector assembly REP 12.7-171.
3. Remove the ejector front plate and support finger assembly, Figure 1.
FRONT REAR
3 2 1
Rotate the encoder wheel Remove the clip and Remove the rear Encoder
until the finger ends align. disengage the gear. pressing plate finger Wheel
4 5
Re-engage the gear Replace the rear
and refit the circlip pressing plate finger
2
1 Remove 2 screws and remove the
Remove screw and remove the
rear finger
front finger
CORRECT INCORRECT
Figure 1 Remove front and rear support fingers
Figure 2 Support Finger End Alignment

REP 12.10-171 Stacker Idler Rolls Replacement
Parts List on PL 12.115. 1. Figure 2. Ensure the sprung brackets are parallel and re-install the idler rolls in the sprung
brackets.
Removal
NOTE: To ease the installation of the idler roll, push the spring bracket downwards from
the top. This will provide clearance from the drive roll above.
WARNING
WARNING
1. Lift the top tray
Incorrect Correct
2. Figure 1. Raise the paper pusher and remove the four stacker idler rolls.
Figure 2 Correct spring bracket position.
1 2. Check that the rolls are held securely.

Raise the paper
pusher
Idler rolls
3
Remove the roll
2
Ease spring brackets
outwards
Figure 1 Paper pusher and idler rolls.

REP 12.11-171 Front Tamper Motor Assembly 4. Remove the front tamper assembly, Figure 2.
Parts List on PL 12.125. NOTE: The front tamper home sensor is removed to prevent the sensor from being dam-
age when the front tamper assembly is removed.
Removal
WARNING
WARNING
1. Remove the front door and front cover REP 12.1-171.
2. Remove the ejector assembly, REP 12.6-171.
3. Remove the tamper motor and bracket assembly, Figure 1. 1
Disconnect and remove
the home sensor
1
Disconnect motor harness
4
Remove the front tamper 3 2
2 assembly Remove 5 screws to release the Disconnect the away
Remove 2 screws support bracket sensor harness
3 Figure 2 Front tamper assembly

Remove the motor and the
support bracket Replacement
Reverse the removal procedures to reinstall the front tamper motor assembly.
Figure 1 Tamper motor

REP 12.12-171 Bin 1 Elevator Motor Assembly Replacement
Parts List on PL 12.105. Reverse the removal procedures to reinstall the bin 1 motor elevator motor assembly.
Removal NOTE: Check that the ‘flats’ on the shaft bearing align with the cut-outs in the bracket.
Check that the Bin 1 lift bar is level before refitting the stacker belt lower pulley.
WARNING
WARNING
1. Remove the front and rear covers REP 12.1-171.
2. Remove the rear drive belt lower pulley to relieve the belt tension.
3. Remove the bin 1 elevator motor assembly Figure 1.
NOTE: The pulley pin may fall when the pulley is removed.
3 2 1
Release the wiring Remove the Remove the circlip, the
from the clamps bearing. upper pulley and the pin.
Figure 1 Stacker Motor Gearbox Assembly

REP 12.13-171 HVF/HVF BM Un-Docking
Removal
WARNING
WARNING
CAUTION
Do not show the customer how to un-dock the HVF / HVF BM. 1
1. Open the front door. Pull the lever forward to release both latches
2. Figure 1, release the docking latch and move the HVF/HVF BM to the right, away from the
machine.
2
Roll the HVF to the right
away from the machine
Figure 1 Docking latch location
NOTE: Where fitted, the tri folder may remain docked to, and moved with, the HVF.
3. Disconnect the harnesses between the machine and the HVF/HVF BM if necessary.
Replacement
CAUTION
Take care to align the HVF to the right side of the machine before rolling the HVF into position.
Misalignment will damage or break the interlock actuator.
Reverse the removal procedure to dock the HVF/HVF BM.

REP 12.14-171 HVF Upper Exit Guide (5c) 6. Figure 2. Remove the inboard pivot screw.

Removal
WARNING
WARNING
4. Remove the HVF rear cover, REP 12.1-171.
5. Figure 1. Remove the outboard pivot screw.
1
Remove the inboard
pivot screw
REAR VIEW
Figure 2 Inboard pivot screw.
1
Remove the outboard
pivot screw
FRONT VIEW
Figure 1 Outboard pivot screw.

7. Figure 3. Remove the upper exit guide. REP 12.15-171 HVF Rear Tamper Assembly
Removal
WARNING
WARNING
2. Remove the right side-cover REP 12.5-171.
3. Remove the ejector assembly REP 12.6-171.
4. Remove the front tamper assembly, REP 12.11-171.
5. Remove the pressing and support motor, Figure 1.
1
Twist the upper exit guide
and lift upwards
Figure 3 Upper exit guide removal.
Replacement
2
Disconnect the motor and
1 encoder harness
Remove 2 screws
Figure 1 Motor removal

6. Remove the rear tamper assembly, Figure 2. Replacement
1. Reverse the removal procedures to reinstall the rear tamper assembly.
2. Ensure that the rear tamper assembly is located correctly, Figure 3.
1
Disconnect 3 PJs
1 2
Ensure that the rear support Ensure that the fixing brackets
pins are located correctly on are located on the tabs at the
the frame bracket front
Figure 3 Rear tamper assembly location

2
Remove 2 screws
and remove the
assembly
Figure 2 Remove rear tamper assembly

REP 12.16-171 BM Flapper 2. Figure 1, remove the BM flapper bracket assembly.

Removal
WARNING
WARNING
Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus-
tomer supply while performing tasks that do not need electricity. Electricity can cause
1. Open the HVF BM front door and fully pull out the BM module.
1
Remove 4 screws
and the ground
2 wire.
Disengage the
drive belt.
4
3 Remove the BM
Disconnect the flapper bracket
BM flapper roll assembly.
home sensor.
Figure 1 Remove the BM flapper bracket

3. Figure 2, remove the BM flapper assembly. REP 12.17-171 BM PWB
Removal
WARNING
WARNING
2
1 Remove the BM flapper
Remove the KL-clip and assembly.
the bearing.
Figure 2 BM flapper assembly removal
4. Figure 3, remove the BM flapper. Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the BM PWB.
CAUTION
If a tri-folder has been connected to the BM PWB, the jumper harness of PJ 563 will have been
replaced by the 12 pin connector of the booklet maker PWB to tri-folder PWB harness. Ensure
that the 12 pin connectors at PJ 555 and PJ 563 are not inverted on replacement of the BM
PWB.
1. Remove the top cover, then the rear cover, REP 12.1-171.
1
2 Remove the E-
Remove the KL-clip, then clip, pin, then the
the bearing. pulley.
Figure 3 BM flapper removal
Replacement

2. Figure 2, remove the BM PWB. Replacement
CAUTION
Figure 2, ensure the BM harness and bin 2 harness are correctly positioned in the retainers to
prevent damaged when the BM is moved to the extremities of its travel.
1. Reverse the removal procedures to replace the BM PWB.
2. The BM PWB is supplied with a label with the customized NVM values for the new BM
PWB. Enter the values into the machine dC131 NVM Read/Write at the following loca-
tions:
• Compile offset - 12-003 (BookMkrCompileOffset)
• Staple offset A4 - 12-004 (BookMkrStapleOffset)
• Fold offset - 12-005 (BookMkrFoldOffset)
• Tamp offset - 12-006 (BookMkrTampRdyOffset)
• Staple offset A3 - 12-013 (BookMkrStapleOffsetL)
• C-fold - 12-009 (BookMkrTriFoldCFold
• Z-fold - 12-010 (BookMkrTriFoldZFold)
• Trifold deskew - 12-011 (BookMkrTriFoldDeskew)
• Staple offset 8.5x13 - 12-012 (BookMkrStapleOffsetM)
3. Adhere the new label on the lower left of the booklet maker frame (above the Mod/Tag
plate), over the existing label.
4. Perform the adjustments that follow:
• ADJ 12.5-171 Booklet Tamping
• ADJ 12.6-171 Booklet Compiling Position
• ADJ 12.7-171 Booklet Crease Position
• ADJ 12.8-171 Booklet Staple Position
Bin 2 harness
Harness retainers
1
BM harnesses Disconnect all PWB PJs
2
3 Remove 8 screws and
If necessary, release harnesses remove the PWB
from the retainers to allow the
PWB to be removed
Figure 2 PWB removal

REP 12.18-171 BM Crease Blade Motor
Purpose
This procedure is used to repair the following components:
• BM crease blade motor encoder sensor, PL 12.170 Item 1.
• BM crease blade motor, PL 12.170 Item 3.
• Motor encoder, PL 12.170 Item 4.
• Bearing, PL 12.120 Item 7.
• Crank, PL 12.170 Item 8.
Removal
WARNING
WARNING
2. Remove the crease blade knob (6d), PL 12.150 Item 4.
3. Remove the crease roll handle (6c), PL 12.150 Item 5.
4. Remove the BM front cover, PL 12.155 Item 3.
5. Remove the left frame plate, PL 12.155 Item 2.
6. Remove the motor cover, PL 12.170 Item 11. It is easier to remove the screw using an
open ended spanner, this means the removal of the BM PWB is not necessary.

7. Figure 1, remove the BM crease blade motor assembly.
8
Remove the motor
assembly from the frame
7
Remove
circlip, front
crank and
bearing
1
Remove 4 screws
2
Remove the E-clip and
bearing, release the
connecting rod
3
Remove the circlip, rear
crank and bearing
5
Disconnect the 6
motor harness Remove E-clip and
bearing, release the
connecting rod
4
Remove 4 screws
Figure 1 Removing the motor assembly

8. Figure 2, remove the BM crease blade motor. REP 12.19-171 BM Crease Roll Motor
Removal
WARNING
WARNING
1 tomer supply while performing tasks that do not need electricity. Electricity can cause
Support the encoder
and slide out the shaft
3 1. Remove the top cover, then the rear cover, REP 12.1-171.
Remove the sensor 2. Remove 4 screws securing the BM PWB mounting plate to the frame, allow the PWB and
from the bracket
mounting plate to hang down, giving access to the BM crease roll motor.
2
Remove the encoder
Figure 2 Removing the motor
Replacement
Reverse the removal procedure to replace the BM crease blade motor.
NOTE: Ensure that the mark on the crease blade knob aligns with the arrow on the front infill
cover when the crease blade is fully withdrawn.

NOTE: As necessary, cut any tie wraps securing the crease roll motor harness. Replacement
3. Remove the crease roll motor assembly, Figure 1. 1. Reverse the removal procedure to replace the BM crease roll motor.
2. Before installing the motor check that the bearing is located on the drive shaft, Figure 2.
Check that the bearing is

on the drive shaft
Figure 2 Location of bearing on drive shaft

3
Pull the motor
assembly off.
1
Remove 3
screws.
2
Disconnect
the motor
harness.
Figure 1 Motor assembly removal

REP 12.20-171 BM Backstop Motor Assembly 2. Figure 1, remove the BM backstop motor.

Purpose 1
Remove
This procedure is used to repair the following components: allen key
• Ground wire, PL 12.160 Item 1. and spring.
• Motor damper, PL 12.160 Item 3.
• BM backstop drive belt, PL 12.160 Item 7.
Removal
2
Remove
WARNING 4 screws.
WARNING
tomer supply while performing tasks that do not need electricity. Electricity can cause 3
death or injury. Moving parts can cause injury. Disconnect the
motor harness.
6
Remove 2 screws to
release the motor from the
bracket, remove 2 screws
to remove the motor and 5
ground wire from the Remove the belt.
damper.
4
Free the motor pulley from the belt
and lift out the motor assembly.
Figure 1 Motor removal
Replacement
Reverse the removal procedure to replace the BM backstop motor.
NOTE: Allow the spring to tension the drive belt while the screws are still loose, then tighten
the 4 screws.

REP 12.21-171 BM Backstop Assembly
Parts List on PL 12.165. CAUTION
The BM harnesses and the backstop assembly harnesses are connected with a catch. Ensure
Removal
the catch is released when disconnecting the solenoid harnesses.
6. Remove the two harness clamps, Figure 1.
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity Lay down the BM assembly to access the
can cause death or injury. Moving parts can cause injury. backstop assembly.
WARNING
2
1. Remove the booklet maker, REP 12.61-171. Use a flat blade screwdriver
2. Rotate the crease roll handle (6c), fully counter clockwise. to push out the harness
3. Remove the crease roll handle (6c), PL 12.150 Item 5. clamp.
3
Use a flat blade screwdriver
to push out the harness
clamp.
Figure 1 Remove the two harness clamps

7. Remove the belt clamp, Figure 2. 11. Remove the shaft from the BM backstop assembly, Figure 4.
1
Remove 2 screws
2 1
Remove the belt clamp Remove the shaft through the BM backstop assembly
bottom of the BM assembly
Figure 2 Belt clamp Figure 4 Remove the shaft
8. Use the allen key, PL 12.160 Item 9 to remove the 2 screws and remove shaft support, PL 12. Remove the BM backstop assembly, Figure 5.
12.165 Item 10.
9. Prepare to remove the shaft from the frame, Figure 3.
Frame locator
1 2 3
2 Rotate the BM back- Slide the BM backstop under
Flex the belt
Remove the E-clip stop into this position the belt
upwards
1
Move the shaft
Figure 5 Remove the backstop assembly
10. Move the backstop assembly to the bottom of the BM assembly.

Replacement REP 12.22-171 BM Entry Roll
1. Reverse the removal procedure to replace the backstop assembly. Parts List on PL 12.150.
2. When installing the shaft ensure that the anti-play shoe has not moved out of position,
Figure 6.
Purpose
• BM entry roll pulley, PL 12.150 Item 14.
• BM entry roll, PL 12.150 Item 15.
Correct position of the anti-play Removal
shoe.
Ensure that the shaft is gripped
securely. WARNING
WARNING
Incorrect position of the anti-play 1. Open the HVF BM front door and fully pull out the BM module.
shoe.
Figure 6 Location of the anti-play shoe.
3. Ensure that all of the cable ties are installed and that the harnesses are in the correct
position.
4. Check that all of the PJ connections on the BM PWB are connected.
5. Return the allen key to the storage position inside the drive belt tensioner spring, PL
12.160 Item 9.
6. Go to ADJ 12.9-171 and complete the adjustments.

5. Figure 1, remove the BM Entry Roll. REP 12.23-171 BM Entry Sensor
Removal
1
Remove E-clip, bearing,
pulley and belt.
WARNING
WARNING
5. Figure 1, remove the BM entry sensor.
2
Remove E-clip and
bearing.
3
Remove the
entry roll.
Figure 1 Roll removal
Replacement
Reverse the removal procedure to replace the BM entry roll.
NOTE: Tension the drive belt by loosening then tightening the screw, ADJ 12.10-171

5
Remove the sensor.
3
Disconnect the 4
sensor harness. Remove the baffle.
2
Remove
2 screws.
1
Remove 2 screws.
Replacement
Reverse the removal procedure to replace the BM entry sensor.

REP 12.24-171 BM Crease Roll Gate Motor REP 12.25-171 BM Compiler Motor and BM Flapper Motor
Removal Removal
WARNING WARNING
WARNING WARNING
Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus- Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus-
tomer supply while performing tasks that do not need electricity. Electricity can cause tomer supply while performing tasks that do not need electricity. Electricity can cause
1. Remove the top cover, then the rear cover, REP 12.1-171. 1. Remove the top cover, then the rear cover, REP 12.1-171.
2. Fully pull out the BM module. 2. Fully pull out the BM module.
3. Figure 1, remove the motor assembly 3. Figure 1, remove the motor assembly.
1
Remove E-clip
and pulley
4
Remove the
motor assembly
2
Remove 2
screws
3
Disconnect the
motor harness 3
Remove 3 screws
2
Disconnect the
ground strap
4 1
Remove the Disconnect the
motor assembly harness
4. Remove 2 screws to remove the relevant motor from the bracket.
4. Remove 3 nuts to release the motor from the bracket. 5. Remove 2 screws to remove the motor from the damper.
Replacement Replacement
Reverse the removal procedure to replace the BM crease roll gate motor. Reverse the removal procedure to replace the BM compiler motor or BM flapper motor.

REP 12.26-171 Back Stop Drive Assembly 10. Figure 1, remove the BM backstop drive shaft and bearings.

Purpose
2
This procedure is used to repair the following components: Remove KL-clip
• BM backstop link springs, PL 12.160 Item 15. and pulley
• BM backstop link, PL 12.160 Item 16.
• BM backstop drive shaft, PL 12.165 Item 14.
• BM backstop belt, PL 12.160 Item 7.
• BM back stop bearing, PL 12.160 Item 11.
• BM back stop idler bracket, PL 12.160 Item 12.
Removal
WARNING
WARNING
5. Remove the LH frame plate, PL 12.155 Item 2.
6. Remove the BM tamper assembly, REP 12.30-171.
7. Remove the backstop motor assembly, REP 12.20-171.
8. Remove the backstop assembly, REP 12.21-171.
9. Remove the crease blade assembly, REP 12.36-171. 3 4 1
Remove KL-clip Remove the Remove E-clip
and bearing drive shaft and bearing
Figure 1 Drive shaft removal

11. Figure 2, remove the backstop link. 12. Figure 3, remove the BM backstop idler bracket assembly.
3
Remove the link
and two springs
2 1 2
Press down on the link and Remove the bracket 1
Press down on the link and
release the rear tensioner link assembly and belt Remove 2 screws
release the front tensioner link
Figure 2 Backstop link removal Figure 3 Idler bracket assembly removal

13. Figure 4, remove the BM backstop belt. REP 12.27-171 BM Staple Heads
1 Removal
Remove KL-clip, tensioner
link and bearing
2 WARNING
Slide the shaft
to one side Take care during this procedure. Sharp edges may be present that can cause injury.
WARNING
1. Fully pull out the BM module.
2. Remove the relevant staple head cover, PL 12.185 Item 14.
3. Pull the stapler bracket handle, PL 12.185 Item 9. Open the staplers fully.
3
Remove the belt
Figure 4 Backstop belt removal
Replacement
Reverse the removal procedure to replace the removed components. Allow the BM backstop
belt to be tensioned correctly before the bracket assembly securing screws are tightened.
Refer to Figure 3.

NOTE: If a 5.5 mm socket and short extension is not available or access to the staple head Replacement
securing screws is difficult, remove the BM stapler bracket assembly, REP 12.28-171, then
1. Reverse the removal procedure to replace the BM staple heads.
remove the relevant staple head.
2. Perform ADJ 12.3-171, Stapler Anvil Alignment.
4. Figure 1, remove the relevant staple head.
2
Loosen 1 screw
using a 5.5mm
socket and
ratchet driver
3
Using a 5.5mm socket
and short extension fully 4 1
loosen the screw until the Disconnect the Remove 2 screws
staple head is released. stapler harness using a 5.5mm
Leave the socket and and remove the socket and
extension in position on stapler ratchet driver
the screw
Figure 1 Staple head removal

REP 12.28-171 BM Stapler Bracket Assembly 3. Figure 1, remove the BM staple head carrier closed sensor actuator.

Purpose
This procedure is used to repair the following parts: 2
• Front follower, PL 12.185 Item 1. Remove
the KL-clip
• Actuator, PL 12.185 Item 2.
• Rear follower, PL 12.185 Item 3.
• Spring, PL 12.185 Item 4.
• BM paper present sensor Q12-190, PL 12.185 Item 5.
• Latch slide, PL 12.185 Item 6.
• Staple bracket handle, PL 12.185 Item 9.
• Stapler bracket assembly, PL 12.185 Item 10.
• Torsion spring, PL 12.185 Item 11. 3
Remove the
• Bearing, PL 12.185 Item 12. actuator
• Spring, PL 12.185 Item 13.
• BM stapler head carrier closed sensor Q12-421, PL 12.185 Item 18.
• Lower shaft, PL 12.185 Item 19.
• Upper shaft, PL 12.185 Item 20.
Removal 1
Remove the
sensor
WARNING
WARNING
Figure 1 Actuator removal
4. Temporarily attach the PWB mounting plate using only the top two screws.
2. Remove 4 screws securing the BM PWB mounting plate to the frame, allow the PWB and
mounting plate to hang down, giving access to the BM staple head carrier closed sensor. 7. Remove the crease roll handle (6c), PL 12.150 Item 5.
9. Remove both staple head covers, PL 12.185 Item 14.

10. Figure 2, lower the stapler bracket.
2 1
Pull the stapler bracket Release the rear follower
handle to open the staplers from the slot using a
fully screwdriver
Figure 2 Lowering stapler bracket

11. Figure 3, remove the latch shaft.
1
Remove KL-clip and pull shaft forward
50 mm (2 inches)
5
Pull the shaft completely
to the rear to remove
2
Remove 2 E-clips and
the front follower
4
Push the shaft to the rear
to release the latch slide
3
Compress the spring, remove
the rear follower and spring
Figure 3 Latch shaft removal

12. Figure 4, prepare to remove the BM stapler bracket assembly.
1
Remove KL-clip
6
Disconnect harnesses
and ground wire
4
Release the spring
from the side frame
5
Remove E-clip
2 3
Disconnect Remove 2 E-clips
ground wire

13. Figure 5, remove the BM stapler bracket assembly. REP 12.29-171 BM Conveyor Belts
Removal
1
Lever out
the bearing
using a WARNING
screwdriver Take care during this procedure. Sharp edges may be present that can cause injury.
WARNING
NOTE: The removal procedure illustrates how to remove the rear conveyor belt. The proce-
dure for the front conveyor belt is similar.
1. Remove bin 2 by disconnecting the harness, removing the thumb screw then lifting the bin
upwards to release.
2 2. Remove the BM bin 2 extension by aligning the pivot pins with the cutouts and snapping
Remove the the extension out of engagement.
bracket 3. Turn over bin 2 and remove the base pan, 3 screws.
assembly
4. Remove the BM bin 2 connector from the base pan, 1 screw.
from the front
Figure 5 Assembly removal
Replacement
Reverse the removal procedure to replace the BM stapler bracket assembly and components.

5. Figure 1, remove the idler roller. 6. Figure 2, remove the BM conveyor belt.
1
Release the belt from the drive
3 pulley
Push the other bearing
though the frame to
remove the idler roller
2
Push out the shaft and
remove one bearing
1
Remove E-clip
2
Feed the belt through
the cut-out to remove
Figure 2 Belt removal
Replacement
Reverse the removal procedure to replace the BM conveyor belts.
Figure 1 Idler roller removal

REP 12.30-171 BM Tamper Assembly and Tamper 1 Motor 6. Figure 1, remove the tamper assembly.

5 4
Purpose Remove 2 screws Remove 2 screws
This procedure is used to repair the following components: and earth connector
• BM tamper 1 motor, PL 12.155 Item 3.
• BM rear tamper arm, PL 12.155 Item 5.
• BM front tamper arm, PL 12.155 Item 6.
• BM rear tamper rack, PL 12.155 Item 7.
• BM front tamper rack, PL 12.155 Item 8.
• BM rear tamper assembly, PL 12.155 Item 9.
• BM front tamper assembly, PL 12.155 Item 10.
• BM tamper gear,PL 12.155 Item 11.
• BM tamper bracket, PL 12.155 Item 12.
• BM tamper rack guide, PL 12.155 Item 13.
• BM tamper guide plate, PL 12.155 Item 15.
• BM rear tamper finger, PL 12.155 Item 16.
• BM front tamper finger, PL 12.155 Item 17.
Removal
WARNING
death or injury. Moving parts can cause injury. 1 2
Remove the cover and If necessary, remove 2 3
disconnect the harness screws to remove the motor Remove 2 screws
WARNING
2. Remove the crease blade knob (6d), PL 12.150 Item 4. 6
3. Remove the crease roll handle (6c), PL 12.150 Item 5. Move the tampers to align with the
slots to release each tamper from the
slot
5. Remove the left frame plate, PL 12.160 Item 17.
7
Remove the tamper
assembly
Figure 1 Tamper assembly removal

7. Figure 2, remove the front and rear tamper assemblies. Also remove the tamper gear and 8. Figure 3, remove the tamper guide plate from each of the tamper assemblies.
tamper motor.
6
Remove 2 screws, 5
remove the motor Remove
the gear
4
Remove 1
E-clip Remove
screw and
tamper finger
End
stop
2
Guide tab Remove the
guide plate
Guide tab
2
1 Remove
3 End stop
Pull out both tamper 4 screws
Remove the BM
assemblies tamper rack guide
Figure 3 Guide plate removal
Figure 2 Dismantling the tamper assembly
Replacement
1. If the tamper racks were removed from the BM tamper rack guide, perform the following:
a. Align the guide tabs on both tamper racks with the slots in the BM tamper rack guide.
Refer to Figure 2.
b. Start both tamper racks into the BM tamper rack guide at the same time. Both
tamper racks must engage with the BM tamper gear simultaneously. To check that
the front and rear tampers are correctly aligned, perform the following:
• Fully push in the tampers.
• The distance between the end stop on each tamper and the ends of the BM
tamper rack guide should be equal. Refer to Figure 2.
• If the distances are different by more than 1mm (0.040 inches). Perform again
step B.
2. Reverse the removal procedure to replace the BM tamper assembly and tamper 1 motor.
3. Perform ADJ 12.5-171 Booklet Tamping.

REP 12.31-171 HVF Buffer Guide Assembly 6. Figure 2. Remove the pivot screw.

Removal
WARNING
WARNING
3. Remove the HVF front cover, REP 12.1-171. 1
4. Remove the HVF rear cover, REP 12.1-171. Remove the
pivot screw
5. Figure 1. At the rear of the finisher, disconnect the two PJs.
Figure 2 Pivot screw removal.
7. Pass the PJs through the cut-out in the rear frame.

8. Withdraw the guide through the front opening.
Replacement
Position the spigot at the guide rear in the hole in the rear frame. The rest of the replacement
1
procedure is the reverse of the removal procedure.
Disconnect the
two PJs
REAR VIEW
Figure 1 Disconnecting PJs.

REP 12.32-171 HVF Input Jam Clearance Guide REP 12.33-171 Buffer Pocket Jam Clearance Guide
Parts List on PL 12.125. Assembly
Removal Parts List on PL 12.125.
Removal
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. WARNING
WARNING
Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus- WARNING
1. Remove the HVF front door, REP 12.1-171. death or injury. Moving parts can cause injury.
2. Remove the HVF top cover, REP 12.1-171. 1. Remove the HVF front door, REP 12.1-171.
3. Remove the HVF front cover, REP 12.1-171. 2. Remove the HVF top cover, REP 12.1-171.
4. Figure 1. Remove the pivot screw at the front of the input guide. 3. Remove the HVF front cover, REP 12.1-171.
5. Remove the buffer pocket roll, REP 12.42-171.
6. Figure 1. At the rear of the HVF, prepare to remove the buffer pocket jam clearance guide.
1
Remove the
pivot screw
5. Remove the guide through the front opening.
Replacement
Position the spigot at the guide rear in the hole in the rear frame. The rest of the replacement
procedure is the reverse of the removal procedure.

2 1
Remove the buffer pocket jam Remove 2 screws.
clearance guide.
1 Bypass feed motor
REAR VIEW Remove 2 screws. (MOT 12-263) ref. only
Figure 1 Rear screw removal. Figure 2 Guide removal.
7. Figure 2. At the front of the HVF, remove the buffer pocket jam clearance guide. Replacement

REP 12.34-171 Inserter Jam Clearance Guide Assembly REP 12.35-171 Diverter Exit Gate
Removal Removal
WARNING WARNING
WARNING WARNING
Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus- Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus-
tomer supply while performing tasks that do not need electricity. Electricity can cause tomer supply while performing tasks that do not need electricity. Electricity can cause
1. Remove the HVF front door, REP 12.1-171 1. Remove the HVF front door, REP 12.1-171.
2. Remove the HVF top cover, REP 12.1-171. 2. Remove the HVF top cover, REP 12.1-171.
3. Remove the HVF front cover, REP 12.1-171. 3. Remove the HVF front cover, REP 12.1-171.
4. Figure 1. Remove the pivot screw from the front end of the Inserter jam clearance guide. 4. Remove the HVF rear cover, REP 12.1-171.
5. Figure 1. At the rear of the HVF, remove the solenoid arm, the K-L clip and the bush from
the diverter shaft.
1
3 Pull the solenoid arm
1 Remove the bush from the shaft
Remove the pivot screw

2
5. Remove the guide through the front opening. Remove the K-L clip
Replacement REAR VIEW

1. The replacement procedure is the reverse of the removal procedure.
Figure 1 Removal preparation

6. Figure 2. Remove the diverter exit gate. REP 12.36-171 Crease Blade Assembly
Diverter Purpose
3 • Connecting rod, PL 12.170 Item 9.
Remove the
diverter exit gate • Crease blade assembly, PL 12.170 Item 13.
• Crease blade support guide, PL 12.170 Item 14.
Removal
WARNING
2 Take care during this procedure. Sharp edges may be present that can cause injury.
Remove the
pivot screw
WARNING
1
Open Guide 5c
Figure 2 Diverter removal
Replacement
CAUTION
After replacement, check the K-L clip is in the correct groove, and the bush cannot be pulled
from the frame.

5. Figure 1, remove the crease blade assembly. 6. Figure 2, remove the front blade support.
1
Remove 2
screws
4
Remove front
blade support
3
Remove E-clip
2
Release the front
connecting rod
and bearing
1
Remove E-clip
Figure 2 Front support removal
3 2
Manoeuvre the blade assembly Remove 4 screws
out from under the front and rear
supports
Figure 1 Crease blade assembly removal

7. Figure 3, remove the rear blade support.
CAUTION
Do not loosen the three red screws that surround the lower support guides
8. Figure 4, remove the support guides (4 places).
4
Remove rear
blade support
3
Remove E-clip
1
Depress the centre
2 of the guide
Release the rear
connecting rod
and bearing
1
Remove E-clip
Red screws -
see caution
Figure 3 Rear support removal 2

Pull the guide outward to remove
Figure 4 Support guide removal
Replacement
• Reverse the removal procedure to replace the crease blade assembly.

REP 12.37-171 Stacker Driving Shaft Bearings NOTE: The upper pulley pin may fall when the pulley is removed.
Parts List on PL 12.115. 4. Remove the front bearings, Figure 2.

Removal
6
WARNING Remove the cir-
Take care during this procedure. Sharp edges may be present that can cause injury. clip, thrust
washer and
inner bearing
WARNING
1. Remove the front and rear covers REP 12.1-171.
2. Remove the stacker motor and gear assembly REP 12.12-171.
3. Remove the rear bearing, Figure 1.
5
Remove 2
screws and
the bracket
5
Remove the
rear bearing 4
Remove the
outer bearing
4
Remove the thrust
washer 1 2 3
Remove the circlip Remove the upper Remove the pulley pin
pulley
3
Remove the circlip
Figure 2 Stacker Shaft Front Bearing
Replacement
Reverse the removal procedures to reinstall the stacker driving shaft front and rear bearings.
2
Remove the gear
NOTE: Make sure that the ‘flats’ on the bearing align with the cut-outs in the bracket or frame.
wheel
1
Remove the circlip
Figure 1 Rear bearing removal

REP 12.38-171 HVF Stacker Driving Belts 3. Remove the stacker driving belt, Figure 1.

Removal
3
WARNING Remove the circlip
Take care during this procedure. Sharp edges may be present that can cause injury. and upper pulley if
required.
WARNING
NOTE: The removal and replacement procedure for the front and rear stacker driving belts is
the same. Support the Bin 1 lift bar if removing the front and rear belts at the same time
1. Remove the front or rear cover to access the front or rear driving belt REP 12.1-171. 4
2. Remove the stacker bin 1 tray REP 12.4-171. Remove the
belt
1
Remove the screw
and belt clamp
2
Remove the circlip and
lower pulley
Figure 1 Stacker Driving Belts
Replacement
NOTE: Check that the bin 1 lift bar is level before fitting the belt clamp.
Reverse the removal procedures to reinstall the front and rear stacker driving belts.

REP 12.39-171 HVF BM Diverter Gate 6. Figure 2. Remove the BM diverter gate.

Removal
WARNING 1
Open Guide 5b
WARNING
from the customer supply, while performing tasks that do not need electricity. Electricity Remove the
can cause death or injury. Moving parts can cause injury. diverter
2
5. Figure 1. prepare to remove the BM diverter gate. Remove the
pivot screw
1
Pull the solenoid arm Figure 2 Diverter removal.
from the shaft.
5 Replacement
Remove the
bush. The replacement procedure is the reverse of the removal procedure.
4 3 2
Remove the spacers. Remove the pivot arm. Remove the K-L clip.
REAR VIEW
Figure 1 Removal preparation

REP 12.40-171 HVF Input Roll 6. Figure 2. At the front of the HVF, remove the circlip and bush.

Removal
WARNING
WARNING
5. Figure 1. Remove the black plastic cover.
1
Remove the circlip
and bush
1
Press in the catches,
(2 places)
Figure 2 Circlip and bush removal.
2
Lift out the cover
Figure 1 Cover removal.

7. Figure 3. At the rear of the HVF, remove the input roll. REP 12.41-171 HVF Inserter Guide Roll
3 Removal
Lift the shaft and remove
the belt from the pulley
WARNING
4
Remove the pulley and WARNING
the bush Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus-
5 2. Remove the HVF top cover, REP 12.1-171.
Remove the input roll
5. Open guide 8a.
6. Figure 1. At the front of the HVF, remove the circlip and the bush.
1
2 Remove the circlip
Slide the pulley and the
bush along the shaft REAR VIEW
Figure 3 Input roll removal.
Replacement
1
Remove the circlip
and the bush

7. Figure 2. At the rear of the HVF, remove the Inserter guide roll. REP 12.42-171 HVF Buffer Pocket Roll
Removal
1
Remove the circlip
WARNING
bush along the shaft
WARNING
3 tomer supply while performing tasks that do not need electricity. Electricity can cause
Slip the belt off of death or injury. Moving parts can cause injury.
the pulley
4 4. Remove the HVF rear cover, REP 12.1-171.
Remove the pulley and
the bush 5. Remove the punch unit, or the punch unit guide, as appropriate.
5
Remove the
Inserter guide roll
REAR VIEW
Figure 2 Inserter guide roll removal
Replacement

6. Figure 1. At the front of the HVF, remove the circlip and bush. 7. At the rear of the HVF, remove the buffer pocket roll. The bracket can be moved if neces-
sary, to improve access, (two screws), Figure 2.
1
Remove the circlip
2
3
Slip the belt off the
pulley
Remove the circlip 4

and the bush Remove the pulley and
the bush
5
Remove the buffer
pocket roll
Bracket
REAR VIEW
Figure 2 Buffer pocket roll removal.
Replacement

REP 12.43-171 HVF Booklet Entrance Roll 6. Figure 2. At the rear of the HVF, remove the booklet entrance roll.

Removal
WARNING
WARNING
5. Figure 1. Remove the circlip and bush at the outboard end of the roll. 5
Remove the
1 booklet
Remove the circlip entrance roll
2 3 4
Slide the pulley and the Slip the belt off the Remove the pulley and
bush along the shaft pulley the bush
REAR VIEW
Figure 2 Booklet entrance roll removal.
Replacement
Remove the circlip

and the bush

REP 12.44-171 HVF Buffer Lower Roll 7. Figure 2. At the rear of the HVF, remove the buffer lower roll.

Removal
5
Remove the buffer
WARNING lower roll
4
WARNING Remove the pulley and
the bush
3
1. Remove the HVF front door, REP 12.1-171. Slip the belt off the
2. Remove the HVF top cover, REP 12.1-171. pulley
3. Remove the HVF front cover, REP 12.1-171. 1 2
4. Remove the HVF rear cover, REP 12.1-171. Remove the circlip Slide the pulley and the
5. Open jam clearance guide 5b. bush along the shaft
6. Figure 1. Remove the circlip and the bush from the outboard end of the roll. REAR VIEW
Figure 2 Buffer lower roll removal.
Replacement
Remove the circlip

and the bush

REP 12.45-171 HVF Buffer Upper Roll 6. Figure 2. Remove the buffer upper roll.

1 2
Removal Remove the circlip Slide the pulley and the
3
WARNING Slip the belt off the pul-
Take care during this procedure. Sharp edges may be present that can cause injury. ley
4
Remove the pulley and
WARNING the bush
Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus- 5
tomer supply while performing tasks that do not need electricity. Electricity can cause Remove the screw
6
Loosen the screw
3. Remove the HVF front cover, REP 12.1-171. 7
Pull the upper part of the fixed
4. Remove the HVF rear cover, REP 12.1-171. guide to the left and remove the
5. Figure 1. Remove the circlip and the bush. buffer upper roll
REAR VIEW
Fixed guide Figure 2 Buffer upper roll removal.
1
Remove the circlip Replacement
and the bush
2
Remove the screw
3
Loosen screw
Figure 1 Circlip and bush removal

REP 12.46-171 HVF Stacker Exit Feed Roll 6. Figure 2. Remove the stacker exit feed roll.

Removal
1
WARNING Remove the idler,
Take care during this procedure. Sharp edges may be present that can cause injury. (1 screw)
2
WARNING Remove the circlip,
pulley and bush
death or injury. Moving parts can cause injury. 3
Remove the stacker
1. Remove the HVF front door, REP 12.1-171. exit feed roll
5. Figure 1. Remove the circlip and bush
REAR VIEW
Figure 2 Stacker exit feed roll removal.
Replacement
Remove the circlip

and the bush

REP 12.47-171 HVF Top Exit Feed Roll 6. Figure 1. Raise the top tray and lower the plate beneath it.

Removal
WARNING
Release the
two links
WARNING
1. If fitted, undock the Inserter, REP 12.82-171.
2
Lower the plate
Figure 1 Lowering the plate.

7. Figure 2. Remove the circlip and bush. Remove the front magnet bracket screws. 8. Figure 3. At the rear of the HVF, Remove the circlip, bush, pulley and the rear screws from
the magnet bracket.
1
Remove the circlip
2
Slide the pulley and
the bush along the
shaft
3
Slip the belt off of
the pulley
4
1 2 5 Remove the pulley and
Remove the circlip and Remove 2 screws Remove 2 screws the bush
the bush
REAR VIEW
Figure 2 Feed Roll Front Fasteners.
Figure 3 Rear component removal.

9. Figure 4. Remove the top exit feed roll. REP 12.48-171 Compiler Paddle Motor Assembly
Removal
WARNING
WARNING
2. Remove the paddle motor assembly, Figure 1.
1
Disconnect the motor
PJ
2
1 Remove the top
Remove the exit feed roll
magnet bracket
Figure 4 Top exit feed roll removal.

2
Remove the 2 bracket
Replacement screws
The replacement procedure is the reverse of the removal procedure. 3
Remove the Paddle Motor
Figure 1 Paddle Motor Assembly
Replacement
Reverse the removal procedures to replace the compiler paddle motor assembly.

REP 12.49-171 Compiler Paddle Unit
Removal
WARNING
WARNING
1. Remove the front, rear and top covers REP 12.1-171.
2. Remove the HVF stapler assembly, REP 12.2-171.
3. Remove the compiler paddle motor assembly, REP 12.48-171. Paddle unit cable
Paddle unit rear
NOTE: The motor coupler should detach with the motor assembly. If the coupler fails to screws connectors
detach, remove the coupler from the paddle module assembly.
4. Remove the PJs and screws securing the ribbon cable connectors, Figure 1. Carefully
push the ribbon cable bulkhead connectors through the frame cut-outs.
Paddle unit
front screws
Figure 1 Paddle Module Attachment
5. Remove the screws (front and rear) and the front grounding strap then manoeuvre the
module downwards, Remove the module through the stapler aperture, Figure 1.
Replacement
CAUTION
Do not damage or strain the paddle module ribbon cables or connectors
Reverse the removal procedures to replace the compiler paddle unit.
Use the correct screws to secure the compiler paddle unit; do not overtighten.

REP 12.50-171 BM Exit Sensor 3. Figure 2, remove the BM exit sensor.

Removal
2
Disconnect
the harness
WARNING and remove
Take care during this procedure. Sharp edges may be present that can cause injury. the sensor
WARNING
1. Remove the BM right hand cover, REP 12.56-171.
2. Remove the exit plate, Figure 1.
1
Remove the screw and
slide out the sensor
Replacement
Reverse the removal procedure to replace the BM exit sensor.
1
Remove 4 screws to release the
exit plate
Figure 1 Remove the exit plate

REP 12.51-171 Compiler Paper Pusher Motor Assembly REP 12.52-171 BM Crease Rolls
Removal Removal
WARNING WARNING
WARNING WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Switch off the electricity to the machine GP 14. Disconnect the power cord from the cus-
from the customer supply, while performing tasks that do not need electricity. Electricity tomer supply while performing tasks that do not need electricity. Electricity can cause
can cause death or injury. Moving parts can cause injury. death or injury. Moving parts can cause injury.
1. Remove the top and rear covers REP 12.1-171. 1. Open the HVF BM front door and fully pull out the BM module.
2. Remove the paper pusher motor assembly, Figure 1. 2. Release the crease roll nip pressure by fully rotating the crease roll handle (6c) counter-
clockwise.
6. Remove the BM right hand top cover, REP 12.56-171.
7. Remove the BM crease roll motor, REP 12.19-171, but do not disconnect the motor har-
ness or remove the motor from the mounting plate.
8. Remove the exit plate
1
Remove motor bracket rear
2
Remove motor bracket
front screws
3
Disconnect the motor PJ
Figure 1 Paper Pusher Motor Assembly
Replacement
Reverse the removal procedures to reinstall the compiler paper pusher motor assembly.

9. Figure 1, Release the crease roll assembly at the rear. 10. Figure 2, Release the crease roll assembly at the front.
1
Remove 3 screws
1
2 Remove 3 screws
Remove E-clip and release the 2
arm Remove the E-clip and release the arm
NOTE: Flat washer between NOTE: Flat washer between the bearing
the bearing and arm and arm
Figure 1 Release the assembly at the rear Figure 2 Release the assembly at the front

11. Figure 3, Flex the front plate to remove the crease roll assembly. 12. Figure 4, remove the crease rolls.
1
Remove the screws
marked with a A.
Remove the E-clips and
bearings marked B.
Remove the external circlips to Remove the external circlips to
remove the rolls remove the rolls
2
Flex the front plate to Front
Rear
remove the crease roll
assembly
Figure 3 Release the front plate Figure 4 Remove the crease rolls
Replacement
Reverse the removal procedures to reinstall the crease roll assembly.

REP 12.53-171 Compiler Paper Pusher 4. Remove the pusher driving motor assembly, REP 12.51-171.
5. Remove the pusher sensor assembly, REP 12.54-171.
6. Remove the front and rear screws and push the left edge of the compiler exit guide plate
Removal downward away from the pinion shaft, Figure 2.
WARNING
WARNING
1. Remove the front, rear and top covers REP 12.1-171.
2. Remove the stacker motor gearbox, REP 12.12-171.
3. Remove the stacker shaft front bearing bracket and the exit guide plate front and rear
screws, Figure 1. Pinion Shaft
Pusher Module
Exit Guide Plate
Figure 2 Pusher Guide and Pinion Shaft
7. Remove the pinion shaft front and rear circlips, the shaft bearings and the front bearing
thrust washers then remove the pinion shaft, Figure 2.
Stacker front bearing
bracket 8. Lift the pusher module out of the guides. The mylar strips and dampers are attached to
the pusher module, Figure 2.
Replacement
Reverse the removal procedures to reinstall the compiler paper pusher.
Figure 1 Stacker Shaft Front Bearing Bracket

REP 12.54-171 Pusher Upper and Lower Sensors REP 12.55-171 HVF PSU Assembly
Removal Removal
WARNING WARNING
WARNING WARNING
from the customer supply, while performing tasks that do not need electricity. Electricity from the customer supply, while performing tasks that do not need electricity. Electricity
1. Remove the top cover REP 12.1-171. 1. Remove the front and rear covers REP 12.1-171.
2. Remove the upper and lower sensor assembly, Figure 1. 2. Remove the PSU module, Figure 1.
1
Remove the 5 screws
1
Remove the screw
2
Disconnect the grounding
strap and the two PJs
2
Disconnect the two PJs
Figure 1 Pusher Sensor Assembly Figure 1 HVF PSU
Reverse the removal procedures to replace the Pusher sensor assembly. Reverse the removal procedures to replace the HVF PSU module.

REP 12.56-171 BM Right Hand Cover 6. Figure 1, remove the BM top cover.

1
Removal Disconnect the
harness to the
BM entry sensor
WARNING
WARNING
2. Open the BM front door and fully pull out the BM module.
2
Remove 2 screws
4. Remove the crease roll handle (6c), PL 12.150 Item 5. and lift and
5. Remove the BM front cover, PL 12.150 Item 3. remove the cover
Replacement
Reverse the removal procedure to replace the BM right hand cover.

REP 12.57-171 HVF Main PWB 2. Disconnect the PJs, remove 9 screws and remove the PWB assembly, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the HVF main
PWB.
WARNING
Figure 2 HVF Main PWB
Replacement
Reverse the removal procedures to replace the HVF Main PWB.

REP 12.58-171 Not Used REP 12.59-171 Crease Roll Gate Assembly
. Parts List on PL 12.180.
Purpose
• Crease roll gate rack gear, PL 12.180 Item 8.
• Crease roll gate rack drive gear, PL 12.180 Item 13.
• Crease roll gate rack, PL 12.180 Item 14.
• Crease roll gate front guide, PL 12.180 Item 15.
• Crease roll gate rear guide, PL 12.180 Item 16.
• Crease roll gate, PL 12.180 Item 19.
Removal
WARNING
WARNING
1. Open the HVF BM front door and fully pull out the BM.
5. Remove the BM right hand cover, REP 12.56-171.
6. Remove the crease roll assembly, REP 12.52-171.
7. Remove the crease roll gate motor, REP 12.24-171.

8. Figure 1, remove the crease roll gate rack drive gear and both crease roll gate rack gears. 9. Figure 2, Remove the front and rear crease roll gate racks.
2
Remove E-clip
and rear rack
1
Remove the E-clip and 2 gears
1
Remove E-clip
and front rack
2
Remove E-clip Figure 2 Removing the racks
and gear
Figure 1 Removing gears

10. Figure 3, remove the crease roll gate. 11. Figure 4, remove the grease roll gate front guide.
Twist the gate

to allow the
shaft to exit the
slot, then lift
out the gate
3
Remove the guide
2
Remove screw
Figure 3 Gate removal
1
Remove two screws
Figure 4 Front guide removal

12. Figure 5, remove the grease roll gate rear guide. REP 12.60-171 BM Paper Guide Assembly
Purpose
• Paper guide, PL 12.150 Item 7.
• Nip spring, PL 12.150 Item 9.
• Nip roll, PL 12.150 Item 10.
• Nip shaft, PL 12.150 Item 11.
NOTE: If only new nip components are being installed, the BM paper guide assembly
does not need to be removed.
Removal
WARNING
WARNING
1. Open the BM front door and fully pull out the BM.
2. Rotate the crease roll handle (6c) fully counterclockwise.
2 1
Remove the rear Remove two screws
guide
Figure 5 Rear guide removal
13. Loosen 3 screws to remove the crease roll gate shaft from the crease roll gate.
Replacement
CAUTION
Ensure that the crease roll gate shaft is positioned centrally within the crease roll gate.
Reverse the removal procedure to replace the crease roll gate assembly.

6. Figure 1, remove the front bearing. 7. Figure 2, remove the rear bearing.
1
Remove 1
the E-clip Remove the
E-clip, then
the bearing.
2
Remove the bearing
Figure 1 Front bearing removal Figure 2 Rear bearing removal

8. Figure 3, remove the BM paper guide assembly. 9. Figure 4, remove the components from the BM paper guide assembly.
4
Carefully disengage the
spring legs from the
guide and remove the
shaft assembly
1
Release the nip
springs to
remove the nip
shaft and nip
rolls
3
Pivot the BM flapper assembly
2 down to rest on the crease
Remove 4 screws. Disconnect the blade.
ground harness.
3
Remove E-clip
4 and front latch
Lift out the BM paper
guide assembly. 2
Remove E-clip and
rear latch
Figure 4 Paper guide dismantling
Replacement
Reverse the removal procedure to replace the BM paper guide assembly.
1
Pull out the 2 harness supports.
Figure 3 Paper guide assembly removal

REP 12.61-171 BM Module 2. Figure 1, disconnect PJ562 and PJ559 from the BM PWB.

Removal
WARNING
Mandatory safety warning. This procedure must be performed by 2 people. The module
is heavy.
WARNING
Do not undock the HVF BM from the machine. The HVF BM is unstable when undocked
from the machine. Do not show the customer how to undock the HVF BM.
WARNING
WARNING
2 1
Release the harness Disconnect PJ562 and
from the retainers. PJ559.
Figure 1 Disconnect the PJs

3. Figure 2, disconnect the harness from bin 2. 4. Figure 3, prepare to remove the BM module.
1
1 2 Align approximately two
Make sure that the top of the paper reams of paper against the
2 Remove 2 screws. edge of the HVF BM.
stack is level with the base of the BM
Disconnect the harness. Secure the module.
harness to the harness retainers.
Figure 2 Disconnect the harness Figure 3 Preparation

5. Figure 4, prepare to remove the BM module. 6. Figure 5, Release the latches.
1
Fully pull out the BM
module.
2
Disconnect the ground harness.
Secure the harness to the harness 2
retainers. Fully push in the slide.
1
Pull up the right side latch to
release the slide from the rail.
4
Fully push in the
slide.
3
Push down the left side latch
to release the slide from the
rail.
Figure 5 Releasing the slides

WARNING
Use safe handling procedures when removing the module. Refer to GP 16. The module
is heavy.
WARNING
is heavy.
CAUTION One person must lift the

Do not damage the BM front cover when the BM module is removed. BM module by the left side
cross member.
NOTE: The BM module weight is 27Kg (59.6 lb.).
NOTE: The BM catch will spring to the rear when the BM module is removed. Refer to Figure 7.
7. Figure 6, remove the BM module.
1
Carefully remove
the BM module.
A second person must lift the

BM module by the booklet exit
slot.
Figure 6 Remove the BM module

Replacement
CAUTION
Do not damage the harnesses when the BM module is installed. Ensure that the rails are cor-
rectly aligned with the slides.
1. Put the BM module on the paper stack in front of the HVF BM.
2. Route the bin 2 harness and the ground harness to the rear of the HVF BM.
3. If a new BM is to be installed, perform the following:
a. Unlatch the slides from the new BM module. Refer to Figure 5.
b. Install the new BM module onto the existing rails in the HVF BM.
4. Figure 7, prepare to install the BM module.
2
Carefully push the BM module into
the HVF BM until the catch is held
under the guide. Do not push the
BM further into HVF BM.
Guide
1
Hold the catch in the forward position.
Figure 7 Position of the catch
5. Reverse the removal procedure to replace the BM module.
CAUTION
Ensure the BM harness and bin 2 harness are correctly positioned in the harness retainers so
that harnesses are not damaged when the BM is moved to the extremities of its travel.
6. Perform the 12D-171 Booklet Quality RAP.

REP 12.62-171 BM Slide Assembly 3. Figure 1, Remove the slide assembly from the HVF BM frame.

Removal
WARNING
WARNING
1. Remove the BM module, REP 12.61-171.
1
Remove screw
2
1 Move the slide to
2 Remove screw the rear and
Move the slide to the rear and remove the slide
remove the slide assembly assembly
Figure 1 Remove the slide assembly

4. Figure 2. Remove the bracket and the slide rail from the right side of the BM module. 5. Figure 3. Remove the two brackets from the slide rail.
3
Remove screw 1
Remove screw
2
4 Remove the bracket
Remove the bracket from from the slide rail
the slide rail
Figure 3 Remove the bracket from the slide rail
3 2 1
Cut the four cable ties Remove four screws
Remove the bracket and the
slide rail to release the harness
Figure 2 Remove the bracket and the slide rail

6. Figure 4, Remove the bracket and the slide rail from the left side of the BM module. 7. Figure 5, Remove the two brackets from the slide rail
1
3 Remove screw
Remove screw
4 2
Remove the bracket from the Remove the bracket from
slide rail the slide rail
2 1
3 Cut the five cable ties to Remove four screws Figure 5 Remove the bracket from the slide rail
Remove the bracket release the harness
and the slide rail Replacement
1. Reverse the removal procedure to replace the slide assembly.
2. Ensure that all of the cable ties are installed and the harness are in the correct position.
3. Check that all of the PJ connections are connected.
Figure 4 Remove the bracket and slide rail

REP 12.63-171 Transport Motor 1 REP 12.64-171 Bypass Feed Motor
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the rear cover REP 12.1-171. 1. Remove the rear cover REP 12.1-171.
2. Remove the transport motor 1 and bracket assembly, Figure 1. 2. Remove the bypass feed motor and bracket assembly, Figure 1.
1
1 Remove the pivot and
Remove the 2 2 bracket screws
bracket screws
2
Remove the pivot
screw
2
3 Disconnect the
motor PJ.
Disconnect the
motor PJ.
Tension Spring Tension Spring
Figure 1 Transport Motor 1 and Bracket Figure 1 Bypass Feed Motor and Bracket
3. Remove 2 screws and the grounding wire to remove the motor and damper from the
bracket.
bracket.
Replacement
Replacement
Reverse the removal procedures to replace the transport motor 1.
Reverse the removal procedures to replace the bypass feed motor.
Set the belt tension ADJ 12.10-171.
Set the belt tension, ADJ 12.10-171.

REP 12.65-171 Buffer Motor REP 12.66-171 Transport Motor 2
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the rear cover REP 12.1-171. 1. Remove the rear cover REP 12.1-171.
2. Remove the buffer motor and bracket assembly, Figure 1. 2. Remove the exit feed motor and bracket assembly, Figure 1.
1
Remove the pivot and
2 bracket screws
1
Remove the pivot and 2
bracket screws
Release Tension Spring

2
from the motor
2
Disconnect the
motor PJ. Tension Spring
Figure 1 Buffer Feed Motor and Bracket Figure 1 Exit Feed Motor and Bracket
bracket. 3. Remove 2 screws and the grounding wire to remove the motor and damper from the
bracket.
Replacement
Replacement
Reverse the removal procedures to replace the buffer motor.
Reverse the removal procedures to replace the exit feed motor.
Fit the pivot screw and set the belt tension, ADJ 12.10-171. Do not tighten the motor bracket
screws fully until the belt is tensioned by the spring. Fit the bracket pivot screw and set the belt tension, ADJ 12.10-171.

REP 12.67-171 Tri Folder Covers 2. Remove the rear cover, the top cover and the right side cover as required, Figure 2.
Parts List on PL 12.200. NOTE: Open the top cover and remove the rear cover to access to the top cover rear fas-
teners and the top cover interlock sensor connector.
Removal
4
WARNING Remove the top cover (4 fasteners).
1
Remove the rear cover
WARNING (4 screws)
1. Remove the screw and front door hinge pin then move the door from the upper pivot.
Remove 4 screws and remove the front cover Figure 1.
2
Remove the door
from the upper
pivot.
3
Open the front door to
access the top cover 2
front fasteners Remove the right hand side cover (5screws).
Figure 2 Top, Rear and Right side covers
Replacement
Reverse the removal procedures to reinstall the Tri-Folder covers.
3 1
Remove 4 screws then Remove 1 screw then
the front cover the front door hinge pin.
Figure 1 Tri-folder Front Door and Cover

REP 12.68-171 Tri-Folder Drive Assembly Replacement
Parts List on PL 12.205. 1. Detach the coupler alignment tool from the drive unit, refer to Figure 1.
2. Install the drive assembly, Figure 2.
Removal
WARNING
WARNING
Slide out the booklet
1. Remove the HVF rear cover, REP 12.1-171. maker.
2. Remove the tri-folder rear cover REP 12.67-171.
3. Remove the tri-folder drive assembly, Figure 1.
Circlip
Drive coupler
2
1 Attach the drive assembly,
Remove 2 screws 4 screws.
2 Figure 2 Attach the drive assembly

Release the coupler
drive belt tension, then
remove the belt.
3
Remove 2 screws,
Drive assembly then the tri-folder drive
assembly.
Figure 1 Drive assembly
4. If necessary, remove the circlip then remove the drive coupler, refer to Figure 1.

3. Centralize the coupler alignment tool onto the crease roll motor encoder disc, PL 12.175 5. Slacken off the drive unit retaining screws, Figure 4.
Item 13 and Figure 3.
Drive unit
1
Position the coupler
alignment tool onto
the crease roll motor
encoder disc.
1
Loosen the drive unit,
4 screws.
2
Carefully slide the BM towards the
drive assembly.
Figure 4 Loosen the drive unit
Figure 3 Centralize the alignment tool
4. Prepare to centralize the drive coupler, refer to Figure 1, with the HVF BM crease roll
motor encoder disc, Figure 3.

6. Centralize the coupler alignment tool with the drive unit coupler, Figure 5. 7. Secure the drive unit in the centralized position, Figure 6.
Alignment tool
Drive coupler
2
Slide out the BM
and remove the
coupler alignment
tool.
2
Ensure the drive coupler is centralized
1
1 with the alignment tool.
Secure the drive unit, 4 screws.
Adjust the position of the
drive unit.
Figure 5 Centralize the drive coupler Figure 6 Secure the drive unit
8. Attach the alignment tool onto the drive assembly for future use.
9. Carefully slide back the BM and engage the drive unit coupler.
10. Check that the harnesses do not obstruct the BM crease roll motor encoder disc.
11. Reverse the removal procedures to replace the tri-folder

REP 12.69-171 Tri Folder Crease Roll Drive Assembly 3. Slacken the tensioner lock screw and move the crease roll tensioner pulley to the left,
then tighten the lock screw, Figure 1.
Parts List on PL 12.205. 4. Remove the clutch and bearing from the idler bracket, Figure 2.
Removal
WARNING
WARNING
1. Remove the Tri Folder rear cover, REP 12.67-171. Access is improved by removing the
top cover.
2. Remove the drive coupling assembly bracket, Figure 1. Clutch torque arm
1
1 Disconnect the
Remove the clutch connector.
drive belt
Bearing
2 2
Remove the Remove the idler assembly
driven pulley Idler Crease roll drive belt
and gear
Figure 2 Idler Assembly and Crease Roll Clutch
Replacement
1. Reverse the removal procedures to reinstall the crease roll clutch and drive coupling
assembly.
2. Replace the idler assembly with the smooth side of the crease roll drive belt towards the
3 idler, then fit the drive belt over the clutch gear, Figure 2.
Remove the feed and
3. Position the clutch torque arm in the slot in the idler bracket, See Figure 2 insert.
the exit roll drive gear
and bearing. 4. Perform ADJ 12.10-171 Motor Drive Belt Tensioning.
4
Remove 5 screws
Tensioner lock screw.
Figure 1 Drive Coupling Assembly

REP 12.70-171 Tri-Folder Feed Roller and Drive Belt Replacement
Parts List on PL 12.205. 1. Reverse the removal procedures to replace the feed roller and drive belt.
2. Before docking the Tri-Folder unit to the HVF, perform ADJ 12.10-171, Motor Driven Belt
Removal Tensioning
WARNING
WARNING
1. Undock the Tri-Folder from the HVF and move the unit to the right to access the left side
of the frame, REP 12.99-171.
2. Remove the drive belt, Figure 1.
Feed Roller
3
Pull the feed roller through
the frame bearing and
remove the drive belt.
1
Release the belt
tension
Driven pulley
2
Remove the circlip and move the feed roller
shaft towards the front to remove the drive
pulley.
Figure 1 Feed Roller and Drive Belt
3. If required, remove the feed roller shaft front circlip and bearing and remove the feed
roller assembly from the Tri-Folder.

REP 12.71-171 TF Assist Gate Solenoid Replacement
Parts List on PL 12.215. 1. Reverse the removal procedures to replace the entry solenoid.
2. Refit the armature and lever before replacing the spring and solenoid coil. If necessary,
Removal get assistance to hold the armature coil in position when replacing the screws.
WARNING
WARNING
1. Open the TF front door, or remove the Bin 2 assembly, then remove the Tri-Folder rear
cover, REP 12.67-171.
2. Disconnect the harness and remove the solenoid and spring, Figure 1. Remove the arma-
ture and lever if required.
Armature and
lever
1 3
Remove 2 screws 2 Remove solenoid and
behind frame Disconnect harness spring
Figure 1 Assist Gate Solenoid

REP 12.72-171 Tri Folder Crease Roll Springs REP 12.73-171 Tri Folder Top Cover and Idler Assemblies
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the front door, front cover and rear cover REP 12.67-171. 1. Undock the tri-folder from the HVF and move it to the right to gain access to the left side
2. Remove the circlip and remove the front or rear spring, Figure 1. of the tri-folder frame, REP 12.99-171.
NOTE: The wiring harnesses to the HVF do not need to be disconnected.
Front Crease Roll Spring Rear Crease Roll Spring
Figure 1 Front and Rear Crease Roll Springs
Replacement
Reverse the removal procedures to replace the front or rear crease roll spring.

2. Remove the top cover door assembly, Figure 1. 3. Remove the idler assemblies, Figure 2.
NOTE: Control the movement of the torsion spring.
1
Remove the top cover
(5 screws).
2
Release the springs, then
remove the idler assembly.
Torsion Spring
2 4 3
Remove the clip. Release the front of the top Remove the
cover door assembly, then front screw.
1 remove.
Remove the rear screw. Figure 2 Idler assembly removal
Figure 1 Top Cover Removal Replacement

1. Reverse the removal procedures to reinstall the idler assemblies and top cover door
assembly.
2. Make sure that the correct self-tapping screws are used to replace the cover base; do not
overtighten the screws.
3. Replace, but do not tighten, the rear pivot shaft screw. Position the cover and torsion
spring then fit the front of the pivot shaft in the frame. Replace and tighten both front and
rear pivot shaft screws.
4. Check that the cable harnesses are not obstructed or touching moving parts when the tri-
folder is docked to the HVF.

REP 12.74-171 Tri Folder Roller Assembly and Diverter NOTE: First remove the lower front and rear screws. Support the roller assembly and
remove the upper front and rear screws. If not supported the assembly will fall inside the
Solenoid Tri Folder frame.
Parts List on PL 12.215. 3. Remove the roller assembly through the front door, Figure 1.
Removal
WARNING
WARNING
1. Undock the Tri-Folder assembly from the HVF, REP 12.99-171. Position and support the
Tri-Folder so that it is safely accessible from the front, rear and left side.
2. Release the crease roll drive belt tension, REP 12.69-171. Disconnect the harness from
the diverter and assist gate solenoids.
1 2 3
Remove 2 rear screws Disconnect sensor harness Remove 2 front screws
Figure 1 Tri Folder Roller Assembly

4. Remove the diverter gate solenoid and crease roll pulleys as required, Figure 2. REP 12.75-171 Bin 1 Limit Switches
Removal
WARNING
Diverter gate Take care during this procedure. Sharp edges may be present that can cause injury.
lever
WARNING
1 can cause death or injury. Moving parts can cause injury.
Remove 2 1. Remove the HVF rear cover, REP 12.1-171.
screws
2
Remove
Diverter gate
solenoid
Crease roll
pulleys
Assist gate solenoid
Figure 2 Positioning The Diverter Gate Lever
Replacement
1. Reverse the removal procedures to reinstall the pulleys, diverter gate solenoid and Tri
Folder roller assembly.
2. Before replacing the roller assembly set the diverter operating lever to the forward (sole-
noid armature extended) position to engage with the right side of the diverter shaft lever,
Figure 2.
3. Check that the diverter gate operates correctly before tensioning the crease roll drive belt.

2. Disconnect the PJs and remove the upper or lower limit switch and bracket as required, REP 12.76-171 Bin 1 Upper Level Sensor
Figure 1.
Removal
WARNING
WARNING
1. Remove the HVF front and rear covers, REP 12.1-171.
Remove the screw and then 2. Disconnect the PJs and remove the receiver or transmitter as necessary, Figure 1.
remove the upper limit switch
Rear receiver
Remove the screw and then

remove the lower limit switch
Figure 1 Bin 1 Limit Switches Front transmitter
Replacement
Reverse the removal procedures to replace the Bin 1 upper and lower limit switches. Figure 1 Bin 1 Upper level sensor
Replacement
Reverse the removal procedures to replace the transmitter or receiver of the bin 1 upper level
sensor.

REP 12.77-171 Tri Folder Door Interlock Switches and Sensor REP 12.78-171 Tri Folder Entry and Assist Gate Sensors
Removal Removal
WARNING WARNING
WARNING
WARNING
1. Remove the Tri Folder front and top covers, REP 12.67-171.
1. Undock the Tri Folder unit from the HVF, REP 12.73-171.
2. Remove the front door and top cover interlock switches and the top cover sensor, Figure 1.
2. Disconnect the PJs and remove the entry and assist gate sensors, Figure 1.
Top cover interlock switch Top cover sensor
Front door interlock switch Assist Gate Sensor

Entry Sensor
LEFT SIDE VIEW
Figure 1 TF Interlock Switches and Cover Sensor
Figure 1 TF Entry and Assist Gate Sensors
Replacement
Reverse the removal procedures to replace the front door and top cover interlock switches and Replacement
the top access cover sensor. Reverse the removal procedures to replace the entry and assist gate sensors.

REP 12.79-171 Tri Folder Exit Sensor REP 12.80-171 Tri Folder PWB
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the Tri Folder top cover, REP 12.67-171.
2. Remove the exit sensor, Figure 1.
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the tri folder
PWB.
1. Remove Tri Folder rear cover, REP 12.67-171.
1
Disconnect the harness and
remove the exit Sensor
Figure 1 Tri Folder Exit Sensor
Replacement
Reverse the removal procedures to replace the exit sensor.

2. Remove the PWB, Figure 2. REP 12.81-171 Tri Folder Main and Bin 2 Tray Harnesses
Removal
WARNING
WARNING
1 from the customer supply, while performing tasks that do not need electricity. Electricity
Disconnect all con- can cause death or injury. Moving parts can cause injury.
nectors from the 1. Remove the Tri Folder rear cover, REP 12.67-171. If removing the TF main harness,
PWB remove the HVF rear cover, REP 12.1-171.
2. Disconnect the PJs and remove the main and Bin 2 tray harnesses, Figure 1.
2
Remove 4 screws,
then the PWB.
Figure 2 Tri Folder PWB
Replacement
Reverse the removal procedures to replace the Tri Folder PWB.

REP 12.82-171 Inserter Undocking
Removal
WARNING
WARNING
CAUTION
Place the Inserter on a suitable surface. Do not damage the Inserter locating pins.
TF Main Harness
Bin 2 Harness CAUTION

Do not show the customer how to undock or dock the Inserter.
1. Open the HVF front door.
2. Undock the inserter, Figure 1.
Bin 2 Harness PJ
Figure 1 TF Main and Bin 2 Tray Harnesses
Replacement
Reverse the removal procedures to replace the main and bin 2 tray harnesses.

REP 12.83-171 Inserter Front and Rear Covers
2 Removal
Lift the inserter vertically
from the HVF and put it on a
suitable surface. WARNING
WARNING
1. Undock the Inserter and put it on a suitable surface, REP 12.82-171.
2. Remove the front and rear covers, Figure 1.
1 2
Move the white latch handle Release the upper tab, then the side
to the rear. tab. Remove the front cover.
Locating Pins
Upper tab
Figure 1 Tray 6 Inserter Undocking
Replacement Upper tab

1. Reverse the undocking procedure to dock the Inserter unit to the HVF.
2. Lock the Inserter onto the HVF by sliding the latch handle towards the front, Figure 1.
1 Side tab
Remove 1 screw
4
Release the upper
3 tab, then the side
Remove 1 screw tab. Remove the
rear cover.
Figure 1 Inserter Front and Rear Covers
Replacement
Reverse the removal procedures to replace the Inserter front and rear covers.

REP 12.84-171 Inserter Motor REP 12.85-171 Inserter PWB
Removal Removal
WARNING WARNING
WARNING
1. Remove the Inserter rear cover, and open the top left door, REP 12.83-171.
2. Remove the inserter motor and bracket, Figure 1.
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the inserter
PWB.
WARNING
1. Remove the inserter rear cover. REP 12.83-171.
1
Disconnect motor 3
harness 2 Remove motor and
Remove 3 screws bracket
Figure 1 Inserter Motor
Replacement
1. Reverse the removal procedures to replace the Inserter motor.
2. Make sure that the correct screws are used to replace the inserter motor.

2. Remove the inserter PWB, Figure 2. REP 12.86-171 Inserter Clutch
Removal
WARNING
WARNING
1. Remove the Inserter rear cover. REP 12.83-171.
2. Remove the inserter clutch, Figure 1.
NOTE: The reverse roll drive idler and the drive belt are not attached to the clutch bracket
or the Inserter frame.
2
Remove 4 screws, then the bracket.
3
Remove the inserter 2 1
PWB Remove 4 screws Disconnect all the PJs from
and release the the PWB
ground strap
Figure 2 Inserter PWB

3
Replacement Disconnect the con-
1. Reverse the removal procedures to replace the Inserter PWB. nector, then remove
the inserter clutch
2. Ensure that the ground strap is secured by one of the fixing screws.
1
Remove the E-clip
and bearing.
Reverse roll drive
belt
FOR CLARITY
INSERTER MOTOR
Reverse roll drive Reverse roll drive
NOT SHOWN
idler pulley
Figure 1 Inserter Clutch Removal

Replacement REP 12.87-171 Inserter Top Cover Interlock Switch
1. Reverse the removal procedures to replace the Inserter clutch. Parts List on PL 12.305.
2. When replacing the bracket, check that the clutch torque arm locates in the locating tab.
Removal
3. Put the reverse roll drive belt over the drive idler and check that the reverse roll idler gear
shaft locates properly into the frame.
4. When the bracket is secured, temporarily remove the circlip and the reverse roll drive pul- WARNING
ley to replace the drive belt over the reverse roll drive pulley.
WARNING
1. Remove the Inserter front cover, REP 12.83-171.
2. Remove the top cover interlock switch, Figure 1.
1
Disconnect the harness.
2
Remove 2 screws, then
remove the switch.
Figure 1 Top Cover Interlock Switch
Replacement
Reverse the removal procedures to replace the Inserter top cover interlock switch.

REP 12.88-171 Inserter Jam Cover Interlock Switch 3. Remove the top cover door and the interlock switch, Figure 1.

3 2 1
Removal Remove 2 screws from
Remove 2 latch Remove the
the rear. rear pivot screw,
pins.
then the top
WARNING cover.
WARNING
1. Remove the Inserter front and rear covers, REP 12.83-171.
2. Remove the inserter motor, REP 12.84-171.
5
Release the cable harness
clips and lift the top inside
cover
4
Remove 2 screws
from the front.
6
Remove the jam cover
interlock switch.
Figure 1 Jam cover Interlock Switch
Replacement
1. Reverse the removal procedures to replace the jam cover interlock switch.
2. When reinstalling the top inside cover and the top cover door make sure that the correct
screws are used and that the screws are not overtightened.

REP 12.89-171 Main Tray and Paper Length Sensors REP 12.90-171 Bottom Tray and Paper Sensors
Removal Removal
WARNING WARNING
WARNING WARNING
1. Pull the lug on one side of the tray to disconnect from the frame pivot. Remove the cover 1. Undock the Inserter, REP 12.82-171.
plate then disconnect the PJs and remove the sensors from the bracket clips, Figure 1 2. Remove the bottom tray sensor bracket, Figure 1.
3
Remove the rele-
vant paper length-
sensor.
2
Remove 2 screws,
then the cover plate.
1
Pull the lug on one side of the
tray to disconnect from the
frame pivot.
Figure 1 Main Tray Assembly
Replacement
Reverse the removal procedures to replace the Inserter main tray and paper length sensors.

NOTE: Observe the position of the two springs when lifting the bottom tray. REP 12.91-171 Inserter Top Cover and Inserter Pickup
Sensor
3 Parts List on PL 12.310.
Remove the pivot shaft
Removal
2
Remove the
circlip and WARNING
bearing
WARNING
Paper width 1. Remove the Inserter Front Cover, REP 12.83-171.
sensors 2. To release the top cover, remove the pivot screw, Figure 1.
3. Remove the inserter pickup sensor, Figure 1.
Top cover pivot screw 1

Release the guide
from the top cover
Paper present
sensor.
4
the sensor bracket. 1
Release the front and rear pivot 2
5 tabs and lift the bottom tray.
Remove the relevant Remove the screw
sensor
3
Figure 1 Bottom Tray and Sensors
4
Replacement Release the sensor from
1. Reverse the removal procedure to replace the bottom tray and paper sensors. the bracket
2. Check that the loading levers are at the same angle and that the tray pivot shaft passes
below the front and rear loading levers. Check that the bottom tray is supported horizon-
Figure 1 Cover and Inserter Pickup Sensor
tally in the frame.
3. Make sure that the bottom tray springs are correctly aligned before engaging the front and Replacement
rear pivot tabs. Reverse the removal procedure to replace the inserter pickup sensor and top cover.

REP 12.92-171 Lower Jam Cover and Acceleration Sensor REP 12.93-171 Inserter LE and TE Sensors
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the front and rear covers, REP 12.83-171. 1. Remove the Inserter front and rear covers, REP 12.83-171.
2. Remove the acceleration sensor. Figure 1. 2. Remove the inserter motor, REP 12.84-171.
3. Remove the pickup roll assembly, REP 12.95-171.
4. Remove the top cover, REP 12.91-171.
5. Remove the top inside cover, REP 12.88-171.
3
Disconnect the harness and
remove the acceleration
sensor.
2
1 Remove 2 screws and
Remove the front lift the inner cover
and rear door stop
and door pivot
screws
Figure 1 Acceleration sensor
Replacement
Reverse the removal procedure to replace the Inserter lower jam cover and the acceleration
sensor.

6. Remove the LE sensor or TE sensor, Figure 1. REP 12.94-171 Inserter Bottom Plate Sensor
Removal
Idle Roll Assembly

WARNING
WARNING
1. Undock the Inserter, REP 12.82-171, and release the front and rear pivot tabs then lift the
bottom tray. Control the movement of the bottom tray springs.
2. Remove the sensor from the bracket, Figure 1.
1
Release the har-
ness clips
3 2 Bottom Tray
Disconnect the harness, Remove 1 screw, then
then remove the relevant the sensor bracket.
sensor.
Figure 1 LE and TE Sensors
Replacement
Reverse the removal procedure to replace the LE and TE paper path sensors. 1
Disconnect Tray down
the harness. sensor
2
Remove the sensor from the
bracket.
Figure 1 Inserter Tray Down Sensor
Replacement
Reverse the removal procedure to replace the Inserter bottom plate sensor.

REP 12.95-171 Inserter Pickup Assembly and Reverse
Feed Roller Link Arm
Parts List on PL 12.310 2
Removal Remove the
plastic clip.
1
Raise the inserter top
WARNING cover.
WARNING
1. Remove the pickup roller assembly from the inserter, Figure 1.
3
Pull the pickup roller assembly towards the 4
front to disengage the roller shaft from the Disengage the shaft from the drive
drive coupling and the link arm. coupling and remove the pickup
roller assembly
Figure 1 Pickup roller assembly removal

2. Remove the reverse roller and coupling from the reverse roller shaft, Figure 2. REP 12.96-171 HVF Fixed and Adjustable Casters
For clarity the top
1
cover is not shown. Release the tab Removal
then remove the
retard cover.
WARNING
WARNING
CAUTION
Do not remove more than one caster at a time unless the HVF frame is properly supported and
stable.
NOTE: The HVF weight is 82kg (181lbs), the HVF BM weight is 109kg (240lbs).
1. If installed undock the Tri Folder from the HVF, REP 12.99-171.
2. If installed, Undock the inserter from the HVF, REP 12.82-171.
3. Undock the HVF from the copier and remove the HVF front and rear covers, REP 12.1-
171.
2 3 4. Get help to lift and support the HVF frame securely at a position close to where the caster
Remove the clip. Remove the reverse feed roller. is to be removed, GP 16. Support the frame approximately 4 inches (approximately 2
reams of paper) above the floor so that the caster is not supporting the unit.
Figure 2 Reverse roller removal
Replacement
1. Reverse the removal procedure to replace the reverse and the pickup roller assemblies.
2. After replacing the pickup roller assembly close the Inserter top cover fully to engage the
link arm with the pickup roller.
3. If a new inserter pickup assembly is installed, reset the inserter feed count to zero. Refer
to dC135 CRU / HFSI Status.

5. Remove the 2 screws and remove the fixed caster, Figure 1. 6. Support the HVF frame. Remove the screw and stop plate and rotate the caster adjust-
ment wheel to unscrew the caster from the frame, Figure 2.
Stop plate
Figure 1 HVF Fixed Caster Removal

Figure 2 HVF Adjustable Caster Removal
Replacement
Reverse the removal procedure to replace the HVF fixed and adjustable casters.

REP 12.97-171 Pause To Unload PWB Assembly REP 12.98-171 Inserter Idle Roller Assembly
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the front door, front cover and top cover, REP 12.1-171. 1. Remove the Inserter front and rear covers., REP 12.83-171.
2. Remove the pause to unload (PTU) PWB, Figure 1. 2. Remove the inserter motor, REP 12.84-171.
3. Remove the inserter clutch, REP 12.86-171.
4. Remove the top cover assembly, REP 12.91-171.
5. Remove the inside top cover and top left door interlock switch, REP 12.88-171.
Bracket
1 2
Disconnect the harness Remove the pause to
unload (PTU) PWB
Figure 1 Remove the PTU PWB
Replacement
Reverse the removal procedure to replace the PTU PWB.

6. Remove the 2 screws at the rear of the idle roller assembly, Figure 1. 7. Relieve the torsion spring tension by moving the loading lever and remove 3 of the four
front loading bracket screws. Remove the idle roller assembly, Figure 2.
NOTE: Check that the loading gear remains engaged with the loading shaft gear.
1 4
Disconnect the har- Remove the idle roller assembly
ness and release the
harness from the
frame
2
Remove 3 screws
4
Remove 2 screws
Idle roller
assembly
3
Turn the loading bracket to access
the 2 screws in step 4.
4
2 3 Remove 2 screws
Remove the clip Remove the clip 1
and idler gear and driven gear Move the load lever to release the
torsion spring tension Load Lever
Figure 1 Idler Assembly Rear Screws
Figure 2 Idle Roller Assembly
Replacement
Reverse the removal procedure to replace the Idle roller assembly.
Replace the loading bracket screws and check that the front loading lever is at the same angle
as the rear loading lever then tension the torsion spring. The loading tray will not operate cor-
rectly if it is not supported horizontally in the Inserter frame.

REP 12.99-171 Tri-Folder Removal 5. Disconnect the HVF to tri-folder bin 2 tray harness from the tri-folder module, REP 12.81-
171.
Parts List on PL 12.200, PL 12.205 6. Disconnect the tri-folder harness from PJ 553 & PJ 563 on the BM PWB, PL 12.175 Item
Removal 10.
7. Undock the tri-folder from the HVF.
Replacement
WARNING
Reverse the removal procedures to replace the tri-folder module.
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply, while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
2. Remove the tri-folder rear cover, REP 12.67-171.
3. Remove the coupler drive belt, REP 12.68-171.
4. Open the tri-folder front door, then remove the front and rear thumb screws, Figure 1.
Rear thumb screw Front thumb screw
Figure 1 Thumb screw Removal

REP 12.100-171 Ejector Paddle Assembly (W/TAG V-004) NOTE: Ensure that the paddle assembly is correctly oriented to fit onto the plastic locat-
ing tab.
Removal
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply, while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Paddle locating tab

WARNING
1. Rotate the ejector paddle assembly until the two short tabs are visible.
2. Squeeze the two short tabs together and pull to remove the ejector paddle assembly,
Figure 1.
Figure 2 Paddle locating tab
Figure 1 Ejector paddle assembly
Replacement
1. Rotate the paddle shaft to ensure that the locating tab is uppermost, Figure 2.
2. Ensure that the longest paddle is positioned towards the stacker tray.
3. Hold the paddle assembly by the two short tabs and clip onto the shaft.

REP 12.101-171 Paddle Wheel
Removal
WARNING
WARNING
NOTE: This procedure shows the replacement of the paddle wheels with the compiler paddle
unit installed. If necessary, remove the compiler paddle unit before replacing the paddle
wheels. Refer to REP 12.49-171.
1. Rotate the paddle until the two rubber blades are visible.
Figure 1 Paddle removal

CAUTION
To ensure that the correct home position of the paddle wheel shaft is maintained, install the
Replacement
new paddle wheels one at a time.
1. Hold the paddle wheel by the two rubber blades and clip onto the shaft.
CAUTION
Ensure all defective paddles are replaced with a paddle of the same type.The two outer pad-
dles are a different type to the three inner paddles.
2. Squeeze the two rubber blades together and pull to remove the paddle wheel from the
shaft, Figure 1.

REP 12.102-171 Docking Latch Assembly
Removal
WARNING
WARNING
1. Un-dock the HVF or HVF BM, REP 12.13-171.
2. Refer to REP 12.1-171. Remove the following covers:
• Top cover, PL 12.100 Item 1.
• Rear cover, PL 12.100 Item 5.
• Front cover, PL 12.100 Item 2.
• Vent cover, PL 12.100 Item 6.
3. Disconnect the front interlock switches, Figure 1.

3
Disconnect the top cover
interlock switch.
2
Release the harness from the
retainers and cable clamps.
4
Release the harness
from all cable clamps.
1
Disconnect the front door
interlock switch.
Figure 1 Front interlock switches

4. Prepare to remove the docking latch assembly, Figure 2. 5. Remove the docking latch assembly, Figure 3.
2
Release the harness
from all cable clamps.
Put the harness through
the flanged hole.
1
Disconnect PJ112.
2
Remove 2 screws
from the front.
3
1 Remove the docking latch
Remove 2 screws assembly.
from the rear.
Figure 2 Preparation Figure 3 Removal

Replacement
CAUTION
Ensure that the front and rear harnesses are routed through the flanged holes. Refer to Figure
1 and Figure 2.
2. Ensure the 2 screws at the front locate in the correct holes, Figure 4.
1
Secure the front of the latch
assembly using the screw holes
shown.
Figure 4 Latch assembly front screw holes

REP 16.1 Network Controller Software Installation REP 16.2 Network Controller (HDD2) W/O TAG 006
Removal Removal
WARNING WARNING
WARNING WARNING
Replacement 1. Pull out the image processing module.
Refer to GP 4 to install the software. 2. Remove the HDD2 from the underside of the module, Figure 1.
NOTE: The Network controller HDD2 is on the left.
2 1
out the HDD2 and bracket.
Figure 1 HDD2 removal

Replacement REP 16.3 Network Controller PWB
2. Ensure that the bracket locates into the slots on the drawer.
Removal
3. When the install is complete perform an AltBoot to synchronize the network controller
PWB to hard drive, GP 4.
WARNING
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the network
controller PWB.
1. Remove the network controller PWB and copy controller PWB as a unit, refer to REP 3.7.
Replacement
1. Join the network controller and copy controller PWBs together before inserting them into
the image processing module.
3. Perform an AltBoot to synchronize the network controller PWB to hard drive. Refer to GP
4 Machine Software.

REP 62.1 Scanner Module
Remove the scanner module.
Removal
WARNING
WARNING
WARNING
is heavy.
2. Disconnect the user interface harness, PL 2.10 Item 7.
3. Disconnect the ITT video / CCB PWB harness, PL 62.10 Item 13.
4. Disconnect the DADH/IIT power comms harness, PL 62.10 Item 12.
2
WARNING Slide the scanner module off
the 2 docking pins and the 4
Use safe handling procedures when removing the module. Refer to GP 16. The module base retainers.
is heavy.
NOTE: The weight of the scanner is 15Kg (33lb).
5. Remove the scanner module, Figure 1.
NOTE: On earlier machines, the scanner module may be secured in position by docking
latches instead of screws, Figure 1.
Remove the following components if a replacement scanner is to be installed.

1. Remove the scanner rear cover, PL 62.10 Item 14.
2. Remove the scanner side cover, PL 62.10 Item 15. 1
3. Remove the User interface assembly, REP 2.1.
1 On earlier machines, push and hold
Remove 2 screws, then push the latches toward the centre of the
4. Transfer the IIT retaining latch assembly, PL 62.10 Item 17 and PL 62.10 Item 18 or on the scanner to the rear to scanner, then push the scanner to
later machines metal plates to the new scanner module. unlatch it. the rear to unlatch it.
Figure 1 Remove the scanner module

Replacement REP 62.2 Top Cover
1. The replacement procedure is the reverse of the removal procedure. Parts List on PL 62.10
2. If a new scanner module has been installed, perform the following:
Removal
a. dC608 Document Feeder Registration.
b. dC609 Document Glass Registration.
c. Enter dC131 NVM Read/Write. Make sure the following IIT DADH NVM settings are WARNING
set to default: Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
• 801-005. from the customer supply while performing tasks that do not need electricity. Electricity
• 801-010.
• 801-015.
• 801-016. WARNING
• 801-017. Take care during this procedure. Sharp edges may be present that can cause injury.
• 801-018. 1. Remove the DADH, REP 5.19.
• 801-020. 2. Remove the scanner module, REP 62.1.
• 801-021. 3. Remove the top cover, Figure 1.
• 801-022.
1
• 801-023. Remove the scanner
• 801-025. rear cover (2 Screws).
• 801-026.
2
Remove the top cover (5
Screws).
Replacement
2. Perform the following procedures:
• ADJ 62.1 Optics Cleaning (W/O TAG 007) or ADJ 62.5 (W/TAG 007).
• dC609 Document Glass Registration.

REP 62.3 CVT Glass, CVT Ramp and Document Glass 3. Remove the CVT ramp and document glass assembly, Figure 1.
Assembly
1
Removal Remove 2 screws.
WARNING
WARNING
1. Remove the top cover, REP 62.2.
2. Remove the CVT glass, PL 62.10 Item 3.
Corner brackets
3
Remove the document glass
and CVT ramp assembly.
2
Loosen 6 screws and rotate 6 glass clamps away
from the document glass.
Figure 1 CVT glass and document glass assembly
Replacement
2. Ensure that the white AGC strips on the document glass and the CVT glass are at the
front and underside of the glass.
3. Ensure that the document glass is located in the corner brackets, Figure 1. Check that the
CVT ramp is located correctly in the pips on the frame.
4. Perform ADJ 62.1 Optics Cleaning as necessary.
5. If a new document glass assembly has been installed, perform the following:
a. dC608 Document Feeder Registration.
b. dC609 Document Glass Registration.

REP 62.4 Scan Carriage Home Sensor (W/O TAG 007)
Do not remove the document glass.
Removal
Do not loosen the two screws securing the setting plate, shown in Figure 1.
2. Figure 1, remove the scan carriage home sensor.
WARNING
Do not loosen.
WARNING
1. Remove the User Interface assembly, REP 2.1.
3
Disconnect the sensor.
4
Remove the
sensor (1
screw).
1 2
Remove the
Pull forward the sensor
screw.
plate.
Figure 1 Scan carriage home sensor
Replacement
1. Install the sensor on to the sensor plate, ensuring the lugs locate correctly in the slot.
2. Re-connect the sensor.
3. Install the sensor plate. Ensure that the three locating lugs are correctly located in the
slots of the mounting plate.
4. The replacement of the removed components in the reverse of the removal procedure.

REP 62.5 Scan Carriage Assembly (W/O TAG 007) 4. Figure 1. Remove the scan carriage assembly.

1
Removal Remove the PJ cover (2
screws) and disconnect the
scan carriage ribbon cable.
WARNING
WARNING
1. Remove the CVT glass, REP 62.3. Loosen 1 screw,
then slide out
2. Remove the CVT ramp and document glass assembly, REP 62.3. the cable.
3. Disconnect the LED exposure lamps ribbon cable, REP 62.11.
3
Loosen 3 screws, then slide
4 out the cables.
Remove the scan carriage.
Figure 1 Carriage removal

Replacement REP 62.6 Carriage Motor and Mounting (W/O TAG 007)
1. Insert the scan carriage ribbon cable through the securing clamp and the square hole. Parts List on PL 62.16
2. Figure 2. Place the scan carriage assembly centrally over the springs on the scan cables.
Slide the scan cables under the fixing tabs.
Removal
NOTE: Observe the spring position between the fixing tabs on the scan carriage assem-
bly. WARNING
1. Remove the scanner top cover, REP 62.2.
2. Remove the carriage motor cover, (2 screws).
3. Figure 1. Prepare to remove the carriage motor.
1
Scribe round
the bracket.
Fixing tab.
Fixing tab. Spring position.
Figure 2 Alignment of the scan carriage
3. Reconnect the scan carriage ribbon cable.

4. Reinstall the PJ cover.
5. Reconnect the exposure lamp ribbon cable. Ensure that the metal connections face
towards the PWB. Secure the cable clamps.
6. Close the exposure lamp ribbon harness securing clip.
7. Perform ADJ 62.2 Scan Carriage Adjustment.
8. Perform ADJ 62.1 Optics Cleaning Procedure.
2
Remove 3
screws.
4. Remove the scanner harness bracket, PL 62.16 Item 14, to allow access to PJ 929.

5. Figure 2. Remove the carriage motor and mounting. Note the orientation of the bracket REP 62.7 Scan Cables (W/O TAG 007)
and the mounting.
Removal
WARNING
1
Release the wiring and WARNING
disconnect PJ 929.
(Press the top of the PJ)
1. Remove the scan carriage, REP 62.5.
3 2. Remove the scan motor cover, (2 screws).
Remove the mount-
ing (2 screws). 3. Slide the cables off the pulleys or capstan.
4. Remove the springs and lift out the cables.
2
Remove the bracket
(2 screws).
Figure 2 Motor and mounting
Replacement
2. Perform ADJ 62.3 Carriage Motor and Scanner Drive Belt.

Replacement 2. Figure 2. Prepare to install the lower scan cable.
1. Figure 1 shows the general arrangement of the scan cables, when correctly installed. NOTE: The lower scan cable is black and is longer than the upper scan cable.
NOTE: The anchor ball is not installed centrally on the scan cables.
6 turns on NOTE: To assist in holding the scan cables in position, use adhesive tape.
each cable.
short end. long end.

Upper scan
cable.
Lower scan cable.
Note that the springs are in longer, black cable.

the same relative position.
2
Wind three turns below the anchor
point on the capstan.
1
Install the anchor ball in the anchor
point.
3
Figure 1 Scan cable arrangement Use adhesive tape to secure the anchor ball in the anchor point.
Figure 2 Mount lower scan cable on the capstan

3. Figure 3. Install the lower scan cable on the rear pulleys. 4. Figure 4. Prepare to install the upper scan cable.
NOTE: The anchor ball is not installed centrally on the scan cable.
2 3
Install the cable around the left, rear, lower pulley. short end. Use adhesive tape to secure the
anchor ball in the anchor point.
long end.
1
Wind three turns above the
anchor point.
1
Install the anchor ball in the
anchor point.
2
Wind three turns below the
anchor point on the capstan.
3
Install the cable around the
right, rear, lower pulley.
Figure 3 Installation of the lower scan cable
Figure 4 Mount upper scan cable on the capstan

5. Figure 5. Install the lower scan cable. 6. Figure 6. Prepare to install the upper scan cable.
1
Wind three turns above the
anchor point.
1
Attach the spring to
the cable.
2 3
Install the cable around Install the cable over the front,
the front, left pulley. right pulley.
Figure 5 Installation of the lower scan cable Figure 6 Installation of the upper scan cable

7. Figure 7. Prepare to install the upper scan cable on the pulleys. 8. Figure 8. Install the upper scan cable.
1
Install the cable around the left
3
rear, upper pulley. Place the cable round the pulley.
2
Attach the spring to the cable.
1
Lift off the right, rear
upper pulley (1 circlip).
5
Reinstall the circlip.
4
Install the pulley on to the shaft.
Figure 7 Installation of the upper scan cable Figure 8 Installation of the upper scan cable
9. Remove the adhesive tape used to secure the anchor balls in the anchor points.
10. Reinstall the scan carriage, REP 62.5.
11. Perform ADJ 62.2 scan carriage assembly.
12. Reinstall the CVT glass and document glass, REP 62.3.
13. Reinstall the scanner top cover, REP 62.2.
14. Reinstall the scan motor cover, (2 screws).
15. Reinstall the scanner module, REP 62.1.
16. Reinstall the DADH, REP 5.19.

REP 62.8 Scan Drive Belt (W/O TAG 007) NOTE: When removing the scan cables from the pulleys, it is not necessary to lift out the
cables from the scanner.
4. Remove the scan cables from the pulleys, REP 62.7.
Removal
5. Remove the scan drive belt, Figure 2.
WARNING
WARNING
1. Remove the scan carriage assembly, REP 62.5.
2. Remove the scan motor, REP 62.6.
3. Secure the scan cables, Figure 1.
1
Remove the scan drive
belt from the capstan.
Insulation tape.
2
1 Carefully thread the scan drive belt over the scan cables.
Secure the scan cables to Remove the scan drive belt.
the capstan.
Figure 2 Removal of the scan drive belt
Replacement
2. Perform ADJ 62.3 Scanner Motor.
Figure 1 Scan cables and capstan

REP 62.9 Input Module Angle Sensor (W/O TAG 007) REP 62.10 LED Exposure Lamps (W/O TAG 007)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the scanner top cover, REP 62.2. 1. Remove the CVT glass, REP 62.3.
2. Figure 1, remove the input module angle sensor. 2. Remove the CVT ramp and document glass assembly REP 62.3.
2
Depress the actuator
to release the sensor.
3 1
Disconnect the sensor from Remove one screw.
the harness and remove.
Figure 1 Input module angle sensor
Replacement
1. Reverse the removal procedures to replace the input module angle sensor.
2. When replacing the input module angle sensor, ensure that the lugs on the sensor are
located in the slot of the frame before tightening the screw.

3. Figure 1. Remove the LED exposure lamp(s). REP 62.11 Exposure Lamp Ribbon Harness (W/O TAG 007)
2 Removal
Remove 1
screw and
clip. WARNING
WARNING
Remove 1 screw and clip. 1. Remove the CVT glass, REP 62.3.
1 1 2. Remove the CVT ramp and document glass assembly REP 62.3.
Disconnect the ribbon harness. Disconnect the ribbon harness.
3. Remove the scanner PWB cover, PL 62.16 Item 9 (three screws).
4. Disconnect the exposure lamp ribbon harness, PJ926 on the scanner PWB, PL 62.16
Item 8.
3
Remove the LED
exposure lamp(s).
Figure 1 Removal of the LED exposure lamps
Replacement
2. Ensure that the ribbon harness is routed flat on the under side of the scan carriage to
avoid rubbing on the scanner PWB cover. Refer to Figure 1.
3. Perform ADJ 62.1 Optics Cleaning.

5. Figure 1. Remove the exposure lamp ribbon harness. Replacement
2. Ensure that the ribbon harness is routed flat on the under side of the scan carriage to
avoid rubbing on the scanner PWB cover. Refer to Figure 1.
1
If necessary, carefully
move the scan carriage
assembly to the left.
3
Remove the harness.
Scan carriage
assembly
2
Carefully lower the
securing clip bar.
Figure 1 Removal

REP 62.12 Scanner PWB (W/O TAG 007) REP 62.13 Scan Carriage Ribbon Cable (W/O TAG 007)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the CVT glass, REP 62.3.
2. Remove the CVT ramp and document glass assembly REP 62.3.
3. Remove the scanner PWB cover, PL 62.16 Item 9.
4. Prepare to remove the scan carriage ribbon cable, PL 62.15 Item 4.
5. Figure 1. Remove the scan carriage ribbon cable.
Figure 1 ESD Symbol
4 5
Disconnect the scan Remove the scan
CAUTION carriage ribbon cable, carriage ribbon
PJ928. cable.
Ensure that ESD procedures are observed during the removal and installation of the scanner PWB.
1. Remove the document glass, REP 62.3.
3. Remove the scanner PWB cover, PL 62.16 Item 9.
4. Disconnect all of the harness connectors from the scanner PWB, PL 62.16 Item 8.
5. Remove four screws securing the scanner PWB.
6. Remove the scanner PWB.
Replacement
3. If a new scanner PWB has been installed, enter dC131 NVM Read/Write. Make sure the
following IIT DADH NVM settings are set to default:
• 801-005.
• 801-010.
• 801-015.
• 801-016.
• 801-017.
• 801-018.
• 801-020.
3 2 1
• 801-021. Disconnect the scan Remove the
Release two harness
• 801-022. carriage ribbon cable. connector cover.
retainers
• 801-023.
• 801-025.
• 801-026. Figure 1 Ribbon cable removal

Replacement REP 62.14 Document Size Sensor 1 and Document Size
Sensor 2 (W/O TAG 007)
CAUTION Parts List on PL 62.16
Take care when replacing the scan carriage ribbon cable. The scan carriage ribbon cable is
Removal
easily damaged.
2. Perform ADJ 62.1 Optics Cleaning. WARNING
WARNING

3. Figure 1. Remove document size sensor 1 (Q62-251). REP 62.15 Scan Carriage Home Sensor (W/TAG 007)
NOTE: The removal of document size sensor 1 (Q62-251) is shown. The removal of doc- Parts List on PL 62.17
ument size sensor 2 (Q62-253) is identical.
Removal
3 WARNING
Remove the document size sensor. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
2
Remove 1 screw. WARNING
1
Disconnect the Take care during this procedure. Sharp edges may be present that can cause injury.
harness. 1. Remove the top cover, REP 62.2.
CAUTION
Do not loosen the two screws securing the setting plate, shown in Figure 1.
2. Prepare to remove the scan carriage home sensor, Figure 1.
1
Peel back the tape
Figure 1 Removal
Replacement
2. Perform ADJ 62.1 Optics Cleaning. 2
Remove 2 screws and pull the sensor
bracket forward.
Do not loosen

3. Remove the scan carriage home sensor, Figure 2. REP 62.16 Carriage Motor (W/TAG 007)
Removal
Locating lug
WARNING
Disconnect harness
1. Remove the scanner top and rear cover, REP 62.2.
2. Mark the position of the motor bracket and remove the motor, Figure 1.
2
Remove screw to release
the sensor
3
Remove sensor
Figure 2 Remove sensor
Replacement
1. Install the sensor on to the sensor plate, ensuring the lugs locate correctly in the slot.
2. Re-connect the sensor, Figure 2.
3. Install the sensor plate. Ensure that the locating lug is correctly located in the slot on the
mounting plate, Figure 2.
3 2 1
Disconnect the motor Scribe a line round the
Remove 3 screws.
harness and remove the motor bracket.
motor.
Figure 1 Remove the motor
Replacement
2. Align the motor bracket with the scribe line on the base of the scanner, Figure 1.

REP 62.17 Exposure Lamp Inverter (W/TAG 007) 4. Remove the exposure lamp inverter, Figure 2.

Removal
WARNING
2. Remove the CVT ramp and document glass assembly, REP 62.3.
3. Release the exposure lamp inverter, Figure 1.
3
Remove the exposure
lamp inverter
2
Note the orientation of the ribbon
harness and the position of the
1 blue stripe.
Disconnect the lamp and ribbon
harness
Figure 2 Remove the inverter
2
Place fingers under the carriage to hold
the cable clamp, then release the 3 clips
from above while pulling the clamp down
1
Remove 2 screws
Figure 1 Release the inverter

Replacement REP 62.18 Exposure Lamp (W/TAG 007)
1. Reverse the removal procedure to replace the exposure lamp inverter. Parts List on PL 62.18
2. When re-connecting the ribbon harness, the blue band printed on the harness must face
as shown in Figure 3.
Removal
3. Ensure the ribbon harness is folded correctly in the harness clamp, Figure 3. Engage two
of the harness clamp clips in the carriage holes. Bend the clamp to engage the third clip.
WARNING
WARNING
3. Manually move the full rate carriage to a central position.
4. Remove the exposure lamp with the end blocks, Figure 1.
Blue tab on ribbon

harness
3
Release the lamp
mounting block from
the carriage at both
ends. Remove the lamp
and end blocks
Figure 3 Ribbon harness
1
Disconnect the lamp harness
from the lamp inverter.
2
Press the catch and slide the
mounting block upwards at both
ends of the lamp
Figure 1 Releasing lamp fasteners

5. Remove the end blocks from the exposure lamp, Figure 2. REP 62.19 Exposure Lamp Ribbon Harness (W/TAG 007)
Removal
WARNING
Slide the end block from the customer supply while performing tasks that do not need electricity. Electricity
from the lugs can cause death or injury. Moving parts can cause injury.
WARNING
3. Remove four screws securing the scanner PWB cover, lift the cover and disconnect
PJ923 on the scanner PWB, PL 62.16 Item 9.
2 4. Disconnect the ribbon harness from the exposure lamp inverter, REP 62.17.
Remove the end block from the
other end of the exposure lamp 5. Release the ribbon harness from the half rate carriage.
Figure 2 Removing end blocks
Replacement
Reverse the removal procedure to replace the exposure lamp.

6. Disconnect and remove the exposure lamp ribbon harness, Figure 1. REP 62.20 Input Module Angle Sensor (W/TAG 007)
Removal
WARNING
WARNING
1. Remove the scanner top cover and rear cover, REP 62.2.
2. Remove the input module angle sensor, Figure 1.
2
Depress the actuator
to release the sensor.
1 2 3
Remove 4 screws, 2 on Disconnect ribbon Lift the lens carriage and
each side of the lens car- harness at PJ 926 release the ribbon harness.
riage assembly.
Figure 1 Release the ribbon harness
Replacement
3 1
Disconnect the sensor from Remove one screw.
the harness and remove.
Figure 1 Input module angle sensor
Replacement
1. Reverse the removal procedures to replace the input module angle sensor.
2. When replacing the input module angle sensor, ensure that the lugs on the sensor are
located in the slot of the frame before tightening the screw.

REP 62.21 Scanner PWB (W/TAG 007) REP 62.22 Document Size Sensor 1 and Document Size
Parts List on PL 62.17 Sensor 2 (W/TAG 007)
Removal Parts List on PL 62.17 Item 14
Removal
WARNING
WARNING
can cause death or injury. Moving parts can cause injury. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the scanner PWB.
4. Disconnect all of the harness connectors from the scanner PWB, PL 62.17 Item 1.
5. Remove four screws securing the scanner PWB.
6. Remove the scanner PWB.
Replacement
3. If a new scanner PWB has been installed, enter dC131 NVM Read/Write. Make sure the
following IIT DADH NVM settings are set to default:
• 801-005.
• 801-010.
• 801-015.
• 801-016.
• 801-017.
• 801-018.
• 801-020.
• 801-021.
• 801-022.
• 801-023.
• 801-025.
• 801-026.

4. Remove document size sensor 1 (Q62-251) or document size sensor 2 (Q62-253), Figure 1. REP 62.23 Scan Cables (W/TAG 007)
NOTE: The removal of document size sensor 1 and document size sensor 2 is identical. Parts List on PL 62.18
Removal
Size sensor 1
Q62-251
WARNING
WARNING
Size sensor 2 Take care during this procedure. Sharp edges may be present that can cause injury.
Q62-253
CAUTION
When moving the scan carriages, hold them by the metal parts only, to avoid damaging the
lamp or mirrors.
2 1 PJ923 on the scanner PWB, PL 62.17 Item 13.
Remove the document size sensor. Disconnect the harness from
Press the side of the sensor to the document size sensor.
release the sensor from the bracket
Figure 1 Remove document size sensor.
Replacement

5. Figure 1 shows the arrangement of the scan cables. Refer to this Figure 1 when installing
the cables.
Capstan
Inboard (silver cable)
Anchor balls Half rate scan

pulleys
End balls
Full rate carriage

clamps
Capstan
Outboard (dark cable)

Half rate scan
pulleys
Fixed pulley
Fixed pulley
Tab to secure the

spring to the frame
Figure 1 Scan cables arrangement

6. Move the full rate carriage to the position shown in Figure 2, with the exposure lamp at the 8. Unhook the tension spring from the outboard cable. Remove the spring from the cable
right end of the frame. Mark the position of the half rate carriage. The anchor balls should and store the spring for later use.
be in the position shown in Figure 2. 9. Remove the outboard cable completely by unhooking the end ball from its retaining
bracket and unwind the cable from the capstan.
10. Repeat steps 6 and 7 for the inboard cable.
Replacement
2 NOTE: The replacement procedure is made easy by holding the windings on the capstan in
Anchor ball position place with tape at all times, until each cable is fully installed. Keep the cable tight to prevent it
on the capstan unwinding.
1. Prepare several short lengths of adhesive tape.

2. If necessary, rotate the capstan to bring the anchor ball recess to the top and slightly to
the right. Check that the half rate carriage is in the start position, as in Figure 2.
3. Place the outboard, dark cable in the position shown in Figure 3. Hold in place on the cap-
stan with adhesive tape.
Inboard
End ball
1
Move the full and half rate carriage to position the
anchor ball on the capstan in the correct position.
Figure 2 Carriage start position Dark cable

Outboard
7. Remove the cable clamps, with captive screws, from the full rate carriage. Move the
cables clear of the carriage and lift the carriage out of the frame. Rest the carriage out of Figure 3 Winding start position
the way of the cables. It is not necessary to disconnect the ribbon cable. Store the cable
clamps for later use.

4. Starting with the end-ball end of the cable, wind on three turns, stopping at each turn to
hold the cable to the capstan with adhesive tape. If necessary, use a fresh length of adhe-
sive each time to ensure the cable is held tightly. Inboard
5. Hold the capstan in position and tape the drive shaft to the top of the scanner frame on
the left. This is to prevent the capstan turning while the cable end is placed in position.
6. Wrap the cable over the half rate scan carriage pulley, as shown in Figure 1, and back to
the end ball holding bracket. If the winding is correct, the end ball will fit tightly onto the
bracket.
7. Wind the loop end of the cable round the capstan three times, as shown in Figure 1, stop-
ping at each turn to hold the cable to the capstan with adhesive tape. If necessary, use a
Cable
fresh length of adhesive each time to ensure the cable is held tightly.
8. Wrap the cable round the fixed pulley as shown in Figure 1, and back round the half rate
scan pulley.
9. Attach the spring to the cable loop and hook the spring to its tab on the frame.
10. Remove the tape from the capstan and from the drive shaft. Ensure all tape is removed
from the area.
11. Repeat steps 2 to 10 for the inboard cable.
12. Fit the full rate carriage and position the ribbon cable round the guide on the half rate car-
riage. Cable
13. Slide both carriages fully to the right, and install the cable clamps so the cable are under
the clamps as shown in Figure 4.
Outboard
Figure 4 Cable clamps
14. Hold the carriages fully to the right and tighten the clamps.
15. Move the carriages from one end to the other to ensure the windings are straight and
even.
16. Reinstall the DADH, REP 5.19.
17. Reinstall the CVT glass and document glass,REP 62.3.

REP 62.24 Scan Idler Pulley (W/TAG 007) 4. Remove the scan idler pulleys, Figure 1.
Parts List on PL 62.18. NOTE: Figures 1 & 2 show the rear scan idler pulley, the procedure for the front scan idler
pulley is similar.
Removal
WARNING
2
Hold the tension in the cable and
slide the pulley off of the shaft
WARNING
3. Carefully move the full rate carriage to the left side of the scanner module.
1
Remove 3
the E-clip Maintain the tension in the cable and
remove the pulley from the cable loop
Figure 1 Scan idler pulley removal

Replacement REP 62.25 Platen Down Sensor (W/TAG 007)
1. Reverse the removal procedure to replace the scan idler pulleys. Figure 2, install the scan Parts List on PL 62.17.
idler pulleys.
Removal
1
Maintain the tension in the WARNING
cable and place the pulley Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
in the cable loop from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
2. Remove the user interface assembly, REP 2.1.
3 2
Install the E-clip Slide the pulley onto the shaft
Figure 2 Scan idler pulley replacement

4. Remove the platen down sensor, Figure 1. REP 62.26 IIT Video / SBC PWB Harness (W/TAG 007)
Removal
WARNING
WARNING
2. Disconnect the IIT video harness from the image processing module, PL 62.10 Item 13.
3. Release the IIT video harness from the support bracket, Figure 1.
1
Remove 2 screws 7. Remove the IIT video harness PJ922 from the scanner PWB, Figure 2.
2
Pull back the tape to
release harness
3
Disconnect harness
1
Figure 1 Remove sensor Release the video harness and clamp
from the support bracket
Replacement
1. The replacement procedure is the reverse of the removal procedure. Figure 1 Release the video harness

REP 62.27 Scan Motor and Scan Carriage Drive Belt (W/
TAG 007)
Removal
WARNING
WARNING
5. Release the securing screws on the scanner motor, REP 62.16.
6. Mark the position of the intermediate drive pulley bracket and remove the securing
screws, Figure 1.
7. Remove the E-clips to release the intermediate drive pulley from the support bracket.
8. To remove the scan motor drive belt
a. Slip the motor drive belt over the intermediate pulley.
9. To remove the scan carriage belt.
a. Slip the scan carriage drive belt over the intermediate pulley.
b. Remove the user interface assembly, REP 2.1.
1
Disconnect video harness 2 3 c. Release the scan carriage drive shaft, Figure 2.
PJ 922 Release the harness Feed the harness d. Move the drive shaft towards the front and slip the scan carriage drive belt over the
clamps through the hole in the
drive shaft, Figure 3.
frame
Figure 2 Disconnect PJ92
Replacement
2. Ensure that the harness is routed correctly and secured in the harness clamps, Figure 2.

2 1
Push the scan drive Remove the E clip
3 shaft in.
2 1
Remove the E clip and Remove 2 screws Scribe round the motor
release the intermedi- bracket.
ate drive pulley
Figure 1 Preparation Figure 2 Release the scan shaft

REP 62.28 Power and Communication Harness (W/TAG
007)
Removal
WARNING
WARNING
2. Disconnect the power harness from the image processing module, PL 62.10 Item 12.
3. Release the power harness from the support bracket, Figure 1.
1 2 3 7. Disconnect all the power and communication PJ’s from the scanner PWB, Figure 2.
Move the scan car- Slip the drive belt over Release the intermediate
riage drive shaft to the the scan carriage pulley. drive pulley and slip the
front. belt over the pulley.
Figure 3 Remove scan belt
Replacement
1
Release the power har-
ness from the support
bracket
Figure 1 Release the power harness

2
1 Un-clip the harness clamps and
Disconnect all the power and communications pass the harness through the rear
PJs from the scanner PWB frame
Figure 2 Disconnect power and comms PJ’s.
Replacement
2. Ensure that the harness is routed correctly and secured in the harness clamps, Figure 2.

REP 70.1 3 Tray Module PWB
Removal
WARNING 1
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Disconnect 8 PJs
2
Remove 7 screws
Figure 1 ESD Symbol
CAUTION
Ensure that ESD procedures are observed during the removal and installation of the 3 tray
module PWB.
1. Remove the (upper) rear cover, PL 81.10 Item 1 and the (lower) rear cover, PL 70.25 Item 8.
2. Remove the 3 tray module PWB, Figure 2.
Figure 2 Remove the 3 tray module PWB
Replacement
2. Perform dC625 Registration / Preheat calibration.

REP 70.2 Upper Left Hand Door Assembly Replacement
Removal CAUTION
When replacing the hinge pin, do not damage the wire harness.
WARNING 2. Make sure that the upper left door assembly is correctly aligned.
WARNING
1. Remove bypass tray feed assembly, REP 81.3.
2. Remove the upper left hand door assembly, Figure 1.
1
Open the door
2
Lift bypass assembly off the hinges
Figure 1 Upper left hand door removal

REP 71.1 Tray 1 and Tray 2 Removal REP 71.2 Tray 1 and Tray 2 Paper Guides
Removal Removal
WARNING WARNING
NOTE: The removal procedure is the same for tray 1 and for tray 2.
CAUTION
1. Remove the paper then remove the tray, REP 71.1.
Do not stack the trays one on top of the other tray. The top tray can damage the bottom tray,
2. To remove the elevate plate assemble, Figure 1.
which cause misfeeds or paper jams.
1. Remove the tray 1 or tray 2, Figure 1.
NOTE: The removal procedure for tray 1 and tray 2 is the same.
2
Lift the plate straight upwards
away from the tray module.
Pull tray out, lift front of tray to remove it
1
Figure 1 Tray 1 and tray 2 removal Lift the plate to an
upright position.
Replacement
The replacement is the reverse of the removal procedure. Make sure that the left tray slide is
located inside the tray stop before inserting the right side of the tray. Refer to Figure 1.
Figure 1 Remove the paper lift plate

3. To remove the paper width guide, Figure 2. 4. Remove the paper width guide and the paper tray, Figure 3.
1 1
Remove 2 pulleys Slide paper length
guide to middle
2
Remove the screw
2
Unhook plastic guide
3
Remove metal guide
4
Slide paper length guide to the opening
and remove the guide through the opening
3
Slide paper width guides to middle and
lift out
Figure 2 Remove the paper width guide Figure 3 Remove the paper length guide
Replacement

REP 71.3 Tray 1 and Tray 2 Lift Gear Assembly 4. Remove the gear assembly, Figure 2.

Removal
WARNING
WARNING
Take care during this procedure. Sharp edges may be present can cause injury.
1. Remove the paper tray, REP 71.1.
2. Remove the paper lift plate, REP 71.2. Quadrant
3. Remove the metal plate, Figure 1.
1
Remove 2 screws
2
Remove 2 screws
2
Remove the gear assembly, quadrant and
the bush behind the quadrant
Figure 2 Lift gear removal
Replacement
Engage the lift gear assembly with the spigots on the rear of the tray. The remainder of the
replacement procedure is the reverse of the removal procedure.
1
Remove E-clip
Figure 1 E-clip removal

REP 73.1 Tray 3 Removal
Removal
WARNING
1. Pull out tray 3.
2. Remove the paper from the tray.
3. Remove the right side cover, PL 70.25 Item 4.
Remove the screw
4. Remove tray 1 and 2, REP 71.1.
5. Remove the screws to release the tray rails, Figure 1.
Remove the screw
Figure 1 Remove tray 3 guide rails
6. Lift and pull to remove the tray complete with the guide rails.

Replacement REP 73.2 Tray 3 Elevator Motor
The replacement is the reverse of the removal procedure. Parts List on PL 73.16
NOTE: When installing tray 3 ensure that the tray rails are located correctly in the base, Figure 2. Removal
WARNING
WARNING
1. Pull out tray 3.
2. Remove the right side cover. PL 70.25 Item 4.
3. Remove the tray 3 motor, Figure 1.
3
Disconnect in-line connector
and connector on sensor.
Locate rail hook in guide hole

1
Remove 2 screws.
Figure 2 Location of the tray rails
2
Remove tray 3 motor and
bracket
Figure 1 Elevator motor removal
Replacement

REP 73.3 Tray 3 Elevator Cables 4. Remove the pulley carriers and pass the cables through the base of the tray, Figure 2.
Parts List on PL 73.15 NOTE: Short cable over the outer pulley and the long cable over the inner pulley.
Removal
Pulley carriers
WARNING
WARNING
NOTE: The elevator drives at the front and at the rear are similar for both trays.
1. Remove tray 3, REP 73.1.
2. Remove the tray 3 front cover, PL 70.25 Item 3 (2 screws from below the cover).
3. Remove the cables from the front drive pulley, Figure 1.
4
Remove the short cable from the
drive pulley.
3 Long cable Short cable

Remove the long cable from the
drive pulley.
Figure 2 Remove front elevator cables
2
Remove the cable gear
shaft spacer.
1
Remove E
clip.
Figure 1 Front elevator cable removal

5. Remove the tray 3 rear elevator cable, Figure 3. REP 73.4 Tray 3 Stack Height Sensor
2 Removal
Remove the metal plate if
fitted
3
Remove the pulley WARNING
carrier Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
4
Remove the drive WARNING
dog and cap
1. Pull out tray 3.
2. Remove Tray 3 paper feed assembly, REP 81.2.
3. Disconnect and remove the stack height sensor, Figure 1.
5
Remove the cable from
the drive pulley.
1
Remove E-clip
6
Pass cable through the
base of the tray
Figure 3 Tray 3 rear cable removal
Replacement
Tray 3 front cables. 2

1 Press the tabs to release the
1. Thread the front short cable (silver) over the inner groove on the pulley Disconnect the harness sensor.
2. Thread the front long cable (yellow) over the outer groove on the pulley.
Tray 3 rear cable.
Figure 1 Stack height sensor
• Thread the rear cable (black) over the inner groove on the pulley.
Replacement

REP 73.5 Tray 3 Home Sensor REP 73.6 Tray 3 Elevator Damper and Gears
Removal Removal
WARNING WARNING
WARNING WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. Take care during this procedure. Sharp edges may be present can cause injury.
The removal procedure is the same for tray 3 and tray 4. 1. Remove tray 3, REP 73.1.
2. To remove the damper from tray 3, Figure 1.
1. Pull out Tray 3
2. Remove the right side cover, PL 70.25 Item 4.
3. Remove the tray 3 home sensor and holder, Figure 1.
1
Disconnect the
harness
2
Remove screw
Figure 1 Tray home switch and holder 2 1

Lift and remove the Remove the screw
Replacement damper
Figure 1 Tray 3 damper

3. To remove the drive gears, Figure 2. REP 75.1 Tray 5 Empty Sensor
Removal
WARNING
Pinch the two sections of the
shaft together and pull off the Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
gears from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
2. Prepare to remove the tray 5 empty sensor, Figure 1.
Figure 2 Remove the gears
Replacement
2. Ensure the gears are correctly aligned, Figure 3.
Align the two gears as shown

and then push the gears onto
the shaft
3
1 2 Lift the upper feed
Disconnect the harness Remove eight screws assembly top cover.
marked A
Figure 3 Install the gears

3. Remove tray 5 empty sensor, Figure 2.
Housing spring position
Figure 4 Spring position
4. Check that the correct screw is used to attach the upper feed assembly top cover.
5. Make sure that the torsion chute spring is positioned on top of the chute upper insert, Fig-
1 ure 5.
Disconnect the harness. 2
Press the tabs to release the
sensor.
Figure 2 Remove tray 5 empty sensor
Replacement
2. Make sure that the torsion nudger spring on the paper feed assembly is in the correct
position, Figure 3.
Locate the torsion nudger

spring under the post.
Figure 3 Spring location
3. Make sure that the housing spring is positioned on top of the takeaway idler roller shaft
Position the torsion chute spring on the
when the upper feed assembly top cover is installed, Figure 4. top of the chute.
6. Check that the harness routing is correct, Figure 1.

REP 75.2 Tray 5 Stack Height Sensor 3. Remove tray 5 stack height sensor, Figure 2.

Removal
WARNING
WARNING
2. Prepare to remove the tray 5 stack height sensor, Figure 1.
Press the tabs to release the sensor
Figure 2 Remove the sensor
Replacement
1

REP 75.3 Tray 5 Down Sensor REP 75.4 Tray 5 Elevator Motor Assembly
Removal Removal
WARNING WARNING
WARNING WARNING
Take care during this procedure. Sharp edges may be present can cause injury. Take care during this procedure. Sharp edges may be present can cause injury.
1. Remove the rear cover, REP 75.8. 1. Remove the paper from the tray.
2. Remove the tray 5 down sensor, Figure 1. 2. Remove the rear cover, REP 75.8.
2 1
Remove sensor from Disconnect the
bracket harness
Replacement

3. Remove the tray 5 elevator motor assembly, Figure 1. Replacement
NOTE: The tray 5 paper tray must be supported before the elevator motor assembly is 1. To help with the installing of a new elevator motor, support the paper tray on two reams of
removed. paper.
2. Make sure that the encoder sensor is position on the elevator motor assembly, Figure 2.
1
4. Check that the harness is routed in the channel on the plastic bracket, Figure 3.
Disconnect:
PJ518 on the
encoder,
PJ530
and
In-line ground Check that the wires in the har-
connectors ness are not trapped and are
free to move
Figure 3 Harness position
5. Ensure that there are no twists in the harness when installing the elevator motor.
6. When the motor is installed, remove the paper supporting the paper tray.
2
5 4 Disconnect the motor
Slide the motor off Remove the 3
connections
the shaft KL clip Release the
cable tie on the
motor
Figure 1 Remove the elevator motor assembly
4. If required remove the encoder sensor from the plastic bracket, Figure 2.
1
Press the tab to release the encoder
sensor
2
Disconnect the harness on
the encoder sensor
Figure 2 Remove the encoder sensor

7. Exercise the elevator motor with one sheet of paper in the tray. Observe that the harness REP 75.5 Tray 5 Upper Limit Switch
tracks properly between the mylar guide and the rear channel. Figure 4.
Mylar guide
Removal
WARNING
Rear channel can cause death or injury. Moving parts can cause injury.
WARNING
1. Remove the rear cover, REP 75.8.
3. Prepare to remove the tray 5 upper limit switch, Figure 1.
1
Remove two screws
Ramp to slide against 2

the mylar, to keep the Remove E-clip
harness in the correct
position
3
Loosen the screw to
release belt tensioner
Figure 4 Location of the harness
8. Check the registration, perform dC625 Registration / preheat Calibration if necessary.
4
Remove two screws

4. Remove the tray 5 upper limit switch and the actuator if required, Figure 2. REP 75.6 Tray 5 Down Limit Switch
Removal
3
Remove screw and
release the spring to
WARNING
remove the actuator Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
2
Remove two
screws and
WARNING
remove switch Take care during this procedure. Sharp edges may be present can cause injury.
1. If the tray must be repositioned, refer to REP 75.4. Disengage the elevator motor from the
tray and move the tray to the required position. Re-engage the elevator motor to hold the
tray.
1 2. Release the paper tray to gain access to the tray 5 down limit switch, Figure 1.
Disconnect harness
Figure 2 Remove tray upper limit switch
Replacement
1
Remove three screws
Tray 5 down limit switch
Figure 1 Release the paper tray

3. Lift the tray to access to the tray 5 down limit switch and the actuator if required, Figure 2. REP 75.7 Un-docking and Docking Tray 5
Removal
WARNING
WARNING
WARNING
2 Remove the E-clip to release Take care not to topple Tray 5. Tray 5 is unstable when undocked from the machine. Do
1 Remove two screws the actuator not show the customer how to undock Tray 5.
Disconnect harness 1. Remove the paper from the tray.
Figure 2 Remove tray 5 down limit switch
Replacement
2. Check that the wires are not trapped when refitting the tray.

2. Engage the transit lock and pull the tray 5 module away from the machine until the lock 3. At the rear of the machine release the latch and pull the tray 5 module away from the
engages, Figure 1. machine, Figure 2.
Press the lever to release

To engage - lift the lever and the latch.
move to the right
Figure 1 Engage transit lock Figure 2 Un-dock the tray 5 module

Replacement 3. Release the transit lock and push the tray 5 module into the docked position against the
machine, Figure 4.
2. Position the tray 5 module and align the docking guides with the machine, Figure 3.
Lift the latch and move to the left to

Align the tray 5 module with the release the lock
docking plate on the machine. Push
the module to dock and lock the tray
5 module to the machine.
Figure 4 Release transit lock
Figure 3 Docking the Tray 5 module
4. Go to ADJ 75.2 Machine to Tray 5 Alignment and complete the adjustment.

REP 75.8 Tray 5 Covers 2. Remove the front or rear cover, Figure 2.

Removal
2
Loosen two screws and
WARNING remove the rear cover.
WARNING
1. To remove the top cover, Figure 1.
1
Rear Remove two screws
Catch located onto

the rear cover
1
Remove two screws at
the front and two at the 2
2 rear Remove the front
Slid the cover to the right to release the post cover
from the frame. Then pull to the front to
release the catch from the rear cover. Figure 2 Front and rear cover
Front
Replacement
2. Check that the top cover is located correctly, Figure 1.
Post located into

the bracket
1
Remove 2 screws
Figure 1 Top cover

REP 75.9 Tray 5 Docking Latch 3. Turn tray 5 onto its end to access the fixing screws on the docking latch main bracket. If
tray 5 has a 11x17 / A3 or 8.5 x 11 / 14 kit, then turn the tray 5 on its side. Figure 2.
Removal
WARNING
WARNING
1. Remove the paper and un-dock the tray 5 module, REP 75.7.
2. Remove the two screws and unhook the spring, Figure 1.
Remove 2 screws
Figure 2 Remove the latch assembly
4. Note the orientation of the latches and then remove the docking latches, Figure 3.
3 1
2 Remove screw
Remove screw Unhook the spring
Remove the fixing screw and

remove the docking latch
Figure 3 Remove docking latch

Replacement REP 75.10 Tray 5 Elevator Rack Assembly
1. The replacement is the reverse of the removal procedure. Parts List on PL 75.68
2. Check that the tabs are located correctly on the base plate when refitting the latch assem-
bly, Figure 4.
Removal
WARNING
WARNING
1. Release the cable clamp from the rear cover, Figure 1.
Check that the tabs are located correctly in the base
Figure 4 Location of the tabs
3. Check that the docking latch spring is located correctly.
1 2
Press the locking clip towards the Slide the cable clamp off the
module. module, in an upwards direction.
Figure 1 Cable clamp
2. Remove any paper from tray 5, then un-dock the module, REP 75.7.
3. Remove the two front door hinge pins, PL 75.60 Item 3, then remove the front door

4. Remove the top, front and rear covers, REP 75.8.
5. Remove the elevator motor assembly, REP 75.4.
6. Remove the frame top brace, PL 75.68 Item 3. 3 4
Remove the elevator motor shaft. Remove the tray assembly from
7. Remove the crash bar, PL 75.68 Item 2. the tray 5 module.
8. Disconnect the transport motor, PL 81.40 Item 2.
9. Disconnect the feed motor, PL 81.40 Item 3.
10. Remove the upper feeder assembly, PL 81.40 Item 1. Refer to REP 82.7.
11. Prepare to remove the tray assembly, Figure 2 and Figure 3.
Access slot
Access slot
1
2 Raise the tray assembly until the rear tray
level drive gear clip and the elevator
1 2 Remove the rear tray level drive gear clip.
motor shaft are in alignment with the
Raise the tray assembly until the tray level drive Remove the front tray level drive gear access slot of the frame.
gear clip is in alignment with the access slot of clip from the elevator motor shaft.
the frame.
Figure 3 Tray assembly rear view
Figure 2 Tray assembly front view
12. Remove the front and rear drive gears, PL 75.68 Item 28.
13. Remove the front elevator rack, PL 75.68 Item 14. Slide the rack upwards within the
frame then lift the rack away from the tray 5 module.

NOTE: Only the front elevator rack has a clearance cut-out to accommodate the tray 5
door switch, Figure 4.
Front elevator rack
1
Ensure the cut-out of the front elevator
rack is orientated towards the tray 5 door
switch.
1 2
Lower the tray. Press the tray down firmly onto the base of the tray 5 module.
Tray 5 door switch
Figure 5 Install the tray
3. Keep the tray assembly against the base of the tray 5 module, then reinstall the elevator
Figure 4 Front elevator rack
motor shaft.
14. Remove the rear elevator rack, PL 75.68 Item 13. Slide the rear elevator rack upwards 4. Raise the tray to ensure that it is in horizontal alignment with the lower feeder assembly,
Figure 6. If necessary remove the elevator motor shaft then repeat the replacement pro-
within the frame, then lift the rack away from the tray 5 module.
cedure from step 2.
Replacement
1. The replacement is the reverse of the removal procedure. Lower feed assembly.
2. After the front and rear drive gears are re-installed ensure that the tray assembly is re-
installed in the same horizontal plane as the base of the tray 5 module, Figure 5.
Tray assembly.
Figure 6 Tray alignment

REP 75.11 Tray 5 Elevator Tray Guides 3. Separate the lift plate from the tray lift top cover, Figure 2.

Removal Remove and turn
over the lift plate
WARNING
WARNING
1. Remove the tray assembly from the tray 5 module, refer to REP 75.10 and perform steps
1 to 11.
2. Remove the infill plate assembly, Figure 1.
1
Remove 5 screws
Figure 2 Tray separation
2 4. Remove the tray 5 elevator harness, Figure 3.

Remove 2
screws 1 2
Remove the Disconnect the
ground screw terminals
3
1 Remove the assembly taking care
Retain the spring using not to lose the spring
a thumb or finger
3
Figure 1 Infill plate assembly removal Release the harness
from the 5 retainers
4
Pass the terminals one at a time
through the frame hole and guide
Figure 3 Harness removal

5. Remove the elevator tray guides, Figure 4.
3
Insert and tighten
2 screws
2
Locate the
retaining plate
dowels in the
locating holes
1
Remove the screw, then
remove the rear elevator 1
2 tray guide Position the spring stop between the spring and the inside end of the cavity
Remove the screw, then remove
the front elevator tray guide
Figure 6 Rear guide assembly install
Figure 4 Elevator tray guides removal
3. The remainder of the installation is the reverse of the removal procedure, refer to REP
Replacement 75.10 and perform the replacement procedure.
1. Re-assemble the elevator tray by reversing the removal steps 3 to 5.

2. Install the rear guide assembly, Figure 5and Figure 6.
3
Position the fix-
ing plate over
the actuator
arm and place
the tongue in
the cutout
1 2
Compress the spring into the cavity and Position the infill plate
retain the spring using a thumb or finger in the tray assembly
Figure 5 Rear guide assembly install

REP 81.1 Tray 1 and Tray 2 Paper Feed Assembly 5. Disconnect the harness from the feed motor as required, Figure 2.

Removal
WARNING
WARNING
1. Remove tray 1 or tray 2 as required, REP 71.1.
2. Remove the rear left cover, PL 70.25 Item 7. Tray 1 feed
3. Remove the lower left door assembly, Figure 1. assembly
harness.
1 Tray 2 feed
Disconnect harness as assembly
required. harness.
Figure 2 Disconnect harness
1
Mark the position of
the hinge.
2
Remove 3 screws.
3
Unlatch and remove the lower
left door assembly.
Figure 1 Lower left door assembly

6. Remove tray 1 or tray 2 feed assembly. Figure 3. REP 81.2 Tray 3 Paper Feed Assembly
1
Tray 1 feed assembly Remove the screws then Removal
the cover
WARNING
WARNING
1. Pull out tray 3.
2. Remove tray 1 and the horizontal transport, REP 82.3.
3. Remove the paper feed assembly, Figure 1.
Tray 2 feed
assembly
2
Remove the screws then slide
the feeder out as required.
Figure 3 Removal
Replacement
2. To install the lower left door assembly. Install the three screws, close the door and align
the hinge with the marking on the frame. Secure the screws and check that the door
opens and closes correctly, Figure 1.
3. If new feed rolls are installed, reset the tray 1 or tray 2 feed count to zero. Refer to dC135
CRU / HFSI Status.
2 1
Push Left, to reveal the harness. Remove the
screw.
Figure 1 Tray 3 feed assembly

4. Disconnect the harness, Figure 2. REP 81.3 Bypass Module
Removal
WARNING
WARNING
CAUTION
Take care when removing the cover. The clips that secure the latch are easily broken.
1. Remove the bypass upper left door cover, Figure 1.
Latch. See CAUTION. 1

remove the top cover
1
Disconnect the harness 5
then slide the feed
Remove the upper
assembly out. left door cover
Figure 2 Disconnect harness 4

Release the top
Replacement clip, then remove
the cover.
1. Install the paper feed assembly and push the tray in slowly.
NOTE: Check that the tray does not touch the feed assembly.
2. If a new feed roll assembly is installed, reset the tray 3 feed count to zero. Refer to dC135
CRU / HFSI Status.
3
Remove 2 screws.
2
Remove 2 screws.
Figure 1 Bypass cover

2. Remove the left cover, PL 81.10 Item 2 4. Release the bypass module, Figure 3.
3. Disconnect the PJ’s, harness clips and harness to nip D solenoid, Figure 2.
4
Disconnect the nip D
solenoid connector.
1
Remove 3 harness clamp 1
screws marked A. Remove 4 screws.
3
Disconnect 2 ground
leads.
2
Disconnect harness
Figure 2 Disconnect harness Figure 3 Bypass module

5. Remove the bypass module, Figure 4. REP 81.4 Tray 1 and Tray 2 Feed Rolls
Removal
WARNING
WARNING
Unhook the module 1. Remove tray 1 or tray 2 as required, REP 71.1.
from the door then
remove the module. 2. Un-clip and release the guide, Figure 1.
1
Lift the bottom of the
assembly away from
the door.
Figure 4 Bypass module

Press the clip to release the guide
Replacement
Figure 1 Release guide

3. Remove tray 1 or tray 2 feed rolls, Figure 2. 3. Ensure that the guide is located correctly on the feeder assembly, Figure 3.
NOTE: The removal procedure is the same for tray 1 or tray 2. The feed and nudger rolls
are the same diameter but the retard roll has a larger diameter.
Ensure that the location lugs

on the guide are positioned
correctly
1
Lift the tab and remove
2 the nudger roll
3 Lift the tab and remove Figure 3 Locate the guide
Lift the tab and remove the retard roll
the feed roll
4. Check the registration, refer to dC625 Registration / Preheat calibration.
Figure 2 Remove the feed rolls 5. When new feed rolls are installed, reset the tray 1 or tray 2 feed count to zero. Refer to
dC135 CRU / HFSI Status.
Replacement
Figure 2. Position the rolls as follows:
• Black roll = retard roll.
• Clear roll = nudger roll.
• Grey roll = feed roll.
2. Make sure that the tabs on the feed roll are located in the drive shaft.

REP 81.5 Tray 3 Feed Rolls REP 81.6 Bypass Tray Feed Rolls
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove tray 3 feed assembly, REP 81.2. 1. Remove the bypass tray cover, refer to REP 81.3.
2. Remove tray 3 feed rolls, Figure 1. 2. Remove the feed rolls, Figure 1.
1 4
Release the guide From underneath the
bypass tray assembly, lift
the tab and remove the
retard roll
2
Lift the tab and remove
the nudger roll
3
4 Lift the tab and remove
Lift the tab and remove the retard roll
the feed roll
Figure 1 Remove the feed rolls
Replacement
• Black roll = retard roll. 3 2 1
Lift the tab and remove Lift the tab and remove Remove 1 screw and
• Clear roll = nudger roll. the feed roll plastic sensor retainer
the nudger roll
Figure 1 Remove feed rolls
2. Make sure that the tabs on the feed roll are located in the drive shaft.
4. When new feed rolls are installed, reset the tray 3 feed count to zero. Refer to dC135
CRU / HFSI Status.

Replacement REP 81.7 Tray 5 Feed Rollers
Figure 1. Position the rolls as follows: Parts List on PL 81.45, PL 81.46
Removal
1. Replacement is the reverse of the removal procedure. WARNING
2. If a new nudger / feed and retard roll are installed, reset the bypass feed count to zero. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Refer to dC135 CRU / HFSI Status. from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
1. Open the tray 5 door and allow the tray to move down.
2. Remove the nudger and the feed roller from the front. Slide the tray 5 module away from
the machine and remove the retard roller, Figure 1.

Replacement
2. Ensure that the tabs on the feed roll are located in the drive shaft.
4. If a new nudger / feed and retard roll are installed, reset the tray 5 feeds count to zero.
Refer to dC135 CRU / HFSI Status.
2
Lift the tab and slide 1
the nudger and feed 1 Lift the tab and slide the retard roll
roll off the drive shaft Lift the guide.
off the drive shaft
Figure 1 Remove the feed rolls

REP 81.8 Tray 1 or Tray 2 Feed Sensor 3. Remove tray 1 or tray 2 feed sensor, Figure 2.

Removal
WARNING
Release the clips and
remove the sensor
WARNING
1. Remove the Tray 1 or tray 2 paper feed assembly REP 81.1,
2. Un-clip and release the guide, Figure 1.
1
Disconnect harness
Figure 2 Remove the feed sensor
Replacement
2. Ensure that the guide is located correctly on the feeder assembly, Figure 3.
Press the clip to release the

guide
Figure 1 Paper guide
Ensure that the location lugs

on the guide are positioned
correctly
Figure 3 Locate the guide

REP 81.9 Tray 3 Feed Sensor 3. Remove tray 3 feed sensor, Figure 2.

Removal 1
Disconnect harness.
WARNING
WARNING
1. Remove tray 3 paper feed assembly, REP 81.2. Release the clips and
remove the sensor
2. Un-clip and release the guide, Figure 1.
Replacement
2. Ensure that the guide is located correctly on the feeder assembly, Figure 3.
1
1 Ensure location lugs on guide
Press tabs to release are positioned correctly.
cover
Figure 1 Release guide
Figure 3 Position the cover

REP 81.10 Bypass Tray Empty Sensor REP 81.11 Tray 5 Feed Sensor
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the bypass tray upper left door cover, PL 70.30 Item 14. 1. Remove the top cover, PL 75.60 Item 10.
2. Remove the tray empty sensor, Figure 1. 2. Prepare to remove the tray 5 feed sensor, Figure 1.
1
Disconnect harness
3
1 2 Lift the upper feed
Disconnect the harness. Remove eight screws assembly top cover.
marked A.
2
Lift arm and remove sensor
Figure 1 Tray empty sensor
Replacement

3. Remove tray 5 feed sensor, Figure 2. 3. Make sure that the housing spring is positioned on top of the takeaway idler roller shaft
when the upper feed assembly top cover is installed, Figure 4.
Housing spring position

2 4. Make sure that the torsion chute spring is positioned on top of the chute upper insert, Fig-
Press the tabs to release the
sensor ure 5.
Figure 2 Remove the feed sensor
Replacement
2. Make sure that the torsion nudger spring on the paper feed assembly is in the correct
position, Figure 3.
Locate the torsion nudger

spring under the post
Figure 3 Spring location
Position the torsion chute spring on the

top of the chute
5. Check that the correct screw is used to attach the upper feed assembly top cover.

REP 81.12 Tray 5 Feed Motor REP 81.13 Nip D Release Solenoid
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the rear cover, PL 75.60 Item 9. 1. Remove the upper left door cover, PL 70.30 Item 14.
2. Remove tray 5 feed motor, Figure 1. 2. Remove the bypass top cover, PL 70.30 Item 9.
3. Remove the nip D release solenoid, Figure 1.
1
the nip release link arm.
NOTE: There is a spring
under the link arm.
1
Remove two screws
2
3
Remove the motor
2
3 Remove the 2 screws and
Disconnect the harness, ground lead.
then remove the nip D
release solenoid.
Figure 1 Remove the feed motor Figure 1 Solenoid removal
1. The replacement is the reverse of the removal procedure. 1. The replacement is the reverse of the removal procedure.

REP 82.1 3 Tray Module Transport Motor 3. Separate the 3 tray transport motor and transport motor bracket, Figure 2.

Removal
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity 3 Tray transport motor
WARNING
Drive coupling
2. Remove the 3 tray transport motor with the transport motor bracket, Figure 1.
NOTE: It is important to mark the position of the transport motor bracket before removal.
6 1
Remove the bracket with 5 Remove 2 screws.
the transport motor. Remove 4 screws. 4
Remove screw and
ground wire.
2 Transport motor bracket

Remove the 3 tray transport motor from
the transport motor bracket.
Figure 2 Transport motor removal
Replacement
3
Loosen the belt 2. Assemble the 3 tray transport motor with the transport motor bracket, Figure 2.
tension screw. 3. Relocate the drive belt onto the 3 tray module transport motor.
4. Refer to Figure 2. Ensure the drive coupling of the transport motor bracket engages cor-
rectly with the coupling on the 3 tray module transport assembly, PL 81.35 Item 8.
5. Ensure that the motor is aligned with the mark, Figure 1.
6. After completing the replacement procedure, perform the dC625 Registration / Preheat
calibration.
1 2
Disconnect harness. Mark the position of the motor
bracket.
7
Disengage the drive belt from the transport
motor, tensioner and pulleys.
Figure 1 Transport motor and bracket

REP 82.2 3 Tray Module Transport Drive Belt REP 82.3 Tray 3 Horizontal Transport Assembly
Removal Removal
WARNING WARNING
WARNING WARNING
2. Remove the 3 tray module transport motor, REP 82.1. CAUTION
3. Remove the transport drive belt, Figure 1. Take care when removing tray 3 support bracket from its snap in mounting.
1. Remove tray 1, REP 71.1.
2. Remove horizontal transport assembly, Figure 1
1
Remove the transport
drive belt.
Figure 1 Transport drive belt Pull out the horizontal transport assembly
Replacement Figure 1 Remove transport assembly
1. Reverse the removal procedure to replace the transport drive belt.

Replacement
calibration.

REP 82.4 Tray 3 Horizontal Transport Rolls
Removal
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity 2
can cause death or injury. Moving parts can cause injury. Remove the bearing,
drive gear and belt.
WARNING 1
Take care during this procedure. Sharp edges may be present that can cause injury. Remove the E-clip.
1. Remove the tray 3 horizontal transport assembly, REP 82.3.
2. Prepare to remove the transport rolls, Figure 1.
1
Remove the E-
clip and bearing.

3. Remove the takeaway rolls, Figure 2. REP 82.5 Tray 5 Transport motor
Removal
WARNING
WARNING
Remove the transport rolls 1. Remove the rear cover, REP 75.8.
from the tray 3 horizontal
2. Remove the drives plate, Figure 1.
1 transport.
Move the transport
rolls to the rear.
1
Figure 2 Remove the transport rolls Remove two screws
Replacement 2
Replacement is the reverse of the removal procedure. Remove E-clip
3
Loosen the screw to
4
Remove 2 screws
5
Disconnect both motor
harnesses
Figure 1 Remove the drives plate

3. Remove tray 5 transport motor, Figure 2. REP 82.6 Tray 5 Transport Drive Belt
Ground wire Removal
WARNING
WARNING
2. Prepare to remove the drive belt, Figure 1.
2
Remove the motor 1 1
Remove two screws Remove two screws
Figure 2 Remove the transport motor

2
Remove E-clip
Replacement
2. Ensure that the ground wire terminal is located under the motor securing screw, Figure 2.
3
Loosen the screw to
4
Remove two screws
5
Release the motor assembly from the drive belt

3. Remove the transport drive belt, Figure 2. REP 82.7 Tray 5 Takeaway Roller
Removal
WARNING
Remove the drive
belt
WARNING
3. Remove the transport drive belt, REP 82.6.
4. Disconnect the harness from the tray 5 door switch, PL 75.60 Item 6.
5. Prepare to remove the upper feeder assembly, Figure 1.
Figure 2 Remove the drive belt
Replacement
2. Allow the tension idler to tension the belt and then tighten the screw, Figure 1.
3 2 1
Lift the upper feeder Remove two screws Remove two screws
assembly

6. Lift the upper feeder assembly and remove the lower feed assembly, Figure 2. 8. Remove the takeaway roller, Figure 4.
2
1 2 1 Remove the takeaway
Lift the upper feed Remove the lower feed Move the takeaway roller from the lower feed
assembly assembly roller to the rear assembly
Figure 2 Remove lower feed assembly Figure 4 Remove the takeaway roller
7. Remove the one way pulley clutch, Figure 3. Replacement

2. Check that the cable routing is correct, Figure 1.
4
Remove the E-clip
and bearing
3
Remove the E-clip
and bearing
2
Remove the one way pulley clutch
1
Remove the E-clip
Figure 3 Remove the one-way pulley clutch

REP 82.8 Confirm Sensor 4. Remove the confirm sensor, Figure 2.

Removal
WARNING
WARNING
1. Open the front door and remove the inner cover, PL 81.11 Item 2.
2. Pull out the marking engine, refer to Marking Unit Service Positions, GP 6.
3. Remove the marking engine plastic guide, Figure 1.
1 2
Remove 2 screws Disconnect harness
Figure 2 Remove Confirm sensor and bracket
1 Replacement
Remove 2 screws 1. Replacement is the reverse of the removal procedure.
calibration.
Figure 1 Remove marking engine plastic guide

REP 82.9 Vertical Transport 6. Release the harness from the cable clips and disconnect the harness from the vertical
transport, Figure 1.
Removal 2
WARNING
WARNING
2. Remove the bypass tray upper left door cover, refer to REP 81.3.
3. Remove the left cover, PL 81.10 Item 2.
4. Remove the mid left door assembly hinge pin, PL 70.30 Item 22, then remove the mid left 1
door assembly, PL 70.30 Item 16. Release the harness
5. Slide out the marking unit. GP 6. from the cable clamps.
Figure 1 Release the harness

7. Remove the vertical transport, Figure 2. 8. If required to install new components on the vertical transport, refer to Figure 3.
Mid door interlock Upper door interlock

switch. switch.
Vertical
Location transport
lugs motor.
Transport roller.
Transport roller.
Transport
roller.
2
Remove 8 screw marked with A.
1 Nip F drive belt.
Nip H drive belt.
Support the vertical transport.
3
Remove the vertical transport.
Figure 2 Release the vertical transport Figure 3 Vertical transport

Replacement REP 83.1 Horizontal Paper Path
Removal
CAUTION
Incorrect routing of the vertical paper path harness can cause the harness to be pinched when
the marking unit is push to the home position. WARNING
2. Ensure that the harness is correctly routed, refer to Figure 1 and Figure 4. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Ensure that the vertical paper
path harness is secured in the
cable clamp behind the vertical
paper path. WARNING
2. Open the left hand upper door, PL 70.30.
3. Remove the horizontal paper path, Figure 1.
Vertical paper path harness
Figure 4 Harness routing
3. Ensure that the vertical transport is correctly located in the location lugs, refer to Figure 2.
calibration.
2 1
Remove the screws Disconnect harness
on the rear frame
4 3
Lift slightly and pull out the hori- Lift the heat shield and hold in
zontal transport the up position
Figure 1 Remove the horizontal paper path

Replacement REP 83.2 Duplex End Sensor, Nip C Solenoid and HPP
1. Replacement is the reverse of the removal procedure. Diverter Solenoid
2. Hold the heat shield up. Locate the rear left hand ‘V’ slots on the horizontal transport with
the guide on the top of the marking unit. Holding the unit level slide back in. Do not force
it, try to align the transport location holes with the location pins and it should fall into place. Removal
3. Run the relevant diagnostic routines, refer to GP 37 Post Part Replacement Routines.
WARNING
WARNING
WARNING
Take care during this procedure. Motors will become hot during normal operation.
1. Remove the horizontal paper path, REP 83.1.

2. Prepare to remove the duplex end sensor, Figure 1. 3. Remove the duplex end sensor, Figure 2.
NOTE: Hold down the cover against the force of the spring when removing screws.
1
Move sensor
retainer to the left
2
Disconnect har-
ness and remove
sensor
1 2
Remove screws marked A. Remove the top cover.
Figure 2 Duplex end sensor removal

4. Remove the nip C solenoid and HPP diverter solenoid, Figure 3. REP 83.3 Duplex Sensor (17)
Removal
1 WARNING
Nip C solenoid Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
2
HPP diverter WARNING
solenoid
Figure 3 Solenoid removal
Replacement
2. When replacing the top cover, place the assembly on a flat surface i.e. a desk with the
curled portion hanging off the desk.
3. Hold the top cover down in the correct position the entire time the screws are being
installed.
4. Install and tighten down the screws in each corner first, then install and tighten the
remaining screws.
5. Perform dC625 Registration / Preheat Calibration.

2. Prepare to remove the duplex sensor (17), Figure 1, 3. Remove the duplex sensor from the underside of the top cover, Figure 2.
2
Remove sensor
1
Disconnect har-
ness
1 2
Remove screws marked A. Remove the cover.
Figure 1 Preparation Figure 2 Duplex sensor (17) removal
Replacement
2. When replacing the top cover, place the assembly on a flat surface i.e. a desk with the
curled portion hanging off the desk.
3. Hold the top cover down in the correct position the entire time the screws are being
installed.
4. Install and tighten down the screws in each corner first, then install and tighten the
remaining screws.
5. Perform dC625 Registration / Preheat Calibration.

REP 83.4 Horizontal Transport Motor 2. Prepare to remove the motor, Figure 1.

Removal 2
WARNING
WARNING
WARNING
3 1
Remove 3 screws Remove the screw and
from the cover. unclip the harness guide.
Figure 1 Cover removal

3. Remove the motor, Figure 2. REP 83.5 Horizontal Transport Drive Belts And Takeaway
Rolls
Removal
WARNING
WARNING
WARNING
1
Remove 2 screws
Figure 2 Transport motor removal
Replacement
NOTE: The current horizontal transport motor PL 82.15 Item 9 is not compatible with machines
built before the following serial numbers:
• XC: BRE235221
• XE: 3642832521
On machines built before the serial numbers stated only the early type of motor can be used to
repair the machine. The early type of motor can be identified by the number 147-0206-00 on
the label and a plastic motor housing with “PWB” moulded on the end. If the early type of motor
is not available, install a new horizontal paper path assembly, PL 82.15 Item 1.
On machines built after the serial numbers stated, early type motors and later type motors are
compatible with the horizontal paper path assembly.

2. Prepare to remove the duplex drive belts, Figure 1. 3. Remove the duplex drive belts and takeaway rolls, Figure 2.
1
slide off the pulleys and belt
2 1
Open the Jam clearance door
Remove screws
3
Remove the door latch
Figure 1 Door latch removal

2
Slide takeaway roll to front
of paper path to remove it
1
slide off the pulleys and belt
Figure 2 Drive belts and takeaway rolls removal
Replacement

REP 89.1 Registration/Preheat Assembly and Lower 3. Remove the registration transport, Figure 1.
Platelet Assembly
Procedure
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity 1
can cause death or injury. Moving parts can cause injury. Disconnect 4 harnesses
WARNING
• Registration/Preheat Assembly Removal
• Lower Platelet Assembly Removal
Registration/Preheat Assembly Removal
CAUTION
Do not touch the printheads.
CAUTION
Protect the surface of the drum with paper.
1. Open the front door. Remove the inner cover, PL 81.11 Item 2.
2. Remove the horizontal transport, REP 83.1. 2 3
Remove the screw. Rotate and lift out the Registration
transport assembly.
Figure 1 Registration transport removal

Replacement 3. If the registration/preheat assembly does not seat properly, verify that the locating tab on
the rear of the registration/preheat assembly is correctly seated in the frame, Figure 3.
2. Ensure the ribbon cable is routed and connected before installation, Figure 2.
1 Correct seating position of

Ribbon cable connected correctly. the locating tab in the frame
Frame
Figure 3 Locating tab on rear of machine
4. When installing the horizontal transport leave the single mounting screw for the registra-
tion / preheat assembly loose. Use the top of the registration / preheat assembly as a
2 guide for when sliding the horizontal transport into position.Tighten the screw after the
Ribbon cable routed correctly. horizontal transport is installed.
5. Enter diagnostics dC131 and enter NVM ID 435-13, 435-14 and 435-15 and reset the val-
ues to zero.
NOTE: Only perform step 5 if new parts (new registration/preheat assembly or new nip A
Figure 2 Location of the ribbon cable rollers) are installed and before the dC625 routine is run.

Lower Platelet Assembly Removal Replacement
1. Open the front door. Remove the inner cover, PL 81.11 Item 2. 1. Replacement is the reverse of the removal procedure.
2. Remove the lower platelet assembly, Figure 4.
1
To open the cover assembly. Turn the
dial to align the hole on the dial with the
arrow, as shown.
2
Raise the cover
assembly.
3
Remove 1 screw.
5
Remove the lower plate
assembly.
4
Disconnect the connector.
Figure 4 Removal

REP 89.2 Registration / Preheat Pumps REP 89.3 Registration / Preheat Assembly Nip A Kit
Removal Removal
WARNING WARNING
WARNING WARNING
1. To remove the upper air pump. 1. Remove the registration / preheat transport, REP 89.1.
a. Remove the registration / pre-heat transport, REP 89.1. 2. Remove the bearing cover, Figure 1.
b. Remove the pump cover, PL 88.10 Item 8.
c. Remove the registration / pre-heat air pump, PL 88.10 Item 5.
2. To remove the lower air pump.
a. Remove the lower air pump assembly. Refer to REP 10.7 and follow steps 1 and 2.
b. Remove the air pump cover, PL 88.10 Item 7.
c. Remove the registration / pre-heat air pump, PL 88.10 Item 5.
Replacement
2. If the registration / preheat assembly has been removed, perform the dC625 Registration
/ Preheat Calibration.
1
Remove 4 screws.
2
Disconnect the
ground harness.
3
Carefully unclip the cover
from the bearings.
Figure 1 Bearing cover removal

3. Remove the front nip A drive belt, nip A pulley and nip A roller, Figure 2. 4. Remove the rear nip A drive belt, nip A pulley and nip A roller, Figure 3.
2
Disengage the drive belt from the front motor.
1
Disengage the drive belt
from the rear motor.
3
Remove the front nip A roller in
the direction of the arrow.
Remove the drive belt and pulley. 2
1 Remove the rear nip A roller in the
Remove the KL-clip direction of the arrow.
and the 2 gears. Remove the drive belt and pulley.
Figure 2 Front belt and roller removal Figure 3 Rear belt and roller removal
Replacement
2. Enter diagnostics dC131 and enter NVM ID 435-13, 435-14 and 435-15 and reset the val-
ues to zero.
NOTE: Only perform step 2 if new parts (nip A kit or new registration / preheat assembly)
are installed and before the dC625 routine is run.
3. Perform the dC625 Registration / Preheat Calibration procedure.

REP 91.1 Carriage Drive Train 3. Disconnect the harnesses from the marking unit driver PWB, Figure 2.

Removal
WARNING
can cause death or injury.
WARNING
1. Slide out the marking unit to the maintenance position, Refer to GP 6.
2. Remove the marking unit enclosure, Figure 1.
1
Disconnect PJ605 and PJ607.
2 1
Loosen 2 outer screws and
Remove the marking unit
remove the middle screw.
enclosure.
Figure 1 Enclosure removal

4. Remove the carriage drive train, Figure 3. REP 91.2 Vertical Gearbox and Motor
Removal
WARNING
WARNING
CAUTION
1 Do not touch the exposed face of the printheads. Surface contamination or minor damage can
Remove the screw, then destroy the printhead.
the upper carriage drive 1. Slide out the marking unit to the maintenance position, Refer to GP 6.
gear.
2
Remove 3 screws then the
drive train.
Figure 3 Carriage drive train removal
Replacement
2. The screw thread is at an angle. Tabs on the gear stop prevent the screw from being
driven in straight, refer to Figure 3 step 1.

2. Remove the marking unit cover, Figure 1. 3. Disconnect the PJ401 from the marking unit driver PWB, Figure 2.
1
1 Disconnect PJ401.
2
Loosen 2 outer screws and
Remove the marking unit
remove the middle screw.
cover.
Figure 1 Enclosure removal Figure 2 Disconnect harness

4. Remove the vertical gearbox and motor, Figure 3.
1
Example of the head maintenance wiper not level.
1
Remove 3 screws then the vertical
gearbox.
Figure 3 Vertical gearbox removal 2

Correctly seated and level head maintenance wiper.
Replacement
2. To ensure the wiper is level:
a. Lower the head maintenance wiper by rotating the upper drive shaft until sufficient
clicking (belt jumping teeth is heard to assure horizontally level).
b. Rotate the upper drive shaft in the opposite direction until the belt clips are at the top
of the tracks.
c. Check that both front and rear belt clips are touching the upper end of the track limit. Figure 4 Level head maintenance wiper
Figure 4 shows the head maintenance wiper fitted level and not level.
3. Ensure that both carriages are parked and the wiper is in the home position, all the way
up or down.

REP 91.3 Head Maintenance Wiper 2. Move the head maintenance wiper shaft down to and out of the removal slots, Figure 1.

2 1
Removal Wiper drive shafts. Turn the upper drive shaft to lower
the wiper drive shafts.
WARNING
WARNING
CAUTION
destroy the printhead.
CAUTION
Do not touch the wiper pads.
3 3
Removal slot. Removal slot.
Figure 1 Move the HM wiper shafts

3. Remove the head maintenance wiper shaft, Figure 2. 4. Remove the head maintenance wiper from shafts, Figure 3.
1
Remove the E-clip.
2
Slide the head mainte-
nance wiper off of the
drive shafts.
1
Remove the upper and lower
wiper shafts from the slats and
belt clips.
Figure 2 HM wiper removal Figure 3 Remove wiper

Replacement
CAUTION
Ensure the head maintenance wiper is in the correct orientation with the wiper facing up,
Figure 4.
2. Before installing the head maintenance wiper check the orientation of the wiper pads,
Figure 4.
Wiper pads
Rear
Front
1
Arrow points towards printheads Example of the head maintenance wiper not level.
Figure 4 Wiper orientation

2
Correctly seated and level head maintenance wiper.
3. To ensure the wiper is level:
a. Lower the head maintenance wiper by rotating the upper drive shaft until sufficient
clicking (belt jumping teeth is heard to assure horizontally level).
b. Rotate the upper drive shaft in the opposite direction until the belt clips are at the top
of the tracks.
c. Check that both front and rear belt clips are touching the upper end of the track limit.
Figure 5 shows the head maintenance wiper fitted level and not level.
4. Ensure that both carriages are parked and the wiper is in the home position, all the way Figure 5 Level head maintenance wiper
up or down.

REP 91.4 Front and Rear Tensioner Base 2. Lower the head maintenance wiper, Figure 1.

Removal
WARNING
WARNING
CAUTION
1
To lower the head maintenance
wiper: Turn the upper drive shaft
until the belts slip.
Figure 1 Lower the head maintenance wiper

3. Release the tension springs, Figure 2. 4. Remove the front and rear tensioner bases, Figure 3.
1
Release the tension 2 1
springs. Remove the e-clip then the Remove the e-clip then
front tensioner base. the rear tensioner base.
Figure 2 Spring release

Figure 3 Tensioner base removal

Replacement REP 91.5 Head Maintenance Belts and Belt Retainer Clips
2. Figure 4 shows the correct route for the front and rear belts.
Removal
up or down.
WARNING
WARNING
Front Belt
CAUTION
1. Remove the head maintenance wiper, refer to REP 91.3 only perform the steps neces-
sary to remove the head maintenance wiper from the marking unit.
Rear Belt
Figure 4 Belt routing

2. Remove the front and rear head maintenance belts, Figure 1. 3. Remove the head maintenance belt clips, Figure 2.
1
Remove 2 E-clips, then the drive shaft.
1
To remove the clip lift the belt
over the tabs.
Figure 2 Head maintenance belt clip
Replacement
3 1. Replacement is the reverse of the removal procedure.
Remove the front and rear 2. The drive shaft is a tight fit in the vertical drive motor.
head maintenance belts.
2
Remove the E-clip and belt 3. Ensure that both carriages are parked and the wiper is in the home position, all the way
pulley. up or down.
Figure 1 Head maintenance belt removal

REP 91.6 Head Maintenance Horizontal Motion Motor 2. Lower the head maintenance wiper, Figure 1.

Removal
WARNING
WARNING
CAUTION
1
To lower the head maintenance
wiper: Turn the upper drive shaft
until the belts slip.
Figure 1 Lower the head maintenance wiper

3. Remove the wiper shuttling yoke, Figure 2. 4. Remove the horizontal motion motor, Figure 3.
NOTE: Keeping the wiper shuttling yoke and horizontal drive cable connected will make
reinstallation easier.
1
Remove the e-clip and
2 1 pulley.
Push the cable guides Remove the e-clip
up to remove them. and pulley. 2
Remove 2 screws.
3
Disconnect harness.
4
Remove the motion
motor.
Figure 3 Motion motor removal
Replacement
2. Figure 4 shows the correct wiper shuttling yoke position.
3
Remove the wiper shuttling yoke
and horizontal drive cable.
Figure 2 Wiper shuttling yoke removal
Ensure the cable sits in this slot.

Ensure the tab is located at the top
left.
Figure 4 Wiper shuttling yoke position
up or down.

REP 91.7 Marking Unit Upper Carriage 3. Disconnect the carriage harness, Figure 1.

Removal A
A
WARNING
WARNING
CAUTION
1
NOTE: Rotate the wiper drive shaft, move the head maintenance wiper to the front of the lower Disconnect harnesses from the stitch/roller motors.
printheads. This is to provide protection during the procedure. Move the head maintenance
2
Disconnect harnesses from the in-
wiper back when the procedure is complete.
line connectors on the carriage
1. If possible print the initial test print pages, TP 1. These test pages are used to check the marked A and release the cable
print quality after the machine has been repaired. Refer to GP 37. clips.
2. Remove upper printheads, REP 91.29.

4. Disconnect the umbilical from the carriage, Figure 2. 6. Disconnect the ground lead, Figure 3.
A
A
A
A
1
Remove the screw to
1 release the ground
Use a bladed screwdriver to unclip the umbilical from the carriage. Insert
lead.
the screwdriver between the umbilical and carriage then rotate the blade to
release the umbilical (4 positions marked A).
Figure 2 Unclip the umbilical
5. Unlock the upper carriage shipping restraint. GP 6.
Figure 3 Disconnect ground lead

7. Remove the marking unit upper carriage, Figure 4. Replacement
2. Ensure all ground lead connections are firmly remade.
3. When installing a new carriage, ensure the shipping restraint clips are removed before
installation, Figure 5.
2 1
1 Remove both shipping
Remove the front and rear Remove the carriage by lifting off
the front and rear pivot. restraint clips.
e-clip and link.
Figure 4 Upper carriage removal
Figure 5 Shipping restraint clips
4. Ensure the harnesses are routed correctly, refer to GP 28.

up or down.

REP 91.8 Upper Carriage Drive Shaft, Cranks, Upper Front 3. Remove marking unit upper drive gear, Figure 1.
and Rear Compliant Links

Removal
1
WARNING Remove the screw
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord then the drive gear.
WARNING
CAUTION
1. Remove marking unit upper printheads, REP 91.29.
2. Remove marking unit upper carriage, REP 91.7.
Figure 1 Drive gear removal

4. Remove the upper carriage drive shaft, cranks and compliant links, Figure 2. REP 91.9 X Axis Drive Motor
1 Removal
Remove the E-clip.
WARNING
WARNING
CAUTION
1. Remove the marking unit carriage, refer to REP 91.7 for upper carriage and REP 91.14
for lower carriage.
2 3
Slide the shaft towards Remove the upper carriage
the front of the drive shaft.
machine.
Figure 2 Drive shaft assembly removal
Replacement
2. Ensure that the bearings are reinstalled at both ends of the drive shaft.
3. The drive gear screw is angled. Tabs on the gear prevent the screw from being driven in
at 90 degrees.
up or down.

2. Remove the x axis drive motor, Figure 1. Replacement
2. Ensure the rotation stop is correctly located when securing the motor to the frame, Figure 2.
Ensure the motor rotation stop

is located correctly onto the
frame.
1 2
Disconnect harness. Remove 3 screws.
Figure 1 Printhead motor removal
Figure 2 Motor Location

REP 91.10 Lower Carriage Drive Shaft, Cranks, Lower 3. Remove the lower drive gear, Figure 1.
Front and Rear Compliant Links

Removal
WARNING
WARNING
Remove the screw
then the drive gear.
CAUTION
1. Remove marking unit lower printheads, REP 91.29
2. Remove marking unit lower carriage, REP 91.14
Figure 1 Lower drive gear

4. Remove the lower carriage drive shaft, cranks and compliant links, Figure 2. REP 91.11 Upper Carriage Ship Restraint Motor
1 Removal
Remove the E-clip.
WARNING
WARNING
CAUTION
Take care not to damage the stitch / roll motors.
1. Remove the marking unit carriage, refer to REP 91.7 for upper carriage and REP 91.14
for lower carriage.
2. Remove carriage mounting bracket, Figure 1.
2 3
Slide the shaft towards Remove the lower carriage 1
the rear of the machine. drive shaft. Disconnect the harness from the bracket.
Figure 2 Drive shaft assembly removal
Replacement
2. Ensure that the bearings are reinstalled at both ends of the drive shaft.
3. The drive gear screw is angled. Tabs on the gear prevent the screw from being driven in
at 90 degrees.
4. Ensure that both carriages are parked and the wiper is in the home position, all the way Note: The cable is routed 2
up or down. through the cutout Remove 4 screws and
the bracket.
Figure 1 Bracket removal

3. Remove the shipping restraint motor, Figure 2. REP 91.12 Purge Line Filter
Removal
WARNING
WARNING
CAUTION
1 Do not touch the exposed face of the printheads. Surface contamination or minor damage can
Remove 3 screws and destroy the printhead.
the restraint motor.
1. Remove the printheads, REP 91.29.
Figure 2 Restraint motor removal
Replacement

2. Remove the purge line filter, Figure 1. Replacement
2. Insert the 2 tabs on the filter into the black housing. Apply a slight downward force on the
filter while sliding the filter into the housing. Ensure there is no gap between the rear of
the cone and the front of the housing, refer to Figure 2. Check that the filter is securely
held in the housing.
3. If the umbilical snap feature breaks off during replacement of the filter, use the replace-
ment clip included with the replacement filter. If necessary, remove the cap from the filter,
Figure 2.
1 2
Push forward from the Disconnect the air
rear then lift at the front. tube.
Figure 1 Purge line filter removal

Clip 1
Ensure the rear of the cone
Cap is against the front of the
housing.
Figure 2 Replacement

REP 91.13 Stitch / Roll Motor 3. Remove the relevant stitch adjust or roll adjust motor, Figure 1.
Parts List on PL 91.20 and PL 91.25 NOTE: The procedure for removing each motor is the same. The removal of printhead 2
roll adjust motor is shown in Figure 1. For clarity, printhead 2 is not shown.
Removal
WARNING
WARNING
1. Move the marking unit into the service position, GP 6.
2. If the roll or stitch motor is to be removed form the lower carriage assembly, also move the
lower printhead carriage into the maintenance position, GP 6.
1
2
Remove the retaining
clip, then remove the
stitch / roll motor.
Figure 1 Stitch / roll motor removal
Replacement
2. Verify the motor assembly cannot rotate relative to the carriage.
3. Check that there is no gap between the carriage and the motor face. If there is a gap,
check the guide pin is located in the hole.
up or down.

REP 91.14 Marking Unit Lower Carriage 3. Disconnect the carriage harness, Figure 1.

Removal A
A
WARNING
WARNING
CAUTION
1
NOTE: Rotate the wiper drive shaft, move the head maintenance wiper to the front of the upper Disconnect harnesses from the stitch/roller motors.
printheads. This is to provide protection during the procedure. Move the head maintenance
2
Disconnect harnesses from the in-
wiper back when the procedure is complete.
line connectors on the carriage
1. If possible print the initial test print pages, TP 1. These test pages are used to check the marked A and release the cable
print quality after the machine has been repaired. Refer to GP 37. clips.
2. Remove lower printheads, REP 91.29.
NOTE: After the printheads are removed leave the carriage in the lower service position.

4. Disconnect the umbilical from the carriage, Figure 2. 5. Disconnect the ground lead, Figure 3.
1
Release the wiring
from the top of the
umbilical.
A
A
A
A
2
Use a flat bladed screwdriver to unclip the umbilical from the carriage. Insert the screw-
driver between the umbilical and carriage then rotate the blade to release the umbilical
(4 positions marked A).
1
Remove the screw to release the
ground lead.
Figure 3 Disconnect ground lead

6. Remove the marking unit lower carriage, Figure 4. Replacement
2. Ensure all ground lead connections are firmly remade.
3. When installing a new carriage, ensure the shipping restraint clips are removed before
installation, Figure 5.
1
1 Remove both shipping
Remove the carriage by unclipping restraint clips.
the front and rear links then lifting
out the carriage.
Figure 4 Lower carriage removal
Figure 5 Shipping restraint clips
4. Ensure the harnesses are routed correctly, refer to GP 28.

up or down.

REP 91.15 Ink Loader Assembly 4. Remove the ink loader backup cover, PL 81.10 Item 8 and ink loader top, PL 81.10 Item
6. Refer to Figure 2.
Removal
3
Remove 3 screws
WARNING marked A.
WARNING
3. Remove the ink loader access cover rear, PL 81.10 Item 7. The cover is secured by a clip
on the left side, Figure 1.
Ink loader access

cover rear.
4
Remove the ink 2
loader top by lifting at Remove 2
the rear then sliding screws.
to the front.
1
Release the clip then remove the
cover towards the rear.
Figure 1 Release the access cover
1
Remove 2 screws, then remove the ink
loader backup cover.
Figure 2 Ink loader backup cover and top cover

5. Disconnect the media path driver PWB, Figure 3. See note. 6. Disconnect the ink loader upper assembly, Figure 4.
Note: View on the underside of the media

path driver PWB.
1 2
Disconnect the harness. Remove the screw.
2
1 Feed the cable through the
Disconnect PJ406. machine frame and release from
the cable clips.
Figure 3 Disconnect harness Figure 4 Disconnect the assembly

7. Release the ink loader bracket, PL 81.10 Item 9, Figure 5. 2. Ensure that the locating pins on the ink loader upper assembly are fully seated into the
holes in the chassis, Figure 7.
1
Remove 2 screws
Figure 5 Release the ink load bracket

Align the pins on the
8. Remove the ink loader upper assembly, Figure 6. ink loader upper
assembly with the
holes in the frame
1 Figure 7 Ink loader locating pins

Slide from the top and allow the
assembly to move downwards
CAUTION
Do not re-use partially melted ink sticks as this may result in cross contamination of the ink
melt reservoir.
3. Check the following to reset the ink level:
a. If you replace part of the ink loader upper assembly and leave the ink level close to
the original (within one ink stick of each color), there is no need to interact with the
NVM values. This should be the majority of cases.
b. If you replace part of the ink loader upper assembly and are going to power up the
machine with a big difference from the original ink level (over one ink stick of a given
color), do the following:
2 i. Remove all of the ink sticks from the ink loader upper assembly.
Support at the bottom
ii. Power up the machine, which will reset the NVM values to zero.
iii. Reload the ink sticks.
This scenario would also apply for cases where the ink level gauges on the UI are
way off (the NVM values have been corrupted). If the NVM values have been cor-
Figure 6 Ink loader upper assembly removal
rupted, refer to OF 9 Ink Stick Count Mismatch.
Replacement

REP 91.16 Ink Loader Melt Plate Assembly 2. Remove the ink loader melt plate assembly, Figure 1.

1
Removal Disconnect the 4
heater harnesses and
the single thermistor
WARNING harness.
WARNING
WARNING
CAUTION
Do not break off the partial used ink block. Do not re-use the partial used ink blocks.
1. Remove the ink loader assembly, REP 91.15. 2
Remove 2 retaining clips, then
the ink loader melt plate
assembly.
Figure 1 Melt plate assembly removal

Replacement REP 91.17 Ink Load Sensor Assembly
2. The 4 heater harnesses are colour coded to the corresponding letter on the ink melt plate
assembly. Ensure the correct harness is connected to the correct colour.
Removal
3. When installing the retaining clips, ensure that the slots on the base of the clips are fully
seated on the plastic tabs on the new ink melt plate assembly, Figure 2.
WARNING
WARNING
WARNING
CAUTION
Record the location of the ink load entry PWB connectors before disconnecting them.
1. Remove the ink loader assembly, REP 91.15.
1
Ensure the clips are seated over the locating
tabs on the ink melt plate assembly.
Figure 2 Clip alignment
4. Refer to the replacement of the ink loader assembly REP 91.15, to reset the ink levels.

2. Remove the ink load sensor assembly, Figure 1. REP 91.18 Ink Transport Motor and Drive Gear
1 Removal
Remove 4 screws
marked A.
WARNING
A 2
Release the metal
retaining clip and WARNING
remove the ink key plate Take care during this procedure. Sharp edges may be present that can cause injury.
A motor.
A WARNING
A 1. Remove the ink loader assembly, REP 91.15.
3
Disconnect 3 PJs 901,
601 and 301.
Figure 1 Ink load sensor assembly
Replacement
2. Take care not to bump or damage the plastic flags on the assembly while inserting it
under the belts.
3. When reinstalling the keyplate motor, ensure the locator pin is seated correctly before
installing the retaining clip.
4. Ensure that the motor harness is connected to the motor before reinstallation.
6. Verify that the keyplate moves by entering one of the following diagnostics codes 93-051,
93-052 or 93-053.

2. Remove the ink transport motor, cover and gear, Figure 1. Replacement
1 2. Refer to Figure 2. Use NYE Rheolube grease PL 26.11 Item 4 to grease the following
Remove 3 screws and
points before reinstalling:
the cover.
a. Worm gear.
b. Compound gear boss.
c. Drive shaft.
2 d. Ink transport drive cover shaft hole.
Disconnect harness.
e. Ink transport drive gear, PL 93.10 Item 6.
A
3 Worm gear.
Remove the drive
gear and motor.
C D
Figure 1 Transport motor removal Ink transport drive Drive shaft.
cover shaft hole.
NOTE: After removal, inspect the compound gear pin and boss for cracks or damage,
Figure 2.
B
Compound gear boss.
Figure 2 Grease points

REP 91.19 Ink Low Sensor Assembly 2. Disconnect PJ601 from the ink load entry PWB, Figure 1.

Removal
WARNING
can cause death or injury. 1
Disconnect PJ601.
WARNING
WARNING
1. Remove the ink loader assembly, REP 91.15.

3. Remove sensor assembly, Figure 2. REP 91.20 Ink Reservoir Assembly
Removal
WARNING
1
Remove 2 screws then
the ink low sensor
assembly. WARNING
CAUTION
CAUTION
The drum is exposed when the marking unit is pulled out.
CAUTION
Allow 30 minutes for the umbilicals and reservoir to cool down before starting this repair. It
takes 30 minutes for the ink to solidify.
1. Slide out the marking unit to the maintenance position, refer to GP 6.
Figure 2 Sensor assembly removal
Replacement

2. Remove the side and umbilical end insulation from the ink reservoir, Figure 1. 3. Disconnect the upper and lower umbilicals from the ink reservoir, Figure 2.
1
Remove the umbilical end
1
insulation. Remove 2 screws then
the umbilical clamp.
2
Remove the side insulation. 2
Disconnect the
umbilicals from the
ink reservoir.
3
Remove the gasket from
the ink reservoir or from
the umbilical.
Figure 1 Insulation removal
Figure 2 Umbilical removal

4. Remove the marking unit enclosure, Figure 3. 5. Disconnect PJ201 from the marking unit heater PWB and PJ801 from the marking unit
driver PWB, Figure 4.
NOTE: A new marking unit heater PWB to solenoid patch PWB harness is supplied with a
new ink reservoir.
2 1
Remove the enclosure. Loosen 2 outer screws then remove
the middle screw.
1 2
Disconnect PJ201. Disconnect PJ801 (see NOTE).
Figure 3 Marking unit enclosure removal

6. Remove the ink reservoir, Figure 5. Replacement
2. Ensure the new marking unit heater PWB to solenoid patch PWB harness is correctly
routed along the marking unit.
3. Ensure that the ink debris is cleared away from the purge hose connections before
removing or re-attaching the hoses to the reservoir.
4. Ensure that the purge hoses are located correctly and that the rib on the tube points
towards the drum, Figure 6.
Ribs
A B
Lower purge hose pair. Upper purge hose pair.
3 2 1 Figure 6 Air tube replacement

Remove 2 screws, then lift the ink Disconnect PJ760 and Disconnect upper and
reservoir to remove it. PJ630 from the sole- lower purge hoses. 5. When replacing the umbilical, ensure that there is only one silicone gasket between the
noid patch PWB. ink reservoir and umbilical.
CAUTION
Do not use a metal tool to clean the interface area between the umbilical and ink reservoir.
Doing so may cause ink leakage.
Figure 5 Ink reservoir removal 6. Ensure there is no ink debris between the ink reservoir and the umbilical before
connection.
7. Take note of the routing of the harness. Remove the old marking unit driver PWB to sole-
noid patch PWB harness from the marking unit.

7. Ensure that the umbilicals are seated correctly, Figure 7. REP 91.21 Reservoir Pump
Removal
1
Ensure the top of the umbilical con-
nector is level with or slightly below
the top of the side insulation, WARNING
as shown by the dashed line. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
CAUTION
Figure 7 Umbilical seating 3. Slide out the marking unit to the maintenance position, Refer to GP 6.
8. Firmly tighten the screws on the umbilical clamp, failure to do so can result in ink leaks.
CAUTION
Failure to properly prime the new umbilical will lead to permanent damage to the ink reservoir
and the new umbilical.
NOTE: Only perform Step 9 if a new umbilical has been installed at the same time as the ink
reservoir. If only the ink reservoir has been replaced then go to Step 10 and do not run dC976.
9. Power the machine directly into IME diagnostics mode, refer to GP 1. This will prevent the
thermals from warming up and delivering / pumping ink from the reservoir through the
umbilicals. When the machine has booted into IME diagnostics mode, log into diagnostics
and perform dC976 Ink Delivery Fault Recovery, to prime the umbilicals.

4. Disconnect PJ130 and the air tube from the ink reservoir assembly, Figure 1. 5. Remove the reservoir pump, Figure 2.
1
Disconnect PJ130. 1
Remove the screw from the under-
2 side of the ink reservoir then
Disconnect the centre air remove the reservoir pump.
pipe air pipe.
Figure 1 Disconnect harness and air tube. Figure 2 Reservoir pump removal
Replacement
2. Perform dC976 Ink Delivery Recovery.

REP 91.22 IOD Assembly 4. Remove abatement plenum, Figure 1.

Removal
WARNING
WARNING
CAUTION
2
3. Remove the cleaning unit, refer to REP 94.1. Remove the abatement
1
Remove 3 screws and the plenum.
lever assembly. Note the
position of the bearing.
Figure 1 Abatement plenum removal
5. Protect the underside of the drum with media to prevent damage.

6. Remove the IOD assembly, Figure 2. 2. Position the front of the IOD even with the back of the IOD, lying over the cable harness.
Slide the assembly into place, allowing the IOD to rotate up and into position, Figure 3.
NOTE: If the assembly begins to bind/wedge during installation, stop and pull the assem-
bly back. Then restart the installation.
2
Use a small screw driver
under the frame near the clip. Rear
Rotate the screw driver blade
to pop the clip out of the hole.
Rotate the IOD assembly
counterclockwise to remove
it.
1
Line the IOD up with the track
guides, then push and rotate to
install.
1
Disconnect harness and
tuck it under the cleaning
unit camshaft.
Figure 2 IOD assembly removal
Replacement
CAUTION
Do not disconnect and reconnect the flex cables at the IOD PWB. The flex cables are easily
Front
Figure 3 IOD replacement
3. Press the retainer clip to seat it into its hole in the IME chassis.
4. Connect the harness. Ensure the connector is fully seated.

5. When refitting the plenum. Ensure that the location lug on the plenum aligns with the pin REP 91.23 Front and Rear Track Guide
on the rear frame, Figure 4.
Removal
WARNING
WARNING
1. Remove the IOD assembly, REP 91.22.
2. Remove the front track guide, Figure 1.
2
3 Align the plenum with the
1 support pin
Push the plenum
Pull the handle into position
Figure 4 Install the plenum
1 2
Remove 2 gold screws. Remove the front track guide
from behind the front bracket.
Figure 1 Front track guide removal

3. Remove the drum and abatement fan assembly from the rear of the machine, Figure 2. 4. Remove the rear track guide, Figure 3.
1 1
Disconnect harnesses. 2 Remove 2 gold screws.
2 Remove the rear track guide
Remove the screw then the from the inside of the machine.
drum and abatement fan
assembly.
Figure 2 Drum and abatement fan removal Figure 3 Rear track guide removal
Replacement
CAUTION
Do not over tighten the screws as the track guide will crack.

REP 91.24 Drum Drive Motor and Belt
Take care when releasing or tensioning the drive belt not to trap or damage the adjacent wiring
Removal
harness.
WARNING CAUTION
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Ensure that the inside surface of the drive belt does not become contaminated with oil, ink or
from the customer supply while performing tasks that do not need electricity. Electricity paper debris during removal or installation. Clean the drive belt as necessary, refer to GP 27.
can cause death or injury. 3. Remove the drum drive belt, Figure 2.
WARNING
2. Remove the drum and abatement fan assembly from the rear of the machine, Figure 1. 1
Release the tension on
the belt by pulling the
lever down and rotating
the drum drive motor.
2
Remove the belt from
the drum pulley.
3
Remove the belt from
the drum drive motor.
1
2 Disconnect harness.
Remove the screw then lift Figure 2 Drum drive belt removal
and remove the abatement
fan assembly.
Figure 1 Drum and abatement fan removal

4. Remove the drum drive motor, Figure 3. 3. When installing the motor, first rotate it counter clockwise before pushing onto the shaft.
Refer to Figure 4.
3
Unhook the spring from
the lever.
4
Remove the e-clip.
2 5
Disconnect the top Rotate the drum drive motor in
harness from the an anti clockwise direction then
1 remove it from the shaft. 1
drum drive motor. Rotate the drum drive motor then push it
from the PSU. onto the shaft. The motor should slide on
without snagging.
Figure 3 Drum drive motor removal

Figure 4 Motor installation
Replacement
CAUTION CAUTION
Before installing a new drum drive belt clean the inside surface GP 27 and remove any loose Ensure that the inside surface of the drive belt does not become contaminated with oil, ink or
fibers. paper debris during removal or installation.
1. Replacement is the reverse of the removal procedure. 4. Clean the drive belt as necessary, refer to GP 27.
2. Before installing the drum drive belt, clean the drum pulley, PL 94.20 Item 3. Refer to GP 27. 5. Ensure the ribbed side of the belt faces inward when replacing it.
6. Check when tensioning the drive belt not to trap or damage the adjacent wiring harness.
7. Remove any debris from the old drive belt that may have accumulated on the cleaning
unit motor or on the rear bottom frame.

REP 91.25 Drum and Front Drum Frame Assembly 17. Install the removal drum alignment tool on the rear of the drum prior to removal, Figure 1.

Removal
WARNING
WARNING
CAUTION
Do not touch the exposed face of the printheads. Surface contamination or minor damage can 1
Align the hole in the tool
with the guide pin.
3. Remove the horizontal paper path assembly, REP 83.1.
4. Remove the exit paper path assembly, REP 10.20.
2
5. Remove the registration/preheat assembly, REP 89.1.
Tighten the T30 screw to
NOTE: Removing the marking unit is optional. If space to store the marking unit is limited then secure the tool
the unit can be left in the machine. But the removal does allow more space to remove the drum
unit.
6. Remove the marking unit, REP 91.28.

7. Remove the transfix roll, REP 10.1. Figure 1 Drum alignment tool
8. Remove the IOD front track guide, REP 91.23.
9. Remove the front drum fan shroud, PL 94.20 Item 7.
10. Remove the front drum thermistor, REP 91.35.
11. Remove the drum position encoder, REP 91.30.
12. Remove the stripper blade and store in a safe place. Refer to REP 10.21.
13. Cover the drum with the drum protector, PL 94.20 Item 13.
14. Remove the drum pulley, REP 91.34.
15. Remove the rear drum thermistor, REP 91.35.
16. Unplug the front transfix motor harnesses, REP 10.4.

18. Prepare to remove drum and front drum frame assembly, Figure 2.
CAUTION
If the marking unit has not been removed. Take care not to contact the printheads with the
drum during removal.
19. Remove drum and front drum frame assembly, Figure 3.
4
Remove 2
recessed long
screws.
3
Remove 2 screws. 1
Support the rear
2 underside of the
Remove screw. If drum with right
transfix linkage is hand through the
obstructing the opening.
removal, rotate the
transfix drive screw,
1 5, until it no longer
Remove 2 screws (T30). High torque is obstructs the screw.
required to remove the screws.
3 2
Remove the drum and Hold front assembly
Figure 2 Preparation front drum frame assem- with left hand.
bly by pulling them away
from the rear assembly.
Figure 3 Removal

20. Release the drum from the front drum frame assembly, Figure 4. NOTE: When installing new drum assembly, the three screw holes referenced in Figure 4
are not pre-tapped. There will be resistance when the screws cut new threads. Ensure the
NOTE: Use the top section of the replacement drum packaging to support the old drum.
screws are fully seated.
This will help to keep the drum stable during the separation.
CAUTION
If the marking unit has not been removed. Take care not to contact the printheads with the
drum during the replacement.
Take care not to contact the drum or pinch the encoder wiring when installing the front frame
assembly.
3. Place the drum and front frame assembly in the machine.
4. Reinstall the screws in the front assembly, Figure 5. Before tightening all the screws,
ensure the pin and bearing are seated correctly, Figure 6. Open and close the stripper
gate, GP 31 checking that the stripper latch mechanism moves freely, Figure 6. If not then
loosen the screws and correct the location of the latching arm before tightening the
screws.
1 2
Remove 3 screws. Separate the drum and front 4
drum frame assembly. Replace 2 long
screws.
3
Figure 4 Release the drum Replace 2 screws.
Replacement
Replacement is the reverse of the removal procedure. Observe the following points at the
appropriate steps.
NOTE: High pressure bearing grease, PL 26.11 Item 3, is used in the following locations. 2
1 Replace screw
• Drum bearing housing in the front drum frame casting.
Replace 2 screws (T30).
• Drum pulley bearing housing in the rear drum frame casting.
• Outside diameter of the transfix roller bearing holder at the front of the transfix roller.
During normal removal and replacement the existing bearing grease used during manufacture
will be sufficient. Only apply grease when both sides of any bearing surface are being
Figure 5 Screw Replacement
replaced, or if the surfaces have been wiped clean. Apply the grease very sparingly.
1. A replacement drum will have a drum protector and drum alignment tool supplied with the
drum. Install these items onto the drum before installing the drum.
2. Attach the drum to the front drum frame assembly.

14. Reinstall the IOD assembly, cleaning unit latch handle and abatement plenum, REP
91.22. Check that the harness is connected.
15. Remove the protective drum cover, PL 94.20 Item 13.
16. Connect the harnesses on the front transfix motor, REP 10.4.
17. Reinstall the transfix roll, REP 10.1.
18. Reinstall the transfix blade, REP 10.6.
19. Reinstall the marking unit if removed, REP 91.28.
20. Reinstall the registration transport, REP 89.1.
21. Reinstall the exit transport, REP 10.20.
22. Reinstall the horizontal paper path transport, REP 83.1.
23. Boot up the machine directly into IME diagnostics mode, GP 1.
25. If a new drum was installed. Enter dC131 NVM Read/Write location 492-70 Prints On This
Drum and reset the value to zero.
2
Pin seated correctly.
1
3 Bearing seated correctly.
Manually rotate the latch
camshaft to verify that the
4 latching mechanism
Install the screw. slides freely.
Figure 6 Correct seating
5. Remove the drum pulley replacement tool.
CAUTION
Take care to reinstall the static eliminator correctly. Refer to REP 91.34. If the static eliminator
is not installed correctly ESD events will result that can cause a build-up of cleaning unit gel
that permanently damages the printheads.
6. Replace the drum pulley, REP 91.34.
7. Reinstall the drum drive motor and belt, REP 91.24. Ensure the inner belt surface and
outer pulley surface are thoroughly cleaned before replacement.
8. Reinstall the rear drum thermistor, REP 91.35.
9. Reinstall the stripper blade. Check that the blade cover is sitting in the guide at the rear of
the machine, REP 10.21.
10. Reinstall the drum encoder, REP 91.30.
11. Reinstall the front drum thermistor, REP 91.35.
12. Reinstall the front shroud, PL 94.20 Item 7.
13. Reinstall the front IOD track guide, REP 91.23.

REP 91.26 Marking Unit Slide Assembly 5. Prepare to remove drawer slide assembly, Figure 1.

Removal
1
Remove service
loop from the
WARNING slide.
WARNING
CAUTION
3. Remove marking unit assembly, REP 91.28.
4. Remove marking unit fan, PL 1.15 Item 23.
2
Remove 2 screws
then the cross brace.

6. Remove slide drawer assembly, Figure 2. REP 91.27 Cleaning Unit Motor Assembly and Home
Sensor
Removal
WARNING
WARNING
1. Remove the rear covers, PL 81.10 Item 1.
2. Remove the rear drum fan shroud, PL 94.20 Item 5.
3. Lower the power supply. Removing the 4 screws that restrain the power supply. Lift the
power supply so the supporting hooks are no longer seated then lower the power supply
onto the machine base. It is not necessary to disconnect the power supply wiring for this
procedure.
1 2
Extend the drawer slide to align Remove 3 screws then remove the
apertures with screw heads. drawer slide.
Figure 2 drawer slide removal
Replacement
2. Take care not to insert any twists into the cable, refer to Figure 1 for correct cable route.

4. Remove the cleaning unit motor assembly, Figure 1. REP 91.28 Marking Unit Assembly
1 Removal
Remove 2 screws.
WARNING
WARNING
CAUTION
2
Disconnect the harnesses, NOTE: If the frame has been damaged then the enclosure assembly is available as a spare,
then remove the motor PL 91.10 Item 12. The marking unit components can be transferred to a new marking unit
assembly. enclosure by following the appropriate repairs.
1. Open front door.

5. If necessary, remove the cleaning unit home sensor, PL 94.10 Item 17 from the motor
assembly.
Replacement
2. After reinstalling the power supply, ensure there are no wires trapped between the rear of
the power supply and the machine frame.

4. Disconnect the harnesses and ground lead to the rear of the marking unit, Figure 1. 5. Remove the right marking unit securing screws, Figure 2.
1
Remove 2 screws.
2 1
Remove the ground
Disconnect 5 harnesses.
lead.
Figure 1 Disconnect harnesses Figure 2 Remove screws

6. Remove the left marking unit securing screws, Figure 3.
CAUTION
Do not touch the printhead faces.
7. Remove the marking unit, Figure 4.
1 2
Remove the screw. Remove the screw.
1
Lift from the left side of the marking unit to avoid
damage to the printheads. Lift the marking unit
Figure 3 Remove screws using front and rear handles.
Figure 4 Marking unit removal

Replacement REP 91.29 Printhead
2. When locating the marking unit onto the rails line up the service loop so that it goes
though the gap between the reservoir and marking unit, refer to Figure 5.
General Guidelines
Be aware of the following:
• Do not use printheads as troubleshooting tools. Do not install, then remove the new print-
head.
• When unpacked, install the new printhead immediately.
• Complete, then return the checklist supplied with the new printhead.
• Two types of printhead and cables can be installed in the machine. Refer to GP 45 to
identify both types. This procedure is clearly marked where a step is relevant to a specific
type of printhead.
Removal
WARNING
WARNING
CAUTION
1
Line up the service loop with the gap
between the reservoir and the marking unit. destroy the printhead. Keep hot printheads level.
1. Open front door.
Figure 5 Marking unit replacement NOTE: For lower printheads, move the lower carriage into its service position to allow
access to the harness connections, refer to GP 6.

4. Type A printhead only. Release the cable clips from the relevant flex cables, Figure 1. 5. Type A printheads only. Disconnect the flex cables, Figure 2.
Flex cable Release the fixing tab, then slide the clip
up and along the flex cable.
Figure 1 Clip removal (type A) 1

Release clips.
2
Rotate forward then lift to disconnect
flex cable.
Figure 2 Cable disconnection (type A)

6. Type B printheads only. Disconnect the flex cables, Figure 3. NOTE: Hooks on the printhead will prevent it from falling after the screws are loosened.
7. Remove the printhead, Figure 4.
2
Disconnect the flex cable.
1
marked A
2
Support the printhead by the black
insulation and undo the 2 screws.
1 Undo each screw a little at a time
Carefully raise the latch. until the printhead becomes free.
Figure 3 Cable disconnection (type B) Figure 4 Printhead removal
8. Set the printhead down on a level surface.

CAUTION
Do not adjust the ball plate screws (A), Refer to Figure 5.
1
Line up the legs behind the
receptacle.
A
2
Rotate back until the connector
clips into place.
A
A
Figure 5 Ball plate screws
Replacement
NOTE: If a type A printhead is being replaced with a type B printhead the following new
cables will also need to be installed: 3
Correctly connected flex cable.
• Video cable (type B) PL 92.10 Item 7
• Wave amp cable (type B) PL 92.10 Item 8
CAUTION
Failure to do the following may result in printhead or drum damage.
2. Remove the faceplate cover and umbilical port cover from a new printhead.
3. If there is solidified ink on the umbilical nozzles, carefully remove the ink.
NOTE: Solid ink on the umbilical nozzles can damage the printhead rear gasket resulting
in ink leakage.
4. Gently push in on printhead when starting the screws.

Figure 6 Cable connection (type A)
5. When screwing the printhead back onto the carriage, start by rotating the left screw 2 rev-
olutions, then alternate between the screws doing approximately 2 revolutions per screw.
6. Type A printheads only. Connect the flex cables, Figure 6.

7. Type A printhead only. Secure the flex cables with the cable clips, Figure 7.
1
Press down on the outside Line up the connector.
edges the clip to install. Carefully push the
connector until it
latches into place.
The clip tab will snap into position to

indicate the correct installation. 2
Correctly connected
flex cable.
Figure 7 Reinstall the cable clips
8. Type B printheads only. Connect the flex cables, Figure 8.
Figure 8 Cable connection (type B)
CAUTION
Failure to do the following may result in printhead or drum damage.
9. If reinstalling the same printhead in the same position, boot the machine directly into IME
diagnostics mode, GP 1. When the machine has booted into IME diagnostics mode, log
into diagnostics and perform dC967 to check head to drum spacing.
NOTE: Booting into IME diagnostics will prevent the normal power up / docking
sequence.
up or down.
NOTE: New printheads may not have all sections of NVRAM initialized. This may cause a
fault when the machine is switched on, refer to 91-519-00 to 91-522-00, 91-655-00 to 91-
690-00, 91-807 to 91-811-00 Printhead NVM Read or Write Error RAP. These faults will
be cleared after performing dC972.

REP 91.30 Drum Position Encoder Assembly
Do not remove gold coloured screws from the encoder.
Removal
4. Remove the drum position encoder, Figure 1.
WARNING
WARNING
1. Open front door.
2. Remove the inner cover, PL 81.11 Item 2. A
3. Remove the front drum shroud, PL 94.20 Item 7.
4
Pull encoder away
from the drum. Feed
the harness through
the centre of the
encoder.
2 3
1 Remove the ground plate Remove 3 silver coloured
Disconnect harnesses. and centre screw, A. screws. See CAUTION.
Do not remove gold coloured
screws.
Figure 1 Encoder removal

Replacement REP 91.31 Umbilical Assembly
2. Orientate the encoder as shown in Figure 2. Feed the harness through the centre of the
encoder and align the drum heater bar with the centre opening.
Removal
WARNING
WARNING
CAUTION
CAUTION
Allow 30 minutes for the umbilicals and reservoir to cool down before starting this repair. It
takes 30 minutes for the ink to solidify.
1. Slide out the marking unit to the maintenance position, refer to GP 6.
2. Remove the upper or lower printheads as required, REP 91.29.
Figure 2 Encoder replacement
3. Rotate the encoder until the screw holes line up and then press it on fully in this orienta-
tion.
4. Replace the lower and upper left screws. Replace the grounding plate, along with the cen-
tre and upper right screws.
5. Reconnect the harness.
NOTE: A new drum position encoder assembly may have one less electrical connector. If
the new encoder does have one less connector, the redundant machine harness should
be safely secured.
6. Ensure the wiring is not pinched when replacing the ground plate and screw, Figure 1.

NOTE: For lower printheads, move the lower carriage into its service position to allow access 4. Remove the required umbilical from the carriage, Figure 2.
to the harness connections, refer to GP 6.
3. Release the wiring harness from the required umbilical, Figure 1.

1
Release the wiring
from the top of the
A A
umbilical.
A
A A
A
A
A A
A
1
Disconnect harnesses from the stitch/roller motors, carriage and the end of the 2
umbilical, Refer to locations marked A. Use a flat bladed screwdriver to unclip the umbilical from the carriage. Insert the screw-
driver between the umbilical and carriage directly below the nozzles (4 positions marked
A), then rotate the screwdriver blade to release the umbilical.

5. Remove the side and end insulation from around the umbilical on the ink reservoir, Figure 3. 6. Remove the required umbilical, Figure 4.
1
Remove the umbilical end
1
insulation and plastic sur- Remove 2 screws then
round. the umbilical clamp.
Lower Umbilical Upper Umbilical
2
Disconnect the required
umbilical and remove it
from the machine.
2
Remove the side insulation.
Figure 3 Insulation removal Figure 4 Umbilical removal

7. Remove the purge hoses from the reservoir, Figure 5.
1
Ensure the top of the umbilical con-
nector is level with or slightly below
the top of the side insulation,
as shown by the dashed line.
A B
Lower purge Upper purge
hose pair. hose pair.
Rib
1
Remove the required purge
hose pair.
Figure 6 Umbilical seating
Figure 5 purge hose removal 7. Tighten the screws on the umbilical clamp, failure to do so can result in ink leaks. IQS 1
Replacement up or down.
1. Replacement is the reverse of the removal procedure. 9. Ensure the harnesses are routed correctly, refer to GP 28.
2. Ensure that the ink debris is cleared away from above and around the purge hose con-
nections before removing or re-attaching the hoses to the reservoir. CAUTION
3. Ensure that the purge hoses are located correctly and that the rib on the tube points Failure to properly prime the new umbilical will lead to permanent damage to the ink reservoir
towards the drum, refer to Figure 5. and the new umbilical.
4. When replacing umbilicals, ensure that there is only one gasket between the umbilical 10. Power the machine directly into IME diagnostics mode, refer to GP 1. This will prevent the
and the ink reservoir (new umbilicals come with a gasket installed). thermals from warming up and delivering / pumping ink from the ink reservoir through the
5. Ensure there is no ink debris between the ink reservoir and the umbilical before connec- umbilicals. When the machine has booted into IME diagnostics mode, perform the follow-
tion. ing:
6. Ensure that the umbilicals are seated correctly, Figure 6. a. Reinsert the waste tray.
b. Close the front door and bypass door.
c. Perform dC976 Ink Delivery Fault Recovery, to prime the umbilicals.
NOTE: If a new umbilical has been installed, perform dC976 a second time. A single
priming routine may not be sufficient in all cases.

REP 91.32 Cleaning Unit Cam Shaft Assembly Replacement
Parts List on PL 94.10 1. Replacement is the reverse of the removal procedure.
2. Before installing a new camshaft, ensure that the slot in the drive gear is aligned with the
Removal slot in the machine frame, Figure 2.
WARNING
WARNING
3. Remove the cleaning unit, refer to REP 94.1.
1
4. Remove the cleaning unit cam shaft, Figure 1.
Ensure the driver gear is aligned
with the slot in the machine
frame.
2
Align the camshaft with the slot in
the machine frame. Ensure the
longer side of the drive pin is
pointing to the right.
Figure 2 Camshaft alignment
3. Ensure that the black cam on the new camshaft points towards the rear of the machine.
Align the drive pin with the slot in the drive gear, longer side pointing to the right. Press
the camshaft into the drive gear until the pin is fully seated, Figure 2.
3
Pull outward and rotate until the drive
1 pin is released from the gear slot at
Remove e-clip the rear.
and bearing.
2
Lift shaft at front until the front cam
clears the machine frame, then
remove the washer.
Figure 1 Cam shaft removal

4. Lower the camshaft into place at the front of the machine. Align the washer with the 5. Ensure the camshaft is seated correctly and that the cam lock is engaged, Figure 4.
machine frame, at the same time as aligning the locating tags on the bottom of the lock
mount with the holes in the machine frame, Figure 3.
2 1
Replace the bearing and e- Ensure the cam lock is
1 2 clip. engaged (Fully forward) and
Place the washer on the shaft, then lower the Cam lock locator and hole. that the cam is in the correct
shaft into place. Ensure the cam lock is seated position as shown.
correctly and that the washer is seated cor-
rectly in the frame.
Figure 4 Cam lock check
Figure 3 Camshaft relocation

REP 91.33 Cleaning Unit Plug Connector REP 91.34 Drum Pulley
Removal Removal
WARNING WARNING
can cause death or injury. can cause death or injury.
WARNING WARNING
1. Remove the rear cover, PL 81.10 Item 1. 1. Remove the rear cover, PL 81.10 Item 1.
2. Remove the cleaning unit, refer to REP 94.1. 2. Remove the rear drum fan shroud, refer to REP 91.24, figure 1.
3. Remove the drum drive motor and belt, REP 91.24. 3. Release the tension on the drum drive belt by pulling the lever down.
4. Remove the cleaning unit plug connector, Figure 1. Remove the drum drive motor and belt, REP 91.24.
4. Move the drum static eliminator away from the drum shaft, Figure 1.
1
Loosen the screw.
2
Move the static elimina-
tor away and lock in posi-
2 tion
1 Squeeze the tabs on either
Disconnect the harness. side of the connector and
push the connector towards
the machine. The connector Figure 1 Move the static eliminator
will fall into the cleaning unit
area, accessible front the
front of the machine.
Figure 1 Plug connector removal
Replacement

5. Prepare to remove the drum pulley, Figure 2.
CAUTION
Take care not to insert the screw driver handle too far into the drum as damage to the heater
may occur.
6. Remove the drum pulley, Figure 3.
1
Insert a screwdriver han-
dle to prevent the drum
pulley from rotating when
turning the centre screw.
See CAUTION
1
Remove 3 long screws.
3
Figure 2 Preparation Use the T-handle T30 driver to 2
unscrew the centre screw. Thread Support the drum pulley.

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708P90672

Xerox® ColorQube® 9203 Family

October 2014 Introduction

Section 4 Repairs / Adjustments

• When there is a personnel or machine safety issue.

Section 5 Parts List

October 2014 Introduction

How to Differentiate Between Machine Variants • Bus Update May 2009

CAUTION • RAP 12-113-00-171, 12-114-00-171, 12-190-00-171, 12-192-00-171 HVF BM Entry

Introduction October 2014

October 2014 Introduction

Introduction October 2014

October 2014 Introduction

Introduction October 2014

October 2014 Introduction

Introduction October 2014

October 2014 Introduction

Introduction October 2014

October 2014 Introduction

Introduction October 2014

DC Voltage Levels and Tolerances

October 2014 Introduction

Hot Surface Symbol

NOTE: This links to General Procedures information. Disassembly Precautions

NOTE: This links to a relevant wiring diagram. Reassembly Precautions

Introduction October 2014

Responsibilities for resolution:

October 2014 Introduction

Introduction October 2014

October 2014 Introduction

Introduction October 2014

October 2014 Introduction

Introduction October 2014

October 2014 Service Call Procedures

October 2014 Service Call Procedures

Service Call Procedures October 2014

October 2014 Service Call Procedures

Service Call Procedures October 2014

Use SCP 4 Subsystem Maintenance to maintain the machine. The

Table 1 HFSI replacement

October 2014 Service Call Procedures

3. If necessary, go to SCP 4 Subsystem Maintenance.

Service Call Procedures October 2014

October 2014 Status Indicator RAPs

Status Indicator RAPs October 2014

October 2014 Status Indicator RAPs

Status Indicator RAPs October 2014

October 2014 Status Indicator RAPs

Status Indicator RAPs October 2014

October 2014 Status Indicator RAPs

Status Indicator RAPs October 2014

Initial Actions Initial Actions

October 2014 Status Indicator RAPs

October 2014 Status Indicator RAPs

Install a new power supply unit, PL 1.15 Item 2. WARNING

+50V Short Circuit Check

Power supply unit Red LED

Figure 1 Component location

October 2014 Status Indicator RAPs