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WorkCentre 7220/7225 Service Documentation

Service Documentation

WorkCentre 7220/7225 Service Documentation

705Pxxxxx

ECAT Issue

November 9, 2012

***Xerox Private Data***

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.

If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold xerox harmless from any third party claims which arise directly or indirectly for such service.

While Xerox has tried to make the documentation accurate, Xerox will have no liability arising out of any inaccuracies or omissions. Changes are periodically made to this document. Changes, technical inaccuracies, and typographical errors will be corrected in subsequent editions.

Prepared by Content Development & Language Services – North America

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©2012 Xerox Corporation. All rights reserved. Xerox®, and Xerox and Design® are trademarks of Xerox Corporation in the United States and/or other countries.

Changes are periodically made to this document. Changes, technical inaccuracies, and typographic errors will be corrected in subsequent editions.

CAUTION

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

About this Manual

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

This manual contains information that applies to NASG (XC) and ESG (XE) copiers.

Service Manual Revision

The Service Manual will be updated as the machine changes or as problem areas are identified.

Organization

The titles of the sections and a description of the information contained in each section are contained in the following paragraphs:

Section 1: Service Call Procedures

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

Section 2: Status Indicator RAPs

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

Section 3: Image Quality

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

Section 4: Repairs/Adjustments

This section contains all the Adjustments and Repair procedures.

Repairs

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

When there is a personnel or machine safety issue.

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

When there is a cleaning or a lubricating activity associated with the procedure. When the part requires an adjustment after replacement.

When a special tool is required for removal or replacement.

Use the repair procedures for the correct order of removal and replacement, for warnings, cautions, and notes.

Adjustments

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

Use the adjustment procedures for the correct sequence of operation for specifications, warnings, cautions and notes.

Section 5: Parts Lists

This section contains the Copier/Printer Parts List.

Section 6: General Procedures/Information

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

Section 7: Wiring Data

This section contains drawings, lists of plug/jack locations, and diagrams of the power distribution wire networks in the machine. Block Schematic Diagrams are found in pdf format in the SGS.

How to Use this Documentation

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

Use of the Block Schematic Diagrams

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

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

Symbology and Nomenclature

The following reference symbols are used throughout the documentation.

Warnings, Cautions, and Notes

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

WARNING

Do not perform repair activities with the power on or electrical power supplied to the machine. The machine could activate and cause serious personal injury when the power is on or electrical power is supplied.

DANGER: Ne pas effectuer de dépannage avec le contact principal activé ou avec l’alimentation électrique appliquée à la machine: celle-ci pourrait démarrer et causer de graves blessures.

AVVERTENZA: Non effettuare alcuna riparazione con la macchina accesa o con l’alimentazione elettrica inserita. La macchina potrebbe avviarsi all’improvviso e causare gravi ferite.

VORSICHT: Es dürfen keine Reparaturarbeiten durchgeführt werden, solange das Gerät eingeschalten oder mit der Stromquelle verbunden ist. Das Gerät kann u.U in den AktivZustand übergehen und somit erhebliche körperliche Schäden verursachen.

AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente. La máquina podría activarse y ocasionar daños personales graves.

CAUTION

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

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

Machine Safety Icons

The following safety icons are displayed on the machine:

WARNING

Use extreme care when replacing the Raster Output Scanner (ROS) or touching the high voltage lead. Discharge the laser assembly by touching the high voltage lead to the machine frame. The ROS utilizes a laser assembly that stores a high voltage charge after the power has been removed and represents a shock hazard that could cause serious personal injury if not discharged.

DANGER: Faire très attention lors du changement du générateur de balayage (ROS) ou lors de la manipulation du câble de haute tension. Décharger le système laser en touchant le câble HT au bâti machine: le ROS utilise un système laser qui retient une haute tension après la coupure de l’alimentation, représentant un risque de choc et de graves blessures.

AVVERTENZA: Fare estrema attenzione nel sostituire il Raster Output Scanner (ROS) o nel toccare il cavo di alta tensione. Scaricare il complessivo laser collegando il cavo di alta tensione col telaio della macchina. Il ROS utilizza un complessivo laser che ritiene una carica di alta tensione dopo il taglio dell’alimentazione con conseguente grave pericolo di scossa elettrica e serie ferite.

VORSICHT: Beim Ersetzen der Lasereinheit (ROS) und beim Umgang mit Hochspannungsleitern ist äußerste Vorsicht geboten. Die Lasereinheit muss durch Berühren des Hochspannungsleiters mit dem Gehäuse des Geräts entladen werden. Nach Betrieb der Lasereinheit (ROS) bleibt immer eine Hochspannungsladung zurück, welche ein hohes Elektroschockrisiko darstellt. Äußerste Vorsicht ist geboten.

AVISO: Use extrema precaución para sustituir el Escáner de salida ráster (ROS) o tocar el cable de alto voltaje. Descargue el sistema láser tocando el cable de alto voltaje del bastidor de la máquina. El ROS utiliza un sistema láser que retiene carga de alto voltaje después de interrumpir la alimentación de energía y representa un grave peligro que puede ocasionar daños personales graves si no se descarga.

Figure 1 Laser Hazard Symbol

Laser Hazard Statement

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

CAUTION

The use of controls or adjustments other than those specified in the Laser Safety Training Program may result in an exposure to dangerous laser radiation.

For additional information, review the Laser Safety Training program.

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

Figure 2 Customer Access Label

WARNING

Do not defeat or electrically bypass the ROS Safety Interlock Switch for any reason. The ROS emits an undetectable laser beam that could cause serious permanent damage to the eyes if directly viewed or viewed from a surface that may have reflected the laser beam.

DANGER: Ne pas shunter le contact de sécurité du ROS, quelle que soit la raison. Le ROS émet un rayon laser indétectable qui peut causer de graves blessures permanentes aux yeux s’il est regardé directement ou par le biais d’une surface qui le réfléchit.

AVVERTENZA: Non ostacolare o bypassare elettronicamente l’interruttore blocco di sicurezza ROS per nessun motivo. Il ROS emette un raggio laser invisibile che può causare gravi ferite permanenti agli occhi se viene guardato direttamente o attraverso una superficie riflettente.

VORSICHT: Den ROS (Rasterausgabescanner)-Sicherheitssperrschalter auf keinen Fall vernichten oder elektronisch umgehen. Der ROS sondert einen nicht feststellbaren Laserstrahl ab, der irreparable Augenschäden verursachen kann, wenn direkt oder über eine Spiegelfläche hineingesehen wird.

AVISO: No intente modificar o desviar electrónicamente el interruptor de seguridad por ningún motivo. El ROS emite un rayo láser que no se puede detectar, que podría puede causar grave daño permanente a los ojos si se lo mira directamente o desde una superficie que refleja el rayo láser.

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

Figure 3 Heated Surface Label

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

Figure 4 Shock Hazard Label

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

Figure 5 ESD warning Label

Electrostatic Discharge (ESD) Field Service Kit

The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of electronic components that are handled by the Field Service Personnel. This program is being implemented now as a direct result of advances in microcircuitry technology, as well as a new acknowledgment of the magnitude of the ESD problem in the electronics industry today.

This program will reduce Field Service costs that are charged to PWB failures. Ninety percent of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service Kit will eliminate these delayed failures and intermittent problems caused by ESD. This will improve product reliability and reduce callbacks.

The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive components are being handled. This includes activities like replacing or reseating of circuit boards or connectors. The kit should also be used in order to prevent additional damage when circuit boards are returned for repair.

The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General Procedures section of the Service Documentation.

Illustration Symbols

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

Signal Nomenclature

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

Figure 7 Signal Nomenclature

DC Voltage Measurements in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead. For example, the following statement may be found in a RAP:

There is +5 VDC from TP7 to TP68.

In this example, the red meter lead would be placed on TP7 and the black meter lead on TP68.

Other examples of a statement found in a RAP might be:

•There is -15 VDC from TP21 to TP33.

•-15 VDC is measured between TP21 and TP33.

•In these examples, the red meter lead would be placed on TP21 and the black meter lead would be placed on TP33.

•If a second test point is not given, it is assumed that the black meter lead may be attached to the copier frame.

Service Call Procedures

Service Strategy

The service strategy for the WorkCentre Copier/Printers is to perform any High Frequency Service Item (HFSI) actions before attempting to repair any problems. Some problems will be corrected by this strategy without the need to diagnose them. The Repair Analysis Procedures (RAPs) will be used for any remaining problems.

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

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

Service Call Procedures

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

Initial Actions

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

Call Flow

Call Flow summarizes the sequence of the Service Call Procedures.

Detailed Maintenance Activities

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

Cleaning Procedures

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

Final Actions

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

Initial Actions

Purpose

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

Procedure

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

a.Question the operator(s). Ask the customer if the problems are related to Xerox Secure Access. Ask about the location of most recent paper jams. Ask about the image quality and the copier/printer performance in general, including any unusual sounds or other indications.

b.After informing the customer, disconnect the machine from the customer’s network.

c.Check that the power cords are in good condition, correctly plugged in the power source, and free from any defects that would be a safety hazard. Repair or replace the power cords as required. Check that the circuit breakers are not tripped.

d.If the problem is Cover or Interlock related, or if there are frequent Machine Status Messages that cannot be reset by performing the required action go the Unresettable Machine Status Messages RAP.

e.If the problem is completely blank output in all modes of operation go the Output is Blank in All Modes RAP.

f.If the machine appears to be inoperative, go to Call Flow and repair the problem. Then continue below.

g.Inspect any rejected copies. Inquire as to, or otherwise determine, the paper quality and weight. The specified papers for optimum image quality with this machine are 24 lb. Xerox Color Xpressions Plus (XC) or 90 gsm Colortech + (XE). Look for any damage to the copies, oil marks, image quality defects, or other indications of a problem.

h.Record the billing meter readings. The meters are diplayed on the UI by pressing:

Machine Status Button, Billing Information Tab.

i.Enter Service Rep. Mode (UI Diagnostic (CSE) Mode).

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

j.Using the usage information gathered in step g, determine what HSFI action may required based on the customer output volume. Refer to the Detailed Maintenance Activities (HFSI) section for the detailed HSFI information. Record any items that may require action.

k.Access UI Diagnostics (UI Diagnostic (CSE) Mode). Select the Service Info tab and use dC120 Fault Counters and dC122 Fault History to display fault information. Classify this information into categories and record the appropriate fault codes:

Information that is related to the problem that caused the service call.

Information that is related to secondary problems.

Information that does not require action, such as a single occurrence of a problem.

l.Check the Service Log for any recent activities that are related to the problem that caused the service call or any secondary problem.

2.Perform any required HSFI activities identified above. Refer to Detailed Maintenance Activities (HFSI).

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

4.Go to Call Flow.

Call Flow

This procedure should be performed at every service call.

Initial Actions

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

NOTE: IIf the problem is Cover or Interlock related, or if there are frequent Machine Status Messages that cannot be reset by performing the required action go the Unresettable Machine Status Messages RAP.

If the problem is completely blank output in all modes of operation go the Output is Blank in All Modes RAP.

Service Call Procedures

Call Flow

Procedure

NOTE: If customers cannot access machine functions because Xerox Secure Access is not functioning properly go to the OF 13-1 RAP to repair the problem, then return here and continue.

If customers cannot access machine functions because the Common Access Card featureis not functioning properly go to GP 21 to determine the problem, then return here and continue.

If a message such as ‘Reinsert an improperly seated consumable” or “Replace any with error” is displayed on the UI, go to the Toner CRUM Mismatch RAP.

Switch on the Main Power. The machine comes to a Ready condition.

YN

Go to the Machine Not Ready.

The reported problem occurs in Print Mode only.

YN

Place the Color Test Pattern on the Document Glass. Make a copy from each paper tray.

The Copier/Printer can copy from all trays. Y N

Access UI Diagnostics (UI Diagnostic (CSE) Mode). Select the Service Info tab and use dC120 Fault Counters and dC122 Fault History to display fault information. A fault code related to the problem is displayed.

Y N

The problem is related to a specific paper tray (for example, erroneous “Tray X out of Paper” message).

Y N

For intermittent problems, Go to GP 23.

1-4 WorkCentre 7220/7225 Service Documentation

A

YN

Access UI Diagnostics (UI Diagnostic (CSE) Mode). Select the Service Info tab and use dC120 Fault Counters and dC122 Fault History to display fault information. A fault code related to the problem is displayed.

Y N

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

Go to the RAP for the displayed fault code.

Check the image quality in the Basic Copier Mode:

•Select a tray that is loaded with 11 X 17 or A3 paper.

•Select the following parameters (Table 1):

Table 1 Basic Copier Mode Settings

•Run four copies of the Color Test Pattern.

The Image Quality of the copies produced is acceptable.

YN

Go to the Image Quality Entry RAP.

Go to Final Actions.

The problem occurs in all print jobs.

YN

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

Go to GP 7 Network Printing Simulation and send a print job. An acceptable print is produced.

YN

•verify machine settings

B

B

•reload system software

•replace the Hard Drive (PL 35.2).

•replace the SBC PWB (PL 35.2).

The problem is in the customer network or the setup. Check the following:

•Ensure that the Static IP/DHCP setting matches the customer’s network

•Verify that the IOT IP address is correct.

•When resolved, go to Final Actions.

Detailed Maintenance Activities (HFSI)

Procedure

1.Clean the ADC Sensor and ROS window on every call.

2.Enter Service Rep. Mode (UI Diagnostic (CSE) Mode).

3.Use dC135 HFSI Counters and the usage information gathered in Initial Actions to determine which HFSI items require replacement.

NOTE: TBD — verify this for Javelin — need SME input — Several service Iiems in Table 1 are Customer Replaceable Units (CRUs). Counters are reset automatically upon installation.

4.Perform the Service Actions in Table 1 for any High Frequency Service Item (HFSI) counters that are over threshold or approaching the threshold. Using the customer’s output volume numbers (high, medium, or low volume), evaluate which HFSI actions should be performed now to avoid an additional service call in the near future.

5.Refer to Cleaning Procedures for detailed cleaning instructions.

6.After servicing an HFSI, enter UI Diagnostic (CSE) Mode and select either the Service Info or the Maintenance tab, then select dC135.

7.Select the appropriate item(s) from the table and press the Reset Counter button. Follow the directions in the window to reset the counters.

8.Threshold values can be changed if required by selecting the Edit Life button and entering the new count.

Cleaning Procedures

Purpose

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

Procedure

CAUTION

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

General Cleaning

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

1.Feed Components (Rolls and Pads)

Use a dry lint free cloth or a lint free cloth moistened with water. Wipe with a dry lint free cloth

2.Toner Dispense Units

Vacuum the Toner Dispense units.

3.Jam Sensors

Clean the sensors with a dry cotton swab.

4.IBT Cleaning

Check the Transfer Belt surface and wipe with a dry lint free cloth. If the surface is excessively dirty, replace the Transfer Belt (PL 6.2).

Do not rub the IBT Cleaning Blade. If it is necessary to clean the blade, use a soft brush or dry swab to brush away contamination. Rubbing will remove the protective coating on the blade.

5.Fuser Components (best cleaned when hot)

Switch off the power. Allow the Fuser to cool enough so that it does not present a burn hazard.

Wipe with a lint free cloth.

6.Scanner

a.Switch off the power.

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

c.Clean the Exposure Lamp with a clean cloth.

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

7.DADF

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

8.Finisher

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

Final Actions

Purpose

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

Procedure

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

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

3.Conduct any operator training that is needed. Ensure that the operator understands that the Automatic Gradation Adjustment procedure in the User Guide should be used to calibrate the colors.

4.Complete the Service Log.

5.Perform the following steps to make a copy of the Demonstration Original for the Customer:

a.Load Tray 1 with 8.5 x 11” (A4) or 11 x 17” (A3) paper.

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

c.Print out the Machine Settings (Configuration Report). Store this report with the service log in Tray 1.

d.Ask the customer to verify the Print and Scan functions.

e.Present the copies to the customer.

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

7.Issue copy credits as needed.

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

Chain 012 (Finisher LX)

Chain 016 — Controller

Chain 019 Image Processing

Chain 020 Embedded Fax

Chain 022 System Faults

Chain 024 — Controller Communications

Chain 041 — IOT Manager (MCU)

Chain 042 — Drives/ NOHAD

Chain 045 — MM

Chain 047 — Output Control

Chain 061 — ROS

Chain 062 — IIT/IPS

Chain 066IIT/IPS

Chain 071 — Tray 1 PH

Chain 072 — Tray 2 PH

Chain 073 — Tray 3 PH

Chain 074 — Tray 4 PH

Chain 075 — Tray 5 (MSI) PH

Chain 077 — Paper Transportation

Chain 089 — RegiCon

Chain 091 — Xerographics

Chain 092 — ProCon

Chain 093 — Development

Chain 094 — Transfer

Chain 095 — SW Upgrade Failure

Other Faults

NOTE: The chain/link fault code for this RAP is an internal machine code and is never displayed or logged in Fault Code History. Use this RAP to troubleshoot persistent machine status conditions that cannot be cleared by performing the indicated process (e.g., loading paper, closing a cover, replacing a CRU, etc). Entry to this RAP is usually via the Machine Status Faults RAP located in the Other Faults section, or a chain/link listing on a BSD.

Initial Actions

Power Off and On

Procedure

Perform the following in order:

1.Reload SW using GP 9

2.Replace the Hard Drive ([PL 35.2]).

3.Replace the SBC PWB (PL 35.2)

NOTE: The chain/link fault code for this RAP is an internal machine code and is never displayed or logged in Fault Code History. Use this RAP to troubleshoot persistent machine status conditions that cannot be cleared by performing the indicated process (e.g., loading paper, closing a cover, replacing a CRU, etc). Entry to this RAP is usually via the Machine Status Faults RAP located in the Other Faults section, or a chain/link listing on a BSD.

Initial Actions

Power Off and On

Procedure

Perform the following in order:

1.Reload SW using GP 9

2.Replace the Hard Drive ([PL 35.2]).

3.Replace the SBC PWB (PL 35.2)

NOTE: The chain/link fault code for this RAP is an internal machine code and is never displayed or logged in Fault Code History. Use this RAP to troubleshoot persistent machine status conditions that cannot be cleared by performing the indicated process (e.g., loading paper, closing a cover, replacing a CRU, etc). Entry to this RAP is usually via the Machine Status Faults RAP located in the Other Faults section, or a chain/link listing on a BSD.

Initial Actions

Power Off and On

Procedure

Perform the following in order:

1.Reload SW using GP 9

2.Replace the Hard Drive ([PL 35.2]).

3.Replace the SBC PWB (PL 35.2)

NOTE: The chain/link fault code for this RAP is an internal machine code and is never displayed or logged in Fault Code History. Use this RAP to troubleshoot persistent machine status conditions that cannot be cleared by performing the indicated process (e.g., loading paper, closing a cover, replacing a CRU, etc). Entry to this RAP is usually via the Machine Status Faults RAP located in the Other Faults section, or a chain/link listing on a BSD.

Initial Actions

Power Off and On

Procedure

Perform the following in order:

1.Reload SW using GP 9

2.Replace the Hard Drive ([PL 35.2]).

3.Replace the SBC PWB (PL 35.2)

302-317 LUI Gets No Response From SRS

LUI gets no response from SRS

Initial Actions

Power Off and On

Procedure

Perform the following in order:

1.Reload SW using GP 9

2.Replace the Hard Drive ([PL 35.2]).

3.Replace the SBC PWB (PL 35.2)

302-320 UI Data Time Out Error

A software error has occurred. User intervention is required to Power Off/Power On the machine. Printing may be disabled.

NOTE: The chain/link fault code for this RAP is an internal machine code and is never displayed or logged in Fault Code History. Use this RAP to troubleshoot persistent machine status conditions that cannot be cleared by performing the indicated process (e.g., loading paper, closing a cover, replacing a CRU, etc). Entry to this RAP is usually via the Machine Status Faults RAP located in the Other Faults section, or a chain/link listing on a BSD.

Procedure

Perform the following in order:

1.Power Off and On

2.Reload SW using GP 9

3.Go to the 303-347 UI Communication Fault RAP

302-321 XEIP Browser Dead

XEIP Browser Dead

NOTE: Set by the XUI when the XEIP browser does not respond or is known to be dead.

Procedure

Perform the following in order:

1.Power Off and On

2.Reload software via AltBoot (GP 9).

3.Replace the Hard Drive ([PL 35.2]).

4.Replace the SBC PWB (PL 35.2)

302-380 UI Communication Fault

Communication via H-H USB netpath connection between NC and UI panel is not working

Procedure

Perform the following in order:

1.Power Off and On

2.Reload SW using GP 9

3.Use BSD 2.1 — UI and BSD 16.1 — SBC to troubleshoot the problem.

4.Replace the USB Cable PL 18.5.

5.Replace the Hard Drive ([PL 35.2]).

6.Replace the SBC PWB (PL 35.2). If replaceing the SBC PWB does not resolve the problem, install the original SBC PWB.

302-381 UI Communication Fault

Communication via USB connection between CC and UI panel is not working.

Procedure

Go to 302-380 UI Communication Fault RAP

302-390 Config Services Not Stable

During power up all configurable services have not achieved a stable state after 5 minutes from power up

NOTE: The chain/link fault code for this RAP is an internal machine code and is never displayed or logged in Fault Code History. Use this RAP to troubleshoot persistent machine status conditions that cannot be cleared by performing the indicated process (e.g., loading paper, closing a cover, replacing a CRU, etc). Entry to this RAP is usually via the Machine Status Faults RAP located in the Other Faults section, or a chain/link listing on a BSD.

Procedure

Go to the Machine Not Ready RAP.

303-306 Downgrade Not Permitted

Downgrade not permitted. A Customer upgrade was attempted, which would result in a downgrade, which is not allowed.

303-307 Upgrade Synchronization Failure

SW Upgrade Synchronization Failure. Customer or CSE tried to perform upgrade resulting in a SW Upgrade Synchronization problem.

Procedure

If a downgrade is required by the customer perform the downgrade using AltBoot in GP 9. If not, power off and then power on the machine.

Initial Actions

Power off and power on the machine.

Procedure

Perform thefollowing in order:

1.Check connections and cables and perform Software Upgrade again using Altboot in GP 9.

2.If the upgrade fails again, use Altboot to reload the SW version that existed on the machine prior to attempting the upgrade.

3.If the previous version loads correctly,download the upgrade SW again, verify that the files are correct for the machine, and attempt the upgrade using different media.

4.Replace the Hard Drive (PL 35.2).

5.Replace the SBC PWB (PL 35.2). If this fails to resolve the problem, reinstall the original SBC PWB and call service support.

303-316 CCM Cannot Communicate with IOT

Controller cannot communicate with IOT.

The scanner and copier are disabled but printing is operational.

Initial Actions

Enter the diagnostic mode dC131, and change the NVM setting in the following location (SWUP NVM Save Switch): [616-116] Change the value to 2

Procedure

Switch the power off then on. If the problem continues, perform GP 9.

Inspect the MCU PWB for loose connections or any obvious electrical/mechanical cause for malfunction. Clean, reseat or replace as required. If this does not resolve the problem replace the following in order:

•Replace the MCU PWB (PL 18.1)

•Replace the Hard Drive (PL 35.2).

•Replace the SBC PWB (PL 35.2)

303-317 IOT NVM Save Failure

IOT NVM Save Failure

Procedure

Switch the power off then on. Fault Code 303-317 is still declared.

YN

If intermittent performance is suspected, inspect the MCU PWB, SBC PWB and SBC NVM PWB for loose connections or any obvious electrical/mechanical cause for malfunction.

This fault can be caused by IOT software corruption or a software version mismatch between the IOT module and the rest of the software:

•If the fault occurred after replacing the MCU PWB, it is probably a software mismatch; perform a Software Upgrade (GP 9).

•If the fault is unrelated to MCU replacement it may be corrupt software; perform an Altboot SW Upgrade.

•If the fault is unrelated to MCU replacement it may be corrupt software; perform an Altboot SW Upgrade.

If this does not resolve the problem replace the following in order,

1.Replace the MCU PWB (PL 18.1)

2.Replace the Hard Drive (PL 35.2).

3.Replace the SBC PWB (PL 35.2).

303-318 IOT NVM Init Failure

IOT NVM Init Failure

Initial Actions

•Disconnect any Foreign Interface devices.

•Obtain all of the following information:

–Saved Machine Settings, if possible.

–NVM value factory setting report (typically it is located in the Tray 1 pocket)

–Any customer setting Auditron account from the system administrator

–Any setting changes (specifically NVM settings) shown on the machine’s service log.

–Any customer settings in the Tools mode.

•If possible, save Critical NVM (dC361 ).

Procedure

Perform dC301 NVM Initialization for the IOT.

After the initialization is complete, use the data accumulated in Initial Actions to restore the machine to its previous configuration.

303-319 IOT NVM Restore Failure

IOT NVM Restore Failure

Procedure

Perform dC361 NVM Restore for the IOT Critical NVM.

If this does not resolve the problem replace the following in order,

1.Replace the MCU PWB (PL 18.1)

2.Replace the Hard Drive (PL 35.2).

3.Replace the SBC PWB (PL 35.2).

303-320 Incompatible Product Type

Incompatible Product Type. SW Upgrade Aborted due to incompatible product type — software set does not match hardware.

Procedure

Perform GP 9 Software Upgrade with the correct Software module or select the correct .dlm file using the Web UI to upgrade the machine.

303-324 Software Upgrade File Transfer Failure

SW Upgrade File Transfer failure

Initial Actions

Power off and power on the machine.

Procedure

Perform thefollowing in order:

1.Check connections and cables and perform SW Upgrade again using Altboot in GP 9.

2.Download the upgrade SW again, verify that the files are correct for the machine, and attempt the upgrade using different media.

3.Replace the Hard Drive (PL 35.2).

4.Replace the SBC PWB (PL 35.2). If this fails to resolve the problem, reinstall the original SBC PWB and call service support.

303-325 Wall Clock Timeout During Power Up

System detects that the Wall Clock has not incremented within 1.5 seconds during Power On.

Procedure

Power OFF and then ON.

If the problem continues, call service support for assistance.

303-326 Upgrade is not Required

Upgrade not required, since the SW Upgrade version is the same as the SW version on the machine.

Procedure

If a software reinstallation is required, perform Forced Altboot using GP 9 .

303-327 Upgrade Failure

Upgrade Failed. this problem could be caused by an internal timing issue (Front side BUS speed set incorrectly), hardware error, user error and others.

Initial Actions

Check connections and reseat PWBs on SBC PWB and attempt another upgrade using GP 9 forced upgrade for the system or platform that failed.

Procedure

The problem is still present:

YN

Return to Service Call Procedures.

Call service support for assistance.

303-329 Upgrade Request During Diagnostics

Upgrade request received during active diagnostics.

Procedure

Exit Diagnostics and perform GP 9 Software Upgrade.

303-330 Upgrade Request During Active Security Feature

Upgrade request received during active Security function.

Procedure

Wait until Security function (Image Overwrite) is completed and perform GP 9 Software Upgrade.

303-331 Communication Fault With NC

Main controller board cannot communicate with Network Controller and unable to reestablish communications for 12 minutes. This problem could be caused by loose connections or improperly seated PWBs.

Procedure

Reseat PWBs on the SBC (Riser PWB, Fax PWB (if installed) and Memory PWBs). The problem continues.

YN

Return to Service Call Procedures.

Go to the Machine Not Ready RAP.

303-332 NC Communications Timeout

CCS unable to reestablish communication with the Network Controller for 12 minutes. This problem could be caused by loose connections or improperly seated PWBs.

Procedure

Reseat PWBs on the SBC (Riser PWB, Fax PWB (if installed) and Memory PWBs). The problem continues.

YN

Return to Service Call Procedures.

Go to the Machine Not Ready RAP.

303-338 Main Controller Has Been Reset

System detect that the main controller on CCM has been reset; either the watch dog timer timed out or the application SW wrote to an illegal address.

Initial Actions

Check that the customer does not have another device configured with the same IP address.

Procedure

Switch the power off then on.

Perform dC361 to restore NVM.

If the problem continues, perform GP 9 SW upgrade.

303-346 UI Communication Timeout

The SBC is unable to reestablish communication with the UI after 30 seconds.

Procedure

Go to the 303-347 .

303-347 UI Communication Fault

BSD-ON: BSD 3.4 — SBC — UI Communication

The SBC cannot communicate with UI PWB.

If communication is not reestablished within 30 seconds, fault code 03-346 will be declared.

NOTE: The UI will not display this fault because of the communication problem with the SBC PWB. This fault can be viewed only with the PWS.

Procedure

NOTE: This fault can occur if the UI software version is not compatible with the SBC software version.

Perform GP 9. If the problem persists, go to the Machine Not Ready RAP.

303-355 CCM POST Failure During NVM Test/NVM Battery

Dead

Power On Self-Test failure detected during the NVM Integrity Test; NVM battery dead

Procedure

The SBC NVM battery may be loose, failing, or has failed. Reseat the SBC NVM PWB battery. If the problem continues, go to REP 3.1 to replace the SBC NVM PWB.

303-380 Distribution PWB Missing or Disconnected

BSD-ON: BSD 3.5 — SBC DADF Communication

PWB is missing or disconnected.

Procedure

Check the connectors between the SBC and the IIT/IPS PWBs.

Power OFF and then ON.

If the problem continues, call service support for assistance.

303-390 Upgrade Automation Failed

Upgrade Automation failed

Procedure

Call service support for assistance.

303-398 SOK 1 Not Detected

SIM Card serial number mismatch. The number recorded on the SIM Card does not match the machine serial number. The first time a SIM is used in a machine the Serial number of the machine is written to the SIM.

Procedure

NOTE: If the problem surfaced after a PWB replacement that required serialization, make sure the serialization was performed correctly (dC132). If the machine is not serialized correctly this could be the cause of the SIM problem.

The SIM belongs to another machine and will not work in the machine it is being tried on. Try a new SIM, of the same type, to install the feature(s) on the machine. If the problem still exists after using the new SIM, call service support for assistance.

Check the configuration page. If the option is listed as” installed/not enabled,” use the Tools menu (see GP 2) to enable.

If the SIMs are not available, contact the Sales Rep. and ensure the feature was ordered by verifying the paperwork with the CBR. If the feature was ordered, a replacement part can be ordered from the Parts List. If it was not ordered, the Sales Rep. should order the SIM/feature using the correct Sales Order Number.

Extended FAX not detected/confirmed

Procedure

Switch the power off then on. If the problem continues, go to the OF 17-1 FAX Entry.

Incompatible FAX software detected at power on

Procedure

Switch the power off then on. If the problem continues, reload FAX software (GP 9).

303-777 Power Loss Detected

Input Power loss detected or software corruption.

Procedure

1.Power off and Power on the machine.

2.Verify customer power outlet voltage is correct.

3.Reload current IOT software or perform an upgrade, as necessary (GP 9).

303-788 Failed to Exit Power Save Mode

CCS Runtime could not enter power saver mode S3.

NOTE: The CC USB could not re-enumerate the UI panel coming out of sleep, which keeps parts of the system in power saver mode S3 and parts awake. This prevents system entry into power saver mode S3 at the next attempt to do so.

Procedure

Switch the power off then on to allow system to enter power save.

303-790 Timezone File Cannot be Set

Timezone file cannot be set. At power up, the timezone setting is not valid due to NVM corruption, or OS file system problem. Time Zone overridden to GMT: DST Disabled.

Procedure

Switch the power off then on.

Perform dC361 to restore NVM.

If the problem continues, perform GP 9 SW upgrade.

Status Indicator RAPs

303-790

305-121 DADF Feed Out Sensor On Jam

BSD-ON:BSD 5.5 — Document Feed (2 of 2)

After feeding started (DADF Feed Motor On (CW)) in Duplex, the DADF Feed Out Sensor did not turn ON within the specified time.

NOTE: When turning the power OFF, turn OFF the power switch first and then the main power switch.

Procedure

Remove the DADF Rear Cover and open the Top Cover. Enter the Diag Mode, turn ON dC330 [005-205]. Activate the Actuator of the DADF Feed Out Sensor manually. Does the display change between High/Low?

YN

Disconnect the DADF Feed Out Sensor connector P/J772. Is High displayed?

Y N

Check the wire between the DADF Feed Out Sensor P/J772-2 and the DADF PWB P/J757-5 for a short circuit. If no problems are found, replace the DADF PWB (PL 51.2).

A

Measure the wire wound resistance of the Motor.

• Between P/J754 pin-B1 and P/J754 pin-B5/B6

•Between P/J754 pin-B2 and P/J754 pin-B3/B4

Is the resistance approx. 1 Ohm for each?

YN

Replace the DADF Feed Motor (PL 51.5).

Replace the DADF PWB (PL 51.2).

Check the following:

•The document path for foreign substances.

•The DADF Feed/Nudger Roll for contamination, wear or revolution failure.

•The DADF Feed Out Sensor Actuator for disengagement, drag and damage.

Is the voltage between the DADF Feed Out Sensor P/J772-1 (+) and P/J772-3 (-) +5VDC?

YN

Check the wires between the DADF PWB P/J757-6 and the DADF Feed Out Sensor P/J772-1, as well as between the DADF PWB P/J757-4 and the DADF Feed Out Sensor P/J772-3 for open circuits and poor contacts.

Replace the DADF Feed Out Sensor (PL 51.6).

Press the Stop button. Turn ON dC330 [005-010] (DADF Feed Motor). Does the DADF Feed

Motor operate?

YN

Is the voltage between the DADF Feed Motor P/J776-5/2 (+) and the GND (-) +24VDC?

YN

Is the voltage between the DADF PWB P/J754-B1/B2 (+) and the GND (-) +24VDC?

YN

Is the voltage between the DADF PWB P/J753-2 (+) and the GND (-) +24VDC?

Y N

Refer to BSD 5.1 — Document Setting and check the +24VDC circuit to the DADF PWB P/J753-2.

Replace the DADF PWB (PL 51.2).

Check the wires between the DADF PWB P/J754-B1 and the DADF Feed Motor P/ J776-5, as well as between the DADF PWB P/J754-B2 and the DADF Feed Motor P/J776-2 for an open circuit and poor contact.

Turn OFF the power and disconnect P/J754 from the DADF PWB.

Status Indicator RAPs

305-121

305-122 DADF Simplex/Side 1 Pre Registration Sensor On

Jam

BSD-ON:BSD 5.5 — Document Feed (2 of 2)

•After Pre-Feed started for the first sheet (DADF Feed Motor On (CW)) in Simplex and Duplex, the DADF Pre Registration Sensor did not turn ON within the specified time.

•After Pre-Feed started for the second sheet onwards (DADF Feed Motor On (CW)) in Duplex, the DADF Pre Registration Sensor did not turn ON within the specified time.

NOTE: When turning the power OFF, turn OFF the power switch first and then the main power switch.

Procedure

Open the Top Cover and remove the Invert Chute. Enter the Diag Mode, turn ON dC330 [005206]. Block the DADF Pre Registration Sensor using a sheet of paper, etc. Does the display change to High?

Y N

Disconnect the DADF Pre Registration Sensor connector P/J774. Does the display change to High?

YN

Check the wire between the DADF Pre Registration Sensor P/J774-2 and the DADF PWB P/J757-11 for a short circuit. If no problems are found, replace the DADF PWB (PL 51.2).

Is the voltage between P/J774-1 (+) and P/J774-3 (-) +5VDC?

YN

Check the wires between the DADF PWB P/J757-12 and the DADF Pre Registration Sensor P/J774-1, as well as between the DADF PWB P/J757-10 and the DADF Pre Registration Sensor P/J774-3 for open circuits and poor contacts.

Replace the DADF Pre Registration Sensor (PL 51.17).

Press the Stop button. Turn ON dC330 [005-010] (DADF Feed Motor). Does the DADF Feed

Motor operate?

YN

Is the voltage between the DADF Feed Motor P/J776-5/2 (+) and the GND (-)

+24VDC?

YN

Is the voltage between the DADF PWB P/J754-B1/B2 (+) and the GND (-)

+24VDC?

YN

Is the voltage between the DADF PWB P/J753-2 (+) and the GND (-) +24VDC?

Y N

Refer to BSD 5.1 — Document Setting and check the +24VDC circuit to the DADF PWB P/J753-2.

Replace the DADF PWB (PL 51.2).

A B C

Check the wires between the DADF PWB P/J754-B1 and the DADF Feed Motor P/ J776-5, as well as between the DADF PWB P/J754-B2 and the DADF Feed Motor P/J776-2 for an open circuit and poor contact.

Turn OFF the power and disconnect P/J754 from the DADF PWB. Measure the wire wound resistance of the Motor.

• Between P/J754 pin-B1 and P/J754 pin-B5/B6

•Between P/J754 pin-B2 and P/J754 pin-B3/B4

Is the resistance approx. 1 Ohm for each?

YN

Replace the DADF Feed Motor (PL 51.5).

Replace the DADF PWB (PL 51.2).

Check the following:

•The document path for foreign substances.

•Overly strong Retard pressure.

•The DADF Pre Registration Sensor Actuator for disengagement, drag and damage.

305-123 DADF Simplex/Side 1 Registration Sensor On Jam

BSD-ON:BSD 5.5 — Document Feed (2 of 2)

BSD-ON:BSD 5.6 — Document Scan and Invert

After Pre Registration operation started (DADF Feed Motor On (CCW)), the DADF Registration Sensor did not turn ON within the specified time.

NOTE: When turning the power OFF, turn OFF the power switch first and then the main power switch.

Procedure

Open the Top Cover and remove the Invert Chute. Enter the Diag Mode, turn ON dC330 [005110]. Turn ON the DADF Registration Sensor using a sheet of paper, etc. Does the display change to «H» (opposite to the voltage level)?

YN

Remove the DADF Rear Cover. Is the voltage between the DADF PWB P/J757-14 (+) and the GND (-) +5VDC?

Y N

Replace the DADF PWB (PL 51.2).

The voltage between the DADF Registration Sensor P/J775-2 (+) and the GND (-) +5VDC?

Y N

A B C

Check the wires between the DADF PWB P/J754-B1 and the DADF Feed Motor P/ J776-5, as well as between the DADF PWB P/J754-B2 and the DADF Feed Motor P/J776-2 for an open circuit and poor contact.

Turn OFF the power and disconnect P/J754 from the DADF PWB. Measure the wire wound resistance of the Motor.

• Between P/J754 pin-B1 and P/J754 pin-B5/B6

•Between P/J754 pin-B2 and P/J754 pin-B3/B4

The resistance approx. 1 Ohm for each?

YN

Replace the DADF Feed Motor (PL 51.5).

Replace the DADF PWB (PL 51.2).

Check the following:

•The document path for foreign substances.

•The Transportation Roll for contamination, wear or revolution failure.

Check the connection between the DADF Registration Sensor P/J775-2 and the DADF PWB P/J757-14 for an open circuit and poor contact.

The voltage between the DADF Registration Sensor P/J775-1 (+) and P/J775-3 (-) +5VDC?

YN

Check the wires between the DADF PWB P/J757-15 and the DADF Registration Sensor P/J775-1, as well as between the DADF PWB P/J757-13 and the DADF Registration Sensor P/J775-3 for open circuits and poor contacts.

Replace the DADF Registration Sensor (PL 51.17).

Press the Stop button. Turn ON dC330 [005-008] (DADF Feed Motor). Does the DADF Feed

Motor operate?

YN

The voltage between the DADF Feed Motor P/J776-5/2 (+) and the GND (-) +24VDC? Y N

The voltage between the DADF PWB P/J754-B1/B2 (+) and the GND (-) +24VDC?

Y N

The voltage between the DADF PWB P/J753-2 (+) and the GND (-) +24VDC?

Y N

Refer to BSD 5.1 — Document Setting and check the +24VDC circuit to the DADF PWB P/J753-2.

Replace the DADF PWB (PL 51.2).

Status Indicator RAPs

305-123

305-125 DADF Registration Sensor Off Jam

BSD-ON: BSD 5.5 — Document Feed (2 of 2)

BSD-ON:BSD 5.6 — Document Scan and Invert

After the DADF Pre Registration Sensor turned OFF, the DADF Registration Sensor did not turn OFF within the specified time.

NOTE: When turning the power OFF, turn OFF the power switch first and then the main power switch.

Procedure

Check the following:

•Transportation failure due to foreign substance in the document path

•The surface of the roll for foreign substance

•The surface of the roll for wear

•Check the sw version of the controller sw — update if required (GP 9).

•DADF Feed Motor: dC330 [005-008] (PL 51.5)

•DADF Registration Motor: dC330 [005-033] (PL 51.5)

•Check the circuit between the DADF Registration Sensor and the DADF PWB

•Check the circuit between the DADF Pre Registration Sensor and the DADF PWB

•DADF Registration Sensor: dC330 [005-110] (PL 51.17)

•DADF Pre Registration Sensor: dC330 [005-206] (PL 51.17)

•DADF PWB failure. (PL 51.2)

305-131 DADF Invert Sensor On Jam (During Invert)

BSD-ON: BSD 5.6 — Document Scan and Invert

After the DADF Registration Sensor turned ON at Invert, the DADF Invert Sensor did not turn ON within the specified time.

NOTE: When turning the power OFF, turn OFF the power switch first and then the main power switch.

Procedure

Check the following:

•Transportation failure due to foreign substance in the document path

•The surface of the roll for foreign substance

•The surface of the roll for wear

•Check the sw version of the controller sw — update if required (GP 9).

•DADF Registration Motor: dC330 [005-033] (PL 51.5)

•Check the circuit between the DADF Registration Sensor and the DADF PWB

•Check the circuit between the DADF Inverter Sensor and the DADF PWB

•DADF Registration Sensor: dC330 [005-110] (PL 51.17)

•DADF Invert Sensor: dC330 [005-211] (PL 51.9)

•DADF PWB failure. (PL 51.2)