Xerox Workcentre 5790 Family 5735 5740 5745 5755 5775 Service Manual

708P90841
November 2014
Xerox WorkCentre 5790 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 WorkCentre 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 ................................................................................................ iii
Change History................................................................................................................ iv
Mod / Tag Identification ................................................................................................... ix
Voltages Resistances and Tolerances ............................................................................ ix
Safety Information ........................................................................................................... xii
Health and Safety Incident reporting ............................................................................... xiii
Translation of Warnings .................................................................................................. xiv
November 2014 Introduction

Xerox WorkCentre 5790 Family i
Introduction November 2014
ii Xerox WorkCentre 5790 Family
About This Manual How To Use This Manual
This manual is part of a multinational service documentation system that is structured in the Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the
standard Xerox service manual format. problem, then follow the directions given.
Organization How to Differentiate Between Machine Variants

The service manual is the document used as the primary information source for repairing and When a procedure, parts list description or other reference is unique across different speeds of
maintaining this family of products and is available as EDOC on a CDROM, or in PDF format. machine, the appropriate speed range will be quoted. For example, 35-55 ppm, 65-90 ppm.
The information within the manual is divided into an introduction and eight other sections. Any artwork will also be specific.
Section 1 Service Call Procedures Some machines are configured as copiers only. Refer to GP 30 Copier Only Machine Identifi-
This section is used to start and complete a service call. The procedures in this section will cation.
either direct you to a Repair Analysis Procedure (RAP), or identify a faulty component or sub-
assembly. NOTE: This manual services all configurations of the machine. Ignore references to options
not installed on the machine.
Section 2 Status Indicator Repair Analysis Procedures
Warnings, Cautions And Notes
This section contains the Repair Analysis Procedures (RAPs) and checkouts necessary to
diagnose, isolate and repair faults other than image quality faults.
WARNING
Section 3 Image Quality
A warning is used whenever an operating or maintenance procedure, practice, condi-
This section contains the Image Quality Repair Analysis Procedures (IQ RAPs), checkouts and
tion or statement, if not strictly observed, could result in personal injury.
setup procedures necessary to diagnose, isolate and repair image quality faults.
A translated version of all warnings is in Translation of Warnings.
Section 4 Repairs/Adjustments
This section contains the instructions for removal, replacement, and adjustment of parts within CAUTION
the machine.
A caution is used whenever an operation or maintenance procedure, practice, condition or
statement, if not strictly observed, could result in damage to the equipment.
Section 5 Parts List
This section contains the detailed and illustrated spare parts list. Any part that is spared or that NOTE: A note is used where it is essential to highlight a procedure, practice, condition or state-
must be removed to access a spared part is illustrated. ment.
Section 6 General Procedures / Information

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-
sary of Terms, Acronyms and Abbreviations.
Section 7 Wiring Data

This section contains PWB locations, PJ Locations and Wiring Diagrams.
Section 8 Accessories
This section contains details of any accessories that the machine may have.
Publication Comments Sheet

A Publication Comment Sheet is provided at the rear of the PDF version of the manual.

Xerox WorkCentre 5790 Family iii About This Manual, How To Use This Manual
Change History REP 8.49 Tray 3 Empty Sensor (W/TAG 151)
This page gives information on major changes to the service manual. Please go to the relevant REP 8.50 Tray 4 Feed Sensor (W/TAG 151)
update. REP 8.51 Tray 4 Stack Height Sensor (W/TAG 151)
REP 8.52 Tray 4 Empty Sensor (W/TAG 151)
Bus Update December 2010 RAP 07-355 Tray 3 Elevator Lift Failure RAP (W/O Tag 151)
Service Manual Update July 2011 Mod/Tag. 151 Introduction of the FAR Feeder HCF
Bus Update March 2012 The following procedures are updated (Generic):
Bus Update May 2012 Introduction (E-mail address change for USA)
Bus Update May 2013 SCP 1 Initial Actions
Bus Update November 2014 SCP 3 Normal Call Actions
Bus Update December 2010 SCP 4 Fault Analysis
The following procedures are updated: SCP 5 Subsystem Maintenance
Change History page added. SCP 7 Machine Features
REP 8.39 Retard Roll Friction Clutch. RAP 01A Ground Distribution
11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlock RAP RAP 01B 0V Distribution
Parts List updated RAP 01E +5V Distribution
TAG: D-006 RAP 01F +12V Distribution RAP
TAG: D-007 RAP 01G +24V Distribution
TAG: V-008 RAP 01H Short Circuit and Overload
TAG: L-001 RAP 01K Sleep Mode
Service Manual Update July 2011 RAP 03-359, 03-407 HCF Communications and Detection Error RAP
This revision of the service manual was produced during the introduction of the W/TAG 151 RAP 03-412 Foreign Device PWB Fault
HCF FAR feeder WC5790F machines, and to support the launch of machine software version RAP 03-423, 424, 433, 434, 821, 822, 831, 832 Print Command Late
SMP 1. Therefore, the updates to the following procedures have been either generic or W/TAG RAP 03C Hard Disk Failure
151 specific. The updates have been listed accordingly below.
RAP 07D Tray 1 and Tray 2 Wrong Size Paper
The following procedures are updated (W/TAG 151 specific): RAP 08-100A Wait Sensor Jam Entry
REP 7.22 Tray 3 and Tray 4 Removal (W/TAG 151) RAP 08-150A, 08-151A Registration Jam RAP (35-55 ppm)
REP 7.23 Tray 3 and Tray 4 Elevator Motor (W/TAG 151) RAP 08-150B, 08-151B Registration Jam RAP (65-90 ppm)
REP 7.24 Tray 3 and Tray 4 Elevator Cables (W/TAG 151) RAP 10-101A, 10-102A, 10-103A Lead Edge Late to Fuser Exit Switch RAP (35-55 ppm)
REP 7.25 Tray 3 and Tray 4 Stack Height Sensor (W/TAG 151) RAP 10-101B, 10-102B, 10-103B Lead Edge Late to Fuser Exit Switch RAP (65-90 ppm)
REP 7.26 Tray 3 and Tray 4 Stack Limiter (W/TAG 151) RAP 10-120, 10-121, 10-126 IOT Exit Sensor
REP 7.27 Tray 3 and Tray 4 Home Switch (W/TAG 151) RAP 11-100, 11-101-171 HVF Entry Sensor
REP 7.28 HCF Control PWB (W/O TAG 151) RAP 11-083-171, 11-440-171 to 11-443-171 Paper Pusher
REP 7.29 Tray 3 and Tray 4 Elevator Damper and Gears (W/TAG 151) RAP 11-157, 11-161-171 HVF Buffer Position Sensor
REP 8.40 Tray 3 Paper Feed Assembly (W/TAG 151) RAP 11-158-171, 11-160-171, 162-171, 163-171 HVF BM Entry
REP 8.41 Tray 4 Paper Feed Assembly (W/TAG 151) RAP 11-173-171 to 11-177-172 HVF Offset Unit
REP 8.42 Tray 3 and Tray 4 Transport Motor (W/TAG 151) RAP 11-371-171 to 11-377-171 HVF Stapler Position and Priming
REP 8.43 Tray 3 and Tray 4 Transport Gear Pulley (W/TAG 151) RAP 11-380-171 HVF Punch Unit Paper Edge Detect
REP 8.44 Tray 3 Transport Assembly (W/TAG 151) RAP 11-451-171 to 11-455-171 HVF Ejector Roll and Lower Paddle
REP 8.45 Tray 3 Feed Sensor (W/TAG 151) RAP 11-460-171 to 11-462-171 HVF Bin 1 Position
REP 8.46 Tray 3 Takeaway Roll Assembly (W/TAG151) RAP 11-465-171 to 11-468-171 Paddle Unit Position
REP 8.47 Tray 3 and Tray 4 Transport Roll (W/TAG 151) RAP 11A-171 HVF Power Distribution
REP 8.48 Tray 3 Stack Height Sensor (W/TAG 151) RAP 11D 2K LCSS Power Distribution

Change History iv Xerox WorkCentre 5790 Family
RAP 11G-110 2K LCSS PWB Damage GP 3 Service Information
RAP 16A Network Error Entry GP 5 Portable Work Station and Tools
RAP 16B FTP or SMB Unable to Connect to Remote Server GP 4 Machine Software
RAP 16C Remote Directory Lock Failed GP 5 Portable Work Station and Tools
RAP 19-404 Compressor Time-out GP 15 How to Set the Machine Configuration
OF1 Audible Noise RAP GP 18 Machine Lubrication
OF3 Dead Machine RAP GP 27 Fuser/Xerographic Module End of Life Extension
OF4a Status Codes RAP GP 30 Copier Only Machine Identification
OF4b Status messages G to N RAP GP 31 How to Set the Date and Time
OF5 Boot Up Failure RAP GP 32 How to Enable HTTP
OF6 Ozone and Air Systems RAP GP 33 How to Configure the PWS to Ping a Device
IQ6 Narrow Bands RAP GP 34 How to Set the IP Address of the PWS
IQ5 Print Damage RAP GP 35 How to Change Ethernet Speed
IQ13 Cockle Deletion RAP GP 36 How to Disable the Firewall of the PWS
REP 8.34 Tray 5 Feed Rolls dC131a NVM Tables
REP 10.1 Short Paper Path Assembly dC132 NVM Initialization
REP 10.2 Inverter Assembly dC 305 UI test
REP 10.15 Intermediate Drive Belt (W/O TAG 114) dC330
REP 11.8-110 Stapler Traverse Assembly Mod/Tag. 114
REP 11.12-171 Bin 1 Elevator Motor Assembly Mod/Tag. 120
REP 11.19-171 BM Crease Roll Motor Mod/Tag. 148
REP 11-27-171 BM Staple Heads Mod/Tag. D006
REP 11.54-171 Sensor Assembly Mod/Tag. D-007
REP 11.101-171 Paddle Wheel Mod/Tag. F-016
REP 12.10-110 Stapler Traverse Assembly Mod/Tag. F017
REP 12.12-110 Paddle Wheel Shaft Assembly Mod/Tag. L003
ADJ 4.1 Machine Lubrication Mod/Tag. L016
ADJ 8.2 Simplex and Duplex Buckle Timing PJ Locations (table 1)
ADJ 10.1 Inverter Decurler Adjustment PJ Locations (table 3)
ADJ 11.14-171 BM Diverter Solenoid Position PJ Locations Figure 15 (PJ76)
PL 5.35 Input Tray Assembly Wiring Diagrams 7
PL 7.60 Tray 5 Covers Wiring Diagrams 8
PL 7.68 Tray 5 Lift assembly (1 of 2) Wiring Diagrams 9
PL 7.68 Tray 5 Lift assembly (2 of 2) Wiring Diagrams 11
PL 10.11 Inverter Assembly (1 of 4) Wiring Diagrams 20
PL 10.12 Inverter Assembly (2 of 4) Wiring Diagrams 46
PL 10.25 Short Paper Path Wiring Diagrams 47
PL 11.12 2K LCSS Bin 1 Control The following Service Bulletins have been incorporated:
PL 11.20 2K LCSS Staple Head Unit/Traverse Assembly T7494-04-26 Deletions on Duplex or Simplex Images
PL 11.135 HVF Stacker T7580-08-27 Announcement of 5790F copier variant
PL 11.150 HVF Main Drives T7964-04-11 Boot up failure-blank UI
PL 31.11 Maintenance/Installation/removal Kits (2 of 5) T7965-04-12 Boot up failure from cold - Green splash screen
PL Common Hardware

Xerox WorkCentre 5790 Family v Change History
Bus Update March 2012 RAP 11-024-171, 11-026-171 Paddle Roller Position
The following procedures are updated: RAP 11-371-171 to 11-377-171 HVF Stapler Position and Priming
Change History RAP 11-380-171 HVF Punch Unit Paper Edge Detect
08-108A Tray 3 or Tray 4 Paper Feed Jam RAP (W/O TAG 151) RAP 14-703B to 14-706B, 712B, 714B, 718B Failure to Calibrate (W/TAG 150)
The following procedures are new: RAP 19-404 Compressor Time-Out
08-108 Tray 3 or Tray 4 Paper Feed Jam Entry RAP RAP OF1 Audible Noise
08-108B Tray 3 or Tray 4 Paper Feed Jam RAP (W/TAG 151) RAP OF3 Dead Machine
Bus Update May 2012 RAP OF4a Status Codes in Numerical Order
The following procedures are updated: RAP OF4b Status Messages in Alphabetical Order
Change History RAP OF5 Boot Up Failure
RAP 01B 0V Distribution RAP OF6 Ozone and Air Systems
RAP 01G +24V Distribution RAP IQ2 Defects
RAP 01H Short Circuit and Overload RAP IQ3 Xerographics
RAP 01J Power On and LVPS Control Signals RAP IQ5 Print Damage
RAP 01K Sleep Mode RAP IQ8 Skew
RAP 03-300, 306, 461, 482, 805, 870 Single Board Controller PWB to IOT PWB Error REP 4.6 Main Drive PWB (65-90 ppm)
RAP 03-320 to 03-324 Single Board Controller PWB to DADH Error REP 14.16 Scan Motor and Scan Carriage Drive Belts (W/TAG 150)
RAP 03-330A, 03-462A Single Board Controller PWB to Scanner Fault (W/O TAG 150) ADJ 3.2 Magnification Adjustment
RAP 03-330B, 03-462B Single Board Controller PWB to Scanner Fault (W/TAG 150) ADJ 9.2 Image Quality Adjustment Routine
RAP 03-340, 03-416 Single Board Controller PWB to Network Controller Fault ADJ 9.4 Xerographics Cleaning
RAP 03-423, 424, 433, 434, 821, 822, 831, 832 Print Command Late Parts List updated
RAP 05A DADH Other Faults GP 14 How to Switch Off the Machine or Switch On the Machine
RAP 07-355 Tray 3 Elevator Lift Failure Entry GP 20 Paper and Media Size Specifications
RAP 07L Tray 3 or Tray 4 Out of Paper (W/O TAG 151) PJ Locations Figure 35
RAP 08-100A Wait Sensor Jam (35-55 ppm) PJ Locations Table 2
RAP 08-100B Wait Sensor Jam (65-90 ppm) PJ Locations Table 6
RAP 08-101 Tray 1 Misfeed Wiring Diagram 8
RAP 08-102 Tray 2 Misfeed Wiring Diagram 9
RAP 08-106 Lead Edge Late to Tray 1 Feed Sensor Wiring Diagram 47
RAP 08-131 Lead Edge Late to Tray 3 Exit Sensor (W/TAG 151) The following procedures are new:
RAP 08-150A, 151A Registration Jam (35-55 ppm) RAP 03D Software Module Failure
RAP 09-060 HVPS Fault Mod/Tag 103
RAP 09-341, 342 Scorotron Cleaning Failure Mod/Tag 152
RAP 09-360, 361, 362, 363 Toner Concentration Sensor Failure Mod/Tag 153
RAP 09-375 Ambient Tempearture Sensor Failure Mod/Tag 154
RAP 09-399 Incompatible Xerographic Module Mod/Tag 155
RAP 09C Photoreceptor Fan Mod/Tag 156
RAP 10-101A, 102A, 103A Lead Edge Late to Fuser Exit Switch (35-55 ppm) Mod/Tag 157
RAP 10-101B, 102B, 103B Lead Edge Late to Fuser Exit Switch (65-90 ppm) The following Service Bulletins have been incorporated:
RAP 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 10-365, 10-380 Fuser 162651 Dead machine RAP (how to troubleshoot a dead LVPS)
Over Temperature 167986 Not compatible, message to replace XCRU
RAP 11-364-110 Stapling Failure 170792 Cleaning streaks, spots, toner bridging, solidified in XCRU
RAP 11F-110 2K LCSS PWB DIP Switch Settings 172538 Detack problem, XCRU stripper finger contamination, marks, spots

Change History vi Xerox WorkCentre 5790 Family
173384 Bold, dark, smeared (blurred) characters, heat damage to drum RAP 08-150A, 151A Registration Jam (35-55 ppm)
338812 XCRU noise, end of cycle grunt, moo, moan RAP 08-150B, 151B Registration Jam (65-90 ppm)
640783 Re-occuring reorder fuser, scanner fualt, replace XCRU message RAP 08-190 Post Jam Clearance Initialization
783324 Output tray 1 out of service, check for obstruction RAP 09-060 HVPS Fault
1055407 Dead machine or blank UI at install RAP 09-310, 09-390 Low Toner Sensor Failure
1139346 08-150 Jams with noise RAP 09-341, 09-342 Scorotron Cleaning Failure
1154339 Ozone Deletions and Seal Repair Kit RAP 09-360, 09-361, 09-362, 09-363 Toner Concentration Sensor Failure
1172776 09-060 HVPS faults caused by a shorted dev bias harness RAP 09-399 Incompatible Xerographic Module
1183941 Erratic operation, shuts down 4 to 6 seconds after power on RAP 09B Waste Toner Full Sensor
1195182 Please check output bin for blank of particially images sheets RAP 10-135, 10-136, 10-137, 10-138 Trail Edge Late from Inverter Sensor
1223654 RX for 113R672 RAP 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-110 Rear Tamper Move
T7748-07-01 Ozone Deletion and Seal Repair Kit Failure
T7764-08-08 Boot up failure after replacing IOT PWB or software module RAP 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 10-365, 10-380 Fuser
Over Temperature
T7769-08-22 Decurler Inverter Unit for OCT Configurations
RAP 11-130-110, 11-132-110 Paper Exiting to Bin 0
T7903-03-30 SIP Diagnostic
RAP 11-140-120, 11-142-120 Sheet Late to Bin 1
T7908-04-02 Toner Contamination
RAP 11-300-120, 11-302-120, 11-303-120 Interlocks
T312692 09-341 Scorotron cleaning failed
RAP 11-320-120, 11-322-120 Ejector Movement Failure
Bus Update May 2013
RAP 11C-120 1K LCSS Power Distribution
The following procedures are updated:
RAP 11-061-171, 11-416-171 HVF BM Creasing
Change History
RAP 11-188-171, 11-189-171 HVF Nip Split
SCP 4 Fault Analysis
RAP 11-140-171, 11-142-171 HVF 2nd to Top Exit Sensor
SCP 5 Subsystem Maintenance
RAP 11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlock
SCP 6 Final Actions
RAP 11-306-171, 11-309-171 HVF Inserter Interlock
RAP 01-300 Front Door Open
RAP 11-307-171, 11-308-171, 11-303-171 Tri-folder Interlock
RAP 03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error
RAP 11-371 to 11-377-171 HVF Stapler Position and Priming
RAP 03-412 Foreign Device PWB Fault
RAP 11-479-171 Inserter paper Length Fault
RAP 03B Mark Service Unavailable
RAP 11A-171 HVF power Distribution
RAP 04A main Drive Motor and Photoreceptor Motor
RAP 11D-171 Booklet Quality
RAP 07-353 Tray 1 Elevator Lift Failure
RAP 11M-171 Curl Suppressor
RAP 14-110B Scan Carriage Home Sensor (W/TAG 150)
RAP 19-401, 19-402, 19-403 Out of Memory Resources
RAP 07A Tray 1and Tray 2 Empty
RAP OF1 Audible Noise
RAP 07D Bypass Tray
RAP OF3 Dead Machine
RAP 07H Tray Out of Service
RAP OF4A Status Codes in Numerical Order
RAP 07J Tray 5 Empty
RAP OF4B Status Messages in Alphabetical Order
RAP 08-101 Tray 1 Misfeed
RAP OF5 Boot Up Failure
RAP 08-103B, 08-113B Tray 3 Misfeed RAP (W/TAG 151)
RAP IQ1 Image Quality Entry
RAP 08-104B, 08-114B Tray 4 Misfeed RAP (W/TAG 151)
REP 7.14 Tray 5 Stack Height Sensor
RAP 08-106 Lead Edge Late to Tray 1 Feed Sensor
REP 7.27 HCF Control PWB (W/TAG 151)
RAP 08-108B Tray 3 or Tray 4 Paper Feed Jam (W/TAG 151)
REP 8.5 Registration Clutch
RAP 08-115A, 08-117A Tray 5 Misfeed (35-55 ppm)
REP 8.24 Tray 1 or Tray 2 Feed Sensor
RAP 08-115B, 08-117B Tray 5 Misfeed (65-90 ppm)
REP 11.1-171 HVF Covers
RAP 08-132 Tray 3 Paper Feed Jam (W/TAG 151)

Xerox WorkCentre 5790 Family vii Change History
REP 11.6-171 HVF Ejector Assembly Removal RAP 07-304B Tray 4 Open During Run (W/TAG 151)
REP 11.11-171 Front Tamper Motor Assembly RAP 10-322, 10-324, 10-325, 10-330, 10-370 Fuser Under Temperature
REP 11.21-171 BM Backstop Assembly RAP 11-130-110, 11-132-110 Paper Exiting to Bin 0
REP 11.48-171 Paddle Module Driving Motor Assembly RAP 11-130-120, 11-132-120 Paper Exiting to Bin 0
REP 11.69-171 Drive Coupling Assembly RAP 11A-171 HVF Power Distribution
REP 11.70-171 Tri-Folder Feed Roller and Drive Belt RAP 20F Fax Tab Not Available
REP 11.73-171 Tri-Folder Top Door Cover and Idler Assemblies REP 11.61-171 BM Module
REP 11.77-171 Tri-Folder Door Interlock Switches and Sensor REP 11.96-171 HVF Fixed and Adjustable Casters
REP 11.80-171 Tri-Folder Control PWB ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield
ADJ 4.1 Machine Lubrication Parts List updated
ADJ 10.1 Inverter Decurler Adjustment GP 3 Service Information
ADJ 11.6-171 Booklet Compiling Position GP 21 Installation Space Requirements
ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield Wiring Diagram 13
Parts List updated
GP 27 Fuser/Xerographic Module End of Life Extension
dC131a NVM Tables Chain 1 to 10
dC604 Registration Setup Procedure
TAGs
PJ Locations Table 1
PJ Locations Table 2
Wiring Diagram 8
Wiring Diagram 9
Wiring Diagram 34
The following procedures are new:
REP 7.29 Tray 5 Elevator Tray Guides
ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield
Mod/Tag 158
Mod/Tag F-012
Mod/Tag L-012
Mod/Tag P-011
Mod/Tag P-050
Mod/Tag P-051
The following Service Bulletins have been incorporated:
1266820 600T02329 Setup Tool Tray 5 or 6
Bus Update November 2014
The following procedures are updated:
Change History
Heath and Safety Incident Reporting
RAP 01D +3.3V Distribution Rap
RAP 03-315, 325, 347, 348, 349, 355, 400 Single Board Controller PWB Failure
RAP 03-320 to 03-324 Single Board Controller PWB to DADH Error
RAP 03E Foreign Device PWB Fault
RAP 05A DADH Other Faults

Change History viii Xerox WorkCentre 5790 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 01B 0V Distribution RAP
+3.3V standby +3.23V to +3.43V 01J Power On and LVPS Control Signals RAP
+3.3V +3.23V to +3.43V 01D +3.3V Distribution RAP. See notes below
+5.V +4.75V to +5.25V 01E +5V Distribution RAP
+12V +11.4V to +12.6V 01F +12V Distribution RAP
These without tag symbols are used to identify the +24V +23.28V to +25.73V 01G +24V Distribution RAP
components or configurations that are used when this
tag is not fitted.
Non-standard voltage levels will be quoted on the relevant circuit diagram. All other voltage lev-
els are plus or minus 10%.
Resistance Tolerances
All resistance measurement tolerances are plus or minus 10%, unless otherwise stated in the
procedure.
Figure 1 Mod/Tag identification symbols
DC Signal Nomenclature
Figure 1 shows the signal nomenclature used in this manual.
Signal description (event that

causes the signal level change)
Voltage supplied to
Logic level when the the signal circuit
signal is available
Wire color
Figure 1 Signal Nomenclature

Xerox WorkCentre 5790 Family ix Mod / Tag Identification, Voltages Resistances and
Table 2 shows the signal tolerances.
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.
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
screen.
Samples of RAP reference text

Throughout the manual there are linked references that extend the diagnostic procedure or
add more information.
Go to Flag 1. Check Q08-300. Refer to:
NOTE: This links to a particular part of the circuit diagram within a RAP.
GP 11 How to Check a Sensor.
NOTE: This links to General Procedures information.
Figure 1, IOT PWB
NOTE: The P/J links to the connector location on the PWB in a circuit diagram.
NOTE: The PWB links the connector to the pin layout on the PWB, referenced in the Wir-
ing Diagram section.
01D +3.3V Distribution RAP.
NOTE: This links to a RAP.
Install new components as necessary:

Tray 1/2 feed sensor, PL 7.30 Item 24.
NOTE: This links to the parts list. If installation of the new component is simple, the parts
list artwork is sufficient to show how the component is assembled in the machine. If instal-
lation of the new component is not simple, the parts listing will contain cross references to
repair procedures and adjustments, as necessary.
Symbols Used in Circuit Diagrams

Refer to Figure 2.

Voltages Resistances and Tolerances x Xerox WorkCentre 5790 Family
Figure 2 Symbols used in circuit diagrams

Xerox WorkCentre 5790 Family xi Voltages Resistances and Tolerances
Safety Information Hot Surface Symbol
The WARNING that follows is for general guidance when live working. This symbol indicates hot surfaces. Take care when servicing the machine.
WARNING
Do not work in a confined space. 1m (39 inches) space is needed for safe working.
Safety Icons Lethal Voltage Symbol
The safety icons that follow are displayed on the machine: This symbol indicates potentially lethal voltages. Take care when servicing the machine when
the power cord is connected.
ESD Caution Symbol
Ozone
During normal operation, this machine produces ozone gas. The amount of ozone produced
does not present a hazard to the operator. However, it is advisable that the machine be oper-
ated in a well ventilated area.
CAUTION
Certain components in this product are susceptible to damage from electrostatic discharge. Toner Cartridge
Observe all ESD procedures to avoid component damage. The product contains a dry imager cartridge that is recyclable. Under various state and local
Laser Radiation Warning Symbol laws, it may be illegal to dispose of the cartridge into the municipal waste. Check with the local
waste officials for details on recycling options or the proper disposal procedures.
Fuses
WARNING
Do not install a fuse of a different type or rating. Installing the wrong type or rating of
fuse can cause overheating and a risk of fire.
Part Replacement
Only use genuine Xerox approved spare parts or components to maintain compliance with leg-
WARNING islation and safety certification. Also refer to GP 26 Restriction of Hazardous Substances
Follow the service procedure exactly as written. Use of controls or adjustments other (R0HS).
than those specified in this manual, may result in an exposure to invisible laser radia-
tion. During servicing, the invisible laser radiation can cause eye damage if looked at Disassembly Precautions
directly.
Do not leave the machine with any covers removed at a customer location.
Location Arrow Symbol
The location arrow symbol points to the location to install, to gain access to, or to release an Reassembly Precautions
object. Use extreme care during assembly. Check all harnesses to ensure they do not contact moving
parts and do not get trapped between components.
General Procedures
Observe all warnings displayed on the machine and written in the service procedures.
Do not attempt to perform any task that is not specified in the service procedures.

Safety Information xii Xerox WorkCentre 5790 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 and 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: [email protected].
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 WorkCentre 5790 Family xiii Health and Safety Incident reporting
Translation of Warnings AVISO: Siga los procedimientos de mantenimiento tal como estn descritos. El uso de
controles o ajustes no especificados en este manual puede tener como resultado la
exposicin a radiacin lser invisible. Durante las operaciones de mantenimiento, la
radiacin de lser invisible puede causar daos en los ojos si se mira directamente a
WARNING
ella.
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 utilise chaque fois qu'une procdure d'utilisation ou de WARNING
maintenance peut tre cause de blessure si elle n'est pas strictement respecte.
Do not install a fuse of a different type or rating. Installing the wrong type or rating of
AVVERTENZA: Un segnale di avvertenza utilizzato ogni volta che una procedura oper- fuse can cause overheating and a risk of fire.
ativa o di manutenzione, una pratica, una condizione o un'istruzione, se non stretta-
DANGER: Ne pas installer de fusible de type ou de calibre diffrent. Il existe un risque
mente osservata, potrebbe causare lesioni personali. de surchauffe voire d'incendie.
VORSICHT: Weist darauf hin, dass ein Abweichen von den angefhrten Arbeits- und AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non installare un fus-
Wartungsanweisungen gesundheitliche Schden, mglicherweise sogar schwere Ver-
ibile di tipo o carica diversi da quelli esistenti.
letzungen zur Folge haben kann.
VORSICHT: Keine Sicherungen anderer Art oder anderer Leistung auf dem IOT-PWB
AVISO:Un aviso se utiliza siempre que un procedimiento de operacin o mantenimiento,
installieren - berhitzungs- und Brandgefahr.
prctica o condicin puede causar daos personales si no se respetan estrictamente.
AVISO: No instale un fusible de potencia o tipo distinto. Un fusible de potencia o tipo
distinto puede producir sobrecalentamiento y el riesgo de incendio.
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 mtre d'espace est ncessaire Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
pour un dpannage en toute scurit.
from the customer supply while performing tasks that do not need electricity. Electricity
AVVERTENZA: Non lavorare in uno spazio limitato; necessario uno spazio di almeno can cause death or injury. Moving parts can cause injury.
un metro attorno alla macchina per la sicurezza dell'operatore.
DANGER : Mettez la machine hors tension. Reportez-vous GP 14. Dconnectez le cor-
VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten. don d'alimentation de l'alimentation du client lorsque vous ralisez des tches qui ne
AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar ncessitent pas d'lectricit. L'lectricit peut tre l'origine de blessures, voire d'un
con seguridad. accident mortel. Les pices amovibles peuvent tre l'origine de blessures.
AVVERTENZA: Spegnere la macchina. Vedere GP 14. Scollegare il cavo di alimentazione
dall'alimentatore quando si eseguono attivit che non richiedono elettricit. L'elettricit
WARNING pu causare morte o lesioni personali. Le parti in movimento possono causare lesioni
Follow the service procedure exactly as written. Use of controls or adjustments other personali.
than those specified in this manual, may result in an exposure to invisible laser radia- VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Siehe auch GP 14. Zie-
tion. During servicing, the invisible laser radiation can cause eye damage if looked at hen Sie das Stromkabel ab, wenn Sie Aufgaben ausfhren, fr die keine Stromversor-
directly. gung bentigt wird. Stromschlge knnen Todesfllen oder Verletzungen verursachen.
DANGER : Les procdures de dpannage doivent tre suivies la lettre. Si les rglages Bewegliche Teile knnen zu Verletzungen fhren.
ou vrifications ne sont pas effectus suivant les instructions de ce manuel, il peut y AVISO: Apague la electricidad de la mquina. Consulte el GP 14. Desconecte el cable de
avoir un risque d'exposition dangereuse au faisceau laser. Celui-ci peut provoquer des alimentacin elctrica de la toma de pared mientras est realizando tareas que no
lsions oculaires s'il est observ directement. necesiten corriente. La electricidad puede causar daos o la muerte. Las partes mviles
AVVERTENZA: Eseguire le procedure di servizio esattamente come descritto. L'utilizzo pueden causar daos.
di dispositivi di controllo o di registrazione diversi da quelli riportati in questo manuale
potrebbe comportare un'esposizione a radiazioni laser invisibili. Tali radiazioni possono
danneggiare gli occhi se si guarda direttamente il fascio laser durante gli interventi di WARNING
servizio. Do not switch on the electricity to the machine while a ground circuit is disconnected.
VORSICHT: Die Wartungsarbeiten genau den Anweisungen entsprechend durchfhren. Ground circuits ensure that the machine remains safe during a fault condition.
Der Umgang mit Steuer- oder Bedienelementen, deren Verwendung nicht ausdrcklich DANGER : Ne pas mettre la machine sous tension si un circuit de mise la masse est
in diesem Handbuch angewiesen wurde, kann dazu fhren, dass unsichtbare Laser- dconnect. Les circuits de mise la masse permettent de garantir la scurit de la
strahlung frei gesetzt wird. Direkter Blickkontakt mit dem Laserstrahl kann bleibende machine lors d'un incident.
Augenschden verursachen. AVVERTENZA: Non accendere la macchina se uno dei conduttori di terra non con-

Translation of Warnings xiv Xerox WorkCentre 5790 Family
nesso. In caso di guasti elettrici, tali conduttori garantiscono la sicurezza del sistema. new fuse can cause overheating and a risk of fire.
VORSICHT: Stromzufuhr zum Gert nicht einschalten, wenn keine Erdung gegeben ist. DANGER : Ne pas rparer de fusible F1 ou en installer un nouveau sur la carte
AVISO: No encienda la mquina mientras est deconectado algn circuito de tierra. Los d'entranement principal. Il existe un risque de surchauffe voire d'incendie.
circuitos de tierra mantienen la seguridad de la mquina en las situaciones de averas o AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
errores. lare un nuovo fusibile F1 sul PWB azionamento principale.
VORSICHT: Die Sicherung F1 auf dem Hauptantriebs-PWB nicht reparieren oder neu
WARNING AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de impulso principal. Un
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. fusible reparado o nuevo puede producir sobrecalentamiento y el riesgo de incendio.
DANGER: Prendre des prcautions lors du relev de la tension de la prise de courant
alternatif. L'lectricit peut entraner des blessures graves voire mortelles.
AVVERTENZA: Procedere con cautela durante la misurazione della tensione CA della WARNING
rete. L'elettricit pu causare infortuni o morte. Avoid exposure to laser beam. Invisible laser radiation.
VORSICHT: Bei der Netzspannungsprfung stets vorsichtig vorgehen DANGER : Eviter toute exposition au faisceau laser. Radiation laser invisible.
AVISO: Tenga cuidado al medir la tensin de la lnea de alimentacin de corriente AVVERTENZA: Evitare l'esposizione al fascio laser. Radiazioni laser invisibili.
alterna. La electricidad puede causar lesiones e incluso la muerte. VORSICHT: Nicht in den Laserstrahl blicken. Verletzungsgefahr durch unsichtbare
Laserstrahlung.
AVISO: Evite la exposicin al rayo lser. Radiacin de lser invisible.
WARNING
Do not repair or install a new fuse F1 on the IOT PWB. Repairing or installing a new fuse
can cause overheating and a risk of fire. WARNING
DANGER : Ne pas rparer de fusible F1 ou en installer un nouveau sur la carte d'alimen- Take care during this procedure. Motors will become hot during normal operation.
tation de la machine. Il existe un risque de surchauffe voire d'incendie.
DANGER : Excuter cette procdure avec prcaution. Les moteurs peuvent devenir trs
AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal- chauds en fonctionnement normal.
lare un nuovo fusibile F1 sul PWB IOT. AVVERTENZA: procedere con cautela durante questa procedura. I motori si riscaldano
VORSICHT: Die Sicherung F1 auf dem IOT-PWB nicht reparieren oder neu installieren - molto durante il funzionamento.
berhitzungs- und Brandgefahr.
VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, da Motoren im Normalbetrieb hei
AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de la IOT. Un fusible rep- werden knnen.
arado o nuevo puede producir sobrecalentamiento y el riesgo de incendio.
AVISO: Tenga cuidado al efectuar este procedimiento. Los motores alcanzan altas tem-
peraturas durante su funcionamiento normal.
WARNING
Do not repair or install a new fuse F1 on the power distribution PWB. Repairing or WARNING
installing a new fuse can cause overheating and a risk of fire.
Do not touch the fuser while it is hot.
DANGER : Ne pas rparer de fusible F1 ou en installer un nouveau sur la carte de distri-
DANGER : Ne pas toucher au four pendant qu'il est encore chaud.
bution lectrique. Il existe un risque de surchauffe voire d'incendie.
AVVERTENZA: Non toccare il fonditore quando caldo.
AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
VORSICHT: Fixierbereich erst berhren, wenn dieser abgekhlt ist.
lare un nuovo fusibile F1 sul PWB distribuzione di alimentazione
AVISO: No toque el fusor mientras est caliente.
VORSICHT: Die Sicherung F1 auf dem Stromverteilungs-PWB nicht reparieren oder neu
AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de distribucin de
WARNING
energa elctrica. Un fusible reparado o nuevo puede producir sobrecalentamiento y el
riesgo de incendio. Take care not to topple the LCSS. The LCSS is unstable when undocked from the
machine. Do not show the customer how to undock the LCSS.
DANGER: Attention ne pas faire tomber la trieuse/agrafeuse petite capacit. Elle n'est
WARNING pas stable lorsqu'elle est dtache de la machine. Ne pas montrer au client comment
Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a dtacher la trieuse/agrafeuse.
AVVERTENZA: fare attenzione a non destabilizzare il modulo della pinzatrice/impilatore

Xerox WorkCentre 5790 Family xv Translation of Warnings
da 2000 fogli. Quando sganciato dalla macchina, il modulo instabile: non mostrare al VORSICHT: Die Testpads (Prfkontakte) der Platine fr das integrierte Fax nicht
cliente come sganciarlo berhren, solange das Gert eingeschaltet ist. An den Pads liegt eine Spannung an; es
VORSICHT: Stapler nicht umstoen. Nach Trennung des Staplers vom Document Centre besteht Stromschlag- bzw. Lebensgefahr!
ist dieser sehr instabil AVISO: No toque la zona terminal de prueba que presenta el circuito impreso del fax
AVISO: Tenga cuidado de que no se caiga el apilador/grapadora de baja capacidad. interno mientras la mquina est encendida, ya que podra haber tensiones peligrosas
Cuando no est acoplada a la mquina es inestable. No le muestre al cliente como desa- que podran provocar lesiones o incluso la muerte.
coplar el apilador/grapadora de baja capacidad.
WARNING
WARNING Only use the correct plug to connect a power lead to a power outlet.
Keep away from the crease blade mechanism when working in close proximity to the DANGER : Toujours utiliser la fiche approprie pour connecter le cordon d'alimentation
booklet maker while the machine is powered on. The crease blade mechanism activates la prise.
quickly and with great force. AVVERTENZA: Usare la spina corretta per connettere il cavo elettrico alla presa.
DANGER: Ne pas s'approcher du mchanisme de la lame de pliage lors d'une activit VORSICHT: Nur Netzkabel mit dem fr die vorhandenen Netzsteckdose geeigneten
proximit de la plieuse/brocheuse pendant que la machine est sous tension. Ce mcan- Netzstecker verwenden.
isme s'active rapidement et avec force. AVISO: Utilice solamente un enchufe apropiado para conectar el cable de alimentacin a
AVVERTENZA: Quando la macchina accesa, tenersi a debita distanza dalla lama di pie- la toma de corriente.
gatura mentre si opera in prossimit della stazione libretto. Il meccanismo della lama di
piegatura si attiva con velocit e forza notevoli.
VORSICHT: Wenn bei eingeschaltetem Gert nahe am Booklet Maker gearbeitet wird, WARNING
von der Schneidevorrichtung fernhalten. Die Schneidevorrichtung wird schnell und mit Take care during this procedure. Sharp edges may be present that can cause injury.
viel Druck ausgelst.
DANGER : Excuter cette procdure avec prcaution. La prsence de bords tranchants
AVISO: Mantngase apartado del mecanismo de la cuchilla hendedora cuando trabaje peut entraner des blessures.
junto al realizador de folletos si la mquina est encendida. Dicho mecanismo se activa
AVVERTENZA: procedere con cautela durante questa procedura. Possono essere pre-
de forma rpida y con mucha fuerza.
senti oggetti con bordi taglienti pericolosi.
VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, damit keine Verletzungen durch
WARNING die scharfen Kanten entstehen.
AVISO: Tenga cuidado al efectuar este procedimiento. Puede haber bordes afilados que
Take care, a hazardous voltage is present at the XXXX. Electricity can cause death or
injury. podran producir lesiones.
DANGER : Faire attention, une tension lectrique dangereuse est prsente au niveau de
la sortie de l'inverseur de la lampe d'exposition.
WARNING
AVVERTENZA: fare attenzione alla carica elettrica di uscita dell'invertitore della lampada
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
di esposizione. L'elettricit pu causare infortuni o morte.
DANGER : Prendre des prcautions lors du relev de la tension de la prise de courant
VORSICHT: Achtung: Spannung am Ausgang des Belichtungslampeninverters.
alternatif. L'lectricit peut entraner des blessures graves voire mortelles.
AVISO: Tenga cuidado; hay tensin peligrosa en la salida del inversor de la lmpara de
AVVERTENZA: Procedere con cautela durante la misurazione della tensione CA della
exposicin. La electricidad puede causar lesiones e incluso la muerte.
rete. L'elettricit pu causare infortuni o morte.
VORSICHT: Bei der Netzspannungsprfung stets vorsichtig vorgehen
WARNING AVISO: Tenga cuidado al medir la tensin de la lnea de alimentacin de corriente
alterna. La electricidad puede causar lesiones e incluso la muerte.
Do not touch the test pads on the embedded fax PWB while the machine is switched on.
Dangerous voltages may be present that could cause death or injury.
DANGER : Ne pas toucher les contacts de test de la carte de circuits imprims du fax
WARNING
intgr tant que la machine est sous tension. Ils reprsentent un risque de chocs lec-
triques qui sont un danger de mort ou peuvent entraner des blessures graves. Do not attempt any repairs to the power cord or safety ground harness/conductor.
AVVERTENZA: non toccare le aree di contatto del PWB del fax incorporato mentre la DANGER : Ne pas tenter de rparer le faisceau/conducteur de mise la masse ou du
macchina accesa. La presenza di voltaggi pericolosi comporta il rischio di morte o cordon d'alimentation.
lesioni personali. AVVERTENZA: non eseguire riparazioni sul cavo dell'alimentazione o sul conduttore di

Translation of Warnings xvi Xerox WorkCentre 5790 Family
terra di sicurezza. AVISO: Tenga cuidado al soltar el enganche. Tiene un resorte comprimido, que puede
VORSICHT: Keine Reparaturen am Netzkabel oder am Schutzleiter vornehmen. causar alguna lesin al soltarlo.
AVISO: No intente reparar el cable de alimentacin ni el conductor/mazo de tierra de
proteccin.
WARNING
Mandatory safety warning. This procedure must be performed by 2 people. The module
WARNING is heavy.
Do not remove the DADH while the DADH is lowered. In the lowered position the coun- DANGER: Avertissement obligatoire. Cette procdure doit tre effectue par 2 per-
terbalance springs are compressed and can cause injury when released. sonnes. Le module est trs lourd.
DANGER : Ne pas retirer le CAD alors qu'il est en position basse. Dans cette position, AVVERTENZA: Avviso di sicurezza obbligatorio. A causa della pesantezza del modulo,
les ressorts compensateurs sont compresss et peuvent entraner des blessures s'ils questa procedura deve essere eseguita da due persone.
se relchent. VORSICHT: Verbindliche Sicherheitsvorschrift - dieser Vorgang muss von zwei Per-
AVVERTENZA: non rimuovere l'alimentatore automatico documenti quando sonen ausgefhrt werden, da das Modul sehr schwer ist.
abbassato. In questa posizione, le molle del contrappeso sono compresse e possono AVISO: Aviso de seguridad obligatorio. Este procedimiento debe ejecutarse entre dos
causare lesioni al rilascio. personas. El mdulo pesa mucho.
VORSICHT: Vorlageneinzug nicht in abgesenkter Position entfernen. Bei abgesenktem
Vorlageneinzug sind die Ausgleichsfedern zusammengedrckt und knnen bei Fre-
igabe Verletzungen verursachen. WARNING
AVISO: No quite el alimentador de documentos automtico si est bajado. Cuando est Use safe handling procedures when removing the module. Refer to GP 16. The module
bajado, los resortes de contrapeso estn comprimidos y pueden causar lesiones al is heavy.
soltarse. DANGER: Conformez-vous aux procdures de manipulation de scurit pour le retrait
du module. Reportez-vous GP 16. Le module est lourd.
AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo.
WARNING Vedere GP 16. Il modulo pesante.
Take care not to topple Tray 5. Tray 5 is unstable when undocked from the machine. Do VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe
not show the customer how to undock Tray 5. auch GP 16. Das Modul ist sehr schwer.
DANGER : Attention ne pas faire tomber le magasin 5. Le magasin 5 nest pas stable AVISO: Utilice los procedimientos de seguridad cuando elimine el mdulo. Consulte el
lorsquil est dtach de la machine. Ne pas montrer au client comment dtacher le GP 16. El mdulo es pesado.
magasin 5.
AVVERTENZA: Fare attenzione a non destabilizzare il vassoio 5. Quando sganciato
dalla macchina, questo vassoio instabile: non mostrare al cliente come sganciarlo. WARNING
VORSICHT: Behlter 5 nicht umstoen.Der Behlter ist nach der Trennung vom Gert Do not break the glass. Broken glass can cause injury.
sehr instabil.Benutzer nicht im Trennen des Behlters vom Gert einweisen. DANGER: Attention ne pas briser la glace sous risque de blessure.
AVISO: Tenga cuidado de que no se caiga la bandeja 5. Cuando no est acoplada a la AVVERTENZA: Per evitare il rischio di lesioni, non rompere il vetro.
mquina, la bandeja 5 es inestable.No le muestre al cliente como desacoplar la bandeja VORSICHT: Glas nicht zerbrechen - Verletzungsgefahr.
5. AVISO: No rompa el cristal. El cristal roto puede ocasionar daos.
WARNING WARNING
Take care when removing the latch. The latch contains a compressed spring, which can Wear protective gloves when using solvents and cleaning agents, PL 26.10 Item 10 .
cause injury when released.
DANGER : Porter des gants de protection lors de l'utilisation de solvants et de produits
DANGER: Faites attention en dverrouillant le levier : il comporte un ressort comprim, de nettoyage, PL 26.10 Item 10.
ce qui prsente un risque de blessure lors du dverrouillage.
AVVERTENZA: utilizzare guanti protettivi durante l'impiego di solventi e soluzioni per
AVVERTENZA: Rimuovere il gancio con cura in quanto contiene una molla compressa pulizia PL 26.10 Item 10.
che pu causare lesioni al rilascio.
VORSICHT: Beim Einsatz von Lsungs- und Reinigungsmitteln Handschuhe tragen PL
VORSICHT: Beim Entfernen der Verriegelung mit Vorsicht vorgehen. Es ist eine unter 26.10 Item 10.
Spannung stehende Feder enthalten, die bei spontaner Freisetzung Verletzungen
AVISO: Pngase guantes de proteccin cuando utilice disolventes y productos de limp-
verursachen kann.
ieza PL 26.10 Item 10.

Xerox WorkCentre 5790 Family xvii Translation of Warnings
OCT-Transporteinheit verwenden. Bei unsachgemer Verwendung bietet die
rechtsseitige Abdeckung Zugang zu sich bewegenden Teilen die Verletzungen verursa-
WARNING chen knnen.
Do not use the on/off switch as a safety disconnect device. The on/off switch is not a AVISO: No utilizar la cubierta derecha (W/TAG 148) con otro dispositivo de salida que no
disconnect device. Disconnect the power cord from the supply to isolate the equipment. sea el conjunto de Transporte de OCT (Bandeja Receptora de Compaginacin). Si no se
DANGER : Ne pas utiliser l'interrupteur comme systme d'arrt d'urgence. Dconnecter utiliza bien, la cubierta derecha deja expuestas piezas mviles que pueden causar
le cordon d'alimentation de la prise pour isoler l'quipement. lesiones.
AVVERTENZA: Non usare l'interruttore di accensione/spegnimento come dispositivo di
sicurezza per il disinserimento dell'elettricit, in quanto l'interruttore non stato diseg-
nato per questa funzione. Per isolare la macchina dalla corrente elettrica, scollegare il
cavo dell'alimentazione dalla presa a muro.
VORSICHT: Der Netzschalter reicht zur Trennung von der Netzspannung NICHT aus. Um
das Gert von der Netzspannung zu trennen, den Netzstecker abziehen.
AVISO: No utilice el interruptor de encendido/apagado como dispositivo de desconex-
in seguro. El interruptor de encendido/apagado no es un dispositivo de desconexin.
Para aislar el equipo totalmente, desconecte el cable de alimentacin de la toma de cor-
riente.
WARNING
USA and Canada. Do not install this machine in a hallway or exit route that does not
have 1.12 m (44 inches) of space additional to the normal space requirements in front of
the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space
is needed in front of the machine in hallway and exit routes.
DANGER : tats-Unis et Canada. Si cette machine est installe dans un couloir ou une
voie de sortie, 1,12 m (44 pouces) d'espace supplmentaire l'espace normal doit tre
disponible devant la machine conformment aux normes de scurit d'incendie.
AVVERTENZA: N/A
VORSICHT: N/A
AVISO: Estados Unidos y Canad. No instale esta mquina en un corredor o ruta de sal-
ida que no tenga 1.12 m (44 pulgadas) de ancho delante de la mquina, sin incluir el
espacio que ocupe la mquina. Este espacio adicional de 1.12 m (44 pulgadas) delante
de la mquina en corredores y rutas de salida es necesario para cumplir los requisitos
de las normas sobre incendios.
WARNING
Do not use the W/TAG 148 right hand cover with an output device other than the OCT
Transport assembly. The right hand cover will expose moving parts if not used correctly.
Moving parts can cause injury.
AVERTISSEMENT: Ne pas utiliser le capot de droite W/TAG 148 avec un priphrique de
sortie autre que le module de transport OCT (bac dcalage). Ce capot expose des
pices mobiles sil nest pas utilis correctement. Les pices mobiles risquent
dentraner des blessures.
AVVERTENZA: Non utilizzare la copertura destra W/TAG 148 con un dispositivo di
uscita tranne il complessivo del trasporto OCT. Se questa copertura non viene utilizzata
in modo corretto, si potrebbero esporre parti meccaniche in movimento con rischio di
infortuni.
ACHTUNG: Rechtsseitige Abdeckung (W/TAG 148) NUR mit Ausgabegerten vom Typ

Translation of Warnings xviii Xerox WorkCentre 5790 Family
1 Service Call Procedures
SCP 1 Initial Actions........................................................................................................ 1-3
SCP 2 First Call Actions .................................................................................................. 1-4
SCP 3 Normal Call Actions ............................................................................................. 1-4
SCP 4 Fault Analysis....................................................................................................... 1-5
SCP 5 Subsystem Maintenance...................................................................................... 1-7
SCP 6 Final Actions ........................................................................................................ 1-9
SCP 7 Machine Features ................................................................................................ 1-9
November 2014 Service Call Procedures

Xerox WorkCentre 5790 Family 1-1
Service Call Procedures November 2014
1-2 Xerox WorkCentre 5790 Family
SCP 1 Initial Actions 6. If this service call is the first service call to this machine, go to SCP 2 First Call Actions. If
this service call is not the first call, go to SCP 3 Normal Call Actions.
Use the Service Call Procedures to find a problem with the machine.
Machine Status
Use the Initial Actions to collect the information on the machine performance. To display a list of the last 6 fault codes on the UI, perform the steps that follow:
1. Press the Machine Status key on the UI.
Also refer to SCP 7 Machine Features. 2. Touch the Fault tab on the UI.
3. Touch the All Faults button on the UI.
Initial Actions To print a fault history report of the last 40 fault codes, perform the steps that follow:
Certain service procedures described within this service manual are unique to the 5790F 1. Simultaneously press the * and Log in/out key on the UI.
copier only machines. Refer to GP 30 for details on how to identify a copier only config-
2. Use the numerical keypad to input the code 734040.
ured machine and their service procedures.
3. Touch the enter tab on the UI.
Switch off the machine, then switch on the machine, GP 14.
If the machine cannot be switched off, go to 03-374 Power Off Failure RAP. NOTE: There will be a short delay of approximately 10 second before the fault history
report is printed.
NOTE: The May 2011 revision of the WC5790F service manual was specifically prepared
to support the launch of machine software version SMP 1, which contains a multitude of To display the event log on the UI, perform the steps that follow:
fixes. 1. Press the Machine Status key on the UI.
Ensure that the machine has the latest available machine software loaded before com- 2. Touch the Fault tab on the UI.
mencing any diagnostic or repair procedures. 3. Touch the Event Log button on the UI.
To display the active messages on the UI, perform the steps that follow:
Procedure 1. Press the Machine Status key on the UI.
2. Touch the Fault tab on the UI
3. Touch the Active Messages button on the UI.
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power lead from
the customer supply while preforming tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
WARNING
Do not work in a confined space. 1m (39 inches) space is needed for safe working.
1. Take note of problems, error messages or error codes. If necessary, refer to Machine Sta-
tus.
2. Ask the operator to describe or demonstrate the problem.
3. If the problem is the result of an incorrect action by the operator, refer the operator to the
user documentation.
4. Check the steps that follow:
a. The power lead is connected to the wall outlet and to the machine.
b. The documents are not loaded in the DADH or on the document glass.
c. The paper is loaded correctly.
d. All paper trays are closed.
e. All covers are closed or installed.
f. If a telephone line cable is installed, make sure that the cable is connected between
the line socket and the wall jack.
g. If a telephone line cable is installed, make sure that the customer telephone line is
functioning.
5. Check the machine service log book for previous actions that are related to this call.

Xerox WorkCentre 5790 Family 1-3 SCP 1
SCP 2 First Call Actions SCP 3 Normal Call Actions
Use the First Call Actions for the first service call. Use the Normal Call Actions to find the reason for the service call.
Initial Actions Initial Actions

Switch off the machine, then switch on the machine, GP 14. Switch off the machine, then switch on the machine, GP 14.
If the machine cannot be switched off, go to 03-374 Power Off Failure RAP. If the machine cannot be switched off, go to 03-374 Power Off Failure RAP.
Procedure Procedure
1. Check the machine configuration with the customer. Check that all the required hardware
NOTE: If an error message appears, go to the RAP for the error message. If necessary refer to
and software is installed. Check that all the required hardware and software is enabled. OF4 Status Codes and Messages RAP.
2. Check that all the machine settings are entered correctly.
Perform the steps that follow:
3. Mark off the hardware options, software options or Tags installed on the Tag matrix cards
and dC111 Tag Matrix. 1. Review the copy, print and Fax samples.
4. 35-55 ppm Only. If the machine has a OCT, install the OCT fingers. Go to REP 12.1. 2. Make sure the user access settings are correct. If necessary refer to the user documenta-
tion.
NOTE: The OCT fingers are supplied with the OCT but must be installed by a CSE at the
3. To prevent the deletion of the customer information and soft machine settings, perform
first service call. They are located in a plastic wallet on the rear of the machine. The OCT NVM Save and Restore. Refer to GP 5.
fingers improve feeding to the OCT.
4. Perform GP 19 Network Clone Procedure.
5. If a fault is found, go to SCP 3 Normal Call Actions. If a fault is not found, go to SCP 6
NOTE: The clone file must be taken whenever the customer changes the network control-
Final Actions.
ler setting or after the system software is changed.
6. Check the machine for waste toner contamination. Refer to the OF11 Waste Toner Con-
tamination RAP. 5. Before pressing the on/off switch or clear the memory, check for a customer job in the
7. Save the NVM. Refer to GP 5 Portable Workstation and Tools. memory.
8. Perform GP 19 Network Clone Procedure. 6. Check and record the total print counter.
7. Check the machine for waste toner contamination. Refer to the OF11 Waste Toner Con-
NOTE: The clone file must be taken whenever the customer changes the network control-
tamination RAP.
ler setting or after the system software is changed.
8. Clean the optical sensors that follow:
9. Enter the machine information and the customer information in the service logbook. (40-90 ppm) DADH feed sensor, PL 5.17 Item 2.
10. If the machine has a tray 5 installed, check the top edge registration, ADJ 7.4. (40-90 ppm) DADH document present sensor, PL 5.35 Item 19.
DADH length sensors, PL 5.35 Item 8.
Tray 1 feed sensor, PL 7.30 Item 24.
W/TAG 151. Tray 3 feed sensor, PL 8.32 Item 6.
W/O TAG 151. Tray 4 feed sensor, PL 8.31 Item 12.
W/TAG 151. Tray 4 feed sensor, PL 8.33 Item 3.
W/TAG 151. HCF exit sensor, PL 8.33 Item 3.
Wait sensor, (35-55 ppm) PL 8.15 Item 3, (65-90 ppm) PL 7.30 Item 25.
Duplex sensor, (35-55 ppm) PL 8.22 Item 4, (65-90 ppm) PL 8.20 Item 4.
Registration sensor, (35-55 ppm) PL 8.15 Item 3, (65-90 ppm) PL 8.17 Item 3.
HVF Bin 1 rear wall sensor, PL 11.140 Item 17.
9. Go to SCP 4 Fault Analysis.

SCP 2, SCP 3 1-4 Xerox WorkCentre 5790 Family
SCP 4 Fault Analysis Messages, Fault Codes and Status Codes
Use the Fault Analysis to identify a fault. If the machine has the problems that follow, go to the 19-401, 19-402, 19-403 Out of
Memory Resources RAP.
Initial Actions A message that there is not enough memory to complete the job.
The machine does not print a complex job.
The customer reports that the print speed is slow.
If the machine cannot be switched off, go to 03-374 Power Off Failure RAP.
If a status code or message is displayed, but not a fault code, go to OF4 Status Code and
Messages RAP.
Procedure If a fault code is displayed, go to the Status Indicator RAP for that code.
Use the machine in all modes until the fault is found. If a fault code and the message Mark Service Unavailable is displayed, perform the Sta-
tus Indicator RAP for that code. If the fault continues after you performed the RAP, go to
Go to the correct procedure for the machine fault. When the fault is cleared, go to SCP 5 Sub- the 03B Mark Service Unavailable RAP.
system Maintenance.
If the user interface does not display the features for output devices that are installed, per-
Power Up Problems form one of the procedures that follow:
Sleep Mode Problems
03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error RAP.
User Interface Problems 11-050-110, 11-360-110 Staple Head Operation Failure RAP.
Messages, Fault Codes and Status Codes DADH Problems
DADH Problems
If the DADH does not detect the documents in the DADH input tray, go to 05B Document
Paper Supply and Paper Feed Problems
Present Failure RAP.
OCT Problems
If the DADH has a fault, but not a fault code, go to the 05A DADH Other Faults RAP.
1K LCSS Problems
If the DADH has detected a document of the wrong size. Perform the procedures that follow:
2K LCSS Problems
14A Scanning Document Size Entry RAP.
HVF, HVF BM, Inserter and Tri-Folder Problems
Fax Problems 05C Document Size Sensor Failure Entry RAP.
Other Problems Paper Supply and Paper Feed Problems
Xerographic Module (XRU) Handling For the paper supply problems that do not have a fault code, perform the procedures that
follow, as appropriate:
Power Up Problems
07A Tray 1 and Tray 2 Empty RAP.
Go to the OF3 Dead Machine RAP if the machine has the problems that follow:
07B Tray 3 and Tray 4 False Paper Level Entry RAP.
The machine will not power up.
07D Bypass Tray RAP.
There is no information on the user interface.
07E Tray 1 and 2 Wrong Size Paper RAP.
There is no LED illumination on the user interface.
07F Tray 3 or Tray 4 Out of Paper Entry RAP.
If all the panel lights are on, the UI touch screen is illuminated and the machine then pow-
07H Tray Out of Service RAP.
ers off. Go to the OF3 Dead Machine RAP.
07J Tray 5 Empty RAP
If the UI displays system unavailable or the machine does not come to a Ready to scan
If tray 5 is not set to the correct paper size, perform ADJ 7.2 Tray 5 Paper Tray Guide Set-
your job state. Go to the OF5 Boot Up Failure RAP.
ting.
If the machine displays a speed mismatch or configuration error, reset the machine
configuration, GP 15. If the machine produces a multifeed, go to the OF8 Multi-feed RAP.
Sleep Mode Problems OCT Problems
If the machine fails to enter or exit sleep mode, go to the 01K Sleep Mode RAP. Go to the 12-301 Offset Catch Tray Failure RAP.
User Interface Problems If the prints adhere to each other in the OCT, go to the OF6 Ozone and Air Systems RAP.
Go to the OF3 Dead Machine RAP if the machine has the problems that follow: 1K LCSS Problems
The machine is silent. If the machine has a 1K LCSS fault, but not a fault code, perform the procedures that fol-
low, as appropriate:
There is no information on the user interface.
11A-120 Bin 1 Overload RAP.
There is no LED illumination on the user interface.
11B-120 Initialization Failure RAP.
If the user interface is not illuminated, go to the OF2 Touch Screen Failure RAP.
11C-120 1K LCSS Power Distribution RAP.
If the user interface is illuminated, but there is no information, go to the 02-309 UI Control
11D-120 1K LCSS to Machine Communication Interface RAP.
Panel Button or Touch Screen RAP.

11E-120 1K LCSS PWB DIP Switch Settings RAP. 11K-171 HVF Initialization Failure RAP.
11F-120 1K LCSS PWB Damage RAP. 11L-171 Tri-Folder Not Detected RAP.
11G-120 Copy Damage in the 1K LCSS RAP. 11M-171 Curl Suppressor RAP
11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. 11N-171 Chad Bin Present and Bin Full RAP.
11J-120 1K LCSS Poor Stacking RAP. 11P-171 Buffer Clamp RAP
If the machine has the problems that follow, go to the 11E-120 1K LCSS PWB DIP Switch If the staples of a booklet are not correct, perform the correct procedure that follows:
Settings RAP: 11-063-171, 11-411-171 HVF BM Staple Unit 1 Failure RAP.
False jam clearance messages. 11-403-171, 11-413-171, 11-414-171 HVF BM Stapler head 2 and Staple Module RAP.
Communication errors between the LCSS and the machine. If the tri-folder paper fold is not in the correct position, perform ADJ 11.2-171 Tri-Folder
If the staples of a stapled set are not correct, go to the 11-364-120 Stapling Failure RAP. Paper Settings.
If the prints bond together in the LCSS trays, go to OF6 Ozone and Air Systems RAP. Fax Problems
2K LCSS Problems For Fax problems with no fault code, perform the procedures that follow, as appropriate:
If the machine has an 2K LCSS fault, but not a fault code, perform the procedures that fol- 20A Fax Entry RAP.
low, as appropriate: 20B Unable To Send A Fax RAP.
11A-110 Offline Stapling Faults RAP. 20C Unable To Send A Fax To Some Machines RAP.
11B-110 Bin 1 Overload RAP. 20D Unable To Receive A Fax RAP.
11C-110 2K LCSS Initialization Failure RAP. 20E Fax Will Not Print RAP.
11D-110 2K LCSS Power Distribution RAP. 20F Fax Tab Not Available RAP.
11E-110 2K LCSS to Machine Communications Interface RAP. 20G Embedded Fax Checkout RAP.
(W/O TAG X-001 machines only) 20H Embedded Fax PWB Voltage Checkout.
11F-110 2K LCSS PWB DIP Switch Settings RAP.
Other Problems
11G-110 2K LCSS PWB Damage RAP.
Hot machine. Go to the OF6 Ozone and Air Systems RAP.
11H-110 Copy Damage in the 2K LCSS RAP.
Convenience stapler faults. Go to the OF13 Convenience Stapler RAP.
11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.
If the customer has lost the System Administration password. Go to dC001 Reset
11K-110 2K LCSS Poor Stacking RAP.
Auditron Master PIN.
If the punched holes are out of position, perform ADJ 11.3-110 Hole Punch Position.
Image quality fault. Go to the IQ1 Image Quality Entry RAP.
If the machine has the problems that follow, go to the 11F-110 2K LCSS PWB DIP Switch
Machine noise. Go to the OF1 Audible Noise RAP.
Settings RAP:
Machine odour. Go to the OF6 Ozone and Air Systems RAP.
False jam clearance messages.
If the UI displays system not available or the machine continues to boot up, go to OF5
Communication errors between the LCSS and the machine.
Boot Up Failure RAP.
If the staples of a stapled set are not correct, go to the 11-364-110 Stapling Failure RAP.
The machine will not turn off. Go to 03-374 Power Off Failure RAP.
If the prints bond together in the LCSS trays, go to OF6 Ozone and Air Systems RAP.
Check the fault history. GP 1 Diagnostic Entry, Facilities and Exit.
HVF, HVF BM, Inserter and Tri-Folder Problems
Foreign device. Go to ACC 1 Foreign Device Checkout.
If the machine has a fault in the HVF or HVF BM, but with no fault code, perform the pro-
Xerox extensible interface platform faults. Go to the OF14 Xerox Extensible Interface
cedures that follow, as appropriate:
Platform RAP.
11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlocks RAP
Xerox secure access faults. Go to the OF15 Xerox Secure Access RAP.
11A-171 HVF BM Power Distribution RAP.
Scan to file failure when using the FTP or SMB protocols. Go to the 16A Network Error
11B-171 HVF BM to Machine Communications Interface and BM Present RAP. Entry RAP.
11C-171 HVF BM Bin 2 Failure RAP. Xerographic Module (XRU) Handling
11D-171 Booklet Quality RAP. The Xerographic Module (XRU) must be protected from light shock and mechanical damage.
11E-171 Copy Damage in the HVF BM RAP. Do not expose the photoreceptor drum to bright lights for extended periods.
11F-171 Mis-Registration in Stapled and Unstapled Sets RAP. When ever the XRU is removed from the IOT, place the XRU in the black plastic bag sup-
11G-171 HVF BM Poor Stacking RAP. plied with the IOT. Store the XRU in a safe place on a clean flat surface, to avoid damage
11H-171 Pause To Unload (PTU) RAP. to the photoreceptor drum surface.
11J-171 Inserter Paper Sensing and +5V Supply RAP. Place the XRU in the black bag if the covers are removed or left open for long periods.

SCP 4 1-6 Xerox WorkCentre 5790 Family
SCP 5 Subsystem Maintenance NOTE: If a range of machine speeds are specified within Table 1, the life expectancy for the
part will be specific for that machine.
Use the Subsystem Maintenance to maintain the machine.
If the speed has not been specified, the life expectancy for the part applies to all machines
within the product family.
Procedure
HFSI
The High Frequency Service Items are shown in Table 2. To change HFSI settings, refer to GP
WARNING 17 High Frequency Service Items.
Switch off the electricity to the machine, GP 14. Disconnect the power lead from the
customer supply while performing tasks that do not need electricity. Electricity can Table 2 High frequency service items
cause the death or injury. Moving components can cause the injury.
The
Go to the correct procedure: recommended
Installation of New Parts life for new
HFSI component Parts list
Lubrication Item Component Description installation reference
How to Clean the Machine DADH feeds Feed roll The total DADH feeds in 180k feeds (35 ppm) PL 5.15
assembly all modes after the last Item 1 or (40-90
Installation of New Parts
HFSI reset ppm) PL 5.17
The design life of the major components is shown in Table 1. Item 1
Table 1 Component design life Tray 1 feed Feed rolls All sheets fed from tray 1 750k feeds PL 8.26
after last HFSI reset
Part Life Parts list reference
Tray 2 feed Feed rolls All sheets fed from tray 2 750k feeds PL 8.26
Fuser module after last HFSI reset
35-55 ppm 400k prints PL 10.8 Item 1 Tray 3 feed Feed rolls All sheets fed from tray 3 1,500k feeds PL 8.30 Item 2
65-90 ppm 400k prints PL 10.10 Item 1 W/O TAG 151 after last HFSI reset
Ozone filter 400k prints PL 9.25 Item 3 Tray 3 feed Feed rolls All sheets fed from tray 3 400k feeds PL 8.32 Item 11
Xerographic module W/TAG 151 after last HFSI reset
35 ppm 200k prints PL 9.22 Item 2 Tray 4 feed Feed rolls All sheets fed from tray 4 1,500k feeds PL 8.31 Item 2
40-90 ppm 400k prints PL 9.20 Item 2 W/O TAG 151 after last HFSI reset
Toner cartridge Tray 4 feed Feed rolls All sheets fed from tray 4 400k feeds PL 8.33 Item 9
35-55 ppm 36.5k prints at 6% area coverage PL 9.17 Item 4 W/TAG 151 after last HFSI reset
65-90 ppm 50k prints at 6% area coverage PL 9.15 Item 4
Tray 1 trans Transport roll The total feeds from tray 2,000k feeds PL 8.25 Item 8
Waste toner bottle 100k PL 9.10 Item 1 1, 2, 3, 4 after last HFSI
DADH feed roll assembly reset
35 ppm 170k feeds PL 5.15 Item 1 Tray 2 trans Transport roll The total feeds from tray 2,000k feeds PL 8.25 Item 8
40-90 ppm 170k feeds PL 5.17 Item 1 2, 3, 4 after the last HFSI
1K LCSS staple cartridge 3k staples PL 26.10 Item 26 reset
2K LCSS staple cartridge 5k staples PL 26.10 Item 11 Tray 3/4 trans Tray 3 and 4 The total feeds from tray 2,500k feeds PL 8.30 Item 18
HVF staple cartridge 5k staples PL 26.10 Item 22 W/O TAG 151 transport roll 3, 4 after the last HFSI
HVF BM staple cartridge 2k staples PL 11.168 Item 8 reset
Tray 3/4 trans Tray 3 and 4 The total feeds from tray 2,500k feeds PL 8.32 Item 4
W/TAG 151 transport roll 3, 4 after the last HFSI
reset
Bypass feeds Bypass tray The total bypass tray 100k feeds PL 7.30 Item 21
feed roll and feeds after the last HFSI
retard pad reset
assembly

Table 2 High frequency service items Lubrication
The To lubricate the machine, refer to ADJ 4.1 Machine Lubrication.
recommended
life for new How to Clean the Machine
component Parts list
Perform ADJ 9.4 Xerographics Cleaning.
Item Component Description installation reference
Clean the takeaway roll idlers, PL 5.20 Item 3. Refer to ADJ 5.4 DADH Cleaning Proce-
Tray 5 feeds Tray 5 feed All sheets fed from tray 5 1,000k feeds PL 8.45 Item 20 dure.
roll kit after last HFSI reset or PL 8.45 Item Clean the upper surfaces of the CVT glass and document glass, refer to:
22
(W/O TAG 150) ADJ 14.1 Optics Cleaning Procedure.
Inserter Inserter feed Total Inserter feeds 80k feeds PL 11.179
(W/TAG 150) ADJ 14.2 Optics Cleaning Procedure.
rolls Part of inserter
pickup assembly (40-90 ppm) Clean the DADH feed sensor and the area around the sensor, PL 5.17 Item 2.
Inverter feeds Nip split shaft The total turned and 2,500k feeds PL 10.11 Item 4 Clean the tray 1 and tray 2 feed sensors and the area around the sensors, PL 8.25.
assembly duplex feeds after the last W/O TAG 151. Clean the tray 4 feed sensor and the area around the sensor, PL 8.31 Item
HFSI reset 12.
Duplex sen- Duplex sen- The total count of the 1,000k actuator (35-55 ppm) PL W/TAG 151. Clean the tray 4 feed sensor and the area around the sensor, PL 8.33 Item 3.
sor sor actuator duplex sensor actuator counts 8.22 Item 4 Clean the duplex sensor and the area around the sensor, (35-55 ppm) PL 8.22 Item 4,
after the last HFSI reset (65-90 ppm) PL 8.20 Item 4.
Bias foam Bias contact The total sides of copies 500k impres- PL 8.15 Item 23 Clean the registration sensor and the surrounding area, (35-55 ppm) PL 8.15 Item 3, (65-
and prints after the last sions 90 ppm) PL 8.17 Item 3.
HFSI reset For special tools and consumables, refer to GP 8 Special Tools and Consumables.
Developer Developer The total sides of copies 2,500k impres- (35-55 ppm) PL Go to SCP 6 Final Actions.
drive gear / and prints after the last sions 9.17 Item 2 or
pulley and the HFSI reset (65-90 ppm) PL
main drive 9.15 Item 2
gear
Post Fuser Post fuser exit The total sides of copies 1,200k impres- PL 10.12 Item 9.
roll. and prints after the last sions
HFSI reset
HVF Paddle Paddle wheel All sheets fed through the 200k feeds PL 11.145 Item
HVF after last HFSI reset 28

SCP 6 Final Actions SCP 7 Machine Features
Use the Final Actions to verify the total operation of the system. Use the Final Actions to com- Configuration Options
plete the service call.
The WorkCentre 5790F is available as a basic machine with trays 1, 2 and a bypass tray. It is
also available in various configurations using the options that follow:
Procedure
Perform the steps that follow. If a fault is identified, go to SCP 4 Fault Analysis: General
For the space requirements, environment range and the print out time. Refer to:
1. If necessary, restore the NVM to the machine. Go to GP 5 Portable Workstation and
GP 21 Installation Space Requirements
Tools.
GP 23 Environmental Data.
2. Perform GP 19 Network Clone Procedure.
GP 25 First Copy / Print Out Time and Power On / Off Time.
NOTE: The clone file will need to be taken whenever the system software is changed. Paper supply and paper handling options
3. Go to SCP 5 Subsystem Maintenance. 3600 sheet high capacity feeder (tray 3 and 4) W/O TAG 151.
4. To clear all fault counters, go to GP 1 Diagnostics Entry, Facilities and Exit. 3600 sheet high capacity feeder (tray 3 and 4) W/TAG 151.
5. Operate the machine in all modes. Make the copies and prints from all trays, use the (35 ppm) 75 sheet duplex automatic document handler (DADH).
DADH and the document glass. (40-90 ppm) 100 sheet duplex automatic document handler (DADH).
6. Make copies and / or prints from all trays and check the registration and copy quality. To 4100 sheet high capacity feeder (tray 5).
reset the registration, go to dC604 Registration Setup Procedure. For copy quality Output options
defects, go to IQ1 Image Quality Entry RAP.
500 sheet offsetting catch tray (OCT).
7. Make a proof copy or print of a customer document.
1250 sheet 2 bin stapler stacker tray (1K LCSS).
8. If some of the customers selections were changed, return the selections to the customer
2250 sheet 2 bin stapler stacker tray (2K LCSS).
settings.
3000 sheet 2 bin stapler stacker with 100 sheet finishing (HVF).
9. Mark off the hardware options, software options or Tags installed on the Tag matrix cards,
dC111. 250 sheet post print inserter, PPI (HVF)
10. If some changes were made to the configuration or options were added, print the configu- 2000 sheet 2 bin stapler stacker with booklet maker (HVF BM).
ration report. Store the configuration report with the machine log book. Discard the previ- 2000 sheet 2 bin stapler stacker with tri-folder (HVF).
ous version of the configuration report. Accessories and Kits
11. Remove and destroy all copies of test patterns. 50 sheet convenience stapler.
12. Make sure the machine and service area are clean. Tray 5 Short edge reg kit (A4 / 8.5x11 inch SEF).
13. If necessary, provide the customer with training. Tray 5 Short edge reg kit (A3 / 17 inch SEF).
14. At the completion of the service call report the three billing counters in order, billing Envelope kit.
counter C13, billing counter C1 and billing counter C2. Assistive UI kit (Xerox copier assistant).
Server Fax kit.
2 hole punch kit.
Legal 2 hole punch kit.
3 hole punch kit.
4 hole punch kit.
Swedish 4 hole punch kit.
Internet Fax kit.
1 Line Fax kit.
2 Line Fax kit.
Network accounting kit.
Scan to file and scan to E-mail.
Scan to PC desktop SE - standard.
Scan to PC desktop SE - professional.

Xerox WorkCentre 5790 Family 1-9 SCP 6, SCP 7
Internet Fax scanning kit.
Server fax scanning kit.
Color scanning enablement kit (an option on 65-90 ppm machines, standard on 35-55
ppm machines W/TAG 150).
FreeFlow SMART send 3.0.
FreeFlow SMART send 3.0 Professional.
Nationalization kits.
Foreign device interface kit.
Tray 2/4 lock kit.
Unicode international printing kit.
Secure access kit.
Common access card.
Memory upgrade (1 GB) kit.
Copier to MFP conversion kit.
NOTE: The service manual covers all of the above configurations. Within the manual, ignore
any references to options that are not installed.
Development History
The WC5790F machines have been developed from the WC5687F and offer the following new
features: Figure 1 WC5735 with stand, document cover and OCT
New model speeds of 35 and 90 ppm.
Color user interface.
Color scanner fitted to all 65-90 ppm machines but an option on 35-55 ppm machines.
The installation of the color scanner on 35-55 ppm machines is identifiable by the striking
of TAG 150.
August 2010. Introduction of the copier only 5790F device in the USSG region only. Refer
to GP 30 for details on the identification and unique service procedures for the copier only
configured machines.
July 2011. Introduction of the Fully Active Retard Roll (FAR) Feeder HCF module. The
FAR Feeder HCF module with proven tray 3 and tray 4 FAR feeder robustness, is
expected to produce significant performance improvements in the field. The major
improvements for the customer will be in feeding non-standard media and /or in non-stan-
dard ambient environments. WC5790F machines with a FAR Feeder HCF module can be
identified by change TAG 151.
Machine Identification
The diagrams that follow illustrate some of the various machine configurations:
Figure 1 WC5735 with stand, document cover and OCT.
Figure 2 WC5740 with DADH, HCF, work shelf and OCT.
Figure 3 WC5745 with DADH, HCF, work shelf and 1K LCSS.
Figure 4 WC5755 with DADH, HCF, work shelf and 2K LCSS.
Figure 5 WC5775 with DADH, HCF, work shelf and HVF. Figure 2 WC5740 with DADH, work shelf and OCT
Figure 6 WC5790 with DADH, HCF, work shelf and HVF BM.

Figure 3 WC5745 with DADH, work shelf and 1K LCSS Figure 5 WC5775 with DADH, work shelf and HVF
Figure 4 WC5755 with DADH, work shelf and 2K LCSS Figure 6 WC5790 with DADH, work shelf and HVF BM

2 Status Indicator RAPs
Chain 1 - Standby Power 03-480 IOT +24V Supply Failure RAP ............................................................................ 2-104
01-300 Front Door Open RAP......................................................................................... 2-5 03-700, 03-780, 03-785, 03-790 Power On / Power Off Event Fault RAP ...................... 2-105
01-305 Left Hand Door Open RAP.................................................................................. 2-7 03-720 ODIO Time-out Error RAP .................................................................................. 2-105
01A Ground Distribution RAP.......................................................................................... 2-8 03-770 IOT PWB Software Reset RAP ........................................................................... 2-106
01B 0V Distribution RAP ................................................................................................. 2-20 03-777 Power Loss Detected RAP.................................................................................. 2-106
01C AC Power RAP ........................................................................................................ 2-33 03A Single Board Controller PWB Module Cooling Fan Failure RAP ............................. 2-107
01D +3.3V Distribution RAP ............................................................................................ 2-36 03B Mark Service Unavailable RAP................................................................................ 2-107
01E +5V Distribution RAP ............................................................................................... 2-39 03C Hard Disk Failure RAP............................................................................................. 2-108
01F +12V Distribution RAP ............................................................................................. 2-42 03D Software Module Failure RAP ................................................................................. 2-108
01G +24V Distribution RAP............................................................................................. 2-45 03E Foreign Device PWB Fault RAP .............................................................................. 2-109
01H Short Circuit and Overload RAP .............................................................................. 2-52
01J Power On and LVPS Control Signal RAP ................................................................ 2-57
Chain 4 - Main Drives
01K Sleep Mode RAP ..................................................................................................... 2-59 04A Main Drive Motor and Photoreceptor Motor RAP .................................................... 2-111
Chain 2 - User Interface Chain 5 - DADH

05-300 DADH Open RAP................................................................................................ 2-113
02-309 UI Control Panel Button or Touch Screen RAP .................................................. 2-65
02-320, 02-380 UI Communication Test RAP ................................................................. 2-65 05-305 DADH Top Cover Open RAP .............................................................................. 2-114
05-310 Document too Short RAP.................................................................................... 2-116
02-390, 02-391, 02-704, 02-706 UI Software Error RAP ................................................ 2-66
05-330, 05-331 DADH Feed Sensor Failure Entry RAP ................................................. 2-116
02-392 Custom Services Access RAP ............................................................................ 2-66
02-705, 02-707, 02-709, 02-712, 02-715 UI Failure RAP ............................................... 2-67 05-330A, 05-331A DADH Feed Sensor Failure RAP (35 ppm)....................................... 2-117
05-330B, 05-331B DADH Feed Sensor Failure RAP (40 to 90 ppm).............................. 2-119
Chain 3 - Machine Run Control 05-335 DADH Takeaway Sensor Failure RAP................................................................ 2-122
03-300, 306, 461, 482, 805, 870 Single Board Controller PWB to IOT PWB Error RAP 2-69 05-340 DADH Registration Sensor Failure RAP ............................................................. 2-124
03-310 Single Board Controller PWB to UI Error RAP.................................................... 2-71 05-345, 05-346 DADH Exit Sensor Failure RAP ............................................................. 2-126
03-315, 325, 347, 348, 349, 355, 400 Single Board Controller PWB Failure RAP ......... 2-72 05-350, 05-352 DADH CVT Sensor Failure RAP............................................................ 2-129
03-320 to 03-324 Single Board Controller PWB to DADH Error RAP ............................. 2-72 05A DADH Other Faults RAP.......................................................................................... 2-132
03-330, 03-462 Single Board Controller PWB to Scanner Fault Entry RAP ................... 2-76 05B DADH Document Present Sensor Failure Entry RAP.............................................. 2-132
03-330A, 03-462A Single Board Controller PWB to Scanner Fault RAP (W/O TAG 150) 2-76 05C Document Size Sensor Failure Entry RAP .............................................................. 2-133
03-330B, 03-462B Single Board Controller PWB to Scanner Fault RAP (W/TAG 150).. 2-79 05D DADH Motor Failure RAP ........................................................................................ 2-133
03-336 FAX Card Self Test Failure RAP......................................................................... 2-81 05E DADH Feed Clutch Failure RAP .............................................................................. 2-135
03-338 FAX Communication Error RAP.......................................................................... 2-82 05F Damaged Documents RAP ...................................................................................... 2-136
03-340, 03-416 Single Board Controller PWB to Network Controller Fault RAP ............ 2-82 05G DADH Document Present Sensor Failure RAP (35 ppm) ....................................... 2-137
03-350, 03-351, 03-354 IOT to Tray 1 and Tray 2 PWB Error RAP................................ 2-83 05H DADH Document Present Sensor Failure RAP (40-90 ppm) .................................. 2-138
03-359, 03-407 HCF Communications and Detection Error RAP ................................... 2-84 05J Document Size Sensor Failure RAP (35 ppm) ......................................................... 2-139
03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error RAP .............................. 2-86 05K Document Size Sensor Failure RAP (40-90 ppm) ................................................... 2-142
03-365 IOT Bus Failure RAP........................................................................................... 2-88
03-366 IOT to Tray 5 Module Communication Failure RAP............................................ 2-89
Chain 6 - ROS
06-020 ROS Motor Failure RAP...................................................................................... 2-145
03-367 S2X Data Transmission Failure RAP .................................................................. 2-91
06-340 ROS Laser Failure RAP ...................................................................................... 2-147
03-371, 03-372 Fuser and Xerographic CRUM Communication Error RAP ................... 2-91
03-374 Power Off Failure RAP........................................................................................ 2-94 06-350 ROS Laser Not Under Control RAP .................................................................... 2-149
03-395, 396, 852, 853 IOT PWB Fault RAP.................................................................... 2-96 Chain 7 - Paper Supply
03-397 Main Motor Not Controlled RAP.......................................................................... 2-97 07-301 Tray 1 Open During Run RAP............................................................................. 2-151
03-401, 03-403 Fax Not Detected RAP........................................................................... 2-99 07-302 Tray 2 Open During Run RAP............................................................................. 2-153
03-412 Foreign Device PWB Fault RAP ......................................................................... 2-99 07-303 Tray 3 Open During Run Entry RAP ................................................................... 2-155
03-415 Tray 5 Module Not Detected / Confirmed RAP ................................................... 2-101 07-303A Tray 3 Open During Run RAP (W/O TAG 151) ................................................ 2-155
03-417 Incompatible Fax Software RAP ......................................................................... 2-103 07-303B Tray 3 Open During Run RAP (W/TAG 151) .................................................... 2-157
03-419, 03-420 Incompatible Software RAP ................................................................... 2-103 07-304 Tray 4 Open During Run Entry RAP ................................................................... 2-158
03-423, 424, 433, 434, 821, 822, 831, 832 Print Command Late RAP........................... 2-104
November 2014 Status Indicator RAPs

07-304A Tray 4 Open During Run RAP (W/O TAG 151) ................................................ 2-158 08-155, 08-156 Bypass Tray Registration Jam Entry RAP ............................................. 2-245
07-304B Tray 4 Open During Run RAP (W/TAG 151).................................................... 2-160 08-155A, 08-156A Bypass Tray Registration Jam RAP (35-55 ppm) ............................. 2-245
07-306 Tray 5 Door Open During Run RAP.................................................................... 2-161 08-155B, 08-156B Bypass Tray Registration Jam RAP (65-90 ppm) ............................. 2-248
07-353 Tray 1 Elevator Lift Failure RAP ......................................................................... 2-162 08-160, 08-161 Duplex Paper Path Jam Entry RAP ....................................................... 2-250
07-354 Tray 2 Elevator Lift Failure RAP ......................................................................... 2-163 08-160A, 08-161A Duplex Paper Path Jam RAP (35-55 ppm) ....................................... 2-251
07-355 Tray 3 Elevator Lift Failure Entry RAP ................................................................ 2-165 08-160B, 08-161B Duplex Paper Path Jam RAP (65-90 ppm) ....................................... 2-254
07-355A Tray 3 Elevator Lift Failure RAP (W/O TAG 151) ............................................. 2-165 08-171 Unexpected Time Out RAP................................................................................. 2-257
07-355B Tray 3 Elevator Lift Failure RAP (W/TAG 151) ................................................. 2-167 08-174 Missing Pre-release Sheet RAP ......................................................................... 2-257
07-360 Tray 4 Elevator Lift Failure Entry RAP ................................................................ 2-170 08-180 Unable to Feed Next Sheet RAP ........................................................................ 2-258
07-360A Tray 4 Elevator Lift Failure RAP (W/O TAG 151) ............................................. 2-170 08-181 Unexpected Time Out in Simplex Inverted Mode RAP ....................................... 2-258
07-360B Tray 4 Elevator Lift Failure RAP (W/TAG 151) ................................................. 2-172 08-182 Unexpected Time Out in Duplex Mode RAP....................................................... 2-259
07-372 Tray 5 Undocked During Run RAP ..................................................................... 2-175 08-190 Post Jam Clearance Initialization RAP ............................................................... 2-259
07-373 Tray 5 Elevator Lift Failure RAP ......................................................................... 2-177
07-374 Tray 5 Elevator Lower Failure RAP .................................................................... 2-180 Chain 9 - Xerographics
07A Tray 1 and Tray 2 Empty RAP ................................................................................. 2-183 09-060 HVPS Fault RAP................................................................................................. 2-261
07B Tray 3 and Tray 4 False Low Paper Level Entry RAP ............................................. 2-184 09-310, 09-390 Low Toner Sensor Failure RAP ............................................................. 2-265
07C Tray 3 and Tray 4 False Low Paper Level RAP (W/TAG 151) ................................ 2-185 09-341, 09-342 Scorotron Cleaning Failure RAP............................................................ 2-267
07D Bypass Tray RAP .................................................................................................... 2-186 09-350 Erase Lamp Failure RAP .................................................................................... 2-268
07E Tray 1 and 2 Wrong Size Paper RAP ...................................................................... 2-188 09-360, 09-361, 09-362, 09-363 Toner Concentration Sensor Failure RAP ................... 2-270
07F Tray 3 or Tray 4 Out of Paper Entry RAP ................................................................ 2-191 09-365 Relative Humidity Sensor Failure RAP ............................................................... 2-273
07G Tray 3 or Tray 4 Out of Paper RAP (W/TAG 151)................................................... 2-192 09-370 Developer Temperature Sensor Failure RAP ..................................................... 2-275
07H Tray Out of Service RAP ......................................................................................... 2-193 09-375 Ambient Temperature Sensor Failure RAP ........................................................ 2-276
07J Tray 5 Empty RAP.................................................................................................... 2-194 09-380 Waste Toner Door Switch Failure RAP............................................................... 2-277
07K Tray 3 and Tray 4 False Low Paper Level RAP (W/O TAG 151) ............................ 2-195 09-399 Incompatible Xerographic Module RAP .............................................................. 2-279
07L Tray 3 or Tray 4 Out of Paper RAP (W/O TAG 151) ................................................ 2-197 09A Photoreceptor Motor RAP........................................................................................ 2-280
09B Waste Toner Full Sensor RAP................................................................................. 2-281
Chain 8 - Paper Transport 09C Photoreceptor Fan RAP .......................................................................................... 2-282
08-100 Wait Sensor Jam Entry RAP ............................................................................... 2-199
08-100A Wait Sensor Jam RAP (35-55 ppm) ................................................................. 2-199 Chain 10 - Fusing and Copy/Print Transportation
08-100B Wait Sensor Jam RAP (65-90 ppm) ................................................................. 2-201 10-101, 10-102, 10-103 Lead Edge Late to Fuser Exit Switch Entry RAP...................... 2-285
08-101 Tray 1 Misfeed RAP ............................................................................................ 2-203 10-101A, 10-102A, 10-103A Lead Edge Late to Fuser Exit Switch RAP (35-55 ppm) ... 2-285
08-102 Tray 2 Misfeed RAP ............................................................................................ 2-206 10-101B, 10-102B, 10-103B Lead Edge Late to Fuser Exit Switch RAP (65-90 ppm) ... 2-289
08-103, 08-113 Tray 3 Misfeed Entry RAP ..................................................................... 2-208 10-107, 10-108, 10-109, 10-110 Trail Edge Late from Fuser Exit Switch RAP............... 2-292
08-103A, 08-113A Tray 3 Misfeed RAP (W/O TAG 151) ................................................ 2-208 10-120, 10-121, 10-126 IOT Exit Sensor RAP................................................................ 2-296
08-103B, 08-113B Tray 3 Misfeed RAP (W/TAG 151).................................................... 2-210 10-132, 10-133, 10-134 Lead Edge Late to Inverter Sensor RAP (65-90 ppm).............. 2-300
08-104, 08-114 Tray 4 Misfeed Entry RAP ..................................................................... 2-213 10-135, 10-136, 10-137, 10-138 Trail Edge Late from Inverter Sensor RAP .................. 2-302
08-104A, 08-114A Tray 4 Misfeed RAP (W/O TAG 151) ................................................ 2-213 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 10-365, 10-380
08-104B, 08-114B Tray 4 Misfeed RAP (W/TAG 151).................................................... 2-215 Fuser Over Temperature RAP ........................................................................................ 2-306
08-106 Lead Edge Late to Tray 1 Feed Sensor RAP ..................................................... 2-218 10-322, 10-324, 10-325, 10-330, 10-370 Fuser Under Temperature RAP ..................... 2-310
08-107 Tray 3 Paper Feed Jam RAP (W/O TAG 151).................................................... 2-220 10-399 Fuser Authorization Failure RAP ........................................................................ 2-314
08-108 Tray 3 or Tray 4 Paper Feed Jam Entry RAP ..................................................... 2-222 10A Fuser Web Motor RAP............................................................................................. 2-314
08-108A Tray 3 or Tray 4 Paper Feed Jam RAP (W/O TAG 151) .................................. 2-222 Chain 11-110 - 2K LCSS
08-108B Tray 3 or Tray 4 Paper Feed Jam RAP (W/TAG 151)...................................... 2-224
11-005-110, 11-006-110, 11-310-110, 11-311-110 Front Tamper Move Failure RAP.... 2-317
08-115, 08-117 Tray 5 Misfeed Entry RAP ..................................................................... 2-227
11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-110
08-115A, 08-117A Tray 5 Misfeed RAP (35-55 ppm) ..................................................... 2-227 Rear Tamper Move Failure RAP ..................................................................................... 2-319
08-115B, 08-117B Tray 5 Misfeed RAP (65-90 ppm) ..................................................... 2-231
11-024-110, 11-025-110 Paddle Roll Failure RAP.......................................................... 2-322
08-131 Lead Edge Late to Tray 3 Exit Sensor RAP (W/TAG 151) ................................. 2-235
11-030-110, 11-334-110, 11-335-110, 11-336-110 Bin 1 Movement Failure RAP ......... 2-324
08-132 Tray 3 Paper Feed Jam RAP (W/TAG 151)........................................................ 2-237 11-043-110, 11-350-110 Hole Punch Operation Failure RAP......................................... 2-328
08-133 Tray 4 Paper Feed Jam RAP (W/TAG 151)........................................................ 2-239
11-050-110, 11-360-110 Staple Head Operation Failure RAP ....................................... 2-331
08-150, 08-151 Registration Jam Entry RAP .................................................................. 2-240
11-053-110, 11-370-110 Staple Head Unit Movement Failure RAP ............................... 2-334
08-150A, 08-151A Registration Jam RAP (35-55 ppm) .................................................. 2-241 11-100-110 2K LCSS Paper Entry RAP.......................................................................... 2-337
08-150B, 08-151B Registration Jam RAP (65-90 ppm) .................................................. 2-243
Status Indicator RAPs November 2014

11-110-110 Sheet Late to Hole Punch RAP.................................................................... 2-338 11-140-171, 11-142-171 HVF 2nd to Top Exit Sensor RAP ........................................... 2-431
11-130-110, 11-132-110 Paper Exiting to Bin 0 RAP...................................................... 2-340 11-157-171, 11-161-171 HVF Buffer Position Sensor RAP ............................................ 2-433
11-140-110, 11-142-110 Sheet Late to Bin 1 RAP.......................................................... 2-343 11-158-171, 11-160-171, 162-171, 163-171 HVF BM Entry RAP................................... 2-435
11-300-110, 11-302-110, 11-303-110 Interlocks RAP .................................................... 2-346 11-164-171, 11-165-171 HVF Buffer Path RAP .............................................................. 2-438
11-320-110, 11-322-110 Ejector Movement Failure RAP ............................................... 2-348 11-172-171 HVF BM Compiler Exit Jam RAP................................................................. 2-441
11-364-110 Stapling Failure RAP.................................................................................... 2-351 11-173-171 to 11-177-171 HVF Offset Unit RAP ............................................................ 2-444
11A-110 Offline Stapling Fault RAP ................................................................................ 2-354 11-180-171, 11-182-171 HVF BM Exit Jam RAP............................................................ 2-446
11B-110 Bin 1 Overload RAP.......................................................................................... 2-358 11-183-171, 11-184-171 HVF BM Paper Jam RAP ........................................................ 2-449
11C-110 2K LCSS Initialization Failure RAP................................................................... 2-359 11-185-171 to 11-187-171 Tri-Folder Exit Sensor and Assist Sensor RAP .................... 2-452
11D-110 2K LCSS Power Distribution RAP .................................................................... 2-360 11-188-171, 11-189-171 HVF Nip Split RAP................................................................... 2-457
11E-110 2K LCSS to Machine Communications Interface RAP ..................................... 2-363 11-191-171, 11-193-171, 11-194-171, 11-196-171 Inserter Paper Jam RAP................. 2-459
11F-110 2K LCSS PWB DIP Switch Settings RAP ......................................................... 2-363 11-198-171, 11-199-171 HVF Paper Jam RAP............................................................... 2-463
11G-110 2K LCSS PWB Damage RAP .......................................................................... 2-364 11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlock RAP ......................... 2-466
11H-110 Copy Damage in the 2K LCSS RAP................................................................. 2-366 11-306-171, 11-309-171 HVF Inserter Interlock RAP ..................................................... 2-469
11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP........................... 2-367 11-307-171, 11-308-171 Tri-folder Interlock RAP ........................................................... 2-471
11K-110 2K LCSS Poor Stacking RAP ........................................................................... 2-367 11-371-171 to 11-377-171 HVF Stapler Position and Priming RAP................................ 2-473
11-380-171 HVF Punch Unit Paper Edge Detect RAP ................................................... 2-478
Chain 11-120 - 1K LCSS 11-392-171 to 11-395-171 HVF Front Tamper Tray RAP ............................................... 2-480
11-005-120, 11-006-120, 11-310-120, 11-311-120 Front Tamper Move Failure RAP.... 2-369 11-396-171 to 11-399-171 HVF Rear Tamper Tray RAP................................................ 2-482
11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120 11-403-171, 11-413-171, 11-414-171 HVF BM Staple Head 2 and Stapler Module RAP 2-484
Rear Tamper Move Failure RAP ..................................................................................... 2-371 11-415-171 HVF BM Crease Roll Gate Home RAP........................................................ 2-486
11-024-120, 11-025-120 Paddle Roll Failure RAP.......................................................... 2-374 11-417-171, 11-418-171 HVF BM Flapper RAP ............................................................. 2-488
11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP ......... 2-376 11-450-171, 11-456-171 to 11-459-171 HVF Ejector Module RAP................................. 2-490
11-050-120, 11-360-120 Staple Head Operation Failure RAP........................................ 2-380 11-451-171 to 11-455-171 HVF Ejector Roll and Lower Paddle RAP............................. 2-493
11-100-120 1K LCSS Paper Entry RAP.......................................................................... 2-382 11-460-171 to 11-462-171 HVF Bin 1 Position RAP ....................................................... 2-497
11-130-120, 11-132-120 Paper Exiting to Bin 0 RAP...................................................... 2-383 11-463-171, 11-464-171 HVF BM +24V Failure RAP ..................................................... 2-501
11-140-120, 11-142-120 Sheet Late to Bin 1 RAP.......................................................... 2-386 11-465-171 to 11-468-171 Paddle Unit Position RAP..................................................... 2-503
11-300-120, 11-302-120, 11-303-120 Interlocks RAP .................................................... 2-389 11-473-171 to 11-478-171 Support Finger Position RAP................................................ 2-505
11-320-120, 11-322-120 Ejector Movement Failure RAP ............................................... 2-392 11-479-171 Inserter Paper Length Fault RAP................................................................. 2-509
11-364-120 Stapling Failure RAP.................................................................................... 2-395 11A-171 HVF Power Distribution RAP ............................................................................ 2-513
11A-120 Bin 1 Overload RAP.......................................................................................... 2-398 11B-171 HVF BM to Machine Communications Interface and BM Present RAP............ 2-517
11B-120 Initialization Failure RAP................................................................................... 2-399 11C-171 HVF BM Bin 2 Failure RAP .............................................................................. 2-518
11C-120 1K LCSS Power Distribution RAP .................................................................... 2-400 11D-171 Booklet Quality RAP ......................................................................................... 2-520
11D-120 1K LCSS to Machine Communications Interface RAP ..................................... 2-403 11E-171 Copy Damage in the HVF BM RAP .................................................................. 2-524
11E-120 1K LCSS PWB DIP Switch Settings RAP......................................................... 2-403 11F-171 Mis-Registration in Stapled and Unstapled Sets RAP ...................................... 2-525
11F-120 1K LCSS PWB Damage RAP ........................................................................... 2-404 11G-171 HVF BM Poor Stacking RAP ............................................................................ 2-525
11G-120 Copy Damage in the 1K LCSS RAP ................................................................ 2-405 11H-171 Pause to Unload (PTU) RAP ............................................................................ 2-526
11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.......................... 2-406 11J-171 Inserter Paper Sensing and +5V Supply RAP................................................... 2-527
11J-120 1K LCSS Poor Stacking RAP............................................................................ 2-406 11K-171 HVF Initialization Failure RAP .......................................................................... 2-531
Chain 11-171 - HVF 11L-171 Tri-Folder Not Detected RAP ............................................................................ 2-532
11M-171 Curl Suppressor RAP....................................................................................... 2-533
11-024-171, 11-026-171 Paddle Roller Position RAP..................................................... 2-407
11N-171 Chad Bin Present and Bin Full RAP ................................................................. 2-534
11-044-171 to 11-047-171 Punch Unit Head and Position RAP ..................................... 2-409
11-056-171, 11-057-171 Inserter Bottom Plate RAP ...................................................... 2-411 11P-171 Buffer Clamp RAP ............................................................................................ 2-537
11-061-171, 11-416-171 HVF BM Creasing RAP ........................................................... 2-413 Chain 12 - Offset Catch Tray
11-062-171 HVF BM Crease Roll Failure RAP ............................................................... 2-416 12-301 Offset Catch Tray Failure RAP............................................................................ 2-539
11-063-171, 11-411-171 HVF BM Staple Unit 1 Failure RAP ......................................... 2-418
11-065-171, 11-383-171 HVF BM Backstop Failure RAP............................................... 2-420 Chain 14 - Scanner
11-066-171, 11-384-171 HVF BM Tamper Failure RAP ................................................. 2-422 14-110 Scan Carriage Home Sensor Entry RAP ............................................................ 2-541
11-083-171, 11-440-171 to 11-443-171 Paper Pusher RAP........................................... 2-424 14-110A Scan Carriage Home Sensor RAP (W/O TAG 150) ......................................... 2-541
11-100-171, 11-101-171 HVF Entry Sensor RAP ........................................................... 2-427 14-110B Scan Carriage Home Sensor RAP (W/TAG 150) ............................................. 2-545
11-130-171, 11-132-171 HVF Top Exit Sensor RAP ...................................................... 2-429 14-310 CCD PWB Not Detected RAP (W/O TAG 150)................................................... 2-548

14-320 CVT Active Hot Line in Wrong State RAP .......................................................... 2-550 22-300 AHA End of Record Error RAP ........................................................................... 2-591
14-322 Platen Active Hot Line in Wrong State RAP (W/O TAG 150) ............................. 2-550 22-306 to 22-315, 22-801, 22-814 System Error RAP .................................................... 2-592
14-340 Scanner AGC Failure RAP ................................................................................. 2-551 22-316, 22-810, 22-820 Capability That Does Not Exist RAP ........................................ 2-592
14-703 to 14-706, 712, 714, 716, 718 Failure To Calibrate Entry RAP .......................... 2-551 22-370 Cannot Communicate to the XSA Database RAP .............................................. 2-593
14-703A to 14-706A, 712A, 714A, 716A, 718A Failure To Calibrate RAP (W/O TAG 150)2-552 22-400 to 22-403, 22-423, 22-426, 22-427, 22-775 Option Install Failure RAP.............. 2-593
14-703B to 14-706B, 712B, 714B, 718B Failure To Calibrate RAP (W/TAG 150).......... 2-554 22-404 to 22-406 Option Install Failure RAP .................................................................. 2-594
14-710 NVM Value Out Of Range RAP .......................................................................... 2-557 22-407 Embedded Fax Install Failure RAP..................................................................... 2-594
14-720 Scan Length Out Of Range RAP ........................................................................ 2-557 22-410 to 22-416, 22-423, 22-425, 22-428, 22-777 Option Remove Failure RAP.......... 2-595
14-730 Scanner Application Card Failure RAP ............................................................... 2-558 22-417 Embedded Fax Remove Failure RAP ................................................................. 2-595
14A Scanning Document Size Entry RAP....................................................................... 2-558 22-419 Embedded Fax Enable Failure RAP ................................................................... 2-596
14B Scanning Document Size RAP (W/O TAG 150) ...................................................... 2-559 22-421 Embedded Fax Disable Failure RAP .................................................................. 2-596
14C Scanning Document Size RAP (W/TAG 150).......................................................... 2-562 22-450 Test Pattern Standard Grey Level Too High RAP .............................................. 2-597
14D Exposure Lamp Failure RAP ................................................................................... 2-564 22-451 Test Pattern Average Grey Level Too Low RAP ................................................ 2-597
22-452 Test Pattern Average Grey Level Too High RAP................................................ 2-598
Chain 16 - Network Controller 22-760 IQA Factor Set to Maximum RAP ....................................................................... 2-598
16A Network Error Entry RAP ......................................................................................... 2-567 22-761 IQA Factor Set to Minimum RAP ........................................................................ 2-599
16B FTP or SMB Unable to Connect to Remote Server RAP......................................... 2-567 22-774 CPSR File Cabinet Enable Failure RAP ............................................................. 2-599
16C Remote Directory Lock Failed RAP ......................................................................... 2-569 22-776 CPSR File Cabinet Disabled Failure RAP .......................................................... 2-600
Chain 19 - Image Processing 22-819, 22-831 to 22-837 Time Out Error RAP .............................................................. 2-600
19-401, 19-402, 19-403 Out of Memory Resources RAP ............................................... 2-571 OF - Other Faults
19-404 Compressor Time-out RAP ................................................................................. 2-571 OF1 Audible Noise RAP.................................................................................................. 2-601
19-406 Loopback DVMA Time-out RAP ......................................................................... 2-572 OF2 Touch Screen Failure RAP ..................................................................................... 2-607
19-407, 19-408 Middle Function DVMA Time-out RAP .................................................. 2-572 OF3 Dead Machine RAP................................................................................................. 2-609
19-409 Video Job Integrity Fault RAP ............................................................................. 2-573 OF4 Status Codes and Messages RAP .......................................................................... 2-613
Chain 20 - Fax OF4a Status Codes in Numerical Order ......................................................................... 2-613
20-302, 20-303 Fax Reset Failure RAP .......................................................................... 2-575 OF4b Status Messages in Alphabetical Order ................................................................ 2-639
OF5 Boot Up Failure RAP............................................................................................... 2-661
20-305 Fax System Low Memory Unrecoverable RAP................................................... 2-575
OF6 Ozone and Air Systems RAP .................................................................................. 2-663
20-320 Fax Fault Not Cleared RAP ................................................................................ 2-576
20-322 Fax Non-Volatile Device not Present RAP.......................................................... 2-576 OF7 IOT PWB Diagnostics RAP ..................................................................................... 2-664
OF8 Multi-feed RAP ........................................................................................................ 2-666
20-323, 20-324 Fax System Memory Low RAP .............................................................. 2-577
OF9 False Fuser End of Life RAP................................................................................... 2-667
20-327 Extended Fax PWB Failure RAP ........................................................................ 2-577
20-331, 20-339, 20-341 Fax Network Line 1 Fault RAP ................................................. 2-578 OF10 Intermittent Failure RAP........................................................................................ 2-668
OF11 Waste Toner Contamination RAP ......................................................................... 2-671
20-332, 20-340 Fax Network Line 2 Fault RAP .............................................................. 2-578
OF12 False Xerographic Module End of Life RAP.......................................................... 2-672
20-342 Fax File Integrity Fault RAP ................................................................................ 2-579
20-701 Fax Phone Book Download Failed Entry RAP .................................................... 2-579 OF13 Convenience Stapler RAP .................................................................................... 2-673
OF14 Extensible Interface Platform RAP ........................................................................ 2-674
20-701A Fax Phone Book Download Failed RAP (W/O TAG X-001) ............................. 2-580
OF15 Xerox Secure Access RAP ................................................................................... 2-674
20-701B Fax Phone Book Download Failed RAP (W/TAG X-001) ................................. 2-580
20-710, 20-711 Image Overwrite Error Entry RAP.......................................................... 2-581
20-710A, 20-711A Image Overwrite Error RAP (W/O TAG X-001)................................. 2-581
20-710B, 20-711B Image Overwrite Error RAP (W/TAG X-001) .................................... 2-582
20A Fax Entry RAP ......................................................................................................... 2-582
20B Unable To Send A Fax RAP .................................................................................... 2-583
20C Unable To Send A Fax To Some Machines RAP .................................................... 2-585
20D Unable To Receive A Fax RAP ............................................................................... 2-586
20E Fax Will Not Print RAP............................................................................................. 2-587
20F Fax Tab Not Available RAP ..................................................................................... 2-587
20G Embedded Fax Checkout ........................................................................................ 2-588
20H Embedded Fax PWB Voltage Checkout (W/O TAG X-001) .................................... 2-589
20J Fax Problems on Digital Networks RAP ................................................................... 2-590
Chain 22 - System Errors

A
01-300 Front Door Open RAP Check that the front door, PL 8.10 Item 10 closes correctly. If not, check the following:
01-300 The front door has opened during machine operation. The jam clearance latch, PL 8.20 Item 5.
(35 ppm) the xerographic module latch, PL 9.22 Item 7.
Procedure (40-90 ppm) the xerographic module latch, PL 9.20 Item 7.
(35-55 ppm) the fuser latch, PL 10.8 Item 5.
(65-90 ppm) the fuser latch, PL 10.10 Item 5.
WARNING The post fuser jam clearance latch, PL 10.15 Item 11.
Ensure that the electricity to the machine is switched off while performing tasks that do The latch cam handle, PL 10.15 Item 14.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
death or injury. Moving parts can cause injury.
Enter dC330, code 01-300 front door interlock, Figure 1. Press start, open and close the front
door. The display changes.
Y N
Go to Flag 2. +12V is available at P/J147 pin 4 on the main drive PWB.
Y N
Go to Flag 2. +12V is available at P/J147 pin 3 on the main drive PWB.
Y N
Go to Flag 2. +12V is available at P/J16 pin 3 on the LVPS and base mod-
ule.
Y N
Go to the 01F +12V Distribution RAP.
Repair the wiring or the connector pins between P/J16 and P/J147.
Door interlock
Remove the main drive module, (35-55 ppm) REP 4.1 or (65-90 ppm) REP 4.5. Go switch S01-300.
to Flag 2. Check the continuity to the xerographic module CRUM at P/J147,
between pins 3 and 4. If necessary, check and repair the wiring between the main
drive module and the xerographic CRUM, REP 1.2.
Go to Flag 1. +12V is available at P/J17, pin 5.

Y N
Install a new LVPS and base module, PL 1.10 Item 3.
Go to Flag 1. +12V is available at P/J17, pin 6.

Y N
Check S01-300 and associated wiring. Refer to:
GP 13 How to Check a Switch.
P/J17, LVPS and base module.
REP 1.2 Wiring Harness Repairs. Figure 1 Component Location
If necessary, install a new door interlock switch, PL 1.10 Item 7.
Go to Flag 3. Open the front door, then measure the signal at P/J26 pin 8 on the IOT
PWB. +3.3V is measured.
Y N
Perform OF7 IOT PWB Diagnostics RAP. If the fault remains, install a new IOT PWB, PL
1.10 Item 2.

Xerox WorkCentre 5790 Family 2-5 01-300
Figure 2 Circuit diagram

01-300 2-6 Xerox WorkCentre 5790 Family
01-305 Left Hand Door Open RAP
01-305 The left hand door has been opened during machine operation.
Procedure
WARNING Left hand door

Ensure that the electricity to the machine is switched off while performing tasks that do interlock, S01-305.
NOTE: To access the left door interlock, remove the interlock cover, PL 7.30 Item 23.
Enter dC330, code 01-305 left door interlock. Press Start, open and close the left hand door,
Figure 1. The display changes.
Y N
Go to Flag 1. Check the left hand door interlock, S01-305. Refer to:
GP 13, How to Check a Switch.
P/J7 on the IOT PWB.
01B 0V Distribution RAP
If necessary, install a new left hand door interlock, PL 7.30 Item 3.
Check that the left hand door closes correctly. If not, check the following:
Hinge pin, PL 7.30 Item 8, is located correctly.
Left hand door latch, part of the LH door, PL 7.30 Item 2.
Check that the interlock cover is not loose, PL 7.30 Item 23. If necessary push the cover
towards the front and tighten the screws.
Figure 1 Component Location

01A Ground Distribution RAP
Use this RAP to identify ground distribution faults.
Procedure
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do
WARNING
Do not switch on the electricity to the machine while a ground circuit is disconnected.
Ground circuits ensure that the machine remains safe during a fault condition.
NOTE: Ground distribution faults must be isolated by continuity checks and visual inspection.
Check all circuits between each connection and ground.
Ground distribution faults can cause the following:

Image quality faults
Paper feed faults.
Paper path faults.
Random logic faults
To diagnose a suspected ground distribution fault, the following must be considered:
Ensure that all the connectors are not damaged. Check crimping for suspect electrical
connections or any mechanical failure that could cause a failed or poor electrical contact.
Refer to REP 1.2 for information concerning wiring harness repairs.
When making a continuity check on a harness, disconnect the harness at both ends, to
ensure that other wiring does not cause continuity readings to be incorrect. Ensure that
any in-line connectors are installed correctly.
When making a check between connectors and ground, preferably use the main frame ground
connection, Figure 1. Alternatively use any unpainted metal part of the machine frame.
Check the ground conductor of the main power cord for continuity or damage, if neces-
sary install a new main power cord, PL 1.10 Item 10.
Check that the ground connections that follow are secure:
Main Frame
Corotron Shield Ground
Corotron Shield Ground Return
DADH Ground Connection
Paper Path
Duplex Paper Path
Registration Transport
Bypass Tray
Tray 3 and 4 (W/O TAG 151)
Tray 3 and 4 (W/TAG 151)
Paper Transport Rolls
Embedded Fax PWB
Tray 5

01-305, 01A 2-8 Xerox WorkCentre 5790 Family
Main Frame
Refer to Figure 1, main input and auxiliary output ground connections. Check for continuity of
less than 1 ohm between the ground contact of each mains connector and the main frame Main frame ground
ground. Check that the hardware is tight and the harness crimping is good. To improve continu- connection.
ity, disconnect the terminals, clean the contact faces and re-assemble.
Main input ground

connection.
Auxiliary output
ground connection.
Figure 1 Component location

Xerox WorkCentre 5790 Family 2-9 01A
Corotron Shield Ground Corotron Shield Ground Return
Refer to Figure 2. Check for continuity of less than 10 ohms between the exposed metal end of Refer to Figure 3. Check the connection of the Faston connector and the tightness of the screw
the corotron shield and ground. To improve continuity, remove the duplex transport, REP 8.7, at the rear of the machine frame. If necessary disconnect the terminals, clean the contact faces
then check the corotron shield ground return, and re-assemble, to improve continuity.
Ground connection
to the machine
frame.
Corotron shield ground return

wire (violet) to machine frame.
Figure 2 Corotron shield ground Figure 3 Corotron shield ground return

01A 2-10 Xerox WorkCentre 5790 Family
DADH Ground Connection Paper Path
Refer to Figure 4. Remove the DADH rear cover, PL 5.10 Item 1. Check for continuity of less Refer to Figure 5. With the duplex transport in the latched position, check for continuity of less
than 1 ohm between the DADH frame and the main frame ground connection. To improve con- than 1M ohms between the ends of the three duplex roll shafts, the steel frame of the duplex
tinuity, check that the hardware is tight and the harness crimping is good. If necessary discon- path and the main frame ground connection. Also check for continuity of less than 10 ohms
nect the terminals, clean the contact faces and re-assemble, to improve continuity. between the steel frame of the duplex path and the ends of the three duplex roll shafts. To
improve continuity, remove and re-install the duplex transport, REP 8.7.
Right hinge ground connection. Motor ground connections.
Duplex roll shafts and the steel frame of duplex path.
Auxiliary DADH ground con-

nections.
Figure 5 Paper path ground check points
NOTE: The (35-55 ppm) duplex transport is shown in Figure 6. The (65-90 ppm) duplex trans-
Left hinge ground connection. port has a duplex duct installed, PL 8.20 Item 12.
Main DADH ground

connection
Figure 4 DADH ground connection

Duplex Paper Path
Refer to Figure 6. Check the duplex paper path ground contact spring and ground wire termi-
nal. If necessary remove and clean the spring, shafts and bearings, then re-assemble to
improve continuity.
Duplex paper path

ground contact spring.
Ground wire terminal.
Figure 6 Duplex path ground contact spring
Registration Transport
Refer to Figure 7. Check for continuity of less than 2k ohms between the ends of the pre-regis-
tration drive roll shaft, the registration roll shaft and the grounding screw. To improve continuity, Pre-registration
remove and re-install the registration transport, REP 8.4. drive roll shaft. Grounding screw.
Registration roll
shaft.
Figure 7 Registration ground check points

Refer to Figure 8. Check the registration ground contact spring and ground wire terminal. If Bypass Tray
necessary remove and clean the spring, shafts and bearings, then re-assemble to improve
Refer to Figure 9. Check for continuity of less than 2k ohms between the ground contact spring
continuity.
and the lift plate (Figure 10). Check for continuity of less than 1 ohm between the bypass paper
guide and the main frame ground connection, when the left hand door is closed. To improve
NOTE: The two bearings in contact with the registration ground contact spring are manufac-
continuity, disconnect the ground terminals clean the spring contact faces and re-assemble, to
tured from conductive plastic. It is not possible to measure the resistance of these bearings
improve continuity. Also check and clean, if necessary the part of the machine frame where the
with the standard multi meter. ground contact spring makes contact.
Bypass paper guide.
Registration ground
contact spring.
Ground wire terminal.

Ground contact spring.
Figure 8 Registration ground contact spring

Figure 9 Bypass tray guide

Refer to Figure 10. Check for continuity of less than 2k ohms between the ground contact Tray 3 and 4 (W/O TAG 151)
spring (Figure 9) and the feed shaft. Check for continuity of less than 2k ohms between the
Refer to Figure 11. Remove the tray 3 front cover, REP 7.2. With tray 3 closed, check for conti-
feed shaft and the main frame ground connection when the left hand door is closed. To
nuity of less than 10k ohms between the tray 3 takeaway roll shaft, the tray 3 transport roll shaft
improve continuity, dismantle the ground connection spring, clean the spring contact faces and and the main frame ground connection. If necessary, perform the following:
re-assemble, to improve continuity.
1. Open the tray. Rotate the shafts. Close the tray and repeat the measurements.
2. To improve continuity, remove tray 3, REP 7.2. Refer to Figure 13, check the tray 3
ground contact spring.
Ground connection 3. If necessary remove and clean the spring, shafts and bearings, REP 8.31, then re-assem-
spring.
ble to improve continuity.
Refer to Figure 12. Remove, then clean the tray 3 and 4 transport drive gear. Clean the
gear on the tray 3 and 4 transport motor, REP 8.11.
4. Clean the area in the back of the tray 3 cavity where the ground spring makes contact.
Lift plate.
Feed shaft.
Figure 10 Bypass tray paper feed
Tray 3 transport Tray 3 takeaway

roll shaft. roll shaft. Tray 3 and 4 transport roll
shaft ground contact spring
(35-55 ppm).
Figure 11 HCF transport roll assembly

Tray 3 and 4 transport drive
gear.
Tray 3 and 4 transport motor.
Tray 3 ground contact spring.
Figure 12 HCF transport drive gear Figure 13 Tray 3 ground contact spring

Refer to Figure 14. Open tray 3, check for continuity of less than 1 ohm between the tray 3 Refer to Figure 15. Open tray 4, check for continuity of less than 1 ohm between the tray 4
metal side wall and the main frame ground connection. To improve continuity, remove, clean metal side wall and the main frame ground connection. To improve continuity, remove, clean
and re-assemble the grounding spring to improve continuity. Also clean the contact area on the and re-assemble the grounding spring to improve continuity. Also clean the contact area on the
metal side wall. metal side wall.
Tray 3 grounding Tray 4 grounding

spring. spring.
Figure 14 Tray 3 grounding spring Figure 15 Tray 4 grounding spring

Tray 3 and 4 (W/TAG 151) 2. To improve continuity, remove the tray 3 takeaway roll, REP 8.46. Refer to Figure 17,
clean the conductive plastic bearings and shaft. Then install the removed components.
Refer to Figure 16. Figure 19 and Figure 20. Remove the tray 3 front cover, PL 7.26 Item 5 (4
screws). With tray 3 closed, check for continuity of less than 10k ohms between the following
points and the main frame ground connection.
Clean inside and outside of the
Tray 3 takeaway roll shaft, PL 8.36 Item 2.
conductive plastic bearings
Tray 3 and 4 transport roll shaft, PL 8.32 Item 4.
Tray 3 lift plate and paper tray guide.
Tray 4 lift plate and paper tray guide.
If necessary, perform the following:
Conductive
plastic
bearing
Conductive
Clean the bearing areas of
plastic
the tray 3 takeaway roll shaft
bearing
Figure 17 Component cleaning
3. If necessary remove the tray 3 and 4 transport roll and bearings, REP 8.47. Refer to Fig-
ure 18, clean the bearings and shaft. Then install the removed components.
Clean inside and outside

of the bearings
Tray 3 and 4 transport roll shaft. Tray 3 takeaway roll shaft.
Bearing
Figure 16 Continuity check points

Bearing Clean the bearing areas of
1. Open the tray. Rotate the shafts. Close the tray and repeat the measurements. the tray 3 and 4 transport roll
Figure 18 Component cleaning

4. Empty tray 3 of paper. Refer to Figure 19, disconnect and clean the tray 3 ground harness 5. Empty tray 4 of paper. Refer to Figure 20, disconnect and clean the tray 4 ground harness
connectors. Then install the removed components. connectors. Then install the removed components.
Connectors Connectors
Tray 4 paper tray guide

Tray 3 paper tray guide
Tray 3 lift plate Tray 4 lift plate
Tray 3 ground harness Tray 4 ground harness
Figure 19 Tray 3 grounding Figure 20 Tray 4 grounding

Paper Transport Rolls Embedded Fax PWB
Refer to Figure 21. Open the left hand door. Rotate the rolls by hand and check for continuity of Refer to Figure 22. Ensure the grounding strip is clean and correctly installed.
less than 10k ohms between the tray 1 and tray 2 transport roll shaft, tray 3 and 4 transport roll
shaft and the main frame ground connection. To improve continuity for the tray 1 and tray 2
transport roll shaft, remove and clean and re-install the shaft and bearing.
To improve continuity for the tray 3 and 4 transport roll shaft, perform the following:
Remove, clean and re-install the tray 3 and 4 transport roll shaft ground contact spring,
Figure 11. If necessary, re-form the spring to make good contact with the end of the shaft.
Remove and clean the tray 3 and 4 transport drive gear. Clean the gear on the tray 3 and
4 transport motor, REP 8.11.
Grounding strip.
Figure 22 Embedded FAX PWB ground connection
Tray 1 transport
roll shaft.
Tray 2 transport
roll shaft. Tray 3 and 4 transport roll shaft.
Figure 21 Paper transport rolls

Tray 5 01B 0V Distribution RAP
Refer to Figure 23. Check the ground connection on the frame, the elevator motor and on the Use this RAP to identify 0V distribution faults.
base of the paper tray. Ensure that the in-line connectors are connected.
Procedural Notes
NOTE: If a voltage is measured between ground and a return 0V line, then the continuity of
that 0V circuit must be checked.
NOTE: To isolate a 0V distribution fault, perform the following:

1. Check the continuity of a harness while the harness is disconnected at both ends. This is
to ensure that other wiring does not cause false continuity readings.
2. Check the continuity and perform a visual inspection of each connection sequentially,
Ground connection back to its source.
under the paper tray. 3. Check that any in-line connectors are installed correctly.
4. Check that all connectors are mechanically good. Check crimping for suspect electrical
connections or any mechanical failure that could cause a failed or poor electrical contact,
GP 7. Refer to REP 1.2 for information concerning wiring harness repairs.
NOTE: The expression return is used to identify the 0V line that completes the circuit for a
particular voltage.
Procedure
WARNING
In-line ground Go to the 0V circuit that has the suspect problem:
Ground connection. connector. 01B +3.3V Return.
01B +5V Return.
01B +12V Return.
01B +24V Return.
Figure 23 Tray 5 ground connections 01B +3.3V Return
Go to the appropriate component in the list that follows that has the suspect 0V supply. Check
the wiring GP 7.
ROS, PL 6.10 Item 4.
Flag 1, P/J18, P/J120.
Bypass tray width sensor, PL 7.30 Item 1 and bypass tray empty sensor, PL 7.30 Item 7.
Flag 5, IOT PWB, P/J10.
Paper path module components (35-55 ppm); IOT exit sensor, PL 10.11 Item 13, duplex
sensor, PL 8.22 Item 4, wait sensor, PL 8.15 Item 3, registration sensor, PL 8.15 Item 3.

01A, 01B 2-20 Xerox WorkCentre 5790 Family
IOT PWB PL 1.10 Item 2.
Flag 4, P/J27.
Flag 6, P/J27.
Tray 1 and 2 control PWB, PL 7.10 Item 2.
Flag 2, P/J271, P/J9.
Flag 4, P/J27.
Single board controller PWB, PL 3.24 Item 3.
Flag 49, P/J137, P/J106.
Flag 48, P/J25, P/J131.
DADH PWB, PL 5.10 Item 5.
Flag 50, P/J132, P/J188, P/J152
Flag 48, P/J25, P/J131.
UI control PWB,PL 2.10 Item 11.
Flag 51, P/J133, P/J130.
Flag 48, P/J25, P/J131.
HCF PWB (W/O TAG 151), PL 7.20 Item 2.
Flag 3, P/J394, P/J272.
Flag 2, P/J271, P/J9.
Flag 4, P/J27.
HCF PWB (W/TAG 151), PL 7.21 Item 2.
Flag 54, P/J7, P/J272.
Flag 2, P/J271, P/J9.
Flag 4, P/J27.
Scanner PWB, W/TAG 150, PL 14.15 Item 4.
Flag 9, P/J920, P/J135.
Flag 48, P/J25, P/J131.
Scanner PWB, W/O TAG 150, PL 14.25 Item 4.
Flag 8, P/J451, P/J452.
Flag 52, P/J135, P/J450.
Flag 48, P/J25, P/J131.
CCD PWB, W/O TAG 150, PL 14.25 Item 19.
Flag 52, P/J135, P/J450.
Flag 48, P/J25, P/J131.
Riser PWB, PL 3.22 Item 3.
Flag 53, P/J138, P/J155.
Flag 48, P/J25, P/J131.
Embedded fax PWB, PL 20.10 Item 4.
Flag 53, P/J138, P/J155, P/J157,
Flag 48, P/J25, P/J131.
Power distribution PWB, PL 3.24 Item 5.
Flag 48, P/J25, P/J131.

Xerox WorkCentre 5790 Family 2-21 01B
Figure 1 +3.3V Return

01B 2-22 Xerox WorkCentre 5790 Family
Figure 2 +3.3V Return

01B +5V Return Power distribution PWB, PL 3.24 Item 5.
Go to the appropriate component in the list that follow that has the suspect 0V supply. Check Flag 22, P/J25, P/J131.
the wiring GP 7. Paper path module components, waste toner switch, PL 9.10 Item 6, left hand door inter-
Xerographic module, xerographic CRUM, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL lock, PL 7.30 Item 2.
9.20 Item 2. Flag 45, P/J7, P/J16.
Flag 17, P/J142, P/J142. Tray 5 control PWB, PL 7.68 Item 8
Flag 16, P/J149, P/J8. Flag 25, P/J502.
Flag 15, P/J27. Hard disk drive, PL 3.22 Item 2.
Fuser module, fuser CRUM, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1. Flag 10, P/J999, P/J139.
Flag 18, P/J146, PJ141 Scanner PWB, W/TAG 150, PL 14.15 Item 4.
Flag 16, P/J149, P/J8. Flag 11, P/J920, P/J136.
Flag 15, P/J27.
Main drive PWB (35-55 ppm) PL 4.15 Item 1 or (65-90 ppm) PL 4.10 Item 1.
Flag 16, P/J149, P/J8.
Flag 15, P/J27.
IOT PWB, PL 1.10 Item 2.
Flag 15, P/J27.
(65-90 ppm) Flag 47, P/J16.
HCF control PWB (W/O TAG 151), PL 7.20 Item 2.
Flag 20, P/J272, P/J63.
Flag 55, P/J394.
Flag 19, P/J9, P/J271.
Flag 15, P/J27.
HCF control PWB (W/TAG 151), PL 7.21 Item 2.
Flag 20, P/J272, P/J63.
Flag 56, P/J7.
Flag 19, P/J9, P/J271.
Flag 15, P/J27.
Flag 19, P/J271, P/J9.
Flag 19, P/J270, P/J9.
Flag 15, P/J27.
Flag 15, P/J19.
Output device, PL 12.10, PL 11.26, PL 11.124, PL 11.130.
Flag 21, PJ151, P/J11.
Flag 15, P/J27.
Flag 24, P/J155, P/J138.
Flag 22, P/J131, P/J25.
Embedded fax, PL 20.10 Item 4.
Flag 24, P/J138, P/J155, P/J157.
Flag 22, P/J25, P/J131.

Figure 3 +5V Return

Figure 4 +5V Return

01B +12V Return
Go to the appropriate component in the list that follows that has the suspect 0V supply. Check
the wiring GP 7.
Flag 26, P/J27.
UI control PWB, PL 2.10 Item 11.
Flag 28, P/J133, P/J130.
Flag 27, P/J25, P/J131.
Flag 29, P/J135, P/J920.
Flag 27, P/J25, P/J131.
Flag 30, P/J138, P/J155.
Flag 27, P/J25, P/J131.
Flag 30, P/J138, P/J155, P/J157.
Flag 27, P/J131, P/J25.
Flag 27, P/J25, P/J131.
Flag 27, P/J25, P/J131.
Flag 30, P/J138, P/J155, P/J101.
Hard disk drive, PL 3.22 Item 2.
Flag 12, P/J139, P/J999.
Flag 27, P/J25, P/J131.

Figure 5 +12V Return

01B +24V Return Flag 58, P/J7.
Go to the appropriate component in the list that follows that has the suspect 0V supply. Check Flag 42, P/J19, P/J270.
the wiring GP 7. Tray 1 and 2 control PWB, PL 7.10 Item 2.
Inverter motor driver PWB, PL 10.11 Item 22. Flag 42, P/J19, P/J270.
Flag 33, PJ45, P/J4. Tray 5 control PWB, PL 7.68 Item 8.
Flag 32, P/J27. Flag 46, P/J502, P/J12, P/J501.
Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9 or (65-90 ppm) PL 8.20 Item 9. Flag 32, P/J27.
Flag 33, PJ91, PJ40, P/J4.
Flag 32, P/J27.
Toner dispense module, (35-55 ppm) PL 9.17 Item 1 or (65-90 ppm) PL 9.15 Item 1.
Flag 34, PJ93, P/J6.
Flag 32, P/J27.
Output device, PL 12.10.
Flag 35, PJ151, P/J11.
Flag 32, P/J27.
HVPS, PL 1.10 Item 5.
Flag 36, PJ55, P/J14.
Flag 32, P/J27.
Flag 32, P/J27.
Flag 38, P/J132, PJ152, P/J188.
Flag 37, P/J25, P/J131.
Power distribution PWB, PL 3.24 Item 5
Flag 37, P/J25, P/J131.
Scanner PWB
(W/O TAG 150) PL 14.25 Item 4.
Flag 39, P/J135, P/J455.
Flag 37, P/J25, P/J131.
(W/TAG 150) PL 14.15 Item 4.
Flag 39, P/J135, P/J920.
Flag 37, P/J25, P/J131.
Main drive PWB, part of the main drive module, (35-55 ppm) PL 4.15 Item 1 or (65-90
ppm) PL 4.10 Item 1.
Flag 40, P/J16, P/J147.
Flag 41, P/J18, PJ120.
HCF PWB (W/O TAG 151), PL 7.20 Item 2.
Flag 43, P/J272, PJ63.
Flag 57, P/J394.
Flag 42, P/J19, P/J270.
HCF PWB (W/TAG 151), PL 7.21 Item 2.
Flag 43, P/J272, PJ63.




A B C
01C AC Power RAP Y N
Install a new fuser connector assembly, (35-55 ppm) PL 4.15 Item 9, (65-
Use this RAP to identify AC power input and output failures.
90 ppm) PL 4.10 Item 9 and a new LVPS and base module, PL 1.10 Item
3.
Procedure
WARNING Install a new LVPS and base module, PL 1.10 Item 3.

not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Install a new LVPS and base module, PL 1.10 Item 3.
Check the power cords to the output device.
1K LCSS, PL 11.124 Item 8.
CAUTION 2K LCSS, PL 11.26 Item 4.
Incorrect voltage may damage the machine. The machine must not be connected to the power HVF, PL 11.157 Item 4
outlet if the voltage is incorrect.
WARNING
Check the AC mains (line) voltage at the customer power outlet. The voltage measured is
within the electrical power requirements, GP 22.
Y N
If the voltage is 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.
Check the main power cord for continuity and damage. The main power cord is good.
Y N
Install a new main power cord, PL 1.10 Item 10. PJ22 power supply for the output device.
Switch on the machine, GP 14. Go to Flag 1. Measure the voltage at the outlet connection,
PJ22, Figure 1. The voltage measured is within the electrical power requirements, GP 22.
Y N
Go to Flag 2. Check for the AC voltage at PJ24 on the LVPS, Figure 2. The AC voltage
is present. PJ21
Y N
Switch off the machine, GP 14. Remove the power cord from PJ21, Figure 1.
Measure the resistance between ACL and ACN at PJ21 on the LVPS, Figure 1. The
resistance reading is greater than 1M Ohms.
Y N
Remove the fuser module. On the fuser module at PJ100 measure the resis-
tance between pin 10 and pins 1, 2, 3 and 4, Figure 3. The reading is infinity,
an open circuit.
Y N
Install a new fuser module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL Figure 1 Input and output connections
10.10 Item 1 and a new LVPS and base module, PL 1.10 Item 3.
Check the wire harness between PJ24 and PJ100, Figure 2. The harness is
good.
A B C

Xerox WorkCentre 5790 Family 2-33 01C
Pin 1
Pin 5
Pin 5
Pin 6
Pin 6 Pin 8
Pin 7
Pin 8
Pin 1
Pin 7 Pin 2
Pin 9
Pin 2 Pin 3
Pin 9 Pin 10
Pin 3
Pin 4
Pin 10 P/J 100

Pin 4
P/J100
CRUM
Figure 3 Fuser module
PJ24
Figure 2 Supply to the fuser module

01C 2-34 Xerox WorkCentre 5790 Family
Figure 4 AC circuit diagram

01D +3.3V Distribution RAP CCD PWB, W/O TAG 150. PL 14.25 Item 19.
Use this RAP to identify +3.3V distribution problems. Flag 13, P/J135, P/J450.
Flag 9, P/J25, P/J131.
NOTE: Short circuit or overload of +3.3V or +5V supply will result in all outputs off, except Riser PWB, PL 3.22 Item 3.
+3.3VSB (standby). Flag 14, P/J138, P/J155, P/J157.
Procedure Flag 9, P/J25, P/J131.
Flag 14, P/J138, P/J157, P/J155.
WARNING Flag 9, P/J25, P/J131.
Ensure that the electricity to the machine is switched off while performing tasks that do Foreign device interface PWB, PL 3.22 Item 4.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Flag 15, P/J201, P/J16.
Flag 18, P/J100.
Refer to Figure 1 and Figure 2. Go to the appropriate component in the list that follows that has
a suspect +3.3V supply. Check the wiring, GP 7.
Flag 1, P/J18, PJ120.
Paper path module components, waste toner door switch, PL 9.10 Item 6, left hand door
interlock, PL 7.30 Item 3.
Flag 8, P/J7.
Flag 5, P/J27.
Bypass tray width sensor and bypass empty sensor, PL 7.30.
Flag 6, P/J10.
Flag 5, P/J27.
Flag 7, P/J5.
Flag 5, P/J27.
Flag 9, P/J25
Flag 10, P/J137, P/J106.
Flag 9, P/J25, P/J131.
Flag 11, P/J132, PJ152, P/J188.
Flag 9, P/J25, P/J131.
Flag 12, P/J133, P/J130
Scanner PWB, W/TAG 150. PL 14.15 Item 4.
Flag 13, P/J135, P/J920.
Flag 13, P/J136, P/J920.
Flag 9, P/J25, P/J131.

01D 2-36 Xerox WorkCentre 5790 Family
Figure 1 +3.3V distribution circuit diagram

Xerox WorkCentre 5790 Family 2-37 01D
Figure 2 +3.3V distribution circuit diagram

01E +5V Distribution RAP Inverter motor driver PWB, PL 10.11 Item 22.
Use this RAP to identify +5V distribution problems. Flag 9, P/J4.

Flag 1, P/J27.
NOTE: Short circuit or overload of +3.3V or +5V supply will result in all outputs off, except Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9 or (65-90 ppm) PL 8.20 Item 9.
+3.3VSB (standby). Flag 11, P/J4.
Procedure Flag 1, P/J27.
Flag 17, P/J137, P/J106.
WARNING Flag 16, P/J25, P/J131.
Ensure that the electricity to the machine is switched off while performing tasks that do Riser PWB, PL 3.22 Item 3.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Flag 16, P/J131, P/J25.
Flag 18, P/J138, P/J155.
Embedded FAX PWB, PL 20.10 Item 4.
a suspect +5V supply. Check the wiring, GP 7.
Flag 18, P/J138, P/J155, P/J157.
Paper path module components (35-55 ppm); developer temperature sensor, PL 9.22
Item 5, relative humidity sensor and ambient temperature sensor, PL 9.20 Item 4, waste Power distribution PWB, PL 3.24 Item 5.
toner full sensor, PL 9.10 Item 2, left door interlock, PL 7.30 Item 3, waste toner door Flag 16, P/J131, P/J25.
switch, PL 9.10 Item 6, registration sensor, PL 8.15 Item 3. IOT PWB, PL 1.10 Item 2.
Paper path module components (65-90 ppm); developer temperature sensor, PL 9.20 Flag 1, P/J27.
Item 5, relative humidity sensor and ambient temperature sensor, PL 9.20 Item 4, waste Tray 5 control PWB, PL 7.68 Item 8.
toner full sensor, PL 9.10 Item 2, left door interlock, PL 7.30 Item 3, waste toner door
Flag 15, P/J502
switch, PL 9.10 Item 6, registration sensor, PL 8.17 Item 3.
Flag 2, P/J7.
Flag 19, P/J139, P/J999.
Flag 1, P/J27.
Flag 16, P/J25, P/J131.
Xerographic CRUM, part of the xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90
ppm) PL 9.20 Item 2. DADH PWB, PL 5.10 Item 5.
Flag 4, P/J142, P/J144. The +5V supply on the DADH PWB is generated on board from the +3.3V supply, refer to
Figure 2.
Flag 3, P/J149, P/J8.
Wait sensor, (65-90 ppm), PL 7.30 Item 25.
Flag 1, P/J27.
Flag 10, P/J16, P/J553.
Fuser CRUM, part of the fuser module, PL 10.10 Item 1.
Flag 5, P/J146, PJ141.
Flag 3, P/J149, P/J8.
Flag 1, P/J27.
Flag 6, P/J19, P/J270.
HCF control PWB (W/O TAG 151), PL 7.20 Item 2.
Flag 7, P/J394, P/J272.
Flag 20, P/J394.
Flag 6, P/J19, P/J270.
Flag 7, P/J272.
Flag 21, P/J7.
Flag 6, P/J19, P/J270.
OCT Module, PL 12.10.
Flag 8, P/J11.
Flag 1, P/J27.

Xerox WorkCentre 5790 Family 2-39 01E
Figure 1 +5V distribution circuit diagram

01E 2-40 Xerox WorkCentre 5790 Family

01F +12V Distribution RAP
Use this RAP to identify +12V distribution problems.
Procedure
WARNING
a suspect +12V supply. Check wiring, GP 7.
Flag 1, P/J131, P/J25.
User interface control PWB, PL 2.10 Item 11.
Flag 2, P/J133, P/J130.
Flag 1, P/J25, P/J131.
Scanner PWB, PL 14.15 Item 4.
Flag 3, P/J920, P/J135.
Flag 1, P/J131, P/J25.
CCD PWB, W/O TAG 150.
Flag 3, P/J450, P/J135.
Flag 1, P/J131, P/J25.
Riser PWB PL 3.22 Item 3.
Flag 4, P/J155, P/J138.
Flag 1, P/J131, P/J25.
Embedded FAX PWB, PL 20.10 Item 4.
Flag 4, P/J157, P/J155, P/J138.
Flag 1, P/J131, P/J25.
Flag 6, P/J26.
Xerographic CRUM, part of the xerographic module, (35 ppm) PL 9.22 Item 2, (40-90
Flag 8, P/J142, PJ144.
Flag 7, P/J147, P/J16.
Main drive PWB (35-55 ppm), PL 4.15 Item 6, (65-90 ppm) PL 4.10 Item 6.
Flag 7, P/J147, P/J16.
Door interlock switch, PL 1.10 Item 7.
Flag 9, P/J17.
Flag 10, P/J137, P/J106.
Flag 1, P/J131, P/J25.
Hard disk drive, PL 3.22.
Flag 11, P/J139, P/J999.
Flag 1, P/J25, P/J131.

01F 2-42 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-43 01F

01G +24V Distribution RAP Procedure
Use this RAP to identify +24V distribution problems.
Initial Actions WARNING

Check the following:
The door interlock switch is closed. death or injury. Moving parts can cause injury.
The xerographic module is correctly installed.
Circuit Information WARNING

The +24V distribution in the machine can be divided into 3 stages; The first stage, +24V Direct Do not repair or install a new fuse F1 on the IOT PWB. Repairing or installing a new fuse
is independent of the other two stages. The second stage, +24V Interlocked is derived from can cause overheating and a risk of fire.
+24V Direct. The third stage, +24V Interlocked From the IOT PWB is derived from both +24V
Direct and +24V Interlocked.
WARNING
+24V failures will result in the following UI messages: Do not repair or install a new fuse F1 on the power distribution PWB. Repairing or
Copying and scanning are unavailable installing a new fuse can cause overheating and a risk of fire.
Copying and printing are unavailable
Typical faults caused by +24Copying and scanning are unavailable failures are; 03-480, 03-
482, 06-340, 09-060, 14-110 and 14-730. WARNING
Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a
+24V Direct new fuse can cause overheating and a risk of fire.
This supply feeds the power distribution PWB, DADH PWB and Scanner PWB. It also feeds
the interlocked +24V circuit internally within the LVPS.This supply is not dependant on any
interlocks and is available at power on. The supply is not fused, but the LVPS will shut the volt- WARNING
age down if the supply is short circuited. The voltage can be measured on the LVPS at P/J25 Do not install a fuse of a different type or rating. Installing the wrong type or rating of
pins 1 and 2, but is more easily accessed on the power distribution PWB at P/J131 pins 1 and fuse can cause overheating and a risk of fire.
2, refer to Figure 2.
+24V Interlocked CAUTION

This supply feeds the IOT PWB, main drive module, paper path module, ROS, Tray 1 and 2 If the surface mounted fuse on the power distribution PWB, IOT PWB or main drive PWB has
control PWB and short paper path assembly. When +24V interlocked is available, CR16 on the blown, do not install a new PWB until the cause of the fault is repaired.
IOT PWB is lit. The availability of +24V interlocked is dependant on the +12V interlock circuit Remove the rear cover, switch on the machine, GP 14. CR13, CR15 and CR36 on the IOT
being complete through the door interlock switch, xerographic module CRUM link and the main PWB are lit and stay lit.
drive PWB, refer to the circuit diagram in the 01-300 Front Door Open RAP. When the +12V Y N
interlock circuit is complete, +24V interlocked will be available at P/J27 pins 1 and 2 on the Go to the OF3 Dead Machine RAP
IOT PWB, Figure 3. If the +24V interlocked supply is shorted, It will shut down the +24V direct
supply from the LVPS. CR16 is lit.
Y N
+24V Interlocked From the IOT PWB +24V is available at P/J27 pin 1 and pin 2, Flag 5.
The availability of +24V interlocked from the IOT PWB is dependant on +24V interlocked being Y N
available at P/J27 pins 1 and 2. The +24V interlocked from the IOT PWB is fused by a surface Switch off the machine, GP 14. Greater than 100 Ohms resistance is measured
mounted fuse F1 (non replaceable), so a short on any of the IOT PWB +24V interlocked out- between P/J27 pin 1 and the machine frame, also between P/J27 pin 2 and the
puts will result in fuse F1 being blown and all +24V interlocked outputs not available. Be aware machine frame.
that a high resistance short circuit on any of the outputs will damage, but not blow fuse F1, Y N
resulting in measurements of +24V at the top cap (input) of fuse F1 and less than +24V (but There is a short circuit on the +24V interlocked circuit. Disconnect P/J27.
not 0V) on the bottom cap of fuse F1. Greater than 100 Ohms resistance is measured on the harness between
P27 pin 1 and the machine frame, also between P27 pin 2 and the machine
frame.
A B C

Xerox WorkCentre 5790 Family 2-45 01G
A B C
Y N Y N
The IOT PWB is shorting the +24V interlocked to ground, a new IOT PWB Install a new LVPS and base module, PL 1.10 Item 3.
will need to be installed. Before installing a new IOT PWB, check the fuse
F1. If the fuse is open circuit the cause of the failure will need to be found, The voltage measured at the top cap of fuse F1 is the same as the voltage measured on
refer to Figure 2, Figure 3 and the Component list. Refer also to the 01H the bottom cap of fuse F1.
Short Circuit and Overload RAP. When the cause of the high resistance Y N
short circuit has been repaired, install a new IOT PWB, PL 1.10 Item 2. A high resistance short circuit has damaged the fuse F1. Identify and repair the cause of
the high resistance short circuit, refer to Figure 2, Figure 3 and the Component list. Refer
Disconnect P/J18, Flag 16 and P/J19, Flag 17. Less than 100 Ohms resis- also to the 01H Short Circuit and Overload RAP. When the cause of the high resistance
tance is measured on the harness between P27 pin 1 and the machine short circuit has been repaired, install a new IOT PWB, PL 1.10 Item 2.
frame, also between P27 pin 2 and the machine frame.
Y N +24V interlocked is available to the IOT PWB, exercise the machine in all possible modes and
Refer to Figure 5 and the Component list to isolate and repair the compo- make a note of what components are energized when the fault occurs. Refer to the Component
nent that is causing the short. list and the appropriate circuit diagram to isolate and repair the problem component or circuit.
Disconnect P/J17, Flag 15 and P/J16, Flag 11. Less than 100 Ohms resis- Component list
tance is measured on the harness between P27 pin 1 and the machine
Refer to Figure 2, Figure 3, Figure 4 and Figure 5. Go to the appropriate component in the list
frame, also between P27 pin 2 and the machine frame.
that follows that has a suspect +24V supply. Inspect then re-seat all PJs and check the wiring,
Y N GP 7.
Refer to Figure 4 and the Component list to isolate and repair the compo-
Paper path module containing: in-line fuse and wiring, GP 7, PL 1.10 Item 9, Figure 1.
nent that is causing the short.
Flag 15, Erase lamp, (35 ppm) PL 9.22 Item 1, (45-90 ppm) PL 9.20 Item 1.
Install a new LVPS and base module, PL 1.10 Item 3. Flag 15, Inverter path solenoid, PL 10.11 Item 14.
Flag 15, Registration clutch, PL 8.15 Item 7.
Switch on the machine, GP 14. +10.9V or greater is available on P/J17 pin 6 (yel- Flag 15, Inverter nip solenoid, PL 10.11 Item 6.
low wire, bottom of connector).
Flag 15, Vacuum transport fan (part of short paper path assembly W/O TAG 114), PL
Y N
10.25 Item 1.
The +12V interlock voltage used to maintain the +24V interlocked circuit is not
available or below specification, go to the 01-300 Front Door Open RAP to fix Flag 15, in-line fuse, PL 1.10 Item 9, Figure 1.
the fault. Power distribution PWB, PL 3.24 Item 5.
Flag 1, P/J25, P/J131.
Switch off the machine, GP 14. Pull out the single board controller PWB module, PL
3.24 Item 1. Disconnect P/J131, Flag 1. Switch on the machine, GP 14. +24V is
Flag 5, P/J27.
available on the harness between P131 pin 1 to the machine frame and P131
pin 2 to the machine frame. Main drive PWB, part of the main drive module, (35-55 ppm) PL 4.15 Item 6, (65-90 ppm)
Y N PL 4.10 Item 6.
Install a new LVPS and base module, PL 1.10 Item 3. Flag 11, P/J147, P/J16.
ROS PL 6.10 Item 4
Components in the single board controller PWB module, scanner or DADH are
Flag 16, P/J18.
shorting the +24V to ground, refer to Flag 1, Flag 2, Flag 3 and Flag 4 to isolate and
repair the short circuit. Tray 1 and 2 control PWB, PL 7.10 Item 2.
Flag 17, P/J270, P/J19.
The fuse F1on the IOT PWB is blown, therefor a new IOT PWB will need to be installed. HCF control PWB (W/O TAG 151), PL 7.20 Item 2.
Before installing a new IOT PWB, find the cause of the failure, refer to Figure 2, Figure 3 Flag 18, P/J272.
and the Component list. Refer also to the 01H Short Circuit and Overload RAP. When the
Flag 23, P/J7.
cause of the high resistance short circuit has been repaired, install a new IOT PWB, PL
1.10 Item 2. Flag 17, P/J270, P/J19.
NOTE: CR16 will light at voltages of less than+24V. Flag 18, P/J272.
The voltage at P/J27 pin 1and pin 2 is equal to or greater than +24V Flag 22, P/J394.
Flag 17, P/J270, P/J19.

01G 2-46 Xerox WorkCentre 5790 Family
Flag 3, P/J188.
Flag 2, P/J132.
Flag 1, P/J131, P/J25.
Tray 5 control PWB, PL 7.68 Item 8.
Flag 20, P/J12.
Flag 21, P/J502, P/J501.
Flag 4, P/J920, P/J135.
Flag 1, P/J131, P/J25.
Scanner PWB, W/O TAG 150, PL 14.25 Item 4.
Flag 4, P/J455, P/J135.
Flag 1, P/J131, P/J25. In-line +24V fuse
Inverter motor driver PWB, PL 10.11 Item 22.
Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9, (65-90 ppm) PL 8.20 Item 9.
Flag 6, P/J4.
Flag 5, P/J27.
Toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL 9.15 Item 1.
Flag 7, P/J6.
Figure 1 +24 volt in-line fuse
Flag 5, P/J27.
Bypass tray feed solenoid, PL 7.30 Item 4.
Flag 8, P/J10.
Flag 5, P/J27.
OCT Module, PL 12.10,
Flag 9, P/J11.
Flag 5, P/J27.
Flag 10, P/J14, P/J55.
Flag 5, P/J27.
Photoreceptor drive motor, part of the main drive module, (35-55) PL 4.15 Item 17, (65-90
Flag 12, P/J151.
Flag 11, P/J147, P/J16.
Ozone fan, PL 9.25 Item 1.
Flag 13. P/J153.
Flag 12, P/J151.
Flag 11, P/J147, P/J16.
Fuser web motor, part of the main drive module, (35-55 ppm) PL 4.17 Item 1, (65-90 ppm)
PL 4.12 Item 1.
Flag 14, P/J154.
Flag 11, P/J147, P/J16.





A
01H Short Circuit and Overload RAP NOTE: To disconnect the connectors PJ16, PJ17, PJ18, PJ19 and PJ25 on the LVPS, open
tray 1 and tray 2. Remove the screw that secures the power and control assembly, PL 1.10.
Procedural Notes Slide the power and control assembly to the left.
NOTE: Refer to Figure 3 for the low voltage distribution. This is an overview of all the low volt-
WARNING age harnesses within the machine.
Ensure that the electricity to the machine is switched off while performing tasks that do NOTE: Refer to GP 7 at every harness check and if necessary perform, REP 1.2.
death or injury. Moving parts can cause injury. To check the output voltages of the LVPS, disconnect the following.
The LEDs, Figure 1, CR12, CR13, CR14, CR15 and CR36 on the IOT PWB are used to Figure 2. PJ16, PJ17, PJ18, PJ19 and PJ25.
indicate that a supply voltage is available. Refer to OF7 IOT PWB Diagnostics RAP. Figure 1. All the PJ connectors on the IOT PWB, except PJ26 Flag 24, PJ27 Flag 25 and
Short circuit or overload of +3.3VSB (standby) will result in all outputs off. PJ5 Flag 15.
Short circuit or overload of +3.3V or +5V will result in all outputs off, except +3.3VSB. Press the on / off switch, PL 1.10 Item 8. The LED CR36 is on.
Y N
Short circuit or overload of +12V or +24V will result in only those outputs being off.
Check for a short circuit on the AC line. Go to 01C AC Power RAP.
In all instances, when the short circuit or overload is removed all the outputs will recover
to normal operating voltages after 10 seconds. Press the on/off switch, PL 1.10 Item 8. The LEDs, CR12, CR13 and CR15 are on and stay
If +3.3VSB is over voltage, all outputs will be off. To restore to normal, switch off the on.
machine, GP 14. Wait two minutes. Switch on the machine. Y N
If +3.3V, +5V or +12V are over voltage, all outputs will be off, except +3.3VSB. To restore Go to Flag 15. Measure the voltage at PJ5, pin 19. Press the on / off switch, PL 1.10 Item
to normal, switch off the machine, GP 14. Wait two minutes. Switch on the machine. 8. The voltage changes from +3.5V to 0V.
If the +24V is over voltage, only the 24V the output will be off. To restore to normal, switch Y N
off the machine, GP 14. Wait two minutes. Switch on the machine. Check the wiring to the on / off switch, GP 7. If necessary, install a new on / off
switch, PL 1.10 Item 8.
WARNING Disconnect PJ26. Measure the voltage at the harness of PJ26, pin 7, Flag 24. +1.16V is
available at pin 7.
Do not repair or install a new fuse F1 on the IOT PWB. Repairing or installing a new fuse Y N
can cause overheating and a risk of fire. Install a new LVPS and base module, PL 1.10 Item 3.
Reconnect PJ26. Measure the voltage at the harness of PJ26, pin 7, Flag 24. Press the
WARNING on / off switch. The voltage changes from +1.16V to 0V and stays at 0V.
Do not repair or install a new fuse F1 on the power distribution PWB. Repairing or Y N
installing a new fuse can cause overheating and a risk of fire. Install new components in the order that follows:
1. Install a new LVPS and base module, PL 1.10 Item 3.
2. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
WARNING PL 1.10 Item 2.
Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a
new fuse can cause overheating and a risk of fire. Disconnect the power cord. Use a service multi-meter set to DC amps. Ensure the meter
leads are connected to the correct meter sockets to measure amps. Connect the black
lead to the machine frame. Reconnect the power cord. Use the probe on the red lead to
WARNING ground PJ26, pin 7 to ground, through the multi-meter. When the LEDs CR27, CR28 and
Do not install a fuse of a different type or rating. Installing the wrong type or rating of CR29 are flashing, press and release the on / off switch and remove the probe. The
fuse can cause overheating and a risk of fire. LEDs, CR12, CR13 and CR15 are ON and stay ON.
Y N
Procedure Set the service multi-meter to measure volts. Ensure the meter leads are connected
Switch off the machine, GP 14. Remove the rear cover, PL 8.10 Item 1. Reconnect the power to the correct meter sockets to measure volts. Measure the voltage at the harness of
cord. CR36 is on, Figure 1. PJ26, pin 7, Flag 24. 0V is measured.
Y N Y N
Go to 01J Power On and LVPS Control Signals RAP. Check that the F1 fuse on the IOT PWB has not failed. Go to 01H +24 Volt Cir-
cuits before a new IOT PWB is installed, PL 1.10 Item 2.
A B C D
01H 2-52 Xerox WorkCentre 5790 Family
B C D
Install a new LVPS and base module, PL 1.10 Item 3. 4. Disconnect PJ10, Flag 20. If the LEDs CR12 and CR13 are on, check the harness, Flag
20, from PJ10 on the IOT PWB, to the bypass tray, PL 7.30, WD 10.
Set the service multi-meter to measure volts. Ensure the meter leads are connected to the 5. Disconnect PJ11, Flag 21. If the LEDs CR12 and CR13 are on, check the harness, Flag
correct meter sockets to measure volts. Measure the voltage at PJ25, pins 1 and 2, Flag 21, from PJ11 on the IOT PWB to the output devices, WD 5.
5. +24V is measured.
6. Disconnect PJ7, Flag 19. If the LEDs CR12 and CR13 are on, check the harness, Flag
Y N
19, from PJ7 to the components that follow:
Measure the voltage at the harness of PJ26, pin 9, Flag 24. 0V is measured.
Y N a. Developer temperature sensor, (35 ppm) PL 9.22 Item 5, (40-90 ppm) PL 9.20 Item
5, WD 10.
Check that the F1 fuse on the IOT PWB has not failed. Go to 01H +24 Volt Cir-
cuits before a new IOT PWB is installed, PL 1.10 Item 2. b. Relative humidity sensor, (35 ppm) PL 9.22 Item 4, (40-90 ppm) PL 9.20 Item 4, WD
10.
Install a new LVPS and base module, PL 1.10 Item 3. c. Ambient temperature sensor, (35 ppm) PL 9.22 Item 4, (40-90 ppm) PL 9.20 Item 4,
WD 10.
Disconnect the power cord. Disconnect the in-line fuse in the harness from PJ17. Recon-
nect PJ16 and PJ17. Set the service multi-meter to measure amps. Ensure the meter d. Waste toner full sensor, PL 9.10 Item 2, WD 10.
leads are connected to the correct meter sockets to measure amps. Clip the black lead to 01H +3.3 Volt and +5 Volt Circuits
the machine frame. Reconnect the power cord. Use the probe on the red lead to ground
PJ26, pin 7 to ground. When the LEDs CR27, CR28 and CR29 are flashing, press and NOTE: After every disconnection, the on / off switch, PL 1.10 Item 8, must be pressed. If CR12
and CR13 are not on, reconnect and go to the next step.
release the on/off switch and remove the probe. The LEDs, CR12, CR13, CR15 and
CR16 are ON and stay ON 1. Perform the steps that follow:
Y N
a. Disconnect PJ137, power distribution PWB. If the LEDs CR12 and CR13 are on,
Check the interlock circuit, Flag 26, Flag 27 and Flag 28. If the circuit is good, check
then check the harness, Flag 11, from the power distribution PWB to PJ106 on the
that F1 fuse on the IOT PWB has not failed. Go to 01H +24 Volt Circuits before a single board controller PWB, WD 3.
new IOT PWB is installed, PL 1.10 Item 2.
b. Disconnect PJ138 from the power distribution PWB. If the LEDs, CR12 and CR13
The LVPS is good. Continue at 01H Initial Isolation Check. are on, then check the harness, Flag 12, to the riser PWB, WD 3
2. If no short circuit is found is found in the +3.3V and +5V circuits, go to 01H +3.3 Volt Circuits.
Disconnect the power cord. Reconnect PJ16 and PJ17. Connect the power cord. Press the on/
off switch. The LED CR16 is ON. 01H +3.3 Volt Circuits
Y N
NOTE: After every disconnection, the on / off switch, PL 1.10 Item 8, must be pressed. If CR12
Check the interlock circuit, Flag 1, Flag 2 and Flag 6. If the circuit is good, go to 01H +24
Volt Circuits before a new a new IOT PWB is installed, PL 1.10 Item 2. and CR13 are not on, reconnect and go to the next step.
1. Disconnect PJ132, power distribution PWB. If the LEDs, CR12 and CR13 are on, then
The LVPS is good. Go to the 01H Initial Isolation Check. check the harness, Flag 8, to the DADH PWB, WD 3.
01H Initial Isolation Check 2. Disconnect PJ133, power distribution PWB. If the LEDs, CR12 and CR13 are on, then
NOTE: After every disconnection, the on/off switch, PL 1.10 Item 8, must be pressed. If CR12 check the harness, Flag 9, to the UI control PWB, WD 3.
and CR13 are not on, reconnect and go to the next step. 3. Disconnect PJ135, power distribution PWB. If the LEDs, CR12 and CR13 are on, then
check the harness, Flag 10, to the Scanner PWB and CCD PWB (W/O TAG 150).
Disconnect the power cord. Reconnect all the disconnected PJ connections on the IOT PWB,
4. If no failure is found in the +3.3V circuits, go to 01H +5 Volt Circuits.
LVPS and the power distribution PWB. Reconnect the power cord. Switch on the machine, GP
14. If ALL the LEDs, Figure 1, CR12, CR13, CR15 and CR16 are OFF, go to step 1. If the 01H +5 Volt Circuits
CR15 is OFF, go to 01H +12 Volt Circuits. If the CR16 is OFF, go to 01H +24 Volt Circuits.
NOTE: After every disconnection, the on / off switch, PL 1.10 Item 8, must be pressed. If CR12
1. Disconnect PJ25, Flag 5. If the LEDs CR12 and CR13 are on, check the harness from and CR13 are not on, reconnect and go to the next step.
PJ25 to PJ131. If the harness is good, go to 01H +3.3 Volt and +5 Volt Circuits.
1. Disconnect PJ8, IOT PWB. If the LEDs CR12 and CR13 are on, then check the harness,
2. Disconnect PJ18, Flag 3. If the LEDs CR12 and CR13 are on, check the harness, Flag 3, Flag 14, to the xerographic CRUM, part of the xerographic module, (35 ppm) PL 9.22 Item
from PJ18 to the ROS, PL 6.10 Item 4. WD 1.
2 or (40-90 ppm) PL 9.20 Item 2, and to the fuser CRUM, part of the fuser module, (35-55
3. Disconnect PJ19, Flag 4. If the LEDs CR12 and CR13 are on, check the harness, Flag 4, ppm) PL 10.8 or (65-90 ppm) PL 10.10 Item 1, WD 6.
from PJ19 on the LVPS, to the Tray 1 and 2 Control PWB, PL 7.10, WD 1.
2. Disconnect PJ9, IOT PWB. If the LEDs CR12 and CR13 are on, then check the harness,
a. (W/O TAG 151) Check the harness at Flag 7, WD 20. Flag 17, to tray 1 and 2 control PWB, PL 7.10 Item 1, WD 10.
b. (W/TAG 151) Check the harness at Flag 29, WD 46 and WD 47. 3. Disconnect PJ4, IOT PWB. If the LEDs CR12 and CR13 are on, then check the harness,
c. Check the harness, Flag 4, from PJ19 on the LVPS, to the Tray 1 and 2 Control Flag 16, to the inverter motor driver PWB, PL 10.11 Item 22, and to the duplex motor
PWB, PL 7.10 Item 2, WD 1. driver PWB, (35-55 ppm) PL 8.22 Item 9, (65-90 ppm) PL 8.20 Item 9, WD 7.

Xerox WorkCentre 5790 Family 2-53 01H
01H +12 Volt Circuits h. If after completing the checks above, the F1 fuse on the IOT PWB fails. Switch off
the machine, GP 14. Install a new IOT PWB, PL 1.10 Item 2.
NOTE: Before disconnection, switch off the machine, GP 14. Switch on the machine, GP 14, to Disconnect PJ3, PJ4, PJ6, PJ11 and PJ14. Switch off the machine, GP 14 before a
check CR15.
PJ is connected. Connect each PJ, one at a time until the PJ is found that causes
CR15 is OFF. Check the harnesses that follow for a short circuit, until CR15 is on, Figure 1. the fuse to fail. Check and repair the harness or install new components as neces-
sary.
1. Disconnect PJ25 on the LVPS. CR15 is ON. Check from PJ25, Flag 5, to the power distri-
bution PWB, WD 2. If the harness from PJ25 to PJ131 is good. Reconnect PJ25 and per- 4. Switch on the machine, GP 14.
form the steps that follow: 5. Disconnect PJ132 on the power distribution PWB, check the harness, to DADH, Flag 8.
a. Disconnect PJ133 on the power distribution PWB. Check the harness, Flag 9, to 6. Disconnect PJ135 on the power distribution PWB check the harness, to the CCD PWB
PJ130 on the UI control PWB, PL 2.10. (W/O TAG 150) or Scanner PWB (W/TAG 150).
b. Disconnect PJ135 on the power distribution PWB. Check the harness, Flag 10, to
the Scanner PWB and CCD PWB (W/O TAG 150).
c. Disconnect PJ138 on the power distribution PWB. Check the harness, Flag 12, to
PJ155 on the riser PWB, PL 3.22 Item 3.
01H +24 Volt Circuits
NOTE: Before disconnection, switch off the machine, GP 14. Switch on the machine, GP 14, to
check CR16.
CR16 is OFF. Check the harnesses that follow for a short circuit, until CR16 is on, Figure 1.
1. Disconnect PJ18 on the LVPS. CR16 is ON. Check from PJ18 to the ROS, PL 6.10 Item
4, WD 1.
2. Disconnect PJ19 on the LVPS. CR16 is ON. Check from PJ19, Flag 4, to the tray 1 and 2
control PWB, WD 1, WD 20 and WD 21.
3. Switch off the machine, GP 14.
If the F1 fuse on the IOT PWB has failed. Set the meter to measure ohms. Connect the
black lead to PJ27 pin 9 or pin 10 and the red lead to the bottom of the F1 fuse on the IOT
PWB. If the output is shorted the measurement will be less than 1 ohm.
a. Disconnect PJ3 on the IOT PWB. If the measurement remains below 1 Ohm, this cir-
cuit is good, move to the next step. If the measurement changes to open circuit, Figure 1 IOT PWB, LED and PJ location
check from PJ3, Flag 13, to the main drive PWB, WD 6.
b. Disconnect PJ4 on the IOT PWB. If the measurement remains below 1 Ohm, this cir-
cuit is good, move to the next step. If the measurement changes to open circuit,
check from PJ4, Flag 16, to the inverter motor, PL 10.11 Item 11, and the duplex
motor, (35-55) PL 8.22 Item 8, (65-90 ppm) PL 8.20 Item 8, WD 7.
c. Disconnect PJ6 on the IOT PWB. If the measurement remains below 1 Ohm, this cir-
cuit is good, move to the next step. If the measurement changes to open circuit,
check from PJ6, Flag 18, to PJ93 on the developer module, WD 10.
d. Disconnect PJ10 on the IOT PWB. If the measurement remains below 1 Ohm, this
circuit is good, move to the next step. If the measurement changes to open circuit,
check from PJ10, Flag 20, to the paper tray bypass, PL 7.30, WD 10.
e. Disconnect PJ11 on the IOT PWB. If the measurement remains below 1 Ohm, this
check from PJ11, Flag 21, to P/J151 and onto the output device, WD 5.
f. Disconnect PJ14 on the IOT PWB. If the measurement remains below 1 Ohm, this
check from PJ14, Flag 22, to PJ55 on the HVPS, PL 1.10, WD 11.
g. Install a new IOT PWB, PL 1.10 Item 2.
Figure 2 LVPS PJ location

Figure 3 Low voltage distribution

Xerox WorkCentre 5790 Family 2-55 01H
Figure 4 +12V interlock circuit diagram

A B C
01J Power On and LVPS Control Signal RAP Check the harness and connector P/J27, if necessary repair the harness/connector
or install a new LVPS and base module, PL 1.10 Item 3.
Use this RAP to check and identify power on and standby signals from the LVPS.
Check the pin to pin connections of P/J27. If the connections are good, install a new IOT
Also use this rap to identify problems that occur at or shortly after installation of machines fitted PWB, PL 1.10 Item 2. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
with a TAG 155 IOT PWB.
installed.
If any of the following problems occur on machines with a TAG 155 IOT PWB, go to the Tag Go to Flag 1. Monitor the voltage at P/J5, pin 19. Press the on/off switch, PL 1.10 Item 8.
155 Procedure:
The voltage changes to 0V.
Machine shuts down 4 to 6 seconds after power on Y N
Machine reboots Check the wiring to the switch, GP 7. If necessary, repair the wiring or install a new on/off
Green screen at power on switch, PL 1.10 Item 8.
Copying and printing unavailable
No media trays available Monitor the voltage at P/J26, pin 7. Switch off the machine, then switch on the machine, GP
Scanner unavailable or failed to initialize 14. Go to Flag 2. The voltage changes from +2.3V to 0V.
Configuration sheet does not auto print at power on Y N
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
IOT memory corruption
2.
Lost communications between the IOT PWB and the SBC PWB (fault code 03-300)
Increased paper jam rate Go to the 01H Short Circuits and Overloads RAP.
General print engine problems Tag 155 Procedure
General finisher problems
Install the TAG 156 IOT jumper kit on J140 of the TAG 155 IOT PWB, Figure 1.
Procedural Notes
NOTE: Short circuit or overload of +3.3VSB (standby) will result in all the LVPS outputs off.
Short circuit or overload of +3.3V or +5V will result in all the LVPS outputs off, except +3.3VSB.
NOTE: For an explanation of the LEDs on the IOT PWB and their function, go to OF7 IOT
PWB Diagnostics RAP.
NOTE: +3.3VSB (standby) is generated from the LVPS when the machine is connected to the
AC supply. +3.3VSB is required to initialize the machine from standby to power on.
NOTE: Ensure that the 01C AC Power RAP is performed before starting this RAP.
Procedure
WARNING
Ensure that the machine is switched off, GP 14. Remove the rear cover, PL 8.10 Item 1.
Reconnect the power cord. Check CR36, Figure 1. CR36 is on.
Y N
Go to Flag 3. +3.3VSB is available at P/J27, between pin 6 and pin 14, on the IOT
PWB.
Y N
Disconnect P/J27. +3.3VSB is available at the disconnected end of the harness,
P/J27, between pins 6 and 14.
Y N
Go to 01C AC Power RAP.
Figure 1 P/J locations on the IOT PWB
A B C

Xerox WorkCentre 5790 Family 2-57 01J
Figure 2 Power ON circuit and dependencies

01J 2-58 Xerox WorkCentre 5790 Family
01K Sleep Mode RAP An incoming Fax job. To indicate a wake up call has been initiated the Fax PWB will gen-
erate a power management event/wake up (PME/wake up) signal. The PME/wake up sig-
Use this RAP to diagnose problems entering or exiting sleep mode.
nal is sent via the riser PWB through the PCI bus to the single board controller PWB to
the IOT PWB. The IOT on/off control circuit detects the PME/wake up line is active and
Sleep Mode Operation enables the PS ON signal to the LVPS, which in turn switches on the low voltage DC out-
The machine is designed to be energy efficient by reducing the power consumption after peri- puts of the machine, and also asserts the LOW PWR signal to enable AC power to the fin-
ods of inactivity. The machine has three power modes: isher.
Standby or run mode - full power consumption. In this mode, the energy saver button, Fig- An incoming print job to the single board controller PWB will generate a power manage-
ure 1, is not illuminated. ment event/wake up (PME/wake up) signal that is passed through single board controller
Low power mode - the fuser temperature is reduced to save power, yet allow a quick PWB to the IOT PWB. This causes the IOT to generate the PS ON signal to the LVPS,
return to run temperature. In this mode, the energy saver button, Figure 1, is illuminated. which in turn switches on the low voltage DC outputs of the machine and also asserts the
LOW PWR signal to enable AC power to the finisher.
Sleep mode - power consumption for the whole machine is reduced to below 10 watts by
powering down all but the essential parts, see the note below. In this mode, the energy Reading or Setting the Power Save Duration Times
saver button, Figure 1, is blinking. Access the power save feature by performing the following:
1. Access the customer administration tools screen, GP 24.
NOTE: When the machine is in sleep mode, +12V sleep is supplied from a special power
supply located within the LVPS to the power distribution PWB. The power distribution 2. Touch the More button.
PWB supplies +3.3V sleep and 12V sleep to power the PWBs that follow: 3. Touch the Power Saver Administration button.
Riser PWB. 4. Set the Standby/Low Power duration times.
Fax PWB. 5. Touch save.
Single board controller (SBC) PWB. The default time for standby mode to low power mode is 15 minutes, the minimum value is 1,
UI control PWB. the maximum value is 120.
Off to Run Mode The default time for low power mode to sleep mode is 45 minutes, the minimum value is 10,
When the On/off button is pressed, the IOT PWB sends the PS ON signal to the LVPS to the maximum value is 120.
power-on the low voltage DC outputs of the machine. The PS ON signal is diode coupled
within the LVPS to the sleep signal, therefore whenever the main power supply is on, the sleep To change either of the timing values, touch the appropriate input area, enter the new value
mode power supply is on. When the machine is in run mode the IOT watchdog signal and the using the keypad. Touch the Save button to confirm the change.
SBC watchdog signal keep the PS ON signal active.
Initial Actions
Run Mode to Sleep Mode
Make sure that the cooling fan, PL 3.24 Item 2 is connected to PJ221 on the Single Board Con-
After a period of machine inactivity that equates to the sum of the low power mode duration troller PWB, not PJ134 on the Power distribution PWB.
plus the sleep mode duration, as set in the customer tools options, both the SBC and IOT
watchdogs are stopped. After approximately 4.5 seconds the PS ON signal goes inactive, If the machine does not go into low power mode and the machine has the embedded Fax
causing the low voltage DC outputs of the machine to switch off. Before the SBC and IOT stop option, ensure that the embedded Fax option has been enabled an set up. Sleep mode will not
their watchdogs, the UI watchdog is started, this causes the sleep signal to be active; this in operate correctly if the embedded Fax option is not set up.
turn keeps the sleep mode power supply on when the main power supply switches off.
Sleep Mode to Run Mode

Exit from sleep mode requires one of the wake events that follows to occur:
An operator presses the on/off switch. This causes the IOT to generate the PS ON signal
to the LVPS, which in turn switches on the low voltage DC outputs of the machine and
also asserts the LOW PWR signal to enable AC power to the finisher.
An operator touches the UI screen or presses any UI buttons. This causes the UI to acti-
vate the PME wake up signal. The wake signal is passed through the single board con-
troller PWB to the IOT. This causes the IOT to generate the PS ON signal to the LVPS,
which in turn switches on the low voltage DC outputs of the machine and also asserts the
LOW PWR signal to enable AC power to the finisher.

Xerox WorkCentre 5790 Family 2-59 01K
A B C D
Procedure Y N
Go to Flag 5 and Flag 7. Check for +12V at the Power distribution
PWB P/J131 between pins 17 and 13, also check for +12V between
WARNING pins 14 and 18. The voltages are good.
Y N
Go to Flag 5 and Flag 7. Check for +12V at the LVPS and base
module P/J25 between pins 3 and 13, also check for +12V
between pins 4 and 14. The voltages are good.
Refer to Sleep Mode to Run Mode. The machine remains in sleep mode after a wake Y N
event. Install a new LVPS and base module, PL 1.10 Item 3.
Y N
Refer to Run Mode to Sleep Mode. The machine remains in standby mode or low Check the wiring and connectors between P/J25 and P/J131.
power mode after both power save duration times have elapsed. Repair the wiring as necessary, REP 1.2.
Y N
The machine switches off when it should enter sleep mode. Install a new Power distribution PWB, PL 3.24 Item 5.
Y N
The system is operating correctly, perform SCP 6 Final Actions. Go to Flag 8. Check the wiring and connectors between P/J138 and P/
J155. Repair the wiring as necessary, REP 1.2.
Perform the following:
Refer to Reading or Setting the Power Save Duration Times. Set both the Install new parts as necessary:
standby mode to low power mode and the low power mode to sleep mode User interface harness, PL 2.10 Item 3.
values to 1 minute.
Disconnect the Fax telephone lines to prevent a power management event.
User interface touch screen PWB, PL 2.10 Item 6.
Disconnect the ethernet connection P/J114 to prevent a power management
User interface touch screen, PL 2.10 Item 5.
event.
Go to Flag 1. Check the voltage at P/J27 pin 8 on the IOT PWB. After 2 minutes
the voltage changes from +3.3V to 0V. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
Y N installed, PL 1.10 Item 2.
Go to Flag 2. Check the wiring and connectors between PJ1 pin 9 and P/J105
pin 7. Refer to the information that follows: Install anew LVPS and base module, PL 1.10 Item 3.
P/J1 IOT PWB.
P/J114 Single Board Controller PWB.
If the embedded fax option is installed, ensure it has been enabled and set up. If the
Go to Flag 3. Check the wiring and connectors between P/J103 pin 3 and PJ81 customer does not use this option, it may be disabled via the tools menu, but the
pin 1. Refer to the information that follows: embedded fax must be set up to allow the operation of the Sleep Mode.
P/J103 Single Board Controller PWB Refer to Reading or Setting the Power Save Duration Times. Set both the standby
P/J81 User interface PWB. mode to low power mode and the low power mode to sleep mode values to 1 minute.
The wiring and connectors are good. Disconnect the input Fax line(s) to prevent a power management event.
Y N Disconnect from the network to prevent a power management event.
Repair the wiring, REP 1.2.
Leave the machine untouched and observe the user interface.
Go to Flag 8. Check for +3.3V at P/J155 between pins 2 and 6, also check for After one minute the energy saver button illuminates, then after a further minute
+12V between pins 4 and 8. Refer to the information that follows: the energy saver button flashes.
Y N
P/J155 Riser PWB.
Install a new IOT PWB, PL 1.10 Item 2. Perform OF7 IOT PWB Diagnostics RAP
The voltages are good. before the new IOT PWB is installed. Return the power save settings to the previous
Y N values and reconnect the Fax and network lines. Perform SCP 6 Final Actions.
Go to Flag 8. Check for +3.3V at the Power distribution PWB P/J138
between pins 2 and 6, also check for +12V between pins 7 and 8. The The system is operating correctly. Return the power save settings to the previous values
voltages are good. and reconnect the Fax and network lines. Perform SCP 6 Final Actions.
A B C D A
01K 2-60 Xerox WorkCentre 5790 Family
A E F G H I J K
Remove the rear cover, PL 8.10 Item 1. Observe the LEDs on the IOT PWB, refer to the OF7 Check the wiring and connectors between P/J25 and P/J131.
IOT PWB Diagnostics RAP. Only CR36 is lit. Repair the wiring as necessary, REP 1.2.
Y N
Disconnect the power cord from the machine. Wait two minutes, then re-connect the Install a new power distribution PWB, PL 3.24 Item 5.
power cord. The machine remains in sleep mode.
Y N Check the wiring and connectors between PJ138 and PJ155. Refer to the
The fault may be intermittent. If the fault re-occurs, perform an Altboot, GP 4. If nec- information that follows
essary, install a new single board controller PWB, PL 3.24 Item 3. P/J138 Power distribution PWB.
P/J155 Riser PWB.
Install a new single board controller PWB, PL 3.24 Item 3.
Repair the wiring as necessary, REP 1.2.
The wake event is from the user interface.
Install new parts as necessary:
Y N
The wake event is from the network. Fax PWB, PL 20.10 Item 4.
Y N Riser PWB PL 3.22 Item 3.
The wake event is from the Fax PWB. Single board controller PWB PL 3.24 Item 3.
Y N
Go to the 01J Power On and LVPS Control Signals RAP, check the operation of Go to Flag 2. Measure the voltage at P/J1 pin 5 on the IOT PWB.
the on/off switch. Arrange for a Fax to be sent from another machine to this machine. The voltage
measured changes from +3.3V to 0V when the Fax arrives at the machine.
Perform the following: Y N
1. Refer to 20A Fax Entry RAP and complete all of the initial actions. Check the wiring and connectors between PJ1 and PJ105. Refer to the
2. Remove and re-seat the Fax PWB and riser PWB, REP 3.2. information that follows:
3. Refer to Reading or Setting the Power Save Duration Times. Set both the P/J1 IOT PWB.
standby mode to low power mode and the low power mode to sleep mode val- P/J114 Single Board Controller PWB.
ues to 1 minute. Repair the wiring as necessary, REP 1.2.
4. Go to Flag 2, Measure the voltage at P/J105 pin 11.
5. Leave the machine untouched, allow the machine to enter sleep mode. Go to Flag 4. Measure the voltage at P/J26 pin 7 on the IOT PWB.
6. Arrange for a Fax job to be sent from another machine to this machine. Arrange for a Fax job to be sent from another machine to this machine. The voltage
measured changes from +3.3V to 0V.
The voltage measured changes from +3.3V to 0V when the Fax arrives at the
Y N
machine.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
Y N PL 1.10 Item 2.
Go to Flag 8. Check for +3.3V at PJ155 between pins 2 and 6, also check for
+12V between pins 4 and 8. Refer to the information that follows:
P/J155 Riser PWB.
The voltages are good. Go to P/J114. Check the network connection. The harness and connectors are good.
Y N Y N
Go to Flag 8. Check for +3.3V at the Power distribution PWB P/J138 Install a new ethernet harness.
between pins 2 and 6, also check for +12V between pins 7 and 8. The
voltages are good. Perform the following:
Y N 1. Refer to Reading or Setting the Power Save Duration Times. Set both the standby
Go to Flag 5 and Flag 7. Check for +12V at the Power distribution mode to low power mode and the low power mode to sleep mode values to 1 minute.
PWB P/J131 between pins 17 and 13, also check for +12V between 2. Disconnect the telephone network harness from the Fax PWB to prevent a power
pins 18 and 14. The voltages are good.
management event.
Y N
3. Go to Flag 2. Measure the voltage at P/J105 pin 11. Refer to the information that fol-
Go to Flag 5 and Flag 7. Check for +12V at the LVPS and base
module P/J25 between pins 3 and 13, also check for +12V lows:
between pins 4 and 14. The voltages are good. P/J114 Single Board Controller PWB.
Y N 4. Leave the machine untouched, allow the machine to enter sleep mode.
Install a new LVPS and base module, PL 1.10 Item 3. 5. Arrange for a print job to be sent from a PC to this machine.
E F G H I J K E

E E
The voltage measured changes from +3.3V to 0V, when the print job arrives at the Y N
machine. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Y N 1.10 Item 2.
Go to Flag 8. Check for +3.3V at PJ155 between pins 2 and 6, also check for +12V
between pins 4 and 8. Refer to the information that follows: Install a new LVPS and base module, PL 1.10 Item 3.
P/J155 Riser PWB.
The voltages are good. Go to Flag 3. Measure the voltage at P/J81 pin 2 on the User interface PWB.
Y N NOTE: Any voltage change will be small. Less than 1V.
Go to Flag 8. Check for +3.3V at the Power distribution PWB P/J138 between
pins 2 and 6, also check for +12V between pins 7 and 8. The voltages are The voltage changes when the UI screen is touched or a UI button is pressed.
good. Y N
Y N Go to Flag 6. +3.3V is available at P/J130 on the User interface PWB between pins 1
Go to Flag 5 and Flag 7. Check for +12V at the Power distribution PWB P/ and 2.
J131 between pins 17 and 13, also check for +12V between pins 14 and Y N
18. The voltages are good. Go to Flag 6. +3.3V is available at P/J133 on the Power distribution PWB
Y N between pins 3 and 4.
Go to Flag 5 and Flag 7. Check for +12V at the LVPS and base mod- Y N
ule P/J25 between pins 3 and 13, also check for +12V between pins Go to Flag 5 and Flag 7. +12V is available at P/J131 on the Power distribu-
4 and 14. The voltages are good. tion PWB between pins 13 and 17 and also between pins 14 and 18.
Y N Y N
Install a new LVPS and base module, PL 1.10 Item 3. Go to Flag 5 and Flag 7. +12V is available at P/J25 on the LVPS and
base module between pins 13 and 3 and also between pins 4 and 14.
Check the wiring and connectors between P/J25 and P/J131. Repair Y N
the wiring as necessary, REP 1.2. Install a new LVPS and base module, PL 1.10 Item 3.
Install a new power distribution PWB, PL 3.24 Item 5. Check the wiring and connectors between P/J25 and P/J131. Repair the
wiring, REP 1.2, as necessary.
Check the wiring and connectors between PJ138 and PJ155. Refer to the infor-
mation that follows Install a new power distribution PWB, PL 3.24 Item 5.
P/J138 Power distribution PWB.
Check the wiring and connectors between P/J133 and P/J130. Repair the wiring,
P/J155 Riser PWB.
REP 1.2, as necessary.
Repair the wiring as necessary, REP 1.2.
User interface harness, PL 2.10 Item 3.
User interface touch screen PWB, PL 2.10 Item 6.
User interface touch screen, PL 2.10 Item 5.
Go to Flag 2. Measure the voltage at P/J1 pin 5 on the IOT PWB. Arrange for a print job
to be sent from a PC to this machine. The voltage measured changes from +3.3V to
Go to Flag 3. Measure the voltage at PJ103 pin 2. Refer to the information that follows:
0V when the print job arrives at the machine.
Y N P/J103 Single Board Controller PWB
Check the wiring and connectors between PJ1 and PJ105. Refer to the information The voltage changes from +3.3V to 0V when the UI screen is touched or a UI button is
that follows: pressed.
P/J1 IOT PWB. Y N
P/J114 Single Board Controller PWB. Check the wiring and connectors between PJ103 and PJ81.
Repair the wiring as necessary, REP 1.2. P/J103 Single Board Controller PWB
P/J81 User interface PWB.
Go to Flag 4. Measure the voltage at P/J26 pin 7 on the IOT PWB. Arrange for a print job Repair the wiring, REP 1.2, as necessary.
to be sent from a PC to this machine. The voltage measured changes from +3.3V to
0V when the print job arrives at the machine.
E L
L
Go to Flag 2. Measure the voltage at P/J105 pin 11. Refer to the information that follows:
P/J114 Single Board Controller PWB
The voltage changes from +3.3V to 0V when the UI screen is touched or a UI button is
pressed.
Y N
Go to Flag 2. Measure the voltage at P/J1 pin 5 on the IOT PWB. The voltage changes from
+3.3V to 0V when the UI screen is touched or a UI button is pressed.
Y N
Check the wiring and connectors between PJ1 and P/J105. Refer to the information that
follows:
P/J1 IOT PWB.
P/J114 Single Board Controller PWB
Repair the wiring, REP 1.2 as necessary.
Go to Flag 4.Measure the voltage at P/J26 pin 7 on the IOT PWB. The voltage changes
from +3.3V to 0V when the UI screen is touched or a UI button is pressed.
Y N Energy saver button.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item 2.


02-309 UI Control Panel Button or Touch Screen RAP 02-320, 02-380 UI Communication Test RAP
02-309 The User Interface Button Test or the Touch Area Test failed during the UI Test. 02-320 The UI does not receive the requested data from the single board controller PWB within
the correct time out period.
Procedure
02-380 UI main controller communications test failed.
WARNING Procedure
death or injury. Moving parts can cause injury. WARNING
CAUTION death or injury. Moving parts can cause injury.
Before a new user interface assembly is installed, identify the software level (GP 4). Check the Perform the next steps:
compatibility of the software on the new user interface assembly. Install the software to meet
1. Switch off the machine, then switch on the machine, GP 14.
the customer machine requirements.
2. Enter dC305 UI test. Perform the Communications Self Test.
Perform the next steps:
3. Go to the 03-310 Single Board Controller PWB to UI Errors RAP.
2. Reload the UI software, GP 4.
3. Check the condition of CR12 and CR15 on the IOT PWB, refer to the OF7 IOT PWB Diag-
nostics RAP.
4. Enter dC305 UI test. Perform the Communications Self Test.
5. Check the harness connections between the user interface, PL 2.10 and the single board
controller PWB, PL 3.24 Item 3.
6. Install new components as necessary:
UI touch screen PWB, PL 2.10 Item 6.
UI touch screen, PL 2.10 Item 5.

Xerox WorkCentre 5790 Family 2-65 02-309, 02-320, 02-380
02-390, 02-391, 02-704, 02-706 UI Software Error RAP 02-392 Custom Services Access RAP
02-390 All of the configured services have not reached a stable state after five minutes from 02-392 User interface/USB communication error.
start.
Procedure
02-391 All the services are not registered when the single board controller PWB/UI synchroni-
Go to the OF14 Extensible Interface Platform RAP.
zation has occurred.
02-704 Application software checksum has failed.
02-706 UI VRAM failure.
Procedure
WARNING
CAUTION
Before a new user interface assembly is installed, identify the software level (GP 4). Check the
2. Enter dC305 UI test. Perform the Application Checksum Verification Test.

02-390, 02-391, 02-704, 02-706, 02-392 2-66 Xerox WorkCentre 5790 Family
02-705, 02-707, 02-709, 02-712, 02-715 UI Failure RAP
02-705 The UI audio tones failed to operate.
02-707 Indicate a fault with a button on the UI control panel.
02-709 Indicate a fault with the touch screen on the UI.
02-712 UI LCD module test failed.
02-715 The LED control panel indicator test has failed.
Procedure
WARNING
CAUTION
Before a new user interface assembly is installed, identify the software level (GP 4). Check the
2. Enter dC305 UI test. Perform the relevant test.

Xerox WorkCentre 5790 Family 2-67 02-705, 02-707, 02-709, 02-712, 02-715
03-300, 306, 461, 482, 805, 870 Single Board Controller
PWB to IOT PWB Error RAP
03-300 The single board controller PWB to IOT communications have failed.
03-306 The IOT PWB has received an inappropriate print command from the single board con-
troller PWB.
03-461 A speed mismatch has been detected between the single board controller PWB and
the IOT PWB, in the NVM settings.
03-482 The single board controller PWB has failed to receive a +24V on signal from the IOT
PWB.
03-805 The IOT PWB has received an un-recognized message from the single board controller
PWB.
03-870 The IOT PWB cannot be recognized by the single board controller PWB.
Initial Actions
WARNING
If the fault occurs during a software upgrade, wait 15 minutes for the software program-
ming operation to complete, before the next action.
Switch off the machine, then switch on the machine, GP 14. If the on/off switch fails to
operate, go to the 03-374 Power Off Failure RAP.
Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur
randomly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
If an 03-300 fault occurs with 03-320, 03-330 and 03-340 fault codes, together with a net-
work controller unavailable message, go to the 03D Software Module Failure RAP.
Procedure
1. Switch off the machine, GP 14. Ensure all the connectors on the single board controller
PWB, PL 3.24 Item 3 and the IOT PWB, PL 1.10 Item 2 are correctly and securely seated.
Switch on the machine, GP 14.
2. If the fault was detected during a software upgrade, go to Flag 1. Check P/J107 on the
single board controller PWB. Re-load the software set, GP 4 Machine Software.
3. Perform OF7 IOT PWB Diagnostics RAP.
4. Go to Flag 2. Check the wiring, GP 7. If necessary, install a new single board controller
PWB module / LVPS / IOT PWB harness, PL 3.24 Item 14.
5. 03-461 Only: Go to the OF7 IOT PWB Diagnostics RAP. Check CR 27 for an indication of
NVM Test Failure.
6. Install a new IOT PWB, PL 1.10 Item 2. Perform OF7 IOT PWB Diagnostics RAP before a
new IOT PWB is installed.
7. Install a new single board controller PWB, PL 3.24 Item 3.

Xerox WorkCentre 5790 Family 2-69 03-300, 306, 461, 482, 805, 870

03-300, 306, 461, 482, 805, 870 2-70 Xerox WorkCentre 5790 Family
03-310 Single Board Controller PWB to UI Error RAP
03-310 The single board controller PWB cannot communicate with the UI within one minute of
power-on or after three retries.
Initial Actions
WARNING
Procedure
1. Ensure all the connectors on the single board controller PWB, PL 3.24 Item 3 and UI con-
trol PWB, PL 2.10 Item 11 are correctly and securely seated.
2. Go to Flag 1, Flag 2 and Flag 3. Check the wiring. Repair or install new harnesses as nec-
essary, PL 2.10.
3. Go to Flag 1. Check the voltages. Refer to:
01B 0V Distribution RAP.
01F +12V Distribution RAP.

03-315, 325, 347, 348, 349, 355, 400 Single Board Controller 03-320 to 03-324 Single Board Controller PWB to DADH
PWB Failure RAP Error RAP
03-315 The single board controller PWB has performed a crash recovery procedure. 03-320 Communications between the single board controller PWB and the DADH have failed.
03-325 A single board controller PWB clock is not functioning. 03-321 Communications between the single board controller PWB and the DADH are out of
sequence.
03-347 The single board controller PWB POST has failed the EPC test.
03-322 The DADH has detected a read/write error.
03-348 The single board controller PWB POST has failed the ASIC test.
03-323 The DADH has detected a software error.
03-349 The single board controller PWB POST has failed the rotation memory test.
03-324 The DADH has detected a boot check sum error.
03-355 The single board controller PWB POST has failed the NVM integrity test.
Initial Actions
03-400 The single board controller PWB cannot detect additional EPC memory.
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 Remove originals from the DADH.
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.
randomly, the cause may be due to electrical noise. Go to the OF10 intermittent Failure
Check that the single board controller PWB cooling fan is operating. If necessary, go to RAP.
the 03A Single Board Controller PWB Cooling Fan Failure RAP.
Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur work controller unavailable message, go to the 03D Software Module Failure RAP.
W/O TAG 005 Procedure
Procedure 1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
1. Ensure all the connectors on the PWBs that follow are correctly and securely seated: Single board controller PWB, PL 3.24 Item 3.
Scanner daughter PWB, PL 3.24 Item 20.
Software module, PL 3.24 Item 8.
Memory module, PL 3.24 Item 12.
(W/TAG 150) Scanner daughter PWB, PL 3.24 Item 20.
Check also, the in-line connector in the communications/power cable, PL 5.10 Item 6.
2. Install new parts as necessary:
(W/TAG 150) Scanner daughter PWB, PL 3.24 Item 20.
01G +24V Distribution RAP.
3. Go to Flag 1 and Flag 2. Check the wiring, GP 7. If necessary, install a new communica-
3. If a 03-315 fault persists, Remove the Fax PWB and riser PWB. If the 03-315 fault is now tion/power cable, PL 5.10 Item 6.
cleared, install new parts as necessary: 4. If the fault was detected during a software upgrade, go to Flag 3. Check the connection.
Fax PWB, PL 20.10. Reload the software, GP 4, Machine Software.
Riser PWB, PL 3.22 Item 3. 5. Install new components as necessary:
Compact flash memory (If an R9 Fax is installed), PL 20.10 Item 3. Single board controller PWB, PL 3.24 Item 3.

03-315, 325, 347, 348, 349, 355, 400, 03-320 to 03-324 2-72 Xerox WorkCentre 5790 Family
W/TAG 005 Procedure
1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
Check also, the in-line connector in the single board controller PWB/DADH comms/scan-
ner power harness, PL 14.15 Item 5.
3. Go to Flag 4 and Flag 5. Check the wiring, GP 7. If necessary, install a new single board
controller PWB/DADH comms/scanner power harness, PL 14.15 Item 5.
4. If the fault was detected during a software upgrade, go to Flag 6. Check the connection.
Reload the software, GP 4, Machine Software.

Xerox WorkCentre 5790 Family 2-73 03-320 to 03-324
Figure 1 Circuit diagram 1

03-320 to 03-324 2-74 Xerox WorkCentre 5790 Family
Figure 2 Circuit Diagram 2

Xerox WorkCentre 5790 Family 2-75 03-320 to 03-324
03-330, 03-462 Single Board Controller PWB to Scanner 03-330A, 03-462A Single Board Controller PWB to Scanner
Fault Entry RAP Fault RAP (W/O TAG 150)
03-330 A single board controller PWB to scanner PWB communications error has been Initial Actions
detected.
03-462 A speed mismatch between the single board controller PWB and the scanner has been WARNING
detected in the NVM.
Procedure 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 03-
330, 03-462 Single Board Controller PWB to Scanner Faults Entry RAP.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur
Perform one of the steps that follow:
For machines W/O TAG 150, go to the 03-330A, 03-462A Single Board Controller PWB to
Scanner Faults RAP (W/O TAG 150).
For machines W/TAG 150, go to the 03-330B, 03-462B Single Board Controller PWB to
Procedure
Scanner Faults RAP (W/TAG 150). 1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
CCD PWB, PL 14.25 Item 19.
NOTE: To gain access to the scanner PWB, remove the document glass, PL 14.20 Item 5
and the scanner PWB cover, PL 14.25 Item 1.
2. Go to Flag 1, Flag 2 and Flag 3. Check the wiring. Repair or install new harnesses as nec-
essary, PL 14.25 Item 5 or PL 14.25 Item 13.
NOTE: Flag 4 indicates the main communication lines.
3. Go to Flag 1 and Flag 2. Check the voltages. Refer to:

4. Re-load the software, GP 4 Machine Software.
5. If necessary, install new components:
Scanner module, PL 14.20 Item 1.

03-330, 03-462, 03-330A, 03-462A 2-76 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-77 03-330A, 03-462A

03-330A, 03-462A 2-78 Xerox WorkCentre 5790 Family
03-330B, 03-462B Single Board Controller PWB to Scanner
Fault RAP (W/TAG 150)
Initial Actions
WARNING
330, 03-462 Single Board Controller PWB to Scanner Faults Entry RAP.
Procedure
1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
CCD PWB, PL 14.15 Item 19.
NOTE: To gain access to the scanner PWB, remove the document glass assembly, PL
14.10 Item 5 and the PWB cover, PL 14.15 Item 1.
2. Go to Flag 1, Flag 2 and Flag 3. Check the harnesses, GP 7. Repair or install new har-
nesses as necessary:
Scanner daughter PWB/scanner PWB video harness, PL 14.15 Item 13.
Single board controller/DADH comms/scanner PWB harness, PL 3.24 Item 7.
01E +5V Distribution RAP.
4. Re-load the software, GP 4, Machine Software.
5. If necessary, install new components:

Xerox WorkCentre 5790 Family 2-79 03-330B, 03-462B

03-330B, 03-462B 2-80 Xerox WorkCentre 5790 Family
03-336 FAX Card Self Test Failure RAP
03-336 Power on self test failure detected on the embedded fax PWB.
Initial Actions
WARNING
Procedure
1. Go to 20G Embedded FAX Checkout.
2. Clear the fax card NVM. Go to dC132, select Embedded Fax NVM initialization and per-
form the routine, Reformat.
3. Install a new embedded fax PWB, PL 20.10 Item 4.

Xerox WorkCentre 5790 Family 2-81 03-330B, 03-462B, 03-336
03-338 FAX Communication Error RAP 03-340, 03-416 Single Board Controller PWB to Network
03-338 No response detected to commands from the single board controller PWB to the Controller Fault RAP
embedded fax PWB.
03-340 The network communications with the single board controller PWB have failed.
Initial Actions 03-416 The network controller software version supplied at power on is not compatible with the
single board controller PWB software.
WARNING Initial Actions

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
Procedure death or injury. Moving parts can cause injury.
Perform the following: Switch off the machine, then switch on the machine, GP 14.
1. Remove, then re-install the embedded fax PWB, PL 20.10 Item 4. Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur
2. Go to 20G Embedded Fax Checkout.
3. (W/O TAG X-001) Install a new compact flash memory, PL 20.10 Item 3.
4. Install new embedded fax PWB, PL 20.10 Item 4.
Procedure
1. Ensure that the ethernet connector P/J114 on the Single Board Controller PWB is
securely connected.
2. Perform the 03C Hard Disk Failure RAP.
3. Reload the software, GP 4 Machine Software.

03-338, 03-340, 03-416 2-82 Xerox WorkCentre 5790 Family
03-350, 03-351, 03-354 IOT to Tray 1 and Tray 2 PWB Error Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur
RAP
03-350 The IOT has detected no response from the tray 1 and 2 control PWB to the ping Procedure
request.
1. Switch off the machine, GP 14. Ensure P/J9 and P/J271 are correctly and securely con-
nected.
03-351 Tray 1 and 2 control PWB has detected a feed buffer overflow.
2. Go to Flag 1. Check the harness. Repair as necessary, GP 7.
03-354 Communications failure. Tray 1 and 2 control PWB has detected a communications 3. Go to Flag 2. Check the +3.3V and 0V lines. Refer to:
failure. P/J271
Initial Actions 01B 0V Distribution RAP.
4. Switch on the machine, GP 14. Perform OF7 IOT PWB Diagnostics RAP.
WARNING 5. Re-load the software, GP 4 Machine Software.
Ensure that the electricity to the machine is switched off while performing tasks that do 6. Install new components as necessary:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
death or injury. Moving parts can cause injury. 1.10 Item 2.
Switch off the machine, then switch on the machine, GP 14. Tray 1 and 2 control PWB, PL 7.10 Item 2.

03-359, 03-407 HCF Communications and Detection Error
RAP
03-359 The HCF has failed to respond to tray 1 and 2 control PWB ping requests.
03-407 The system has failed to detect the HCF module at power on.
Initial Actions
WARNING
Procedure
1. Ensure the P/Js on the tray 1 and 2 control PWB, PL 7.10 Item 2 and the (W/O TAG 151)
HCF PWB, PL 7.20 Item 2 or (W/TAG 151) HCF PWB, PL 7.21 Item 2 are correctly and
securely connected.
2. Go to Flag 1. Check the harness. Repair as necessary, GP 7.
3. Go to Flag 1. Check the power supply lines. Refer to:
4. Go to Flag 2. Check for the presence of pulses on the two data lines, using the AC volts
range of the meter.
NOTE: Pulses should be measured approximately every 20 seconds. Between pulses,

the voltage should be approximately 1.5VAC.
5. As necessary, install new components:

(W/O TAG 151) HCF control PWB, PL 7.20 Item 2.
(W/TAG 151) HCF control PWB, PL 7.21 Item 2.
6. Reload the software, GP 4, Machine Software.

03-359, 03-407 2-84 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-85 03-359, 03-407
03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error 2. Go to Flag 1 and Flag 2. Check the harnesses. Repair as necessary, GP 7.
3. Perform the OF7 IOT PWB Diagnostics RAP.
RAP
4. OCT Only. If the problem persists install a new OCT, PL 12.10 Item 2.
03-360 The IOT to output device communications have failed.
5. 1K LCSS Only. Perform the following:
03-408 The IOT has failed to detect the OCT at power on. Go to the 11C-120 1K LCSS Power Distribution RAP. Check the +5V and +24V sup-
ply from the power supply module to the 1K LCSS PWB. Ensure that the voltages
03-410 The system failed to detect the output device at power on. are steady.
Ensure that there is a good ground continuity between the power supply module, PL
03-418 The system has detected that the output device software is not compatible with the
image processing software. 11.124 Item 2 and the 1K LCSS frame.
Initial Actions Power supply module, PL 11.124 Item 2.
1K LCSS PWB, PL 11.124 Item 1.
6. 2K LCSS Only. Perform the following:
WARNING
Remove fuse F1 from the 2K LCSS PWB. Check the fuse. If the fuse is good, re-
Ensure that the electricity to the machine is switched off while performing tasks that do install the fuse. If fuse F1 is blown, install a new 2K LCSS PWB, PL 11.26 Item 1.
Go to the 11D-110 2K LCSS Power Distribution RAP. Check the +5V and +24V sup-
ply from the power supply module to the 2K LCSS PWB. Ensure that the voltages
1K LCSS Only. Un-dock the 1K LCSS from the machine, refer to REP 11.11-120 1K are steady.
LCSS Removal. Check that the docking actuator, PL 11.102 Item 7 is correctly installed.
Ensure that there is a good ground continuity between the power supply module, PL
2K LCSS Only. Perform REP 11.13-110 LCSS Un-docking. Check that the docking actu- 11.26 Item 2 and the 2K LCSS frame.
ator, PL 11.4 Item 7 is correctly installed.
HVF and HVF BM Only. Perform 11-300-171, 11-302-171, 11-303-171, HVF Un-docking
Power supply module, PL 11.26 Item 2.
RAP. Check that the docking actuator, PL 11.130 Item 17, is correctly installed.
2K LCSS PWB, PL 11.26 Item 1
7. HVF and HVF BM Only. Perform the following:
Ensure the output device power cord is connected to PJ22 on the Power and Control
Module. Go to the 11A-171 HVF Power Distribution RAP. Check the +5V and +24V supply
from the power supply module to the HVF PWB. Ensure that the voltages are steady.
randomly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP. Ensure that there is a good ground continuity between the power supply module, PL
11.157 Item 1 and the HVF frame.
Procedure
Power communications cable, PL 11.157 Item 7.
Power supply module, PL 11.157 Item 1.
CAUTION 8. If the correct output device is not detected, go to Flag 3. Check that the voltages on the
Do not connect the output device power cord directly to the AC wall outlet. The output device device ID lines are correct according to the table in Figure 1. Install new components as
cannot operate without the machine. The machine controls the distribution of electricity to the necessary:
output device for correct power on and power off sequencing. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
NOTE: No parts of the OCT are spared. Where necessary, install a new OCT, PL 12.10 Item 2. 1.10 Item 2.
NOTE: Figure 1 and Figure 2 show the external connections to the output devices.
1. As necessary, ensure that the connectors that follow are correctly and securely con- HVF PWB, PL 11.157 Item 2.
nected: OCT, PL 12.10 Item 2.
OCT Only. P/J495 on the OCT PWB, P/J151 on the Power and Control Module and
1K LCSS Only. P/J3 on the 1K LCSS PWB, P/J151 on the Power and Control Mod-
ule and P/J11 on the IOT PWB.
2K LCSS Only. P/J301 on the 2K LCSS PWB, P/J151 on the Power and Control
Module and P/J11 on the IOT PWB.

03-360, 03-408 to 03-410, 03-418 2-86 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-87 03-360, 03-408 to 03-410, 03-418
03-365 IOT Bus Failure RAP
03-365 The communications driver has failed.
NOTE: This fault code can occur when the driver fails because of system electrical noise.
Initial Actions
WARNING
Procedure
NOTE: The IOT controller should clear an I2C bus fault indication after five seconds.
1. Ensure the P/Js on the IOT PWB, PL 1.10 Item 2 are correctly seated.
2. Check that there is continuity between the upper and lower registration guide. Ensure that
the screw that secures the upper and lower registration guides is tight, Figure 1.
3. Check that there is continuity between the halo guide and the registration guide. Raise
and lower the short paper path assembly, PL 10.15, several times to ensure that the con-
tinuity is consistent. If the continuity is inconsistent, perform the following:
Examine the registration and halo guide bias contact for deformation or damage, PL
8.15 Item 23.
Ensure the transfer / detack harness is routed correctly at the rear of the short paper
path, refer to REP 10.1.
4. This fault may be caused by a ground fault, perform 01A Ground Distribution RAP.
6. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item 2.

03-360, 03-408 to 03-410, 03-418, 03-365 2-88 Xerox WorkCentre 5790 Family
03-366 IOT to Tray 5 Module Communication Failure RAP
03-300 The IOT PWB has detected a communications failure with the tray 5 module.
Upper registration
guide
Initial Actions
Lower registration
guide WARNING
Halo guide not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Check the condition of P/J501 on the sleeved harness from the tray 5 module, paying
attention to the condition of the pins.
Check that P/J501 is correctly and securely connected at the rear of the machine.
Registration and halo
guide bias contact
Procedure
1. Go to Flag 1 and check the wiring. Repair the wiring as necessary, GP 7.
2. As necessary, perform the following:
Perform OF7 IOT Diagnostics RAP.
Install a new tray 5 control PWB, PL 7.68 Item 8.
Install a new IOT PWB, PL 1.10 Item 2.
Registration guides
securing screw.


03-367 S2X Data Transmission Failure RAP 03-371, 03-372 Fuser and Xerographic CRUM
03-367: The single board controller PWB does not receive the S2X ready line signal within 10 Communication Error RAP
seconds of scan start.
03-371: The fuser CRUM communications have failed.
Procedure 03-372: The xerographics CRUM communications have failed.
Initial Actions
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
1. Install a new single board controller PWB, PL 3.24 Item 3. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Ensure the fuser module, (35-55 ppm), PL 10.8 Item 1 or (65-90 ppm), PL 10.10 Item 1 is
correctly installed.
Ensure the xerographic module, PL 9.20 Item 2 is correctly installed.
Procedure
CAUTION
Remove the fuser and xerographic modules to prevent damage to the CRUMs when checking
for continuity.
1. Ensure the P/Js on the IOT PWB, PL 1.10 Item 2 and the main drive motor and PWB
assembly, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item 6 are correctly and
securely connected.
2. Perform OF7 IOT PWB Diagnostics RAP.
3. Switch off the machine, GP 14. Go to Flag 1. Disconnect P/J8 on the IOT PWB. Switch
on the machine, GP 14. Make a copy. Check the fault history for new occurrences of 03-
371 and 03-372 faults. If new occurrences are not listed, install a new IOT PWB, PL 1.10
Item 2.
4. Go to Flag 1. Check the harness, GP 7 and measure the voltages. As necessary, refer to:
NOTE: PJ141 and PJ144 are in-line connectors on the rear panel, (refer to Flag 2 and
Flag 3). They are connected when the module is installed and are susceptible to damage.
Remove any torn paper / debris from the contacts.
5. 03-371 Only: Go to Flag 2. Check the harness. Remove any torn paper / debris from the
fuser CRUM connector, (35-55ppm) PL 4.17 Item 12 or (65-90ppm) PL 4.12 Item 12.
Repair as necessary, REP 1.2.
6. 03-372 Only: Go to Flag 3. Check the harness. Remove any torn paper / debris from the
xerographic CRUM connector, (35-55ppm) PL 4.17 Item 4 or (65-90) PL 4.12 Item 4.
Repair as necessary, REP 1.2.

03-371 Only: Fuser connector assembly, (35-55 ppm) PL 4.15 Item 9 or (65-90
03-371 Only: Fuser Module, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10
Item 1.
03-372 Only: Xerographic module, PL 9.20 Item 2.
Main drive motor PWB assembly, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL
4.10 Item 6.
Main Drive Module, (35-55 ppm) PL 4.15 Item 1 or (65-90 ppm) PL 4.10 Item 1.


03-374 Power Off Failure RAP Y N
Install a LVPS and base module, PL 1.10 Item 3.
03-374 The single board controller PWB has detected that the LVPS is still on, 30 seconds
after a power off request.
Go to Flag 2. Measure the voltage at P/J1 pin 15 on the IOT PWB. Operate the on / off switch.
A single low pulse is detected.
Initial Actions Y N
Go to Flag 2. Check the wiring. Repair as necessary, GP 7. Install new components as
necessary:
WARNING Single board controller PWB, PL 3.24 Item 3.
Ensure that the electricity to the machine is switched off while performing tasks that do Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 1.10 Item 2.
If possible, switch off the machine, then switch on the machine GP 14. If the UI fails to Go to Flag 2. Set the meter to measure frequency. Check the pulses at P/J1 pin 13, on the IOT
respond, perform the 03-310 Single Board Controller PWB to UI Errors RAP. PWB. These are approximately 1Hz pulses. The pulses have stopped.
Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur Y N
randomly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item 2.
If the drives module has recently been removed, then check the pins and connections at
Check that all associated wiring is in good condition, GP 7.
Reload the software, GP 4, Machine Software.
Procedure
Ensure the P/Js on the IOT PWB, PL 1.10 Item 2 and the single board controller PWB, PL 3.24
Item 3 are correctly and securely connected. The fault is still present.
Y N
Perform SCP 6 Final Actions.
Remove the left hand cover, PL 8.10 Item 3. Go to Flag 1. Measure the voltages at the on/off
switch terminals. The voltages are +3.3V and 0V.
Y N
Go to:
GP 13 How to check a switch.
P/J5.
01B, 0V Distribution RAP.
01J Power On and LVPS Control Signals RAP.
If necessary, install a new on/off switch, PL 1.10 Item 8.
NOTE: The LVPS is software controlled. When the voltage on PJ26 is low, the LVPS should be
on. When the voltage on PJ26 pin 7 is high, the LVPS should be off.
Go to Flag 3. Measure the voltage at P/J26 pin 7 on the IOT PWB. Operate the on / off switch.
Select power down then confirm from the UI. The voltage changes from low to high within
30 seconds.
Y N
Install new components as required:
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Check the state of the LVPS by observing the power indication LEDs on the IOT PWB, (refer to
the OF7 IOT PWB Diagnostics RAP). The LVPS has switched off.


03-395, 396, 852, 853 IOT PWB Fault RAP 8. As necessary, install new components:
03-395 The IOT has cycled without printing. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
03-396 The photoreceptor is detected not turning while the laser is on. LVPS and base module, PL 1.10 Item 3.
03-852 IOT has detected that it is out of timers.
03-853 IOT has detected that it is nearly out of timers.
Also use this RAP for fault code 06-350 ROS Laser Not Under Control.
Initial Actions
WARNING
RAP.
Procedure
1. Ensure all the P/Js on the IOT PWB, PL 1.10 Item 2 are correctly and securely con-
nected.
2. 03-395 Only: This fault can be caused by the following:
a. A poor ground on the duplex tray or a paper path problem. Check the active fault list
for an 08-XXX or 09-XXX. Go to the indicated RAP.
b. A paper guide in a paper tray being set to the wrong paper size. Check the paper
guide settings in the paper trays.
c. An HVPS fault, perform the 09-060 HVPS Fault RAP.
3. Perform the OF7 IOT PWB Diagnostics RAP.
4. Reload the software set, GP 4, Machine Software.
NOTE: The supply harness is a flying lead that is a part of the LVPS and is not spared
separately.
5. Go to Flag 1. Check the voltages. As necessary, refer to:

01B 0V Distribution RAP. Figure 1 Circuit diagram
6. 03-853 Only: Print off a fault history report then troubleshoot any codes that coincide with
the 03-853 fault, refer to SCP 1.
7. 03-396 Only: If necessary, go to the 04A Main Drive Motor and Photoreceptor Motor RAP.
Perform the photoreceptor motor checkout.

03-395, 396, 852, 853 2-96 Xerox WorkCentre 5790 Family
03-397 Main Motor Not Controlled RAP
03-397 The IOT software has detected that the main motor is not being controlled. The soft-
ware that monitors the main motor and the photoreceptor motor was not reset within the
expected time.
Initial Actions
WARNING
RAP.
Procedure
Ensure that the connectors that follow are securely connected:
LVPS and base module, PL 1.10 Item 3.
Main drive motor and PWB, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item 6.
The fault is still present.
Y N
Go to Flag 1 and Flag 2. Check the wiring, GP 7. The wiring is good.

Y N
Repair the wiring, GP 7.
Go to Flag 1. Check the voltages at P/J16, pins 1 and 2 on the LVPS. The voltages are cor-
rect.
Y N
As necessary, refer to:
Go to Flag 2. Measure the voltage at P/J3 pin 3, on the IOT PWB. Enter dC330 code 04-010,
Main Motor On. Stack the photoreceptor motor code, 09-010. The voltage changes from
high to low and the main motor runs.
Y N
Perform the OF7 IOT PWB Diagnostics RAP. If necessary, install new components:
Main drive motor and PWB, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item
6.
Reload the software, GP 4, Machine Software. If necessary, install new components:

Perform the OF7 IOT Diagnostics RAP before installing a new IOT PWB, PL 1.10 Item 2.
Main drive motor and PWB, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item 6.


03-401, 03-403 Fax Not Detected RAP 03-412 Foreign Device PWB Fault RAP
03-401 The embedded fax PWB has not been detected or confirmed. 03-412 The foreign interface device was not detected at power on.
03-403 The extended fax PWB has not been confirmed or detected. Initial Actions
Procedure
WARNING
WARNING not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
death or injury. Moving parts can cause injury. CAUTION
Switch off the machine, then switch on the machine, GP 14. Do not show the customer how to install a temporary shorting link. Do not leave a shorting link
installed.
Perform the following: Switch off the machine, then switch on the machine, GP 14.
1. Check that the embedded fax PWB has been installed, PL 20.10 Item 4. Ensure the foreign interface PWB, PL 3.22 Item 4 is securely connected to the single
2. (W/O TAG X-001) Check that the compact flash is inserted correctly, PL 20.10 Item 3. board controller PWB, PL 3.24 Item 3.
NOTE: Do not attach a foreign interface vend adaptor with this configuration of foreign inter-
4. Install a new embedded fax PWB, PL 20.10 Item 4. face PWB.
(W/O TAG X-001) Repeat the above checks for the extended fax PWB, and if necessary, install
a new extended fax PWB, PL 20.10 Item 2. Procedure
Go to Flag 1. Check the harness. The harness is good.
Y N
Perform the following as necessary:
Repair the harness. Refer to GP 7.
Install a new foreign interface harness, PL 3.22 Item 5.
NOTE: Do not attempt to repair the harness from PJ124 to the foreign device.
Check the +3.3V supply to P/J201 at pins 1, 5, 9, 16 and 22 on the single board controller
PWB, The +3.3V supply is good.
Y N
Go to:
Disconnect the foreign device. Install a temporary shorting link between pins 2 and 3 on P/
J124. Check the voltage at PJ124 pin 2. 0V is measured.
Y N
Install a new foreign interface PWB, PL 3.22 Item 4.
If the fault remains, the foreign device is faulty.
Disconnect the foreign device. Install a temporary shorting link between pins 1 and 3 on P/
J124. Check the display. Ensure the machine is now enabled to scan or print. The machine
is enabled.
Y N
The enable circuits are working correctly.

NOTE: Currently the signals used for billing, e.g. machine function, premium tray, etc. cannot
be adequately measured with a standard meter.

03-415 Tray 5 Module Not Detected / Confirmed RAP
03-415 The IOT PWB has not detected the tray 5 module at startup, or has failed to detect the
tray 5 module during printing.
Initial Actions
WARNING
Check that the sleeved harness from the tray 5 module is correctly and securely con-
nected to PJ501 at the rear of the machine.
Procedure
Switch off the machine, GP 14. Go to Flag 1. Check that there is continuity between P/J12,
pins 3 and 4. There is continuity.
Y N
Check the wiring between P/J12 and P/J501. Repair the wiring as necessary, GP 7.
Check the wiring between P/J501and P/J512 on the Tray 5 control PWB. Repair
the wiring as necessary, GP 7.
Check the condition of P/J501, paying attention to the condition of the pins. Repair
the wiring as necessary, GP 7.
Check the loop between pins 19 and 20 on P/J501. Repair the wiring as necessary,
GP 7.
Switch on the machine, GP 14. With P/J501 disconnected, check for +3.3V at P/J12, pin 3.
Check for 0V at P/J12, pin 4.
As necessary, perform the following:
Go to 01D +3.3V Distribution RAP.
Go to 01B 0V Distribution RAP.
Perform OF7 IOT PWB Diagnostics RAP before installing a new IOT PWB, PL 1.10 Item 2.


03-417 Incompatible Fax Software RAP 03-419, 03-420 Incompatible Software RAP
03-417 The Fax software version supplied at power up is not compatible with the image pro- 03-419 The IOT, DADH or user interface software version supplied at power on is not compati-
cessing software. ble with the image processing software.
Procedure 03-420 The tray 5 module software version supplied at power on is not compatible with the
image processing software.
WARNING Procedure
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. Reload the software, GP 4.
3. Install a new embedded fax PWB, PL 20.10 Item 4.
1.10 Item 2.

03-423, 424, 433, 434, 821, 822, 831, 832 Print Command 03-480 IOT +24V Supply Failure RAP
Late RAP 03-480 The IOT has detected a +24V supply fault.
03-423 The IOT detected print command late with respect to page sync in simplex 3 mode.
Initial Actions
03-424The IOT detected print command late with respect to page sync in simplex 4 mode.
03-433 The IOT detected print command late with respect to page sync in duplex 3 mode. WARNING
03-434 The IOT detected print command late with respect to page sync in duplex 4 mode. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
03-821 The IOT detected print command late with respect to page sync in simplex 1 mode. Measure the voltage from F1 fuse on the IOT PWB to the machine frame. The F1 is a small
white fuse under PJ27 on the IOT PWB. Refer to 01G +24V Distribution RAP, Figure 4. If the
03-822 The IOT detected print command late with respect to page sync in simplex 2 mode. voltage is less than +24V, install a new LVPS, PL 1.10 Item 3.
03-831 The IOT detected print command late with respect to page sync in duplex 1 mode.
Procedure
03-832 The IOT detected print command late with respect to page sync in duplex 2 mode. 1. Perform the OF7 IOT PWB Diagnostics RAP.
All of the above faults will be seen as output pages out of order caused by confused software.
Procedure
NOTE: These codes record events in the fault history file, but may not prevent the machine
operating normally. These faults will also result in a blank sheet being delivered to the output
tray.
1. Delete the job. Switch off, then switch on the machine, GP 14.
2. Reload the software, GP 4.
4. If the fault remains, perform the OF7 IOT PWB Diagnostics RAP.

03-423, 424, 433, 434, 821, 822, 831, 832, 03-480 2-104 Xerox WorkCentre 5790 Family
03-700, 03-780, 03-785, 03-790 Power On / Power Off Event 03-720 ODIO Time-out Error RAP
Fault RAP 03-720 The image processing software has not detected on ODIO (On Demand Image Over-
write) completion response within 45 minutes. This indicates that a memory module may be
03-700 This fault code in the fault history file indicates that the single board controller PWB
module has performed the power on sequence. hung up, or may have crashed while overwriting an image.
03-780 This fault code in the fault history file indicates that quick restart has been selected Initial Actions
from the power down options pop up window.
03-785 This fault code in the fault history file indicates that power off has been selected from WARNING
the power down options pop up window. Ensure that the electricity to the machine is switched off while performing tasks that do
03-790 This fault code in the fault history file indicates that power off has been selected from death or injury. Moving parts can cause injury.
the machine fault pop up window. Switch off the machine, then switch on the machine, GP 14.
Procedure
Procedure
These codes record events in the fault history file, but do not prevent the machine operating
When the response time has been exceeded, the system records the event with this fault code
normally. They will be visible in the fault history file adjacent to the fault that caused the user to
and then returns the machine to normal operation. If the machine is not operating normally,
switch off the machine, then switch on the machine. They can therefore be used as an aid to
perform the following:
identifying the root cause of faults.
1. Check the Fax confirmation report and the ODIO confirmation report to establish which
memory module is not overwriting.
(W/O TAG X-001) Fax compact flash memory, PL 20.10 Item 3.
(W/TAG X-001) Embedded fax PWB, PL 20.10 Item 4.

03-770 IOT PWB Software Reset RAP 03-777 Power Loss Detected RAP
03-770 This fault code in the fault history file indicates that the IOT PWB has been reset due to 03-777 This fault code in the fault history file indicates that the system has previously detected
a software fault. a power input loss.
Procedure Procedure
This code records an event in the fault history file, but does not prevent the machine operating
normally.
WARNING
1. Check with the customer that the AC mains (line) input power supply is not experiencing
interruptions.
2. Check with the customer that the machine does not share a power supply with any other
equipment. Sharing a power supply may cause the safety over current device to switch off
the electricity to the machine. This would cause a 03-777 fault. If possible, ensure the
machine is connected to a dedicated power supply.
3. Go to the 01C AC Power RAP and check the power input circuit and its connectors.
4. Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur
RAP.

03A Single Board Controller PWB Module Cooling Fan 03B Mark Service Unavailable RAP
Failure RAP Before performing this RAP, any relevant status code RAP must have been performed.
Use this RAP if the single board controller PWB module cooling fan is suspected of failure.
Initial Actions
Procedure
WARNING
WARNING Ensure that the electricity to the machine is switched off while performing tasks that do
death or injury. Moving parts can cause injury. Switch off the machine, then switch on the machine, GP 14.
Procedure
CAUTION
1. Switch off the power, disconnect the power cord and ensure all the P/Js are properly
Note the orientation of the cooling fan, PL 3.24 Item 2 before installing a new component.
installed on the IOT PWB, PL 1.10 Item 2 and single board controller PWB, PL 3.24 Item
1. Go to Flag 1. Check the cooling fan in the single board controller PWB module. Refer to: 3.
GP 10, How to Check a Motor. 2. Reload the software, GP 4, Machine Software.
P/J221 on the Single Board Controller PWB. 3. Ensure that the output device communications cord is connected and secure, at PJ151 on
01F, +12V Distribution RAP. the Power and Control Assembly at the rear of the machine.
01B, 0V Distribution RAP. 4. Install new components:
2. If necessary, install new components: Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Cooling fan, PL 3.24 Item 2. 1.10 Item 2.
Single board controller PWB, PL 3.24 Item 3. Single board controller PWB, PL 3.24 Item 3.

Xerox WorkCentre 5790 Family 2-107 03A, 03B
03C Hard Disk Failure RAP 03D Software Module Failure RAP
Use this RAP to determine failure of the hard dIsk drive. Use this RAP to determine failure of the software module.
Initial Actions Failure Symptoms

The machine may intermittently display the following re-occurring messages:
Scanner fault (but no scanner fault code in fault history)
WARNING
Re-order but do not replace the fuser module (but no fuser fault code in fault history)
Local interface problem detected
death or injury. Moving parts can cause injury. Network controller unavailable
Perform the Boot Up Failure RAP OF5. Network controller unavailable together with many of one or more of 03-300, 03-320,
03-330 and 03-340 fault codes in fault history
The machine displays a replace xerographic module message, even though the xero-
Procedure
graphic module is new or fairly new and nowhere near the end of life total
1. Switch off the machine GP 14.
After a new xerographic module has been installed, in machine status/supplies, the xero-
2. Go to Wiring Diagram 4, check the wiring between the hard disk drive, power distribution graphic module image count should be 0 and projected life should be 365 days. But
PWB and single board controller PWB, GP 7. instead the projected life is 0 days, which triggers the replace xerographic module now /
3. Repair the wiring or install a new harness where necessary. no prints can be made until the xerographic module has been replaced message. In this
4. Check for +5V distribution, refer to the 01E +5V Distribution RAP. case, it not just the machine logic erroneously reporting end of life, the CRUM in the xero-
5. Check for +12V distribution, refer to the 01F +12V Distribution RAP. graphic module has been killed and will not function even if installed in a working
machine.
6. Perform the Forced AltBoot Software Loading Procedure GP 4.
7. If necessary, install new components: Procedure
Hard disk drive, PL 3.22 Item 2. The cause of all the failure symptoms is a defective software module, perform the following:
Power distribution PWB, PL 3.24 Item 5. 1. Install a new software module, PL 3.24 Item 8.
Single board controller PWB, PL 3.24 Item 3. 2. Install a new xerographic module, PL 9.20 Item 2 (40 to 90 ppm) PL 9.22 Item 2 (35 ppm).

03C, 03D 2-108 Xerox WorkCentre 5790 Family
A
03E Foreign Device PWB Fault RAP Disconnect the foreign device. Install a temporary shorting link between pins 2 and 3 on P/
J124. Check the voltage at P/J124 pin 1. 0V is measured.
Use this RAP when the foreign interface device is not detected at power on.
Y N
Install a new foreign interface PWB, PL 3.22 Item 4. If the fault persists, the foreign device
Initial Actions is faulty.
Install a temporary shorting link between pins 1 and 3 on P/J124. Check the display. Ensure
WARNING the machine is now enabled to scan or print. The machine is enabled.
Ensure that the electricity to the machine is switched off while performing tasks that do Y N
not need electricity. Refer to GP XX. Disconnect the power cord. Electricity can cause Install a new foreign interface PWB, PL 3.22 Item 4. If the fault persists, perform the 03D
death or injury. Moving parts can cause injury. SBC PWB Diagnostics RAP.
The enable circuits are working correctly.

CAUTION
NOTE: Currently the signals used for billing, e.g. machine function, or premium tray, cannot be
Do not show the customer how to install a temporary shorting link. Do not leave a shorting link
adequately measured with a standard service meter.
installed.
Ensure the foreign interface PWB, PL 3.22 Item 4 is securely connected to the single
board controller PWB, PL 3.24 Item 1.
Ensure the foreign device is enabled, refer to GP 24 Customer Administration Tools.
Select Tools > Accounting settings > Accounting mode > Auxiliary access > Auxiliary
device type. Select, if listed your type of device (?) or Generic > O.K, then exit Tools.
NOTE: Do not attach a foreign interface vend adaptor with this configuration of foreign inter-
face PWB.
Procedure
Go to Flag 1. +3.3V is available at P/J100 between pins 2 and 3, also between pins 1 and
3.
Y N
Disconnect the foreign device from P/J124. +3.3V is available at the connector on the
machine, between pins 2 and 3, also between pins 2 and 3.
Y N
Disconnect P/J100. +3.3V is available at J100 on the foreign interface PWB
between pins 2 and 3, also between pins 1 and 3.
Y N
Disconnect the foreign interface PWB. +3.3V is available at P/J201 on the
single board controller PWB at pins 1, 5, 9, 16 and 22.
Y N
Check the voltages that follow:
+5V supply to the +3V generator on the SBC PWB. Refer to the 01D
+3.3V Distribution RAP.
+5V return supply to the +3V generator on the SBC PWB. Refer to
the 01B 0V Distribution RAP.
If the supplies are good, perform the 03D SBC PWB Diagnostics RAP.
Install a new foreign device interface harness, PL 3.22 Item 4.
The foreign device is faulty.

A


04A Main Drive Motor and Photoreceptor Motor RAP Install new components as necessary:
Use this RAP to determine failures of the main drive motor and the photoreceptor motor. Main drive motor and PWB assembly (35 ppm), PL 4.15 Item 6.
Main drive motor and PWB assembly (40- 55 ppm), PL 4.15 Item 6.
Procedure Main drive motor and PWB assembly (65 - 90 ppm), PL 4.10 Item 6.
WARNING
Go to Flag 1. Check for +24V between P/J147 pin 1 and pin 2 on the Main Drive PWB. +24V
is measured.
Y N
Ensure that the drum cartridge is correctly installed and that the CRUM connector is not
damaged.
Check the wiring, GP 7, to the LVPS. Refer to:
01H Short Circuit and Overload RAP.
Enter dC330, code 04-010 main drive motor and code 09-010 photoreceptor motor, Figure 1.
Press Start. The main drive motor and the photoreceptor motor turn.
Y N Photoreceptor
If the photoreceptor motor does not turn, go to the 04A Photoreceptor Motor Checkout. If motor
the main drive motor does not turn, go to the 04A Main Drive Motor Checkout.
Check all the wiring and connections between the IOT PWB and the main drive module for
damage and loose connections.
04A Photoreceptor Motor Checkout

Go to Flag 3 and Flag 4. Check the wiring, GP 7. Refer to:
P/J3, IOT PWB.
P/J148, Main Drive PWB.
Main drive motor and PWB assembly (35 ppm), PL 4.15 Item 6.
Main drive motor and PWB assembly (40-55 ppm), PL 4.15 Item 6.
Main drive motor and PWB assembly (65-90 ppm), PL 4.10 Item 6.
Main drive module (35 ppm), PL 4.15 Item 1.
Main drive module (40-55 ppm), PL 4.15 Item 1.
Main drive module (65-90 ppm), PL 4.10 Item 1.
Main drive motor
2.
04A Main Drive Motor Checkout
Go to Flag 2. Check the wiring, GP 7. Refer to: Figure 1 Component location
P/J3, IOT PWB


05-300 DADH Open RAP
05-300 The DADH closed switch detects that the DADH is open during run.
Initial Actions
WARNING
DADH closed
Magnet switch
death or injury. Moving parts can cause injury. S05-300
Check that the DADH magnet is installed and aligned correctly. Refer to Figure 1.
Procedure
NOTE: (W/O TAG 150) To get access to the bulkhead connector, remove the user interface
assembly, PL 2.10 Item 1. To get access to the DADH closed switch, remove the top cover, PL Bulkhead
14.20 Item 3, from the scanner module. To get access to the scanner PWB, remove the docu- connector
ment glass, PL 14.20 Item 5 and the scanner PWB cover, PL 14.25 Item 1.
NOTE: (W/TAG 150) To get access to the bulkhead connector, remove the user interface
assembly, PL 2.10 Item 1. To get access to the DADH closed switch, remove the top cover, PL
14.10 Item 3, from the scanner module. To get access to the scanner PWB, remove the docu- Figure 1 Component location
ment glass, PL 14.10 Item 5 and the scanner PWB cover PL 14.15 Item 1.
Enter dC330 code 05-300 to check the DADH closed switch, S05-300. Open and close the
DADH. The display changes.
Y N
Go to Flag 1. Check S05-300.
References:
(W/O TAG 150) P/J453 and the bulkhead connector.
(W/TAG 150) P/J927 and the bulkhead connector.
The 3.3V return in the 01B 0V Distribution RAP.
DADH closed switch (W/O TAG 150), PL 14.25 Item 6.
DADH closed switch (W/TAG 150), PL 14.15 Item 6.
Scanner PWB (W/O TAG 150), PL 14.25 Item 4.
Scanner PWB (W/TAG 150), PL 14.15 Item 4.
Perform the steps that follow. Install new components as necessary:

Check that S05-300 is installed correctly.
Check the DADH frame for distortion, go to ADJ 5.2. If the DADH frame is distorted, install
a new DADH, PL 5.10 Item 9.

05-305 DADH Top Cover Open RAP
05-305 The DADH top cover interlock switch detects that the top cover is open.
Initial Actions
WARNING
Remove all documents from the DADH.
Check the top cover interlock actuator, 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.
Procedure
Enter dC330 code 05-305 to check the DADH top cover interlock switch, S05-305. Activate
S05-305. The display changes.
Y N
References:
P/J187, DADH PWB.
The 24V return in the 01B 0V Distribution RAP.
Figure 2 Circuit diagram Install new components as necessary:
DADH top cover interlock switch (35 ppm), PL 5.15 Item 11.
DADH top cover interlock switch (40-90 ppm), PL 5.17 Item 11.
Check that S05-305 is installed correctly. Install new components as necessary.

Actuator
DADH top
cover Figure 2 Circuit diagram
interlock
switch
S05-305

05-310 Document too Short RAP 05-330, 05-331 DADH Feed Sensor Failure Entry RAP
05-310 The DADH detects a document that is shorter than 110mm. 05-330 The DADH feed sensor does not detect the lead edge of the document within the cor-
rect time after the feed motor runs.
Initial Actions
05-331 The DADH feed sensor does not detect the trail edge of the document within the cor-
rect time.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Procedure
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Identify the speed of the machine, refer to SCP 7 Machine Features. Perform one of the steps
death or injury. Moving parts can cause injury. that follow:
Remove all documents from the DADH. If the speed of the machine is 35 ppm, go to the 05-330A, 05-331A DADH Feed Sensor
Make sure that the documents are longer than 110mm (4.3 inches). Failure RAP (35 ppm).
Check for toner contamination on and in the locality of the feed sensor Q05-330, PL 5.17 If the speed of the machine is 40-90 ppm, go to the 05-330B, 05-331B DADH Feed Sen-
Item 2. sor Failure RAP (40-90 ppm).
Procedure
If the documents are longer than 110mm, go to the procedures that follow:
05-330, 05-331 DADH Feed Sensor Failure Entry RAP.
05-335 DADH Takeaway Sensor Failure RAP.
05-350, 05-352 DADH CVT Sensor Failure RAP.
05-340 DADH Registration Sensor Failure RAP.

A
05-330A, 05-331A DADH Feed Sensor Failure RAP (35 Install new components as necessary:
DADH feed sensor, PL 5.15 Item 2.
ppm)
Initial Actions
Enter dC330 code 05-020 to run the DADH feed motor, MOT05-020. MOT05-020 runs.
Y N
WARNING Go to the 05D DADH Motor Failure RAP.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause While MOT 05-020 runs, stack the code 05-025 to energize the DADH feed clutch, CL05-025.
NOTE: The feed clutch disengages after 30 seconds. The feed motor stops after 3 minutes.
330, 05-331 DADH Feed Sensor Failure Entry RAP. CL05-025 energizes, the nudger rolls and the feed rolls rotate.
Remove all documents from the DADH. Y N
Make sure that the customer is not using damaged documents. If the DADH damages the
documents, go to the 05F Damaged Documents RAP. Go to the 05E DADH Feed Clutch Failure RAP and check CL05-025.
Figure 1. Make sure that the feed sensor actuator is not damaged. If necessary, install a ADJ 5.1, DADH Drive Belt Adjustment.
new feed sensor, PL 5.15 Item 2.
Enter dC330 code 05-010 to energize the DADH feed solenoid, SOL05-010. The feed roll
Figure 1. Check that the feed roll assembly is installed correctly, go to REP 5.14.
assembly lowers, then raises after 10 seconds.
Figure 1. Make sure that the feed rolls are clean and rotate freely, refer to ADJ 5.4. If nec- Y N
essary, install a new feed roll assembly, PL 5.15 Item 1 or feed roll assembly cover, PL Go to Flag 2. Check SOL05-010.
5.15 Item 21. References:
Figure 2. Check the operation of the feed yoke. Make sure that the feed yoke shaft is GP 12 How to Check a Solenoid or Clutch.
under the clip. Make sure that the feed yoke spring is connected to the feed assembly and
P/J183, DADH PWB and P/J201.
to the feed yoke.
While the DADH feed solenoid is de-energized, make sure that the feed gates are locked
in the down position. Manually activate the DADH feed solenoid then make sure that the The 24V return in the 01B 0V Distribution RAP.
feed gates move freely. Manually de-activate the DADH feed solenoid, PL 5.15 Item 5. Install new components as necessary:
DADH feed solenoid, PL 5.15 Item 5.
NOTE: The feed solenoid remains activated (after being energized) until the last docu-
ment has been fed. Then a reverse pulse de-actuates the armature to lift the nudger roll. DADH feed assembly, PL 5.15 Item 18.
Check the location of the feed solenoid spring. Make sure the spring is correctly located
on the solenoid armature. Perform the steps that follow:
Clean the DADH feed sensor and the area around the sensor, PL 5.15 Item 2. Check that the DADH feed sensor, Q05-330 is installed correctly. If necessary, install a
Clean the takeaway rolls, PL 5.35 Item 6. Refer to ADJ 5.4. new feed roll assembly, PL 5.15 Item 1.
Ensure the feed motor drive belt and CVT motor drive belt are tensioned correctly, ADJ
Procedure 5.1.
Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover When large documents are fed (A3 or 11x17 inch), check the following:
interlock switch closed. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-330. The CVT motor rotates freely, refer to 05D DADH Motor Failure RAP
Activate Q05-330. The display changes. The CVT drive belt, refer to ADJ 5.1 DADH Drive Belt Adjustment.
Y N
That the CVT roll is clean and rotates freely, refer to ADJ 5.4.
Go to Flag 1. Check Q05-330.
References: NOTE: If necessary install a new CVT motor, PL 5.25 Item 9.
Go to the 05E DADH Feed Clutch Failure RAP and check CL05-025.
P/J184 DADH PWB.
Make sure that the size of the documents are sensed correctly. Refer to the 05C Docu-
01D +3.3V Distribution RAP. ment Size Sensor Failure RAP.
The 3.3V return in the 01B 0V Distribution RAP.

CVT motor MOT 05-030
Clip
Top cover interlock switch
DADH feed motor Feed yoke and spring

MOT05-020
DADH feed clutch

CL05-025
Feed yoke shaft
Feed
gates
DADH feed solenoid DADH feed sensor DADH feed roll

P/J201 SOL 05-010 Q05-330 assembly

Feed
gates

05-330B, 05-331B DADH Feed Sensor Failure RAP (40 to 90
ppm)
Initial Actions
WARNING
330, 05-331 DADH Feed Sensor Failure Entry RAP.
Make sure that the customer is not using damaged documents. If the DADH damages the
documents, go to the 05F Damaged Documents RAP.
Figure 1. Check that the feed roll assembly is installed correctly, go to REP 5.14.
Figure 1. Make sure that the feed rolls are clean and rotate freely, refer to ADJ 5.4. If nec-
essary, install a new feed roll assembly, PL 5.17 Item 1 or feed roll assembly cover, PL
5.17 Item 21.
Figure 2. Check the operation of the feed yoke. Make sure that the feed yoke shaft is
under the clip. Make sure that the feed yoke spring is connected to the feed assembly and
to the feed yoke.
Figure 2. Check that the feed yoke actuates and locks the feed gates in the down posi-
tion. If necessary install a new feed yoke, PL 5.17 Item 6.
Clean the DADH feed sensor and the area around the sensor, PL 5.17 Item 2.
Clean the takeaway rolls, PL 5.35 Item 6. Refer to ADJ 5.4.
Procedure
Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover
interlock switch closed. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-330.
Activate Q05-330. The display changes.
Y N
References:
P/J184,DADH PWB
DADH feed sensor, PL 5.17 Item 2.
Y N
Go to the 05D DADH Motor Failure RAP.
While MOT 05-020 runs, stack the code 05-025 to energize the DADH feed clutch, CL05-025.

Xerox WorkCentre 5790 Family 2-119 05-330A, 05-331A, 05-330B, 05-331B
NOTE: The feed clutch disengages after 30 seconds. The feed motor stops after 3 minutes.
CVT motor MOT 05-030
CL05-025 energizes, the nudger rolls and the feed rolls rotate.
Y N
Perform the steps that follow: Top cover interlock switch
ADJ 5.1 DADH Drive Belt Adjustment.
DADF feed motor
MOT05-020
Enter dC330 code 05-010 to energize the DADH nudger motor, MOT05-010.
NOTE: 40-90 ppm machines are fitted with a nudger motor, PL 5.17 Item 5, not a feed solenoid
SOL 05-010, PL 5.15 Item 5 as installed on 35 ppm machines. The component control code DADF feed clutch
05-010 is used to energize both the nudger motor and feed solenoid. However, the UI displays CL05-025
the message doc handler feed solenoid on both configurations.
The feed roll assembly lowers, then raises after 10 seconds.

Y N
Go to Flag 2. Check nudger motor, MOT05-010.
References:
GP 10 How to Check a Motor
DADH feed assembly, PL 5.17 Item 8.
If TAG D-003 has not been struck, install a shim kit, PL 5.17 Item 29.

Check that the DADH feed sensor, Q05-330 is installed correctly. If necessary, install a
new feed roll assembly, PL 5.17 Item 1.
Ensure the feed motor drive belt and CVT motor drive belt are tensioned correctly, ADJ
5.1.
When large documents are fed (A3 or 11x17 inch), check the items that follow:
Check that the CVT motor rotates freely, refer to 05D DADH Motor Failure RAP.
Check the CVT drive belt, refer to ADJ 5.1 DADH Drive Belt Adjustment.
Check that the CVT roll is clean and rotates freely, refer to ADJ 5.4. DADF nudger motor DADH feed sensor DADF feed roll
P/J201 MOT 05-010 Q05-330 assembly
NOTE: If necessary install a new CVT motor, PL 5.25 Item 9.
Make sure that the size of the documents are sensed correctly. Refer to the 05C Docu-
ment Size Sensor Failure RAP.

Clip
Feed yoke and spring
Feed yoke shaft

Feed
gates
Feed
gates

A
05-335 DADH Takeaway Sensor Failure RAP Perform the steps that follow:
05-335 The DADH takeaway sensor does not detect the lead edge of the document within the Check that the DADH feed sensor, Q05-335 is installed correctly.
correct time. Go to the 05E DADH Feed Clutch Failure RAP and check the DADH feed clutch.
Make sure that the takeaway roll is clean and rotates freely, refer to ADJ 5.4.
Initial Actions Make sure that the takeaway roll idlers are clean and rotate freely, refer to ADJ 5.4.
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.
WARNING
ADJ 5.1 Feed Motor Drive Belt Adjustment.
death or injury. Moving parts can cause injury. DADH takeaway roll, PL 5.35 Item 6.
Remove all documents from the DADH. DADH input tray assembly, PL 5.35 Item 1.
Figure 1. Make sure that the takeaway sensor actuator is not damaged. If necessary, DADH top access cover assembly, PL 5.20 Item 17.
install a new takeaway sensor, PL 5.20 Item 11. DADH feed assembly (35 ppm), PL 5.15 Item 18.
Clean the feed rolls, refer to ADJ 5.4. If necessary, install a new feed roll assembly, (35 DADH feed assembly (40-90 ppm), PL 5.17 Item 18.
ppm) PL 5.15 Item 1 or (40-90 ppm) PL 5.17 Item 1. If the fault continues, make sure that documents correctly continue past the previous sensor in
the document path. Refer to the 05-330, 05-331 DADH Feed Sensor Failure Entry RAP.
Procedure
NOTE: To get access to the DADH takeaway sensor, remove the DADH top cover, PL 5.20
Item 15.
Open the DADH top cover. Enter dC330 code 05-335 to check the DADH takeaway sensor,
Q05-335, Figure 1. Activate Q05-335. The display changes.
Y N
References:
01B 0V Distribution RAP. Refer to the 3.3V return.
DADH takeaway sensor, PL 5.20 Item 11.
Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover interlock switch closed.
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.
A
Takeaway roll idlers
Feed motor tension spring

P/J191
DADH feed motor

MOT05-020
Feed motor
drive belt
DADH feed roll

assembly
DADH takeaway sensor

Takeaway roll Feed assembly
Q05-335

05-340 DADH Registration Sensor Failure RAP Y N
Go to Final Actions.
05-340 The DADH registration sensor does not detect the lead edge of the document within
the correct time.
This fault can be caused by the DADH feed motor running too slowly in reverse. Refer to the
Initial Actions 05D DADH Motor Failure RAP. If the fault continues, go to Final Actions.
Final Actions
WARNING Perform the steps that follow:
Ensure that the electricity to the machine is switched off while performing tasks that do Check that Q05-340 is installed correctly.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Make sure that the CVT idler rolls are clean and rotate freely, refer to ADJ 5.4.
death or injury. Moving parts can cause injury. Make sure that the CVT roll is clean, refer to ADJ 5.4.
Remove all documents from the DADH. Make sure the feed motor drive belt and the CVT motor drive belt are tensioned correctly,
Figure 1. Make sure that the registration sensor actuator is not damaged. If necessary, ADJ 5.1.
install a new registration sensor, PL 5.25 Item 1. Install new components as necessary:
Remove the DADH top cover assembly, PL 5.20 Item 16. Make sure the harnesses are DADH CVT roll, PL 5.25 Item 5.
routed correctly and away from the document path, Figure 1. DADH top access cover assembly, PL 5.20 Item 17.
Clean the takeaway rolls, PL 5.35 Item 6. Refer to ADJ 5.4. If the fault continues, make sure that documents correctly exit the previous sensor in the docu-
Procedure ment path. Refer to the 05-350, 05-352 DADH CVT Sensor Failure RAP.
NOTE: To access the DADH registration sensor, remove the DADH top cover, PL 5.20 Item 15.
Open the top access cover assembly. Enter dC330 code 05-340 to check the DADH registra- Ground harness
tion sensor, Q05-340, Figure 2. Activate Q05-340. The display changes.
Y N
References:
P/J186, DADH PWB
01B 0V Distribution RAP, refer to the 3.3V return.
DADH registration sensor, PL 5.25 Item 1.
Enter dC330 code 05-030 to check the DADH CVT motor, MOT05-030. MOT05-030 runs.
Y N
The CVT roll rotates. DADH registration

Y N sensor Q05-340
Check the CVT motor drive belt, PL 5.25 Item 11.
Check the CVT motor tension spring. Make sure that the CVT motor drive belt ten-
sion is correct, ADJ 5.1.
Sensor harnesses
Check the CVT roll pulley, refer to GP 7.
If necessary, install a new DADH CVT roll, PL 5.25 Item 5.
The fault only occurs in duplex mode. Figure 1 Component location

DADH registration
sensor Q05-340
CVT motor tension spring
CVT motor MOT05-030
CVT motor drive belt
Top cover interlock

switch
DADH feed motor

MOT05-020
CVT roll

05-345, 05-346 DADH Exit Sensor Failure RAP Y N
05-345 The DADH exit sensor does not detect the lead edge of the document within the correct
time in the forward mode.
Check the CVT motor tension spring. Check the CVT motor drive belt tension, ADJ
05-346 The DADH exit sensor does not detect the trail edge of the document within the correct 5.1.
time in the forward mode. Check the CVT roll pulley, refer to GP 7.
Initial Actions
NOTE: The exit roll idlers remain lowered for 30 seconds.
Enter dC330 code 05-050 to energize the DADH duplex solenoid, SOL05-050, to lower the exit
WARNING
roll idlers Figure 3. The exit roll idlers lower.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform the steps that follow:
Go to Flag 2. Check SOL050-050.
Remove all documents from the DADH exit tray. Raise the DADH, remove all documents
References:
that are wound around the CVT roll.
GP 12 How to Check a Solenoid or Clutch.
Figure 1. Make sure that the exit sensor actuator is not damaged. If necessary, install a
new exit sensor, PL 5.30 Item 2. P/J181, DADH PWB and P/J205.
Make sure that the customer has set the document width guides correctly. 01D +3.3V Distribution RAP.
Procedure Check the baffle assembly link arm, PL 5.30 Item 13. Make sure that the link arm is
connected correctly to the DADH duplex solenoid, refer to REP 5.5.
NOTE: On 35 ppm machines, the DADH exit sensor is actuated by a flag. On 40-90 ppm Install new components as necessary:
machines, the DADH exit sensor is a reflective type sensor.
DADH duplex solenoid, PL 5.30 Item 4.
Enter dC330 code 05-345 to check the DADH exit sensor, Q05-345, Figure 1. Raise the DADH PWB, PL 5.10 Item 5.
DADH. Activate Q05-345. The display changes. Baffle assembly, PL 5.30 Item 5.
Y N
Go to Flag 1. Check Q05-345. Enter dC330 code 05-020 to run the DADH feed motor, MOT05-020. MOT05-020 runs.
References: Y N
GP 11 How to Check a Sensor. Go to the 05D DADH Motor Failure RAP.
P/J189, DADH PWB.
(35 ppm) 01D +3.3 Distribution RAP. The exit roll rotates.
Y N
(35 ppm) 01B 0V Distribution RAP, refer to the 3.3V return.
(40-90 ppm) 01E +5V Distribution RAP.
Check the feed motor drive belt, PL 5.35 Item 5.
(40-90 ppm) 01B 0V Distribution RAP, refer to the 5V return.
Check the feed motor tension spring. Check the feed motor drive belt tension, ADJ
Install new components as necessary: 5.1.
DADH exit sensor, PL 5.30 Item 2. Check the exit roll and pulley, PL 5.35 Item 6 and PL 5.35 Item 15, refer to GP 7.
DADH PWB, PL 5.10 Item 5. If necessary, install a new DADH input tray assembly, PL 5.35 Item 1.
Close the DADH. Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. The fault only occurs in duplex mode.
Hold the top cover interlock switch closed. Enter dC330 code 05-030 to run the DADH CVT Y N
motor, MOT05-030, Figure 2. MOT05-030 runs. Go to Final Actions.
Y N
The CVT roll rotates.
A
A
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
Baffle assembly
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 05E DADH Feed Clutch Failure RAP. Duplex gate
Final Actions
Perform the steps that follow: DADH exit sensor
For 05-345 and 05-346 faults: Q05-345
Check that the pre-scan idlers are clean and rotate freely, refer to ADJ 5.4.
Check that the post-scan idlers are clean and rotate freely, refer to ADJ 5.4.
Check the CVT ramp assembly for damage and rough edges, (W/O TAG 150) PL
14.20 Item 13 or (W/TAG 150) PL 14.10 Item 13.
Check the duplex gate for damage and rough edges, PL 5.25 Item 12.
Check that Q05-345 is installed correctly.
Make sure the feed motor drive belt and CVT motor drive belt are tensioned cor-
rectly, ADJ 5.1. Post scan idlers
Top access cover assembly, PL 5.20 Item 17.
Baffle assembly, PL 5.30 Item 5.
For 05-346 faults: Pre-scan idlers
Make sure that the exit rolls are clean and rotate freely, refer to ADJ 5.4.
Make sure that the exit roll idlers are clean and rotate freely, refer to ADJ 5.4. Figure 1 Component location
Make sure the tension springs on the exit roll shaft are in the correct position, refer to
REP 5.5
Check the exit roll static eliminator and ground harness, PL 5.35 Item 7.
Check the restack arm for damage or rough edges, PL 5.35 Item 3.
DADH exit roll, PL 5.35 Item 6.
DADH input tray assembly, PL 5.35 Item 1.
If the fault continues, make sure that documents correctly exit the previous sensor in the docu-
ment path. Refer to the 05-340 DADH Registration Sensor Failure RAP.

CVT motor Feed motor tension spring
tension spring CVT motor
MOT05-030 Feed motor
MOT05-020
Top cover interlock Feed motor drive belt

switch
Exit roll pulley

Duplex solenoid
SOL05-050
Exit roll
CVT roll CVT roll pulley and drive belt Feed Rolls Feed clutch
Exit roll idlers

05-350, 05-352 DADH CVT Sensor Failure RAP
05-350 The DADH CVT sensor does not detect the lead edge of the document within the cor-
rect time in the forward mode.
05-352 The DADH CVT sensor does not detect the lead edge of the document within the cor-
rect time in the reverse mode.
Initial Actions
WARNING
Figure 1. Make sure that the CVT sensor actuator is not damaged. If necessary, install a
new CVT sensor, PL 5.20 Item 12.
Procedure
NOTE: To get access to the DADH CVT sensor, remove the DADH top cover, PL 5.20 Item 15.
Enter dC330 code 05-350 to check the DADH CVT sensor, Q05-350, Figure 1. Activate Q05-
350. The display changes.
Y N
References:
P/J186 and P/J191, DADH PWB.
DADH CVT sensor, PL 5.20 Item 12.
Enter dC330 code 05-030 to check the DADH CVT motor, MOT05-030. MOT05-030 runs.
Y N
The CVT roll rotates.

Y N
Check the CVT motor tension spring. Make sure that the CVT motor drive belt ten-
sion is correct, ADJ 5.1.
Check the CVT roll pulley, refer to GP 7.
A

Xerox WorkCentre 5790 Family 2-129 05-345, 05-346, 05-350, 05-352
A
The fault only occurs in duplex mode (fault code 05-352).
Y N CVT motor tension spring
NOTE: The exit roll idlers remain lowered for 30 seconds. CVT motor
MOT05-030
Enter dC330 code 05-050 to check the DADH duplex solenoid, SOL05-050, to lower the exit
roll idlers, Figure 2. The exit roll idlers lower.
Y N
CVT motor
drive belt
References:
P/J181, DADH PWB. Top cover interlock
01D +3.3V Distribution RAP. switch
P/J191
Install new components as necessary: Feed motor
MOT05-020
DADH duplex solenoid, PL 5.30 Item 4.
Baffle assembly, PL 5.30 Item 5. Feed clutch
CL05-025
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 05E DADH Feed Clutch Failure RAP.
The fault is caused if the DADH feed motor runs too slowly in reverse, refer to the 05D 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 that the takeaway roll, PL 5.35 Item 6 is clean, refer to ADJ 5.4. If necessary, install
a new takeaway roll.
Check that the CVT sensor, Q05-350 is installed correctly, PL 5.20 Item 12.
Check the takeaway roll static eliminator and ground harness, PL 5.35 Item 7.
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- DADH CVT sensor Duplex solenoid
ment path. Refer to the 05-335 DADH Takeaway Sensor Failure RAP. CVT roll Q05-350 Feed rolls SOL05-050

Exit roll idlers
Figure 2 Component location Figure 3 Circuit diagram

05A DADH Other Faults RAP 05B DADH Document Present Sensor Failure Entry RAP
This RAP gives the additional information on common DADH problems. Perform the RAP for Use this RAP when the DADH document present sensor performs as follows:
all current fault codes before this RAP is performed. The sensor detects a document when a document is not present in the input tray during
the startup procedure.
Procedure The sensor detects a document when a document is not present in the input tray after a
Go to the correct RAP: jam.
05B DADH Document Present Sensor Failure Entry RAP. The sensor does not detect a document when a document is present in the input tray.
05C Document Size Sensor Failure Entry RAP. Procedure
05D DADH Motor Failure RAP. Identify the speed of the machine, refer to SCP 7 Machine Features. Perform one of the steps
05E DADH Feed Clutch Failure RAP. that follow, as appropriate:
05F Damaged Documents RAP. If the speed of the machine is 35 ppm, go to the 05G DADH Document Present Sensor
If the documents are not stacking correctly when exiting the DADH, or if 2 sided originals are Failure RAP (35 ppm).
jamming when they go back into the DADF, perform the following If the speed of the machine is 40-90 ppm, go to the 05H DADH Document Present Sensor
1. Clean or install new components: Failure RAP (40-90 ppm).
Exit roll assembly, PL 5.35 Item 17
Takeaway roll assembly, PL 5.35 Item 6
2. Ensure that the following static eliminators are in a good condition and are touching the
shafts, where appropriate:
Static eliminator (small), PL 5.35 Item 7
Static eliminator, PL 5.17 Item 14
Static eliminator, PL 5.15 Item 14
Static eliminator (large), PL 5.35 Item 10
3. Use a service meter to verify that the wires to the static eliminators are well grounded, giv-
ing a resistance reading of less than 3 ohms to ground. if necessary the resistance read-
ing may be improved by removing, cleaning and re-installing the ground wires.
NOTE: If the poor stacking problem continues and the machine is in an area with very low
humidity or the documents have high quantities of static, install static eliminator (large), PL
5.35 Item 10A.

05C Document Size Sensor Failure Entry RAP 05D DADH Motor Failure RAP
Use this RAP when the DADH is in the Auto Paper Select mode and does not detect the cor- Procedure
rect size of paper.
Also use this RAP when the DADH detects a document in the input tray when the document WARNING
tray is empty.
Initial Actions death or injury. Moving parts can cause injury.
Go to the correct procedure:
WARNING DADH Feed Motor Failure
Ensure that the electricity to the machine is switched off while performing tasks that do DADH CVT Motor Failure
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause NOTE: The component location is shown in Figure 1.
Make sure that strong lighting is not above the DADH. DADH Feed Motor Failure
Remove all documents from the DADH and input tray. NOTE: In duplex mode, the DADH feed motor runs in the forward and reverse direction. The
Make sure that the sensors and the area around the sensors are clean. duplex mode component control code is provided to reverse the drive of the feed motor.
Go to Flag 1. Check the DADH feed motor, MOT05-020.
Procedure
Identify the speed of the machine, refer to SCP 7 Machine Features. Perform one of the steps References:
that follow, as appropriate: GP 10 How to Check a Motor.
If the speed of the machine is 35 ppm, go to the 05J DADH Document Size Sensor P/J181, DADH PWB and P/J204.
Failure RAP (35 ppm).
If the speed of the machine is 40-90 ppm, go to the 05K DADH Document Size Sensor
01B 0V Distribution RAP, refer to the 24V return.
Failure RAP (40-90 ppm).
DADH feed motor, PL 5.15 Item 16.
DADH CVT Motor Failure
Go to Flag 2. Check the DADH CVT motor, MOT05-030.
References:
GP 10 How to Check a Motor.
DADH CVT motor, PL 5.25 Item 9.

Xerox WorkCentre 5790 Family 2-133 05C, 05D
CVT motor
MOT05-030
Feed motor
MOT05-020

05E DADH Feed Clutch Failure RAP
Use this RAP when the DADH feed clutch does not operate correctly.
Also use this RAP if the feed clutch energizes at the wrong time in duplex mode, which causes:
Mis-feeds.
The feed rolls to reverse and eject the original documents into the DADH input tray.
Procedure
WARNING
Go to Flag 1. Check the DADH feed clutch, CL05-025, Figure 1.
References:
DADH feed clutch, PL 5.15 Item 9.
PJ202 Feed clutch
CL05-025
Figure 2 Circuit Diagram

05F Damaged Documents RAP
Use this RAP if the documents get damaged by the DADH. Baffle assembly
Procedure
WARNING
Duplex gate
1. If the DADH damages the bottom of the documents mid-way along the lead edge, install a
new feed roll assembly, (35 ppm) PL 5.15 Item 1 or (40-90 ppm) PL 5.17 Item 1. CVT roll
2. ADJ 5.2 DADH height adjustment.
3. Check the input tray for damage, PL 5.35 Item 1.
Make sure that the document width guides move freely.
Check that the takeaway roll assembly and exit roll assembly, PL 5.35 Item 6 for
damage and contamination, refer to ADJ 5.4.
Check the restack arm for damage, PL 5.35 Item 3.
4. Open the DADH top access cover assembly, PL 5.20 Item 17.
Check the document path for damage.
Check the takeaway roll idlers and CVT roll idlers, PL 5.20 Item 3 for damage. Make Post scan idlers
sure the idlers are clean and rotate freely, refer to ADJ 5.4.
5. Raise the DADH. Lower the baffle assembly, Figure 1.
Remove any pieces of paper.
Pre-scan idlers
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, Figure 1 Component location
ADJ 5.4.
Check the pre-scan idlers, PL 5.25 Item 6 and post scan idlers, PL 5.30 Item 6 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 5 for damage.
Check the exit roll idlers for damage, PL 5.30 Item 8. Make sure the idlers are clean
and rotate freely, ADJ 5.4.
6. Check the CVT ramp assembly, (W/O TAG 150) PL 14.20 Item 13 or (W/TAG 150) PL
14.10 Item 13 for damage.
7. Make sure that the customers documents are within the specification, refer to GP 20.

05G DADH Document Present Sensor Failure RAP (35
DADH document
ppm) present sensor
Q05-310
Initial Actions
WARNING
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05B
DADH Document Present Sensor Failure Entry RAP.
Check the actuator for the document present sensor, PL 5.15 Item 12.
The DADH document present 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 the anti-
static fluid, refer to ADJ 5.4.
Procedure
Enter dC330 code 05-310 to check the DADH document present sensor, Q05-310, Figure 1.
The display changes. Figure 1 Component location
Y N
References:
P/J184, DADH PWB.
DADH document present sensor, PL 5.15 Item 13.
Make sure that the area around the sensor is clean. If the problem continues, install new com-
ponents as necessary:
DADH document present sensor actuator, PL 5.15 Item 12.

05H DADH Document Present Sensor Failure RAP (40-90
DADH document
ppm) present sensor
Q05-310
Initial Actions
WARNING
DADH Document Present Sensor Failure Entry RAP.
Clean the DADH document present sensor and the area around the sensor, PL 5.35 Item
19.
The DADH document present 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 the anti-
static fluid, refer to ADJ 5.4.
Procedure
Enter dC330 code 05-310 to check the DADH document present sensor, Q05-310, Figure 1. Figure 1 Component location
The display changes.
Y N
References:
P/J184, DADH PWB.
Make sure that the area around the sensor is clean. If the problem continues, install new com-
ponents as necessary:

A
05J Document Size Sensor Failure RAP (35 ppm) References:
Initial Actions
P/J184, DADH PWB.
WARNING 01B 0V Distribution RAP, refer to the 3.3V return.
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 DADH feed sensor, PL 5.15 Item 2.
death or injury. Moving parts can cause injury. DADH PWB, PL 5.10 Item 5.
DADH Document Present Sensor Failure Entry RAP. Enter dC330 code 05-340 to check the DADH registration sensor, Q05-340. Activate Q05-340.
Make sure that a spot light or any direct light source is not above the DADH. The display changes.
Remove all documents from the DADH and input tray. Y N
Make sure that the sensors and the area around the sensors are clean.
References:
Procedure
P/J186, DADH PWB.
Enter dC330 code 05-315 to check the DADH length sensor 1, Q05-315, Figure 1. Activate
Q05-315. The display changes.
Y N 01B 0V Distribution RAP, refer to the 3.3V return.
Go to Flag 1. Check Q05-315. Install new components as necessary:
References: DADH registration sensor, PL 5.25 Item 1.
GP 11 How to Check a Sensor. DADH PWB, PL 5.10 Item 5.
P/J190, DADH PWB.
01D +3.3 Distribution RAP. Completely open the DADH width guides. Go to Flag 5. Measure the voltage at P/J190 pin 8.
Completely close the DADH width guides. The voltage changes from 3.3V to 0V.
Y N
Install new components as necessary: Remove the DADH input tray assembly, PL 5.35 Item 1. Make sure the arm of the DADH
DADH length sensor 1, PL 5.35 Item 8. width guide sensor is installed correctly, Figure 2. Check the mechanical operation of the
DADH PWB, PL 5.10 Item 5. width guides. Install new components as necessary:
DADH width sensor, PL 5.35 Item 11.
Enter dC330 code 05-320 to check the DADH length sensor 2, Q05-320. Activate Q05-320. DADH input tray assembly, PL 5.35 Item 1.
Y N Make sure that the chain 5 NVM parameters for the detection of the size of paper are correct.
Go to Flag 2. Check Q05-320. Refer to dC131.
References: Install new components as necessary:
GP 11 How to Check a Sensor. DADH PWB, PL 5.10 Item 5.
P/J190, DADH PWB. DADH input tray assembly, PL 5.35 Item 1.
DADH length sensor 2, PL 5.35 Item 8.
Open the DADH top cover. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-
330. Activate Q05-330. The display changes.
Y N

DADH registration
sensor Q05-340 DADH width
sensor
Q05-325
Arm
DADH width guides
DADH feed sensor DADH length sensor 1 DADH length sensor 2

Q05-330 Q05-315 Q05-320


A
05K Document Size Sensor Failure RAP (40-90 ppm) References:
Initial Actions
P/J184, DADH PWB.
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 DADH feed sensor, PL 5.17 Item 2.
death or injury. Moving parts can cause injury. DADH PWB, PL 5.10 Item 5.
DADH Document Present Sensor Failure Entry RAP. Enter dC330 code 05-340 to check the DADH registration sensor, Q05-340. Activate Q05-340.
Make sure that a bright light is not above the DADH. If necessary, adjust the position of The display changes.
the machine. Y N
Remove all documents from the DADH and input tray. Go to Flag 4. Check Q05-340.
References:
Make sure that the sensors and the area around the sensors are clean.
P/J184, DADH PWB.
Procedure
Enter dC330 code 05-315 to check the DADH length sensor 1, Q05-315, Figure 1. Activate
Q05-315. The display changes. 01B 0V Distribution RAP, refer to the 3.3V return.
Y N Install new components as necessary:
Go to Flag 1. Check Q05-315. DADH registration sensor, PL 5.25 Item 1.
References: DADH PWB, PL 5.10 Item 5.
P/J190, DADH PWB. Completely open the DADH width guides. Go to Flag 5. Measure the voltage at P/J190 pin 8.
01D +3.3 Distribution RAP. Completely close the DADH width guides. The voltage changes from 3.3V to 0V.
Y N
Remove the DADH input tray assembly, PL 5.35 Item 1. Make sure the arm of the DADH
Install new components as necessary: width guide sensor is installed correctly, Figure 2. Check the mechanical operation of the
DADH length sensor 1, PL 5.35 Item 8. width guides. Install new components as necessary:
DADH PWB, PL 5.10 Item 5. DADH width sensor, PL 5.35 Item 11.
DADH input tray assembly, PL 5.35 Item 1.
Enter dC330 code 05-320 to check the DADH length sensor 2, Q05-320. Activate Q05-320.
The display changes. Make sure that the chain 5 NVM parameters for the detection of the size of paper are correct.
Y N Refer to dC131.
References: DADH PWB, PL 5.10 Item 5.
GP 11 How to Check a Sensor. DADH input tray assembly, PL 5.35 Item 1.
P/J190, DADH PWB.
DADH length sensor 2, PL 5.35 Item 8.
Open the DADH top cover. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-
330. Activate Q05-330. The display changes.
Y N
A
DADH width
sensor
Q05-325
DADH registration
sensor Q05-340
Arm
DADH width
guides
DADH feed sensor DADH length sensor 1 DADH length sensor 2

Q05-330 Q05-315 Q05-320


A B
06-020 ROS Motor Failure RAP Go to Flag 1. Check the following voltages at P/J18 on the LVPS:
06-020. This fault code has two failure modes. +24V between pins 1 and 2.
1. The ROS motor ready signal was not received by the IOT PWB within the set time of the +3.3V between pins 3 and 4.
ROS being powered on. The voltages are good.
Y N
2. The IOT PWB recognizes a change of state of the ROS motor ready signal during opera-
Go to the relevant RAP:
tion.
01B 0V Distribution RAP, refer to the 3.3V return and 24V return.
Initial Actions
WARNING
Enter the dC330 output code 06-020 to run the ROS motor. Go to Flag 2. 0V is avail-
able at P/J2 pin 1 on the IOT PWB.
Y N
Go to Flag 3. 0V is available at P/J2 pin 6 on the IOT PWB.
Y N
Avoid exposure to laser beam. Invisible laser radiation.
Figure 1. Check that the harness connector at PJ2 on the IOT PWB is fully inserted. NOTE: The ROS must be removed from the machine, REP 6.1, to disconnect P/
Figure 1. Check that the harness connector at PJ121 on the ROS is fully inserted. J120 and P/J121. The ROS PWB where P/J120 and P/J121 are connected may
not be marked with the correct PJ numbers. P/J120 can be identified as a four way
power harness. P/J121 can be identified as a seven way signal harness.
Procedure
Go to Flag 1, Flag 2 and Flag 3. Disconnect P/J120 and P/J121 and check the wir-
ing. The wiring is good.
Y N
Repair the wiring.
Install a new ROS, PL 6.10 Item 4.
Go to Flag 2. 0V is available at P/J2 pin 1.

Y N
NOTE: The ROS must be removed from the machine, REP 6.1, to disconnect P/J120
and P/J121. The ROS PWB where P/J120 and P/J121 are connected may not be
marked with the correct PJ numbers. P/J120 can be identified as a four way power har-
ness. P/J121 can be identified as a seven way signal harness.
Switch off the machine, then switch on the machine, GP 14. The 06-020 fault still exists. Check the continuity of the seven way signal harness between P/J2 and P/J121. The
Y N harness is good.
Perform SCP 6 Final Actions. Y N
Install a new ROS power distribution/communication harness, PL 6.10 Item 5.
Enter the dC330 output code 06-020 and listen for the ROS motor. The ROS motor gives a
distinctive ascending frequency sound, of a short duration (5 to 6 seconds) during tran- Install a new ROS, PL 6.10 Item 4.
sition from standby to run.
Y N If the fault condition persists, perform the following:
The xerographic module is fully home and the front door is fully closed or the front Check the condition of the associated wiring and connectors. Repair the wiring or install
door interlock is cheated. new components as necessary.
Y N
Correct the condition. If necessary go to the 01-300 Front Door Open RAP.
A B

Install a new ROS, PL 6.10 Item 4.
P/J121
P/J120
ROS P/J2 (harness) P/J18 (harness)

A B
06-340 ROS Laser Failure RAP Enter the dC330 output code 06-020. Go to Flag 2. The ROS motor gives a distinctive
ascending frequency sound, of a short duration (5 to 6 seconds) during transition
06-340. The IOT PWB has not detected the ROS laser reaching the operating speed.
from standby to run.
Y N
Procedure Go to the 06-020 ROS Motor Failure RAP.
NOTE: The ROS must be removed from the machine, REP 6.1, to disconnect P/J122
WARNING and P/J121. The ROS PWB where P/J122 and P/J121 are connected may not be
Ensure that the electricity to the machine is switched off while performing tasks that do marked with the correct PJ numbers. P/J122 can be identified as a four way power har-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause ness. P/J121 can be identified as a seven way signal harness.
Check the wiring at Flag 1, Flag 2 and Flag 3. The wiring is good.
Y N
Repair the wiring or install new harness, PL 6.10 Item 5.
WARNING
Avoid exposure to laser beam. Invisible laser radiation. Install a new ROS, PL 6.10 Item 4.
Go to Flag 4. Check P/J113 on the single board controller PWB is securely connected. If the
fault is still present, remove the ROS, REP 6.1. Go to Flag 4. Ensure that PJ122 on the ROS is
securely connected. If the fault is still present, go to Flag 4 and check the continuity of the ROS
data cable ( P/J113 to P/J122). The ROS data cable is good.
Y N
Install a new ROS power distribution/communications harness, PL 6.10 Item 5.
Install new parts in the following order:

2.
P/J121
Go to Flag 3. Connect a service meter to P/J2 pin 7 and make a set of 5 copies. 0V is mea-
P/J122
sured at P/J2 pin 7 on the IOT PWB during run.
Y N
The xerographic module is fully home and the front door is fully closed or the front
door interlock is cheated.
Y N
Correct the condition.
Go to Flag 1. Disconnect P/J18 from the LVPS. Check the following voltages on the
LVPS:
+24V between pins 1 and 2.
+3.3V between pins 3 and 4. P/J120
The voltages are good.
Y N
Go to the relevant RAP:
01B 0V Distribution RAP, refer to the 3.3V return and 24V return.
01D +3.3V Distribution RAP. P/J2 (harness) P/J18 (harness)
ROS
A B


06-350 ROS Laser Not Under Control RAP
06-350. The IOT monitor has not received a reset command from the IOT ROS controller for
more than 5 seconds during print.
Procedure
Perform the 03-395, 396, 852, 853 IOT PWB Faults RAP.

07-301 Tray 1 Open During Run RAP
07-301 Tray 1 was opened during run when the paper is fed from tray 1.
Initial Actions
WARNING
Ensure the tray is pushed fully home, Figure 1.
Check for obstructions behind the tray.
Procedure
Enter dC330 code 07-301 tray 1 home switch, S07-301. Press Start. Open and fully close the
tray. The display changes.
Y N
Go to Flag 1. Check S07-301. Refer to:
GP 13 How to Check a Switch. Tray 1 and 2
Tray 1 home (H) +5V. Check at the switch terminal on the PWB, Figure 2. control PWB
Tray 1 and 2 control PWB, PL 7.10 Item 2. Tray home Tray 1 home switch
actuator cam (top switch) S07-301
Check the paper size leaf spring is mounted correctly, PL 7.10 Item 3. Figure 1 Component location
If TAG 101 has not been struck then install a paper feed module frame repair kit, PL 31.14
Item 4.
Check the actuator cam on the paper tray, Figure 1.
If the problem continues, install new Tray 1 and 2 control PWB, PL 7.10 Item 2.

Check the voltage at the
switch terminal
Tray 1 home switch
Figure 3 Tray 1 circuit diagram
Figure 2 Tray 1 home switch test point

07-302 Tray 2 Open During Run RAP
07-302 Tray 2 was opened during run when the paper is fed from tray 2.
Initial Actions
WARNING
Ensure that the tray is pushed fully home, Figure 1.
Procedure
Y N
GP 13 How to Check a Switch. Tray 1 and 2
Tray 1 home (H) +5V. Check at the switch terminal on the PWB, Figure 2. control PWB
Tray 1 and 2 control PWB, PL 7.10 Item 2. Tray home Tray 2 home switch
actuator cam (top switch) S07-302
Check the paper size leaf spring is mounted correctly, PL 7.10 Item 3. Figure 1 Component location
If TAG 101 has not been struck then install a paper feed module frame repair kit, PL 31.14
Item 4.
Check the actuator on the paper tray, Figure 1.
If the problem continues, install new Tray 1 and 2 control PWB, PL 7.10 Item 2.

Check the voltage at the switch
terminal
Tray 2 home switch Figure 3 Tray 2 circuit diagram
Figure 2 Home switch test point

07-303 Tray 3 Open During Run Entry RAP 07-303A Tray 3 Open During Run RAP (W/O TAG 151)
07-303 Tray 3 open during run when the paper is fed from tray 3. Initial Actions
Procedure
Go to the relevant procedure: WARNING
(W/O TAG 151) go to the 07-303A Tray 3 Open During Run RAP (W/O TAG 151). Ensure that the electricity to the machine is switched off while performing tasks that do
(W/TAG 151) go to the 07-303B Tray 3 Open During Run RAP (W/TAG 151). not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
303 Tray 3 Open During Run Entry RAP.
Ensure that the tray is pushed fully home.
Check the switch actuator, Figure 1.
Procedure
Y N
P/J392, HCF control PWB.
Tray 3 home switch, PL 7.20 Item 4.
HCF control PWB, PL 7.20 Item 2.
Check the switch holder, PL 7.20 Item 3.

If the problem continues, install new components as necessary:

Xerox WorkCentre 5790 Family 2-155 07-303, 07-303A
Tray 3 home
switch
S07-303
Switch actuator

07-303A 2-156 Xerox WorkCentre 5790 Family
07-303B Tray 3 Open During Run RAP (W/TAG 151)
Initial Actions
WARNING Sensor flag

Check the sensor flag, Figure 1.
Procedure
Enter dC330 code 07-303 tray 3 home sensor, Q07-303. Press Start. Open and fully close the
Tray 3 home sensor Q07-303
Y N
Tray 3 home sensor, PL 7.21 Item 4.
Check the sensor holder, PL 7.21 Item 3.


Xerox WorkCentre 5790 Family 2-157 07-303B
07-304 Tray 4 Open During Run Entry RAP 07-304A Tray 4 Open During Run RAP (W/O TAG 151)
07-304 Tray 4 open during run when the paper is fed from tray 4. Initial Actions
Procedure
(W/O TAG 151) go to the 07-304A Tray 4 Open During Run RAP (W/O TAG 151). Ensure that the electricity to the machine is switched off while performing tasks that do
(W/TAG 151) go to the 07-304B Tray 4 Open During Run RAP (W/TAG 151). not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Procedure
Y N
Check the switch holder, PL 7.20 Item 3.


07-304, 07-304A 2-158 Xerox WorkCentre 5790 Family
Tray 4 home
switch
S07-304
Switch actuator

Xerox WorkCentre 5790 Family 2-159 07-304A
07-304B Tray 4 Open During Run RAP (W/TAG 151)
Initial Actions
WARNING
death or injury. Moving parts can cause injury. Sensor flag
Check the sensor flag, Figure 1.
Tray 4 home
Procedure sensor S07-304
Enter dC330 code 07-304 tray 4 home sensor, Q07-304. Press Start. Open and fully close the
Y N
P/J1 HCF control PWB.
Check the sensor holder, PL 7.21 Item 3.


07-304B 2-160 Xerox WorkCentre 5790 Family
07-306 Tray 5 Door Open During Run RAP
07-306 Tray 5 door open during run when the paper is fed from tray 5.
Initial Actions
WARNING
Ensure that the door is pushed fully home.
Tray 5 door
Procedure switch
Switch
S07-306
Enter dC330 code 07-306 tray 5 door switch, S07-306 Press Start. Open and fully close the actuator
door The display changes.
Y N
GP 13 How to Check a Switch. Figure 1 Component location
01E +5V Distribution RAP
P/J507, Tray 5 control PWB.
Tray 5 door switch, PL 7.60 Item 6.

Tray 5 door switch, PL 7.60 Item 6

A
07-353 Tray 1 Elevator Lift Failure RAP Perform the following:
Check the feeder / elevator motor drive gears, Figure 1.
07-353 Tray 1 stack height sensor did not actuate within the correct time after the feed / eleva-
Check the tray 1 stack height mechanism on the feeder assembly,
tor motor turned on.
If the fault still occurs then go to 07A Tray 1 and Tray 2 Empty RAP.
Initial Actions
WARNING
Check the stack height mechanism actuator on the back of the tray, Figure 1.
Check the drive gears and coupling on the tray.
Check the elevator drive coupling on the feeder assembly.
Procedure
Enter dC330 code 07-336 tray 1 stack height sensor, Q07-336. Press Start. Pull out tray 1 and
push fully home. The display changes
Y N
Stack height
GP 11 How to Check a Sensor. mechanism
P/J274, Tray 1 and 2 control PWB actuator
Tray 1 stack height sensor, PL 8.26 Item 8. Drive gears

CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
out before MOT07-010 is run in diagnostics.
Enter dC330 code 07-010 tray 1 feed / elevator motor, MOT07-010. Pull out tray 1. Press
Start. The motor runs
Y N
Go to Flag 2. Check MOT07-010. Refer to:
P/J274, Tray 1 and 2 control PWB.
Tray 1 Feed / elevator motor, PL 8.26 Item 8.
A
07-354 Tray 2 Elevator Lift Failure RAP
07-354 Tray 2 stack height sensor did not actuate within the correct time after the feed / eleva-
tor motor turned on.
Initial Actions
WARNING
Check the stack height mechanism actuator on the back of the tray, Figure 1.
Check the drive gears and coupling on the tray.
Check the elevator drive coupling on the feeder assembly.
Procedure
push fully home. The display changes
Y N
Tray 2 stack height sensor, PL 8.26 Item 8.
CAUTION
Enter dC330 code 07-020 tray 2 feed / elevator motor, MOT07-020. Pull out tray 2. Press
Start. The motor runs
Y N
Figure 2 Circuit diagram Install new components as necessary:
Tray 2 Feed / elevator motor, PL 8.26 Item 6.
A

A
Check the feeder / elevator motor drive gears, Figure 1.
Check the tray 2 stack height mechanism on the feeder assembly,
If the fault still occurs then go to 07A Tray 1 and Tray 2 Empty RAP.
Stack height
mechanism
actuator
Drive gears

07-355 Tray 3 Elevator Lift Failure Entry RAP 07-355A Tray 3 Elevator Lift Failure RAP (W/O TAG 151)
07-355 Tray 3 stack height sensor does not actuate within the correct time after the elevator Initial Actions
motor turned on.
NOTE: Rapid closure of tray 4 when tray 3 is being elevated may cause this fault. WARNING
Procedure Ensure that the electricity to the machine is switched off while performing tasks that do
Go to the relevant procedure:
(W/O TAG 151) go to the 07-355A Tray 3 Elevator Lift Failure RAP (W/O TAG 151).
Make sure that the correct RAP is used. To identify the correct RAP to use go to the 07-
(W/TAG 151) go to the 07-355B Tray 3 Elevator Lift Failure RAP (W/TAG 151). 355 Tray 3 Elevator Lift Failure Entry RAP.
Check that the tray elevator cables and mechanisms are located correctly.
Check the tray 3 home switch, Figure 1.
If the tray only elevates up by 25mm (1 inch) and stops. Go to 07E RAP and check the
tray empty actuator.
Procedure
Enter dC330 code 07-303 tray 3 home switch, S07-303. Press Start. Pull out the tray and push
back in. The display changes.
Y N
manually activate the stack height sensor on the paper feed assembly. The display changes
Y N
Tray 3 stack height sensor, PL 8.30 Item 21
Disconnect P/J396 on the HCF control PWB, Flag 3. Connect a service meter between pin 1
and pin 3 on the wiring side of the connector. Continuity is measured when the switch is
deactivated and open circuit is measured when the switch is actuated.

Y N
Tray 3 paper feeder, PL 8.30 Item 2.
Stack limit switch
HCF control PWB, PL 7.20 Item 2. S07-393
Stack height sensor

CAUTION Q07-383
Enter dC330 code 07-030 tray 3 elevator motor, MOT07-030. Pull out tray 3. Press Start. The
motor runs
Y N
Tray 3 elevator motor, PL 7.20 Item 1.

Check elevator cables, PL 7.15 Item 4, PL 7.15 Item 6, PL 7.15 Item 7.
Check elevator motor drive coupling, PL 7.20 Item 1.
Tray 3 feed sensor
Check tray elevator drive gears and drive coupling, PL 7.15. Q08-103
Check the tray 3 empty sensor actuator, PL 8.30 Item 1.
If the fault still occurs go to 07E Tray 3 or Tray 4 Out of Paper RAP.
HCF control PWB
Tray 3 elevator Tray 3 home switch
MOT07-030 S07-303 Tray 3 feed assembly

07-355B Tray 3 Elevator Lift Failure RAP (W/TAG 151)
Initial Actions
WARNING
355 Tray 3 Elevator Lift Failure Entry RAP.
Procedure
Enter dC330 code 07-303 tray 3 home sensor, Q07-303. Press Start. Pull out the tray and push
Y N
manually activate the stack height sensor on the paper feed assembly. The display changes
Y N
and pin 2 on the wiring side of the connector. Continuity is measured when the stack limit
switch is deactuated and open circuit is measured when the switch is actuated.
Y N
Figure 2 Circuit diagram Go to Flag 3. Check the stack limit switch. Refer to:
A

Xerox WorkCentre 5790 Family 2-167 07-355A, 07-355B
A
Tray 3 over elevate switch, PL 8.32 Item 9.
CAUTION
Re-connect P/J10. Enter dC330 code 07-030 tray 3 elevator motor, MOT07-030. Pull out tray
3. Press Start. The motor runs
Y N
Go to Flag 4. Check MOT07-030. Refer to: Tray 3 feed
GP 10 How to Check a Motor. assembly
Tray 3 elevator motor, PL 7.21 Item 1. Tray 3 stack height
HCF control PWB, PL 7.21 Item 2. sensor Q07-383

Check the elevator cables, PL 7.18 Item 4, PL 7.18 Item 6, PL 7.18 Item 8. Tray 3 over
Check the elevator drives gear coupling, PL 7.19 Item 10. elevate switch
If the fault still occurs go to 07E Tray 3 or Tray 4 Out of Paper RAP.

Tray 3 feed
assembly
HCF control PWB
Tray 3 home
sensor Q07-303
Tray 3 elevator
MOT07-030

07-360 Tray 4 Elevator Lift Failure Entry RAP 07-360A Tray 4 Elevator Lift Failure RAP (W/O TAG 151)
07-360 Tray 4 stack height sensor does not actuate within 7 seconds after the elevator motor is Initial Actions
turned on.
NOTE: Rapid closure of tray 3 when tray 4 is being elevated may cause this fault. WARNING
(W/O TAG 151) go to the 07-360A Tray 4 Elevator Lift Failure RAP (W/O TAG 151).
(W/TAG 151) go to the 07-360B Tray 4 Elevator Lift Failure RAP (W/TAG 151).
CAUTION
Failure of the tray 4 feed motor, MOT 08-840 can cause damage the 24V circuit of the HCF
Control PWB. Before replacing a HCF Control PWB ensure the tray 4 feed motor is opera-
tional.
Check the tray 4 feed motor, MOT08-840. Go to 08-104, 08-114 Tray 4 Misfeed RAP.
If the tray only elevates up by 25mm (1 inch) and stops. Go to 07E RAP and check the
tray empty actuator.
Procedure
Enter dC330 code 07-304 tray 4 home switch, S07-304. Press Start. Pull out the tray and push
Y N
Enter dC330 code 07-384 tray 4 stack height Sensor, Q07-384. Press Start. Pull out tray 4 and
manually actuate the stack height sensor on the paper feed assembly. The display changes.
Y N
A
A
Go to P/J398 pin 6 on the HCF control PWB, Flag 4. Manually activate the tray 4 stack limit
switch (S07-394) on the paper feed assembly. The voltage changes.
Y N
GP 13 How to Check a Switch. Tray 4 feed
assembly
P/J398, HCF control PWB. Stack limit switch
01G +24V Distribution RAP. S07-394
01B 0V Distribution RAP. Stack height sensor
Install new components as necessary: Q07-384
Tray 4 paper feeder, PL 8.31 Item 4.
CAUTION
motor runs.
Y N

Check elevator cables, PL 7.15 Item 4, PL 7.15 Item 5, PL 7.15 Item 7.
Check elevator motor drive coupling, PL 7.20 Item 1.
Tray 4 elevator motor
Check elevator drive gears and drive coupling, PL 7.15. MOT07-040
Tray 4 home switch
Check the tray 4 empty sensor actuator, PL 8.31 Item 1. HCF control PWB S07-304
If the fault still occurs then go to 07E Tray 3 or Tray 4 Out of Paper RAP.

07-360B Tray 4 Elevator Lift Failure RAP (W/TAG 151)
Initial Actions
WARNING
CAUTION
Failure of the tray 4 feed motor, MOT 08-840 can cause damage the 24V circuit of the HCF
Control PWB. Before replacing a HCF Control PWB ensure the tray 4 feed motor is opera-
tional.
Check the tray 4 feed motor, MOT08-840. Go to 08-104, 08-114 Tray 4 Misfeed RAP.
Procedure
Enter dC330 code 07-304 tray 4 home sensor, Q07-304. Press Start. Pull out the tray and push
Y N
Enter dC330 code 07-384 tray 4 stack height Sensor, Q07-384. Press Start. Pull out tray 4 and
manually actuate the stack height sensor on the paper feed assembly. The display changes.
Y N
Figure 2 Tray 4 Circuit diagram
A
07-360A, 07-360B 2-172 Xerox WorkCentre 5790 Family
A
and pin 2 on the wiring side of the connector. Continuity is measured when the stack limit
switch is deactuated and open circuit is measured when the switch is actuated.
Y N
Go to Flag 3. Check the stack limit switch. Refer to:
Tray 4 over elevate switch, PL 8.33 Item 9.
CAUTION
out before MOT07-040 is run in diagnostics. Tray 4 feed
assembly
motor runs.
Y N
Stack height
GP 10 How to Check a Motor. sensor Q07-384
01G +24V Distribution RAP. Tray 4 over elevate
01B 0V Distribution RAP. switch S07-394
Tray 4 elevator motor, PL 7.21 Item 1. Figure 1 Component location

Check the elevator cables, PL 7.18 Item 4, PL 7.18 Item 5, PL 7.18 Item 7.
Check elevator drives gear coupling, PL 7.19 Item 10.
If the fault still occurs then go to 07E Tray 3 or Tray 4 Out of Paper RAP.

Tray 4 feed
assembly
Tray 4 elevator
motor MOT07-040
Tray 4 home
sensor Q07-304
HCF control PWB
Figure 3 Tray 4 Circuit diagram

07-372 Tray 5 Undocked During Run RAP
07-372 Tray 5 was undocked during run when the paper is fed from tray 5. Tray 5 docking
switch S07-372
Initial Actions
WARNING
Ensure the tray is pushed fully home, Figure 1.
Check for obstructions between the tray and the machine.
Procedure
Enter dC330 code 07-372 tray 5 docking switch, S07-372. Press Start. Undock and dock tray
5, refer to REP 7.19. The display changes.
Y N
Tray 5 docking switch, PL 7.64 Item 1 Tray 5 docking location pin
Tray 5 control PWB, PL 7.68 Item 8
Check the docking latch on tray 5 is latched onto the machine, Figure 2.
Check the that the rail assembly is located correctly to the machine.

Docking latch
Rail assembly

A B
07-373 Tray 5 Elevator Lift Failure RAP Go to PJ504 pin 4 on the Tray 5 control PWB, Flag 3. Manually activate the tray upper
limit switch (S07-412) on the paper feed assembly. The voltage changes.
07-373 A signal was not detected by the encoder when the elevator motor was driving up.
Y N
Initial Actions GP 13 How to Check a Switch.
P/J504, Tray 5 control PWB
WARNING 01G +24V Distribution RAP.
Ensure that the electricity to the machine is switched off while performing tasks that do 01B 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 5 stack upper limit switch, PL 7.68 Item 12
Check for obstructions behind the tray. Tray 5 control PWB, PL 7.68 Item 8.
Procedure Enter dC330 code 07-406 tray 5 elevator motor encoder sensor, Q07-406. Press Start.
Manually lift the motor to activate the sensor. The display changes
Figure 1. Ensure the cable holder PL 7.68 Item 23 is not trapped behind the elevator motor
Y N
bracket PL 7.68 Item 6. The cable holder is correctly positioned.
Y N
Reposition the cable holder so that it does not become trapped behind the elevator motor GP 11 How to Check a Sensor.
bracket. P/J506, Tray 5 control PWB.
Install new components as necessary: 01E +5V Distribution RAP.
Cable holder PL 7.68 Item 23. 01B 0V Distribution RAP.
Open and close the tray 5 door. The tray moves up.
Elevator motor encoder sensor, PL 7.68 Item 5
Y N
Enter dC330 code 07-306 tray 5 door interlock switch. Press Start. Manually toggle the Tray 5 control PWB, PL 7.68 Item 8
the door interlock switch. The display changes.
Y N Enter dC330 code 07-373 tray 5 elevator motor, MOT07-373. Press Start. The motor
Check the wiring to the switch, REP 1.2. runs
Go to Flag 1. Check S07-306. Refer to: Y N
Tray 5 door interlock switch, PL 7.60 Item 6
Tray 5 elevator motor, PL 7.68 Item 4
Tray 5 control PWB, PL 7.68 Item 8
Enter dC330 code 07-402 tray 5 stack height sensor, Q07-402. Press Start. Manually acti-
vate the stack height sensor on the paper feed assembly. The display changes The tray 5 elevator motor is operating correctly. Perform ADJ 7.6 Tray 5 Stack Height
Y N Sensor and Retard Shield, then perform SCP 6 Final Actions.
The tray 5 elevator motor is operating correctly. Perform ADJ 7.6 Tray 5 Stack Height Sensor
and Retard Shield, then perform SCP 6 Final Actions.
Tray 5 stack height sensor, PL 8.45 Item 7
A B

Stack height sensor
Q07-402
Tray upper
limit switch
S07-412 Tray upper limit
switch actuator
S07-412
Cable holder
Tray 5 elevator Door interlock

motor encoder switch
Q07-406 S07-306
Tray 5 elevator
MOT07-373
Tray 5 control PWB
Figure 1 Component location Figure 2 Component location


A B
07-374 Tray 5 Elevator Lower Failure RAP Go to PJ504 pin 6 on the Tray 5 control PWB, Flag 3. Manually activate the tray 5 down
limit switch (S07-415) on the paper tray, Figure 2. The voltage changes.
07-374 A signal was not detected by the encoder when the elevator motor was driving down.
Y N
Initial Actions GP 13 How to Check a Switch.
WARNING 01G +24V Distribution RAP.
Ensure that the electricity to the machine is switched off while performing tasks that do 01B 0V Distribution RAP.
death or injury. Moving parts can cause injury. Tray 5 down limit switch, PL 7.70 Item 2.
Check for obstructions behind the tray. Tray 5 control PWB, PL 7.68 Item 8.
Procedure Enter dC330 code 07-406 tray 5 elevator motor encoder sensor, Q07-406. Press Start.
Manually lift the motor to activate the sensor. The display changes
Figure 1. Ensure the cable holder PL 7.68 Item 23 is not trapped behind the elevator motor
Y N
bracket PL 7.68 Item 6. The cable holder is correctly positioned.
Y N
Reposition the cable holder so that it does not become trapped behind the elevator motor GP 11 How to Check a Sensor.
bracket. P/J506, Tray 5 control PWB.
Install new components as necessary: 01E +5V Distribution RAP.
Cable holder PL 7.68 Item 23. 01B 0V Distribution RAP.
Open and close the tray 5 door. The tray moves down.
Elevator motor encoder sensor, PL 7.68 Item 5.
Y N
Enter dC330 code 07-306 tray 5 door interlock switch. Press Start. Manually toggle the Tray 5 control PWB, PL 7.68 Item 8.
the door interlock switch. The display changes.
Y N Enter dC330 code 07-373 tray 5 elevator motor, MOT07-373. Press Start. The motor
Check the wiring to the switch and if necessary install a new switch, PL 7.60 Item 6. runs
Go to Flag 1. Check S07-306. Refer to: Y N
Tray 5 door interlock switch, PL 7.60 Item 6.
Enter dC330 code 07-405 tray 5 stack down sensor, Q07-405, Figure 1. Press Start. Man-
ually activate the stack down sensor actuator. The display changes The tray 5 elevator motor is operating correctly.
Y N
Go to Flag 2. Check Q07-405. Refer to: The tray 5 elevator motor is operating correctly.
Tray 5 stack down sensor, PL 7.68 Item 9.
A B
Cable holder
Tray 5 elevator
motor encoder
sensor
Q07-406
Tray 5 elevator
motor
MOT07-373 Tray down limit
switch
S07-415
Located in the paper
tray, press the plate
Tray 5 control under the paper tray
PWB to actuate the
switch.
Stack down sensor

Q07-405


07A Tray 1 and Tray 2 Empty RAP
Use this RAP when the copier display instructs the operator to add paper to the tray that is not
empty.
NOTE: Tray 1 and tray 2 feed mechanisms are identical.
Procedure
WARNING
Pull out the relevant tray.
Enter the relevant code to monitor the tray empty sensor: Tray 1 empty sensor Q07-331
Tray 1 empty sensor, Q07-331. Enter dC330 code 07-331. Press Start. Tray 2 empty sensor Q07- 342
Tray 2 empty sensor, Q07-332. Enter dC330 code 07-332. Press Start.
Manually actuate the tray empty sensor. The display changes. Figure 1 Component location
Y N
Tray 1: Go to Flag 1. Check S07-331. Tray 2: Go to Flag 2. Check Q07-332. Refer to:
Tray 1 P/J274, Tray 1 and 2 control PWB.
Tray 2 P/J275,Tray 1 and 2 control PWB
01E +5 V Distribution RAP.
Install new components as necessary.
Tray 1 empty sensor, Figure 1, PL 8.26 Item 8.
Tray 2 empty sensor, Figure 1, PL 8.26 Item 8.

Check that the sensor is free of paper dust.
Check the paper feed mechanism, PL 8.26 Item 1.

07B Tray 3 and Tray 4 False Low Paper Level Entry RAP
Use this RAP when the copier displays tray 3 or tray 4 is low on paper when the tray is full. The
tray is low on paper message will appear when the tray capacity is at 10%.
The machine measurers the time taken for the tray to elevate after being closed, to determine
the amount of paper remaining in tray 3 or tray 4. This measurement only occurs if the tray has
been open for a minimum of 30 seconds. If the tray is closed within 30 seconds the time-out of
the last known paper level is used and no new timing is calculated.
NOTE: A low paper condition will be declared if the stack is below approximately 190 sheets.
Procedure
07C Tray 3 and Tray 4 False Low Paper Level RAP (W/TAG 151)
07K Tray 3 and Tray 4 False Low Paper Level RAP (W/O TAG 151)

07C Tray 3 and Tray 4 False Low Paper Level RAP (W/TAG
151)
Initial Actions
WARNING
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 07B Tray
3 and Tray 4 False Low Paper Level Entry RAP.
Procedure Tray 4 level encoder

Pull out the relevant tray and allow it to move fully down. Close the tray. The tray moves up.
Y N
P/J2, HCF control PWB
Go to 07-355 Tray 3 Elevator Lift Up Failure RAP.
Tray 3 level encoder
Pull out the tray and load a ream of paper (500 sheets). Wait for 30 seconds before closing the
tray. The message tray is low on paper has changed. Figure 1 Component location
Y N
Tray 3: Go to Flag 1. Check the tray 3 level encoder, Q07-338. Tray 4: Go to Flag 2.
Check the tray 4 level encoder Q07-339. Refer to:
NOTE: In this check place a piece of paper between the sensor. The check is diffi-
cult due to the problem in moving the timing disc.
Figure 1.
The low paper sensor appears to be working correctly. If the customer is only adding small
amounts of paper at a time then the message (Tray is low on paper) will be displayed. If the
tray is filled with 190 sheets or more, the message is cancelled.

07D Bypass Tray RAP
Use this RAP to identify and correct problems when using the bypass tray.
Initial Actions
WARNING
Check the condition of the media used in the bypass tray. Refer to IQ1 and GP 20.
Check that the width guide is touching the edge of the paper, Figure 1.
If there is a width sensing problem, then check that the bypass tray width sensing potenti-
ometer is not damaged, part of input tray assembly, PL 7.30 Item 1.
Procedure
Enter dC330 code 07-335 to bypass tray empty sensor Q07-335. Press Start. Manually actuate
the sensor. The display changes.
Y N
Go to Flag 2.Check Q07-335. Refer to:
P/J10, IOT PWB.
01D +3.3 V Distribution RAP.
Bypass tray empty sensor, PL 7.30 Item 7.
1.10 Item 2.
Go to Flag 1. Monitor the voltage on the IOT PWB at PJ10 pin 1 and move the guide in and
out. The voltage varies from 0V to +3V.
Y N
The width sensor is a potentiometer. The arm on the potentiometer is attached to the
bypass tray side guide. This gives a variable voltage to indicate the paper width set-
ting.
P/J10, IOT PWB.
Bypass tray width sensor, part of input tray assembly, PL 7.30 Item 1.
1.10 Item 2.
Enter dC330 code 08-050 feed solenoid, SOL08-050. Press Start. The solenoid energized.

07C, 07D 2-186 Xerox WorkCentre 5790 Family
Y N
Go to Flag 3. Check SOL08-050. Refer to:
P/J10, IOT PWB.
01G +24 V Distribution RAP.
Feed solenoid, PL 7.30 Item 4.
1.10 Item 2.

Ensure that the customer is not filling the tray above the max fill line.
Clean the feed roll and retard pad with a cloth dampened with water.
If necessary install a new feed roll and retard pad assembly, PL 7.30 Item 21.
Feed solenoid
SOL08-050
PJ636
PJ36
Feed roll
Width sensor Tray empty sensor

guide Q07-350 Q07-335


07E Tray 1 and 2 Wrong Size Paper RAP
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.
Initial Actions
WARNING
Check that the tray paper guides are set up to the edges of the paper.
The guides are located in the slots in the base of the tray if a standard paper size is used.
Check the actuator ribbon on the side of the tray, Figure 1.
Procedure
Check the relevant tray:
Tray 1, Go to Table 1. Compare the paper size in the tray to the size switches actuated.
Tray 2. Go to Table 2. 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 Tray 1 and 2
activate the paper size switch. The display changes. control PWB
Y N
Tray 1: Go to Flag 1. Tray 2: Go to Flag 2. Check the relevant size switch. Refer to:
Tray 1 size switch 1, 2, 3 and 4 at the switch on the PWB, Figure 2.
Tray actuator ribbon Paper size leaf spring
Tray 2 size switch 1, 2, 3 and 4 at the switch on the PWB, Figure 4,

Check the paper tray, PL 7.10 Item 1.
Check the paper size leaf spring, PL 7.10 Item 3.
Go to dC132, perform the copier NVM initialisation.

Size switch 4 test point Table 1 Tray 1 paper size table
Size Size Size Size
switch 4 switch 3 switch 2 switch 1
Paper (S07-314) (S07-313) (S07-312) (S07-311)
Size switch 3 test point
A4 LEF +5V +5V 0V +5V
A4 SEF 0V +5V 0V +5V
A5 LEF 0V 0V 0V +5V
A3 SEF +5V 0V +5V +5V
216 x 315mm SEF 0V +5V +5V 0V
216 x 330mm SEF 0V 0V +5V 0V
Size switch 1 test point 8.5 x 11 LEF 0V +5V 0V 0V
8.5 x 11 SEF 0V 0V +5V +5V
8.5 x 5.5 LEF 0V +5V +5V +5V
11 x 17 SEF +5V 0V +5V 0V
8.5 x 14 SEF +5V +5V 0V 0V
8.5 x 12.4 SEF 0V +5V +5V 0V
8.5 x 13 SEF 0V 0V +5V 0V
Figure 2 Tray 1 size switch test points


Figure 4 Tray 2 size switch test point
Table 2 Tray 2 paper size table

Size Size Size Size
switch 4 switch 3 switch 2 switch 1
Paper (S07-324) (S07-323) (S07-322) (S07-321)
A4 LEF +5V +5V 0V +5V
A4 SEF 0V +5V 0V +5V
A5 LEF 0V 0V 0V +5V

Table 2 Tray 2 paper size table 07F Tray 3 or Tray 4 Out of Paper Entry RAP
Size Size Size Size Use this RAP when the copier display instructs the operator to add paper to a tray that is not
switch 4 switch 3 switch 2 switch 1 empty.
Paper (S07-324) (S07-323) (S07-322) (S07-321)
A3 SEF +5V 0V +5V +5V 07-543 Tray 3 out of service.
216 x 315mm SEF 0V +5V +5V 0V
07-544 Tray 4 out of service.
216 x 330mm SEF 0V 0V +5V 0V
8.5 x 11 LEF 0V +5V 0V 0V The above status codes and messages may be generated if the actuator is missing from the
8.5 x 11 SEF 0V 0V +5V +5V tray empty sensor.
8.5 x 5.5 LEF 0V +5V +5V +5V
11 x 17 SEF +5V 0V +5V 0V Procedure
8.5 x 14 SEF +5V +5V 0V 0V Go to the relevant procedure:
8.5 x 12.4 SEF 0V +5V +5V 0V 07G Tray 3 or Tray 4 Out of Paper RAP (W/TAG 151)
8.5 x 13 SEF 0V 0V +5V 0V 07L Tray 3 or Tray 4 Out of Paper RAP (W/O TAG 151)

Xerox WorkCentre 5790 Family 2-191 07E, 07F
07G Tray 3 or Tray 4 Out of Paper RAP (W/TAG 151) NOTE: Figure 1 shows the tray 3 paper feed assembly. The position of the sensor on the tray 4
paper feed assembly is identical.
Initial Actions
WARNING
NOTE: Tray 3 and tray 4 paper feed assemblies are almost identical.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 07F
Tray 3 or Tray 4 Out of Paper RAP
Check that the feed head drops when the tray is pushed fully home.
Procedure
Enter the relevant code to monitor the tray empty sensor:
Actuate the tray empty sensor with a piece of paper. The display changes.
Y N
Tray 3: Go to Flag 1. Check Q07-333. Tray 4: Go to Flag 2. Check Q07-334. Refer to:
Tray 3 P/J1, HCF control PWB.
01B 0V Distribution RAP. Tray 3 empty sensor Q07-333
Install new components as necessary: Tray 4 empty sensor Q07-334
Tray 3 empty sensor, PL 8.32 Item 6.
Tray 4 empty sensor, PL 8.33 Item 3.
HCF Control PWB, PL 7.21 Item 2.
The fault may be intermittent, check the wiring and connectors between the HCF control PWB
and the sensor.

07H Tray Out of Service RAP
The IOT has detected a fault in the tray and determines that the tray is out of service. The fol-
lowing status codes and messages will be displayed.
Initial Actions
WARNING
Check that the tray is pushed fully home.
Check the feed heads.
Procedure
If tray 1 or tray 2 are out of service. Check the following and install new components as neces-
sary:
Paper tray 1 and 2 assembly, PL 7.10 Item 26.
Paper tray 2 assembly, PL 7.10 Item 27.
Tray 1 and 2 paper feed assembly, PL 8.26 Item 1, PL 8.26 Item 2.
If tray 3 or tray 4 are out of service, go to one of the following RAPs:
07F Tray 3 or Tray 4 Out of Paper RAP (W/O TAG 151).
07G Tray 3 or Tray 4 Out of Paper RAP (W/TAG 151).
If tray 5 is out of service, go to 07J Tray 5 Empty RAP.

Xerox WorkCentre 5790 Family 2-193 07G, 07H
07J Tray 5 Empty RAP
Use this RAP to solve problems associated with the tray 5 empty sensor.
Initial Actions
WARNING
Tray 5 empty
Check that the hole in the tray, directly under the sensor is clear and empty, Figure 1.
sensor Q07-401
Check the sensor for contamination.
Procedure
Enter dC330 code 07-401 tray 5 empty sensor. Press Start.
Manually actuate the tray empty sensor. The display changes.
Y N
Tray 5 empty sensor, PL 8.45 Item 6. Check the hole in
Tray 5 control PWB, PL 7.68 Item 8. the tray is clear
The fault may be intermittent. Perform the steps that follow: Figure 1 Component location
Check the wiring harness for damaged wire, GP 7.
Check that Tray 5 empty sensor is located correctly.

07K Tray 3 and Tray 4 False Low Paper Level RAP (W/O
TAG 151)
Initial Actions
WARNING
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 07B Tray
3 and Tray 4 False Low Paper Level Entry RAP.
Procedure
Pull out the relevant tray and allow it to move fully down. Close the tray. The tray moves up.
Y N
Pull out the tray and load a ream of paper (500 sheets). Wait for 30 seconds before closing the
tray. The message tray is low on paper has changed.
Y N
Tray 3: Go to Flag 1. Check low paper sensor, Q07-343. Tray 4: Go to Flag 2. Check low
paper sensor, Q07-344. Refer to:
NOTE: In this check place a piece of paper between the sensor. The check is diffi-
cult due to the problem in moving the timing disc.
Figure 2 Circuit diagram Figure 1.
The low paper sensor appears to be working correctly. If the customer is only adding small
amounts of paper at a time then the message (Tray is low on paper) will be displayed. If the
tray is filled with 190 sheets or more, the message is cancelled.

Xerox WorkCentre 5790 Family 2-195 07J, 07K
Tray 4 low paper sensor
HCF control PWB
Tray 3 low paper sensor P/J 390

07L Tray 3 or Tray 4 Out of Paper RAP (W/O TAG 151) NOTE: Figure 1 shows the tray 3 paper feed assembly. The position of the sensor on the tray 4
paper feed assembly is identical.
Initial Actions
WARNING
NOTE: Tray 3 and tray 4 paper feed assemblies are almost identical.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 07F
Tray 3 or Tray 4 Out of Paper RAP
Check that the feed head drops when the tray is pushed fully home.
Procedure
Enter the relevant code to monitor the tray empty sensor:
Actuate the tray empty sensor with a piece of paper. The display changes.
Y N
Tray 3: Go to Flag 1. Check Q07-333. Tray 4: Go to Flag 2. Check Q07-334. Refer to: Tray 3 empty sensor Q07-333
GP 11 How to Check a Sensor. Tray 4 empty sensor Q07-334
01E +5V Distribution RAP. Figure 1 Component location
Tray 3 paper feed assembly, PL 8.30 Item 1.
HCF Control PWB, PL 7.21 Item 2.
The fault may be intermittent, check the wiring and connectors between the HCF control PWB
and the sensor.

Xerox WorkCentre 5790 Family 2-197 07L

07L 2-198 Xerox WorkCentre 5790 Family
08-100 Wait Sensor Jam Entry RAP 08-100A Wait Sensor Jam RAP (35-55 ppm)
08-100 The lead edge of the paper failed to actuate the wait sensor within the correct time from Initial Actions
feed sensor 1.
Procedure WARNING
Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps Ensure that the electricity to the machine is switched off while performing tasks that do
that follow: not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
If the speed of the machine is 35-55 ppm, go to 08-100A Wait Sensor RAP (35-55 ppm) Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
If the speed of the machine is 65-90 ppm, go to 08-100B Wait Sensor RAP (65-90 ppm). 100 Wait Sensor Jam Entry.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
Check for obstructions in the paper path.
Check wait sensor actuator, Figure 1.
Check that the left hand door is latched correctly.
Check that the interlock cover has not come loose. PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws.
Make sure the correct paper size is displayed for the size of paper in the tray.
Procedure
NOTE: The front door interlock must be cheated when checking +24V components.
Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.

Manually actuate the wait sensor. The display changes.
Y N
P/J5, IOT PWB.
Wait sensor, PL 8.15 Item 3.
1.10 Item 2.
Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Press Start. Open left hand door and
manually actuate the sensor. The display changes.
Y N

A
Enter dC330 code 08-025 transport roll drives motor, MOT08-025. Press Start. The motor
runs.
Y N
Transport roll drives motor, PL 8.25 Item 5.
The transport rolls rotate.

Y N
Check the drive belt and gears, GP 7, PL 8.25 Item 2, PL 8.25 Item 3.
Transport roll drives motor
Check the following: MOT08-025
The bearing, shaft and rolls on the transport roll assembly, GP 7, PL 8.25 Item 8.
The idler rolls in the left hand door, GP 7, PL 7.30 Item 2.
The transport drive belt, PL 8.25 Item 2.
The transport rolls for wear, PL 8.25 Item 8.
Tray 1 feed sensor

Q08-101
Wait sensor
Q08-100

08-100B Wait Sensor Jam RAP (65-90 ppm)
Initial Actions
WARNING
100 Wait Sensor Jam Entry RAP.
Check that the interlock cover has not come loose. PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws.
Make sure the correct paper size is displayed for the size of paper in the tray.
Procedure
Manually actuate the wait sensor. The display changes.
Y N
P/J16, IOT PWB.
1.10 Item 2.
Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Press Start. Open left hand door and
manually actuate the sensor. The display changes.
Y N

Xerox WorkCentre 5790 Family 2-201 08-100A, 08-100B
A
Enter dC330 code 08-025 transport roll drives motor MOT08-025. Press Start. The motor
runs.
Y N

Y N
Check the drive belt and gears, GP 7, PL 8.25. Transport roll drives motor
MOT08-025
The transport rolls for wear, PL 8.25 Item 8.
Tray 1 feed sensor Wait sensor

Q08-101 Q08-100

08-101 Tray 1 Misfeed RAP
08-101 The lead edge of the paper failed to actuate the tray 1 feed sensor within the correct
time after feeding paper from tray 1.
Initial Actions
WARNING
Check the condition of the paper in tray 1. Refer to IQ1 and GP 20.
Check that the paper guides are set correctly.
Observe the feeder and check for obstructions.
Turn and change the paper in the tray.
Check that the tray elevates to the feed position. Refer to 07-353 Tray 1 Elevator Lift Fail-
ure RAP.
Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
Check for damage to the chamfered edge on the left side of the tray. Repair the damaged
edge or install a new paper tray, PL 7.10 Item 1.
If the paper has excessive curl and is causing the paper to be skewed when fed from the
tray. Install TAG 002 on the paper tray to constrain the effect of the curl.
Check the paper feeder PL 8.26 Item 2 fully descends. If the paper feeder shaft is binding
with the edge of the housing slot, apply plastislip grease to the contact areas.
Procedure
NOTE: To help fault diagnosis, install the tray 1 paper feed assembly in the tray 2 paper feed
assembly position. With tray 1 removed, the operation of the feed assembly can be observed.
Refer to REP 8.1.
Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Figure 1. Press Start. Open the left
hand door and manually actuate the sensor. The display changes.
Y N

Xerox WorkCentre 5790 Family 2-203 08-100B, 08-101
A B
Enter dC330 code 08-025 transport roll drives motor, MOT08-025. Press Start. The motor If necessary install new components, PL 8.26.
runs.
Y N Perform the following:
Go to Flag 2. Check MOT08-025. Refer to: Clean the feed roll using a cloth dampened with water.
GP 10 How to Check a Motor. Check the roll assembly, PL 8.26 Item 3.
P/J273, Tray 1 and 2 control PWB. Check the feed assembly, PL 8.26 Item 1.

Y N
Check the drive belt, pulley and pulley idler, PL 8.25.
CAUTION
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT08-
010 is run in diagnostics.
Enter dC330 code 08-010 tray 1 feed/elevator motor, MOT08-010, Pull out the tray. Press
Start. The feed rolls rotate.
Y N
Remove the feed assembly from the machine. Manually rotate the feed roll shaft. The
drive gears rotate.
Y N
Check the drive gears for damage. If necessary install new components, PL 8.26.
Install the tray 1 feed assembly.

Instal new Components as necessary:
Tray 1 feed/elevator motor, PL 8.26 Item 6.
The nudger roll rotates.

Y N
Check the nudger roll drive belt and drive coupling for damage. If necessary install new
components, PL 8.26.
Remove the paper tray. Manually activate the retard nip split mechanism. The retard roll
moves against the feed roll.
Y N
Check the retard roll drive coupling and mechanism for damage.
B
MOT08-025
Tray 1 feed sensor

Q08-101 Tray 1 and 2 transport rolls

A
08-102 Tray 2 Misfeed RAP 01G +24V Distribution RAP.
08-102 The lead edge of the paper failed to actuate the tray 2 feed sensor within the correct 01B 0V Distribution RAP.
time after feeding paper from tray 2. Install new components as necessary:
Transport roll drives motor PL 8.25 Item 5.
Initial Actions

WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Check the drive belt and gears, GP 7, PL 8.25 Item 2.
CAUTION
Check that the paper guides are set correctly.
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08-
Observe the feeder and check for obstructions.
Turn and change the paper in the tray.
Enter dC330 code 08-020 tray 2 feed/elevator motor, MOT08-020. Pull out the tray. Press
Check that the tray elevates to the feed position. Refer to 07-354 Tray 2 Elevator Lift Fail-
Start. The motor runs.
ure RAP.
Y N
Check that the left hand door is latched correctly. Remove the feed assembly from the machine. Manually rotate the feed roll shaft. The
Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the feed rolls rotate.
right and tighten the two screws Y N
Check for damage to the chamfered edge on the left side of the tray. Repair the damaged Check the drive gears for damage. If necessary install new components, PL 8.26.
edge or install a new paper tray, PL 7.10 Item 1.
If the paper has excessive curl and is causing the paper to be skewed when fed from the Install the tray 2 feed assembly.
tray. Install TAG 002 on the paper tray to constrain the effect of the curl. Go to Flag 3. Check MOT08-020. Refer to:
Check the paper feeder PL 8.26 Item 1 fully descends. If the paper feeder shaft is binding GP 10 How to Check a Motor.
with the edge of the housing slot, apply plastislip grease to the contact areas. P/J275, Tray 1 and 2 control PWB.
Procedure 01E +5V Distribution RAP.
NOTE: The front door interlock must be cheated when checking +24V components. 01G +24V Distribution RAP.
Enter dC330 code 08-102 tray 2 feed sensor, Q08-102. Figure 1. Press Start. Open the left
hand door and manually actuate the sensor. The display changes. Instal new Components as necessary:
Y N Tray 2 feed/elevator motor, PL 8.26 Item 6.
Go to Flag 1.Check Q08-102. Refer to: Tray 1 and 2 control PWB PL 7.10 Item 2.
P/J276, Tray 1 and 2 control PWB. The nudger roll rotates.
Y N
Check the nudger roll drive belt and drive coupling for damage.
01B 0V Distribution RAP. If necessary install new components, PL 8.26.
Tray 2 feed sensor, PL 7.30 Item 24. Remove the paper tray. Manually activate the retard nip split mechanism. The retard roll
Tray 1 and 2 control PWB, PL 7.10 Item 2. moves against the feed roll.
Y N
Enter dC330 code 08-025 transport roll drives motor, MOT08-025. Press Start. The motor Check the retard roll drive coupling and mechanism for damage.
runs. If necessary install new components, PL 8.26.
Y N
Go to Flag 2. Check MOT08-025. Refer to: Perform the following:
GP 10 How to Check a Motor. Clean the feed roll using a cloth dampened with water.
P/J273, Tray 1 and 2 control PWB. Check the feed roll assembly, PL 8.26 Item 3.
Check the feed assembly, PL 8.26 Item 1.
A
MOT08-025
Tray 2 feed sensor


08-103, 08-113 Tray 3 Misfeed Entry RAP 08-103A, 08-113A Tray 3 Misfeed RAP (W/O TAG 151)
08-103 The lead edge of the paper failed to actuate the tray 3 feed sensor within the correct Initial Actions
time after feeding paper from tray 3.
08-113 Tray 3 sensor did not de-actuate within the correct time after the sensor was actuated. WARNING
Procedure not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Go to the relevant procedure: death or injury. Moving parts can cause injury.
(W/TAG 151) go to the 08-103B, 08-113B Tray 3 Misfeed RAP (W/TAG 151). Make sure that the correct RAP is used. To identify the correct RAP to use go to the 08-
(W/O TAG 151) go to the 08-103A, 08-113A Tray 3 Misfeed RAP (W/O TAG 151). 103, 08-113 Tray 3 Misfeed Entry RAP.
Check the tray 3 feed sensor actuator arm, PL 7.15 Item 9.
Check that the spacers are on the paper feed assembly, refer to REP 8.2.
If the misfeed occurs between 15 and 20 paper feeds, then go to 07-355 Tray 3 Elevator
Lift Failure RAP.
Procedure
Remove the rear cover, PL 7.25 Item 1. Locate tray 3 feed sensor, Q08-103. Figure 1.
Enter dC330 code 08-103 tray 3 Feed Sensor, Q08-103. Press Start. Manually block and
unblock the sensor. The display changes.
Y N
Enter dC330 code 08-045 tray 3 and 4 transport motor, MOT08-045. Press Start. The motor
runs.
Y N
Tray 3 and 4 transport motor, PL 8.30 Item 7.

08-103, 08-113, 08-103A, 08-113A 2-208 Xerox WorkCentre 5790 Family
Y N Check the tray 3 corner separation strip for paper cut damage. If necessary, install new
Check the gears and drive belt, GP 7, PL 8.30 Item 8, PL 8.30 Item 9. components, PL 7.15 Item 22.
Check the tray 3 top edge flexure spring for paper cut damage. If necessary, install new
components, PL 7.17 Item 12.
CAUTION If the fault still occurs, check the following, GP 7:
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08- The takeaway roll assembly, PL 8.35 Item 2.
030 is run in diagnostics. The transport roll assembly, PL 8.35 Item 11.
Enter dC330 code 08-030 tray 3 feed motor, MOT08-030. Pull out the tray. Press Start. The The transport roll bearing, PL 8.35 Item 3.
motor runs.
Y N

Clean the feed roll using a cloth dampened with water.
Check the feed roll assembly, PL 8.30 Item 6.
1. Check for TAG 110.
2. If W/O TAG 110, install feed roll kit PL 8.30 Item 20.
3. Strike TAG 110.
NOTE: TAG 110, PL 8.30 Item 20 feed roll kit must be installed to trays 3 and 4 simulta-
neously. Refer to RAP 08-104, RAP 08-114, PL 8.31 Item 10.
Check the tray 3 feed assembly, PL 8.30 Item 1. Refer to REP 8.2 and check the feed
head housing location. Tray 3 feed motor Tray 3 and 4
Check the tray 3 stack height sensor actuator on the feed assembly, PL 8.30. MOT08-030 transport motor
MOT08-045
Check the tray is level.
HCF control Tray 3 feed sensor
1. Remove the tray front cover. PWB Q08-103
2. Elevate the tray to the stack height position.
3. Hold the elevator drive gear and pull out the tray. Check that the tray is level. Figure 1 Component location
4. If the tray is not level then install new elevator cables, PL 7.15 Item 10.
Check the stack height.
1. Remove the front tray cover.
3. Hold the elevator drive gear and pull out the tray.
4. Check that the paper stack does not stop below the separator strips.
Also check in the run mode that the stack does not fall below the separator strips.
5. If the paper stack stops below the separator strips, then install new elevator cables,
PL 7.15 Item 10.

08-103B, 08-113B Tray 3 Misfeed RAP (W/TAG 151)
Initial Actions
WARNING
103, 08-113 Tray 3 Misfeed Entry RAP.
Lift Failure RAP.
Procedure
Locate the tray 3 feed sensor, Q08-103, Figure 2. Enter dC330 code 08-103 tray 3 feed sensor,
Q08-103. Press Start. Manually actuate the sensor using white paper. The display changes.
Y N
Enter dC330 code 08-045 HCF transport motor, MOT08-045, Figure 1. Press Start. The
motor runs.
Y N
P/J6 , HCF control PWB.
HCF transport motor, PL 8.36 Item 13.
Figure 2 Circuit diagram Observe the tray 3 and 4 transport roll, PL 8.32 Item 4 and the takeaway roll assembly, PL 8.36
Item 2. The transport roll and takeaway roll rotate.

08-103A, 08-113A, 08-103B, 08-113B 2-210 Xerox WorkCentre 5790 Family
Y N 2. Remove the tray 3 front cover.
Check the following: 3. Manually elevate the tray to the top of its travel by rotating the elevator cable drum at
Drive coupling, PL 8.36 Item 7. the front of the tray.
Drive belt, PL 8.36 Item 6. 4. At the three locations where the metal paper tray protrudes through the outer plastic
Transport gear pulley, PL 8.36 Item 12. frame of tray 3, check that the top surface of the metal paper tray is the same dis-
tance from the inside top of the slots
5. If the tray is not level, install new elevator cables, PL 7.18 Item 4, PL 7.18 Item 6 and
PL 7.18 Item 8.
CAUTION
Check the tray 3 paper tray guide for paper cut damage. If necessary, install new compo-
nents, PL 7.19 Item 7.
If the fault still occurs, refer to GP 7 and check the following:
Enter dC330 code 08-030 tray 3 feed motor, MOT08-030, Figure 1. Pull out the tray. Press
Start. The motor runs. The takeaway roll assembly, PL 8.36 Item 2.
Y N The idler roll assembly, PL 8.36 Item 8.
Go to Flag 3. Check MOT08-030. Refer to: The tray 3 and 4 transport roll, PL 8.32 Item 4.
GP 10 How to Check a Motor. The idler roll assembly, PL 8.33 Item 2.
Tray 3 feed motor, PL 8.32 Item 11.
HCF control PWB, PL 7.21 Item 2. HCF transport
motor MOT08-045
Locate the tray 3 feed clutch, CL08-033. Figure 2. Enter dC330 code 08-030 tray 3 feed motor,
MOT08-030, stack the code 08-033 tray 3 feed clutch, CL08-033. Pull out tray 3 and observe
the tray 3 feed and nudger rolls. Press Start. The rolls rotate.
Y N
Go to Flag 4. Check CL08-033. Refer to:
Tray 3 paper feed assembly, PL 8.32 Item 1. HCF control PWB Tray 3 feed motor MOT08-030
Clean the feed roll, nudger roll and retard roll using a cloth dampened with water.
Check the feed roll, nudger roll and retard roll for wear. If necessary install a new feed roll
kit (W/TAG 151), PL 31.11.
Perform the following adjustments:
ADJ 8.3 Tray 3 and Tray 4 Retard Roll Pressure (W/Tag 151)
ADJ 8.4 Tray 3 and Tray 4 Nudger Roll Pressure (W/Tag 151)
Check the tray 3 stack height sensor actuator on the feed assembly, PL 8.32 Item 7.
1. Pull out tray 3 and remove all of the paper from the tray.

Tray 3 feed clutch
CL08-033
Tray 3 feed sensor

Q08-103

08-104, 08-114 Tray 4 Misfeed Entry RAP 08-104A, 08-114A Tray 4 Misfeed RAP (W/O TAG 151)
08-104 The lead edge of the paper failed to actuate the tray 4 feed sensor within the correct Initial Actions
time after feeding paper from tray 4 (W/O TAG 151).
08-104 The lead edge of the paper failed to actuate the tray HCF exit sensor within the correct WARNING
time after feeding paper from tray 4 (W/TAG 151).
08-114 Tray 4 sensor did not de-actuate within the correct time after the sensor was actuated
(W/O TAG 151).
08-114 The HCF exit sensor did not de-actuate within the correct time after the sensor was 104, 08-114 Tray 4 Misfeed Entry RAP.
actuated (W/TAG 151). Check the condition of the paper in tray 4. Refer to IQ1 and GP 20.
Check that the paper feed assembly is installed correctly, refer to REP 8.3.
Procedure Ensure that the tray is pushed fully home.
Go to the relevant procedure: If the misfeed occurs between 15 and 20 paper feeds, then go to 07-360 Tray 4 Elevator
(W/O TAG 151) go to the 08-104A, 08-114A Tray 4 Misfeed RAP (W/O TAG 151). Lift Failure RAP.
(W/TAG 151) go to the 08-104B, 08-114B Tray 4 Misfeed RAP (W/TAG 151). Check that the left hand door is latched correctly.
Procedure
Enter dC330 code 08-104 tray 4 feed sensor, Q08-104, Figure 1. Press Start. Pull out tray 4
and manually actuate the sensor. The display changes.
Y N
How to Check a Sensor.
runs.
Y N

Xerox WorkCentre 5790 Family 2-213 08-104, 08-114, 08-104A, 08-114A
A
The transport rolls rotate. 4. Check that the paper stack does not stop below the separator strips.
Y N Also check in the run mode that the stack does not fall below the separator strips.
Check the drive belt and gears, GP 7, PL 8.30 Item 9, PL 8.30 Item 8.
5. If the paper stack stops below the separator strips, then install new elevator cables,
PL 7.15 Item 11.
Check the tray 4 corner separation strip for paper cut damage. If necessary, install new
CAUTION components, PL 7.15 Item 22.
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08- Check the tray 4 top edge flexure spring for paper cut damage. If necessary, install new
040 is run in diagnostics. components, PL 7.17 Item 12.
Enter dC330 code 08-040 tray 4 feed motor, MOT08-040. Pull out the tray. Press Start. The
motor runs. Tray 4 feed sensor
Y N Q08-104
GP 10 How to Check a motor.
Tray 4 feed assembly, PL 8.31 Item 4.

Check the feed roll assembly, PL 8.31 Item 2.
1. Check for TAG 110.
2. If W/O TAG 110, install feed roll kit PL 8.31 Item 10.
3. Strike TAG 110.
NOTE: TAG 110, PL 8.31 Item 10 feed roll kit must be installed to trays 3 and 4 simulta-
neously. Refer to RAP 08-103, RAP 08-113, PL 8.30 Item 20.
Check the tray 4 feed sensor is located correctly and that the flag actuator has free move-
ment. If necessary install a new tray 4 feed sensor, PL 8.31 Item 10. Tray 4 feed motor Tray 3 and 4
MOT08-040 transport motor
Check the tray 4 paper feed assembly, PL 8.31 Item 1. Refer to REP 8.3 replacement pro- MOT08-045
cedure and check the feed head housing location. HCF control PWB
Check that the spacers for tray 3 paper feed assembly have not been installed into tray 4.
Refer to REP 8.2.
Check the tray 4 stack height sensor actuator on the feed assembly, PL 8.31.
1. Remove the tray front cover.
3. Hold the elevator drive gear and pull out the tray. Check that the tray is level.
4. If the tray is not level then install new elevator cables, PL 7.15 Item 11.
Check the stack height.
1. Remove the front tray cover.
3. Hold the elevator drive gear and pull out the tray.

08-104B, 08-114B Tray 4 Misfeed RAP (W/TAG 151)
Initial Actions
WARNING
104, 08-114 Tray 4 Misfeed Entry RAP.
Lift Failure RAP.
Procedure
Enter dC330 code 08-104 tray 4 feed sensor, Q08-104, Figure 2. Press Start. Manually actuate
Y N
Enter dC330 code 08-045 HCF transport motor, MOT08-045. Press Start. The motor runs.
Y N
Figure 2 Circuit diagram HCF transport motor, PL 8.36 Item 13.
Observe the tray 3 and 4 transport roll, PL 8.32 Item 4 and the takeaway roll assembly, PL 8.36
Item 2 The transport roll and takeaway roll rotate.

Xerox WorkCentre 5790 Family 2-215 08-104A, 08-114A, 08-104B, 08-114B
Y N 2. Remove the tray 4 front cover.
Check the following: 3. Manually elevate the tray to the top of its travel by rotating the elevator cable drum at
Drive coupling, PL 8.36 Item 7. the front of the tray.
Drive belt, PL 8.36 Item 6. 4. At the three locations where the metal paper tray protrude through the plastic outer
Transport gear pulley, PL 8.36 Item 12. frame of tray 4, check that the top surface of the metal paper tray is the same dis-
tance from the inside top of the slots.
5. If the tray is not level then install new elevator cables, PL 7.18 Item 4, PL 7.18 Item 5
and PL 7.18 Item 7.
CAUTION
Check the tray 4 paper tray guide for paper cut damage. If necessary, install new compo-
nents, PL 7.19 Item 6.
motor runs.
Y N
HCF transport
P/J5, HCF control PWB. motor
01G +24V Distribution RAP. MOT08-045
Locate the tray 4 feed clutch, CL08-034. Figure 1. Enter dC330 code 08-040 tray 4 feed motor,
MOT08-040, stack the code08-034 tray 4 feed clutch, CL08-034. Pull out tray 4 and observe
Tray 4 feed motor
MOT08-040
Y N
HCF control PWB

Check the feed roll, retard roll and nudger roll for wear, If necessary install a new feed roll
kit (W/TAG 151), PL 31.11.
Perform the following adjustments:
ADJ 8.4 Tray 3 and Tray 4 Nudger Roll Pressure (W/Tag 151)
Check the tray 4 stack height sensor actuator on the feed assembly, PL 8.33.
1. Pull out tray 4 and remove all of the paper from the tray.

Tray 4 feed clutch
Tray 4 feed sensor

Q08-104

A
08-106 Lead Edge Late to Tray 1 Feed Sensor RAP P/J276, Tray 1 and 2 control PWB.
08-106 The lead edge of the paper was late to tray 1 feed sensor when feeding from tray 2. 01E +5V Distribution RAP.
The fault will also occur when feeding from tray 3 or tray 4 providing the trail edge of the sheet 01B 0V Distribution RAP.
has cleared the tray 4 feed sensor. Install new components as necessary:
Initial Actions Tray 1 and 2 control PWB, PL 7.10 Item 2.
Enter dC330 code 08-025 transport roll drives motor, MOT08-025. Press Start. The motor
WARNING runs.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Go to Flag 3. Check MOT08-025. Refer to:
death or injury. Moving parts can cause injury. GP 10 How to Check a Motor.
Check the condition of the paper in tray 2. Refer to IQ1 and GP 20. P/J273, Tray 1 and 2 control PWB.
Check for obstructions in the paper path. 01G +24V Distribution RAP.
Check that the left hand door is latched correctly. 01B 0V Distribution RAP.
Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the Install new components as necessary:
right and tighten the two screws Transport roll drives motor, PL 8.25 Item 5.
Ensure that the tray is pushed fully home. Tray 1 and 2 control PWB, PL 7.10 Item 2.
Ensure that the correct size of paper is displayed.
If intermittent jams are occuring from all trays except the bypass tray, clean the tray 1 feed The transport rolls rotate.
sensor, PL 7.30 Item 24 and the tray 2 feed sensor, PL 7.30 Item 24. Y N
If the jam occurs when feeding from tray 2. Check if the paper has excessive curl and is Check the drive belt and pulleys, PL 8.25 Item 2, PL 8.25 Item 3.
causing the paper to be skewed when fed from the tray. Install TAG 002 on the paper tray
to constrain the effect of the curl. Check the following:
Procedure
NOTE: The front door interlock must be cheated when checking +24V components. If the fault occurs when feeding from tray 3 or tray 4 but not tray 2 then check the position-
Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Press Start. Open the left hand door ing of the tray 3 / 4 transport pinch rolls, PL 8.30 Item 18, and the transport motor bracket,
and manually actuate the sensor, Figure 1. The display changes. PL 8.30 Item 14, REP 8.11.
Y N Install new components as necessary.
Component location, Figure 1.
Enter dC330 code 08-102 tray 2 feed sensor, Q08-102. Press Start. Manually actuate the sen-
sor, Figure 1. The display changes.
Y N
A
MOT08-025
Tray 1 feed sensor

Q08-101
Tray 2 feed sensor

A
08-107 Tray 3 Paper Feed Jam RAP (W/O TAG 151) Perform the following:
08-107 The lead edge of the paper was late to tray 4 feed sensor when feeding from tray 3. Figure 2. Check the tray 3 transport rolls, PL 8.35, PL 8.30.
Go to RAP 08-103, 08-113 Tray 3 Misfeed RAP.
Initial Actions
WARNING
Check for obstructions in tray 3 paper path, Figure 2.
Check the tray 4 feed sensor, Figure 1.
Procedure
Enter dC330 code 08-104 tray 4 feed sensor, Q08-104. Press Start. Manually actuate the tray
4 sensor. The display changes.
Y N
01E +5V Distribution RAP. Tray 4 feed
01B 0V Distribution RAP. sensor
Q08-104
Tray 3 and 4 transport motor
Tray 4 feed sensor, PL 8.31 Item 12. MOT08-045
runs.
Y N

Y N
Figure 2. Check the drive belt and drive coupling, PL 8.30 Item 9.
A
Drives coupling
Drive belt
Tray 3 paper
path rolls
Tray 4 paper
path rolls

08-108 Tray 3 or Tray 4 Paper Feed Jam Entry RAP 08-108A Tray 3 or Tray 4 Paper Feed Jam RAP (W/O TAG
08-108 The lead edge of the paper was late to tray 2 feed sensor when feeding from tray 3 or 151)
tray 4.
Initial Actions
Procedure
(W/O TAG 151 ) go to the 08-108A Tray 3 or Tray 4 Paper Feed Jam RAP (W/O TAG Ensure that the electricity to the machine is switched off while performing tasks that do
151). not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
(W/TAG 151 ) go to the 08-108B Tray 3 or Tray 4 Paper Feed Jam RAP (W/TAG 151). death or injury. Moving parts can cause injury.
108 Tray 3 or Tray 4 Paper Feed Jam Entry RAP.
Check the condition of the paper in tray 3 and tray 4. Refer to IQ1 and GP 20.
Ensure that the left door assembly is pushed fully home.
Procedure
Y N
runs.
Y N
A
A
Y N
Check the gears and drive belt, PL 8.30 Item 8, PL 8.30 Item 9, GP 7.

Check the tray 3 and tray 4 transport rolls, PL 8.30 Item 18, GP 7.
If the fault occurs when feeding from tray 4. Go to RAP 08-104, 08-114 Tray 4 Misfeed
RAP.
If the fault occurs when feeding from tray 3. Check the following, GP 7:
The takeaway roll assembly, PL 8.35 Item 2.
The transport roll assembly, PL 8.35 Item 11.
The transport roll bearing, PL 8.35 Item 3.
Go to RAP 08-103, 08-113 Tray 3 Misfeed RAP
Tray 3 and 4 transport

motor MOT08-045
Tray 2 feed sensor

Q08-102

08-108B Tray 3 or Tray 4 Paper Feed Jam RAP (W/TAG 151)
Initial Actions
WARNING
108 Tray 3 or Tray 4 Paper Feed Jam Entry RAP.
Check the condition of the paper in tray 3 and tray 4. Refer to IQ1 and GP 20.
Ensure that the left door assembly is pushed fully home.
Procedure
Y N
Y N
Figure 2 Circuit diagram P/J6, HCF control PWB.

Y N
Refer to Figure 2. Check the following, install new components as necessary:
A
A
Drive belt, PL 8.36 Item 6.
Drive coupling, PL 8.36 Item 7.
Idler roll assembly, PL 8.36 Item 8.
Tray 3 and 4 transport roll, PL 8.32 Item 4.

If the fault occurs when feeding from tray 3, go to 08-132 Tray 3 Paper Feed Jam RAP
(W/TAG 151).
If the fault occurs when feeding from tray 4, go to 08-133 Tray 4 Paper Feed Jam RAP
(W/TAG 151).
HCF transport motor

MOT08-045
Tray 2 feed sensor

Q08-102

Drive coupling
Drive belt
Takeaway roll
assembly
Idler roll assembly

08-115, 08-117 Tray 5 Misfeed Entry RAP 08-115A, 08-117A Tray 5 Misfeed RAP (35-55 ppm)
08-115 The lead edge of the paper was late to the wait point sensor. Initial Actions
08-117 The lead edge of the paper failed to reach the feed sensor within the correct time after
paper feed. WARNING
Procedure not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps death or injury. Moving parts can cause injury.
that follow: Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
115, 08-117 Tray 5 Misfeed RAP.
If the speed of the machine is 35-55 ppm, go to 08-115A, 08-117A Tray 5 Misfeed RAP
(35-55 ppm)
Check that the left hand door is correctly latched, Figure 2.
If the speed of the machine is 65-90 ppm, go to 08-115B, 08-117B Tray 5 Misfeed RAP
(65-90 ppm). Check that the paper tray is set to the correct paper size.
Check that tray 5 is set to the correct paper configuration. Enter dC131 NVM chain 8, at
location 08-313 Tray 5 Configuration.
Procedure
Y N
Enter dC330 code 08-117 tray 5 feed motor, MOT08-117. Open the door. Press Start. The
motor runs.
Y N
The feed shaft rotates.

A
Y N One way pulley clutch, PL 8.47 Item 4.
Check the drive gears between the motor and the feed shaft. Install new components as Take away roller, PL 8.47 Item 5.
necessary:
Motor drive gear, PL 8.40 Item 5. Enter dC330 code 08-110 T5 wait point sensor, Q08-110. Press Start.
Gear 30T bearing, PL 8.40 Item 21.
NOTE: For trays 1 to 5 the input code 08-100 wait sensor is used to check the operation of the
Gear, PL 8.45 Item 14. wait sensor. In addition tray 5 uses the input code 08-110 T5 wait point sensor, to check the
paper present signal from the IOT PWB to the tray 5 control PWB.
The feed roll rotates
Y N Open the left hand door and manually actuate the wait sensor, Figure 2. The display
Check the one way coupling, feed roll and clutch. Install new components as necessary: changes.
One way coupling, PL 8.45 Item 4. Y N
Clutch, PL 8.45 Item 13. Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.
Manually actuate the wait sensor, Figure 2. The display changes.
Feed roll, PL 8.45 Item 12.
Y N
The nudger roll rotates Go to Flag 2. Check Q08-100. Refer to:
Y N GP 11 How to Check a Sensor.
Check the nudger roll and the one way gear. Check the drive belt between the feed roll P/J5, IOT PWB.
and the nudger roll. Install new components as necessary: 01D +3.3V Distribution RAP.
One way gear, PL 8.45 Item 3.
Nudger roll, PL 8.45 Item 10.
The retard roll rotates Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
PL 1.10 Item 2.
Y N
Check the retard roll, retard clutch and clutch. Install new components as necessary:
Retard clutch, PL 8.47 Item 11. Go to Flag 5. Manually actuate the wait sensor.
Check for a signal change on the IOT PWB at P/J12 pin 10 and on the tray 5 control
Clutch, PL 8.47 Item 7.
PWB at P/J512 pin 5.
Retard roll, PL 8.47 Item 2. Check the wiring between the IOT PWB and the tray 5 control PWB.
Enter dC330 code 08-046 tray 5 transport motor, MOT08-046. Press Start. The motor runs. Tray 5 control PWB, PL 7.68 Item 8.
Y N
1.10 Item 2.
P/J503, Tray 5 control PWB Perform the steps that follow:
01G +24V Distribution RAP. ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield.
01B 0V Distribution RAP. Clean the feed roll using a cloth dampened with water.
Install new components as necessary: Install a new feed, nudger and retard roll, PL 8.45 Item 21.
Tray 5 transport motor, PL 8.40 Item 2.
Run the motor for 30 seconds. The motor runs at a constant speed, without slowing.
Y N
Install a new tray 5 transport motor, PL 8.40 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:
A
Tray 5 feed sensor
Q08-105
Tray 5 feed motor

MOT08-117
Tray 5 transport
motor MOT08-046
Tray 5 control PWB
Left hand door
Wait sensor Q08-100



08-115B, 08-117B Tray 5 Misfeed RAP (65-90 ppm) Y N
Check the drive gears between the motor and the feed shaft. Install new components as
Initial Actions necessary:
Motor drive gear, PL 8.40 Item 5.
Gear 30T bearing, PL 8.40 Item 21.
WARNING
Gear, PL 8.45 Item 14.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause The feed roll rotates
death or injury. Moving parts can cause injury. Y N
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08- Check the one way coupling, feed roll and clutch. Install new components as necessary:
115, 08-117 Tray 5 Misfeed RAP. One way coupling, PL 8.45 Item 4.
Check the condition of the paper in tray 5. Refer to IQ1 and GP 20. Clutch, PL 8.45 Item 13.
Check that the left hand door is correctly latched, Figure 2. Feed roll, PL 8.45 Item 12.
Check that the paper tray is set to the correct paper size.
Check that tray 5 is set to the correct paper configuration. Enter dC131 NVM chain 8, at The nudger roll rotates
location 08-313 Tray 5 Configuration. Y N
Check the nudger roll and the one way gear. Check the drive belt between the feed roll
and the nudger roll. Install new components as necessary:
Procedure One way gear, PL 8.45 Item 3.
NOTE: The front door interlock must be cheated when checking +24V components. Drive belt, PL 8.40 Item 7.
Nudger roll, PL 8.45 Item 10.
The retard roll rotates
Y N
Y N
Check the retard roll, retard clutch and clutch. Install new components as necessary:
GP 11 How to Check a Sensor. Retard clutch, PL 8.47 Item 11.
P/J505, Tray 5 control PWB Idler roll, PL 8.47 Item 7.
01E +5V Distribution RAP. Retard roll, PL 8.47 Item 2.
Install new components as necessary: Enter dC330 code 08-046 tray 5 transport motor, MOT08-046. Press Start. The motor runs.
Tray 5 feed sensor, PL 8.45 Item 6. Y N
Enter dC330 code 08-117 tray 5 feed motor, MOT08-117. Open the door. Press Start. The P/J503, Tray 5 control PWB
motor runs. 01G +24V Distribution RAP.
Y N 01B 0V Distribution RAP.
Tray 5 transport motor, PL 8.40 Item 2.
01B 0V Distribution RAP. Run the motor for 30 seconds. The motor runs at a constant speed, without slowing.
Install new components as necessary: Y N
Tray 5 feed motor, PL 8.40 Item 3. Install a new tray 5 transport motor, PL 8.40 Item 2.
The take away roller rotates.
Y N
The feed shaft rotates.
Check the drive belt and the one way pulley clutch for damage, GP 7. Check the belt ten-
sioner. Install new components as necessary:
A

A
One way pulley clutch, PL 8.47 Item 4.
Take away roller, PL 8.47 Item 5. Tray 5 feed sensor
Q08-105
Enter dC330 code 08-110 T5 wait point sensor, Q08-110. Press Start.
NOTE: For trays 1 to 5 the input code 08-100 wait sensor is used to check the operation of the
wait sensor. In addition tray 5 uses the input code 08-110 T5 wait point sensor, to check the
paper present signal from the IOT PWB to the tray 5 control PWB.
Open the left hand door and manually actuate the wait sensor, Figure 2. The display Tray 5 feed motor
changes. MOT08-117
Y N
Manually actuate the wait sensor, Figure 2. The display changes.
Y N
Tray 5 transport
Go to Flag 2. Check Q08-100. Refer to: motor MOT08-046
P/J16, IOT PWB.
Tray 5 control PWB
PL 1.10 Item 2.
Go to Flag 5. Manually actuate the wait sensor.

Check for a signal change on the IOT PWB at P/J12 pin 10 and on the Tray 5 control
PWB at P/J512 pin 5.
Check the wiring between the IOT PWB and the tray 5 control PWB. Figure 1 Component location
1.10 Item 2.

ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield.
Install a new feed, nudger and retard roll, PL 8.45 Item 21.

Left hand door
Wait sensor
Q08-100


A
08-131 Lead Edge Late to Tray 3 Exit Sensor RAP (W/TAG 151) Locate the tray 3 feed clutch, CL08-033. Figure 1. Enter dC330 code 08-030 tray 3 feed motor,
MOT08-030, stack the code 08-033 tray 3 feed clutch, CL08-033. Pull out tray 3 and observe
08-131 The lead edge of the paper is late to the tray 3 exit sensor.
Y N
Initial Actions Go to Flag 3. Check CL08-033. Refer to:
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 01B 0V Distribution RAP.
death or injury. Moving parts can cause injury. Install new components as necessary:
Check the condition of the paper in tray 3. Refer to IQ1 and GP 20. Tray 3 paper feed assembly, PL 8.32 Item 1.
Ensure that the tray is pushed fully home. HCF control PWB, PL 7.21 Item 2.
If a misfeed occurs between 15 and 20 paper feeds, then go to 07-355 Tray 3 Elevator Lift
Failure RAP. Perform the following:
Procedure Check the feed roll, nudger roll and retard roll for wear. If necessary install a new feed roll
kit (W/TAG 151), PL 31.11.
Locate the tray 3 exit sensor, Q08-109. Figure 2. Enter dC330 code 08-109 tray 3 exit sensor,
Q08-109. Press Start. Manually actuate the sensor using white paper. The display changes.
Y N
P/J19, HCF control PWB. Tray 3 feed
clutch
Tray 3 exit sensor, PL 8.32 Item 6.
CAUTION
HCF control PWB Tray 3 feed motor MOT08-030
motor runs.
Y N

Tray 3 exit sensor
Q08-109

A
08-132 Tray 3 Paper Feed Jam RAP (W/TAG 151) Figure 2, idler roll assembly, PL 8.36 Item 8.
08-132 The lead edge of the paper was late to the HCF exit sensor when feeding from tray 3. Tray 3 and 4 transport roll, PL 8.32 Item 4
Perform the 08-103, 08-113 Tray 3 Misfeed RAP.

Initial Actions
WARNING
Check for obstructions in tray 3 paper path, Figure 2.
Check the HCF exit sensor, Figure 1.
Procedure roll
Enter dC330 code 08-108 HCF exit sensor, Q08-104. Press Start. Manually actuate the HCF
exit sensor. The display changes.
Y N
01B 0V Distribution RAP. HCF exit sensor
HCF transport Q08-108
Install new components as necessary: motor MOT08-045
HCF exit sensor, PL 8.33 Item 3.
Enter dC330 code 08-045 HCF transport motor, MOT08-045. Press Start. The motor runs. Figure 1 Component location
Y N

Y N
Figure 2, drive belt, PL 8.36 Item 6.
Figure 2, drive coupling, PL 8.36 Item 7.
A

Drive coupling
Drive belt
Takeaway roll
assembly
Idler roll assembly

08-133 Tray 4 Paper Feed Jam RAP (W/TAG 151)
08-133 The lead edge of the paper was late to the HCF exit sensor when feeding from tray 4.
Initial Actions
WARNING
Check the HCF exit sensor, Figure 1. roll
Procedure
Enter dC330 code 08-108 HCF exit sensor, Q08-104. Press Start. Manually actuate the HCF
exit sensor. The display changes.
Y N
GP 11 How to Check a Sensor. HCF exit
sensor
P/J3, HCF control PWB. Q08-108
01B 0V Distribution RAP. HCF transport motor MOT08-045
HCF exit sensor, PL 8.33 Item 3. Figure 1 Component location
Y N

Y N
Check the tray 3 and 4 transport roll, PL 8.32 Item 4
Perform the 08-104, 08-114 Tray 4 Misfeed RAP.

08-150, 08-151 Registration Jam Entry RAP
08-150 The lead edge of the paper failed to actuate the registration sensor within the correct
time after the paper was released from the wait point.
08-151 The trail edge of the paper was late to the registration sensor after the registration
clutch, CL08-070 on.
Procedure
Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps
that follow:
If the speed of the machine is 35-55 ppm, go to 08-150A, 08-151A Registration Jam RAP
(35-55 ppm)
If the speed of the machine is 65-90 ppm, go to 08-150B, 08-151B Registration Jam RAP
(65-90 ppm).

A
08-150A, 08-151A Registration Jam RAP (35-55 ppm) Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.
Open the left hand door and manually actuate the wait sensor. The display changes.
Initial Actions Y N
WARNING
P/J5, IOT PWB.
death or injury. Moving parts can cause injury. 01B 0V Distribution RAP.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08- Install new components as necessary:
150, 08-151 Registration Jam Entry RAP. Wait sensor, (35-55 ppm) PL 8.15 Item 3.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Check for obstructions in the paper path. 1.10 Item 2.
Check the registration sensor actuator and the wait sensor actuator, Figure 1. Enter dC330 code 04-010 main drive motor. Press Start. The motor runs.
Check that the left hand door is latched correctly. Y N
Check that the interlock cover has not come loose, PL 7.30 Item 23. Push the cover to the Go to the 04A Main Drive Motor and Photoreceptor Motor RAP.
right and tighten the screws
While the motor is running, add code 08-070 registration clutch, CL08-070. Press Start.
Check that the short paper path assembly latches without excessive force, PL 10.25 Item
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism. NOTE: The registration clutch will switch off after 5 seconds.
If the fault code is 08-151 and two sheets of paper are jammed at the registration rolls. Go
Switch the registration clutch on / off up to 10 times. The jam clearance knob 4c, PL 8.15
to OF8 Multifeed RAP.
Item 10, rotates when the registration clutch is energized.
If the fault code 08-151 occurs from the bypass tray. Go to the 07D Bypass Tray RAP.
Y N
If the power and control assembly has been moved prior to a 08-150. Check that PJ148 is Go to Flag 3. Check CL08-070. Refer to:
pushed fully home on the Main Drives PWB.
Check the transport drive belt.
P/J5, IOT PWB.
Ensure that all connectors on the tray 1 and 2 Control PWB, PL 7.10 Item 2 and on the
IOT PWB, PL 1.10 Item 2 are correctly and securely seated. P/J17, LVPS.
If the fault is 08-150 and the paper is fed from tray 1 or tray 2. Check if the paper has Fuse, PL 1.10 Item 9, GP 7.
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG 01G +24V Distribution RAP.
002 on the paper tray to constrain the effect of the curl. 01B 0V Distribution RAP.
Check for skew, refer to IQ8. Install new components as necessary:
If the fault occurs when feeding from tray 5, perform ADJ 7.6 Tray 5 Stack Height Sensor
Registration clutch, (35-55 ppm) PL 8.15 Item 7.
and Retard Shield.
Procedure 1.10 Item 2.
NOTE: Ensure that the front door interlock is cheated when checking +24V components.
Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Open the left hand door Check the registration transport rolls and registration rolls, (35-55 ppm) PL 8.15 Item 1,
and manually actuate the registration sensor. The display changes. GP 7.
Y N
Check the drives plate on the registration clutch for damage and contamination. Refer to
the replacement procedure in REP 8.5. If necessary, install a new registration clutch, PL
GP 11 How to check a Sensor. 8.15 Item 7.
P/J5, IOT PWB. Check the tray 1 and 2 transport motor, PL 8.25 Item 5. Ensure that the motor runs correctly.
01D +3.3V Distribution RAP. Check the tray 1 and 2 transport roll assemblies, transport drive belt and pulleys, PL 8.25
01B 0V Distribution RAP. Item 2, PL 8.25 Item 3, GP 7. Install new components as necessary.
Install new components as necessary: Install a new tray 1 and 2 control PWB, PL 7.10 Item 2.
Registration sensor, (35-55 ppm) PL 8.15 Item 3. Refer to Figure 2. Make sure PJ44 is securely connected.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL Check the fuser drive gear, PL 4.17 Item 10 for wear. If necessary, install a new fuser
1.10 Item 2. drive gear.
A

Registration rolls
Registration
clutch
CL08-070
Registration sensor
Q08-150 Registration
transport rolls
Left hand door

Wait sensor Q08-100

A
08-150B, 08-151B Registration Jam RAP (65-90 ppm) Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.
Open the left hand door and activate the wait sensor. The display changes.
Initial Actions Y N
WARNING
P/J16, IOT PWB.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08- Install new components as necessary:
150, 08-151 Registration Jam Entry RAP. Wait sensor, PL 7.30 Item 25.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Check for obstructions in the paper path. 1.10 Item 2.
Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the Enter dC330 code 04-010 main drive motor. Press Start. The motor runs.
right and tighten the two screws Y N
Go to the 04A Main Drive Motor and Photoreceptor Motor RAP.
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
While the motor is running, add code 08-070 registration clutch, CL08-070. Press Start.
If the fault code is 08-151 and two sheets of paper are jammed at the registration rolls. Go
to OF8 Multifeed RAP. NOTE: The registration clutch will switch off after 5 seconds.
If the fault code 08-151 occurs from the bypass tray. Go to the 07D Bypass Tray RAP.
Switch the registration clutch on / off up to 10 times. The jam clearance knob 4c, PL 8.17
If the power and control assembly has been moved prior to a 08-150. Check that PJ148 is
Item 10, rotates when the registration clutch is energized.
pushed fully home on the Main Drives PWB.
Y N
Check the transport drive belt. Go to Flag 3. Check CL08-070. Refer to:
Ensure that all connectors on the tray 1 and 2 Control PWB, PL 7.10 Item 2 and on the
IOT PWB, PL 1.10 Item 2 are correctly and securely seated.
P/J5, IOT PWB.
If the fault is 08-150 and the paper is fed from tray 1 or tray 2. Check if the paper has
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG P/J17, LVPS.
002 on the paper tray to constrain the effect of the curl. Fuse, PL 1.10 Item 9, GP 7.
Check for skew, refer to IQ8. 01G +24V Distribution RAP.
If the fault occurs when feeding from tray 5, perform ADJ 7.6 Tray 5 Stack Height Sensor 01B 0V Distribution RAP.
and Retard Shield. Install new components as necessary:
Procedure Registration clutch, (65-90 ppm) PL 8.17 Item 7.
NOTE: Ensure that the front door interlock is cheated when checking +24V components. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Figure 1. Open the left
hand door and activate the registration sensor. The display changes. Perform the following:
Y N
Check the registration transport rolls and registration rolls, (65-90 ppm) PL 8.17 Item 1,
GP 7.
GP 11 How to check a Sensor.
P/J16, IOT PWB. the replacement procedure in REP 8.5. If necessary, install a new registration clutch, PL
01E +5V Distribution RAP. 8.17 Item 7.
01B 0V Distribution RAP. Check the tray 1 and 2 transport motor, PL 8.25 Item 5. Ensure that the motor runs cor-
Install new components as necessary: rectly.
Registration sensor, (65-90 ppm) PL 8.17 Item 3. Check the tray 1 and 2 transport roll assemblies, transport drive belt and pulleys, PL 8.26
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL Item 1, GP 7. Install new components as necessary.
1.10 Item 2. Install a new tray 1 and 2 control PWB, PL 7.10 Item 2.
Refer to Figure 2. Make sure PJ44 is securely connected.
A

Registration
nip rolls
Registration clutch
CL08-070
Registration Registration sensor

transport rolls Q08-150
Left hand door

Wait sensor Q08-100

08-155, 08-156 Bypass Tray Registration Jam Entry RAP 08-155A, 08-156A Bypass Tray Registration Jam RAP (35-
08-155 The lead edge of the paper failed to actuate the registration sensor within the correct 55 ppm)
time after start of feed from the bypass tray.
Initial Actions
08-156 The IOT detects that a sheet fed from the bypass has arrived to early at the registration
sensor.
WARNING
that follow:
If the speed of the machine is 35-55 ppm, go to 08-155A, 08-156A Bypass Tray Registra- 155, 08-156 Bypass Tray Registration Jam Entry RAP.
tion Jam RAP (35-55 ppm) Check the condition of the paper in the bypass tray. Refer to IQ1 and GP 20.
If the speed of the machine is 65-90 ppm, go to 08-155B, 08-156B Bypass Tray Registra- Check for obstructions in the paper path.
tion Jam RAP (65-90 ppm). Check that the left hand door is latched correctly.
If 08-155 is displayed, check the bypass tray empty actuator, 07D Bypass Tray RAP.
Procedure
Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Figure 2. Manually actu-
ate the registration sensor. The display changes.
Y N
P/J5, IOT PWB.
Registration sensor, PL 8.15 Item 3.
1.10 Item 2.
Enter dC330 code 04-010 main drive motor, code 08-070 registration clutch, CL08-070. Press
Start. The jam clearance knob, 4c, PL 8.15 Item 10, rotates.
Y N
P/J5, IOT PWB.
P/J17 LVPS.
Fuse, PL 1.10 Item 9, GP 7.
Enter dC330 code 08-050 feed solenoid, SOL08-050. Press Start. The solenoid energizes.

Y N
Feed roll
GP 12 How to Check a Solenoid or Clutch. drive gear
Figure 1.
P/J10, IOT PWB.
Feed solenoid, PL 7.30 Item 4.
1.10 Item 2.

Check the registration transport rolls and registration nip rolls, Figure 2, PL 8.15 Item 1.
Feed solenoid
If the fault still occurs, check the drives plate on the registration clutch for damage and SOL08-050
contamination. Refer to the replacement procedure in REP 8.5.
Check the idler roll and upper guide on the feed head, Figure 1.
Clean the feed roll and retard pad using a cloth dampened with water.
If necessary install a new feed and retard pad, PL 7.30 Item 21. Feed roll
Bypass tray
Upper guide
and idler rolls

Registration nip rolls
Registration sensor
Q08-150
Registration clutch Registration

CL08-070 transport rolls
Left hand door
Wait sensor Q08-100

08-155B, 08-156B Bypass Tray Registration Jam RAP (65- Y N
90 ppm) GP 12 How to Check a Solenoid or Clutch.
Initial Actions Figure 1.
P/J10, IOT PWB.
WARNING
death or injury. Moving parts can cause injury. Feed solenoid, PL 7.30 Item 4.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08- Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
155, 08-156 Bypass Tray Registration Jam Entry RAP. 1.10 Item 2.
Check the condition of the paper in the bypass tray. Refer to IQ1 and GP 20.
Check the registration transport rolls and registration nip rolls, Figure 2, PL 8.17 Item 1.
If the fault still occurs, check the drives plate on the registration clutch for damage and
Check the idler roll and upper guide on the feed head, Figure 1.
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism. Clean the feed roll and retard pad using a cloth dampened with water.
If 08-155 is displayed, check the bypass tray empty actuator, 07D Bypass Tray RAP. If necessary install a new feed and retard pad, PL 7.30 Item 21.
Procedure
Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Figure 2. Activate the reg-
istration sensor. The display changes.
Y N
P/J16, IOT PWB.
Registration sensor, (65-90 ppm) PL 8.17 Item 3.
1.10 Item 2.
Enter dC330 code 04-010 main drive motor, code 08-070 registration clutch, CL08-070. Press
Start. The jam clearance knob, 4c, PL 8.17 Item 10, rotates.
Y N
P/J5, IOT PWB.
P/J17 LVPS.
Enter dC330 code 08-050 feed solenoid, SOL08-050. Press Start. The solenoid energizes.

Feed roll Registration
drive gear nip rolls
Feed solenoid
SOL08-050
Registration clutch
CL08-070
Registration Registration sensor
Feed roll transport rolls Q08-150
Bypass tray
Left hand door
Upper guide
and idler rolls Wait sensor Q08-100

08-160, 08-161 Duplex Paper Path Jam Entry RAP
08-160 The lead edge of the first sheet of a job fed into the duplex path failed to actuate the
Duplex sensor in the correct time.
08-161 The trail edge is late to the duplex sensor after of the first sheet of a job fed into the
duplex path failed to actuate the duplex sensor in the correct time.
Procedure
that follow:
If the speed of the machine is 35-55 ppm, go to 08-160A, 08-161A Duplex Paper Path
Jam RAP (35-55 ppm)
If the speed of the machine is 65-90 ppm, go to 08-160B, 08-161B Duplex paper path
Jam RAP (65-90 ppm).

08-155B, 08-156B, 08-160, 08-161 2-250 Xerox WorkCentre 5790 Family
A
08-160A, 08-161A Duplex Paper Path Jam RAP (35-55 ppm) Install new components as necessary:
Duplex motor, (35-55 ppm) PL 8.22 Item 8.
Initial Actions
Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9.
WARNING 1.10 Item 2.
Y N
Check the drive belt and pulleys, (35-55 ppm) PL 8.22 Item 2, PL 8.22 Item 10.
160, 08-161 Duplex Paper Path Jam Entry RAP. Enter dC330 code 10-030 Inverter Motor, 10-030, Figure 1. Press Start. The motor runs.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Y N
Check for paper in the inverter and duplex transport. Go to Flag 3. Check MOT10-030. Refer to:
Check for obstructions in the paper path. GP 10 How to Check a Motor.
If skew occurs when A5 paper is duplexed. Check for contact between the drive rolls and P/J4, IOT PWB.
the nip rolls, (35-55 ppm) PL 8.22 Item 13. P/J45, P/J55.
WARNING
Inverter motor, PL 10.11 Item 11.
Take care during this procedure. Motors will become hot during normal operation.
NOTE: The front door interlock must be cheated when checking +24V components. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Enter dC330 code 08-160 duplex sensor, Q08-160. Press Start. Manually actuate the sensor,
Figure 1. The display changes.
Y N
Y N
Check drive gears, GP 7, PL 10.15.
P/J5, IOT PWB. Enter dC330 code 10-050 inverter nip solenoid, SOL10-050, Figure 1. Press Start. The sole-
01D +3.3V Distribution RAP. noid energizes.
01B 0V Distribution RAP. Y N
Duplex sensor, (35-55 ppm) PL 8.22 Item 4.
P/J5, IOT PWB.
1.10 Item 2. P/J17, LVPS.
Enter dC330 code 08-060 duplex motor, MOT08-060, Figure 1. Press Start. The motor runs. 01G +24V Distribution RAP.
Inverter Nip Solenoid, PL 10.11 Item 6.
P/J4, IOT PWB.
P/J50, P/J91, duplex motor driver PWB. 1.10 Item 2.
01E +5V Distribution RAP. Enter dC330 code 10-045 inverter path solenoid, SOL10 045, Figure 1. Press Start. The sole-
01B 0V Distribution RAP. noid energizes.

Y N
GP 12 How to check a Solenoid or Clutch.
P/J5, IOT PWB.
P/J17, LVPS.
Inverter path solenoid, PL 10.11 Item 14.
1.10 Item 2.
Check the following, refer to GP 7:

Duplex nip rolls, (35-55 ppm) PL 8.22 Item 7.
Nip split shaft assembly, PL 10.11 Item 4.
Idler rolls, PL 10.12 Item 15.
Duplex motor
MOT08-060
Inverter nip
solenoid
SOL10-050
Duplex sensor
Q08-160
Inverter motor Inverter path
MOT10-030 solenoid
SOL10-045

Figure 2 Circuit diagram Figure 3 Circuit diagram

A
08-160B, 08-161B Duplex Paper Path Jam RAP (65-90 ppm) Install new components as necessary:
Duplex motor, (65-90 ppm) PL 8.20 Item 8.
Initial Actions
Duplex motor driver PWB, (65-90 ppm) PL 8.20 Item 9.
WARNING 1.10 Item 2.
Y N
Check the drive belt and pulleys, (65-90 ppm) PL 8.20 Item 2, PL 8.20 Item 10.
160, 08-161 Duplex Paper Path Jam Entry RAP. Enter dC330 code 10-030 Inverter Motor, 10-030, Figure 1. Press Start. The motor runs.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Y N
Check for paper in the inverter and duplex transport. Go to Flag 3. Check MOT10-030. Refer to:
Check for obstructions in the paper path. GP 10 How to Check a Motor.
If skew occurs when A5 paper is duplexed. Check for contact between the drive rolls and P/J4, IOT PWB.
the nip rolls, (65-90 ppm) PL 8.20 Item 14. P/J45, P/J55.
WARNING
NOTE: The front door interlock must be cheated when checking +24V components. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Enter dC330 code 08-160 duplex sensor, Q08-160. Press Start. Activate the sensor, Figure 1.
Y N
Y N
Check drive gears, GP 7, PL 10.15.
P/J5, IOT PWB. Enter dC330 code 10-050 inverter nip solenoid, SOL10-050, Figure 1. Press Start. The sole-
01E +5V Distribution RAP. noid energizes.
01B 0V Distribution RAP. Y N
Duplex sensor, (65-90 ppm) PL 8.20 Item 4.
P/J5, IOT PWB.
1.10 Item 2. P/J17, LVPS.
Enter dC330 code 08-060 duplex motor, MOT08-060, Figure 1. Press Start. The motor runs. 01G +24V Distribution RAP.
Inverter Nip Solenoid, PL 10.11 Item 6.
P/J4, IOT PWB.
P/J50, P/J91, duplex motor driver PWB. 1.10 Item 2.
01E +5V Distribution RAP. Enter dC330 code 10-045 inverter path solenoid, SOL10 045, Figure 1. Press Start. The sole-
01B 0V Distribution RAP. noid energizes.
A
Y N
GP 12 How to check a Solenoid or Clutch.
P/J5, IOT PWB.
P/J17, LVPS.
1.10 Item 2.
Check the following, refer to GP 7:

Duplex nip rolls, (65-90 ppm) PL 8.20 Item 7.
Idler rolls, PL 10.12 Item 15.
Duplex motor
MOT08-060
Inverter nip
solenoid
SOL10-050
Duplex sensor
Q08-160
Inverter motor Inverter path
MOT10-030 solenoid
SOL10-045

Figure 2 Circuit diagram Figure 3 Circuit diagram

08-171 Unexpected Time Out RAP 08-174 Missing Pre-release Sheet RAP
08-171 The IOT detects an unexpected event for a known sheet. A sheet left in the machine 08-174 The IOT detected a missing pre-release sheet.
after jam clearance.
Initial Actions
Initial Actions
WARNING
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. Enter the machine status mode and check for the active messages. Refer to OF4 Status
Enter the machine status mode and check for the active messages. Refer to OF4 Status Codes and Message RAP for the jam clearance procedure.
Codes and Message RAP for the jam clearance procedure. Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
Check the condition of the paper in all trays, Refer to IQ1 and GP 20. Check for obstructions in the registration paper path.
Check for obstructions in the paper path. Make sure that all covers and paper guides are closed, and latch correctly.
Make sure that all covers and paper guides are closed, and latch correctly.
Check for paper in the output device. Procedure
If the initial actions did not resolve the problem. Switch off the machine, then switch on the
Procedure machine, GP 14. If a fault code is displayed then go to the appropriate RAP.
machine, GP 14. If a fault code is displayed then go to the appropriate RAP.

08-180 Unable to Feed Next Sheet RAP 08-181 Unexpected Time Out in Simplex Inverted Mode
08-180 The machine has detected that the previous sheet has not correctly fed through the RAP
paper path.
08-181 The IOT detected an unexpected time out for a known simplex inverted sheet of paper.
WARNING WARNING
death or injury. Moving parts can cause injury. death or injury. Moving parts can cause injury.
Clear the paper path. Enter the machine status mode and check for the active messages. Refer to OF4 Status
Codes and Message RAP for the jam clearance procedure.
Procedure Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
35-55 ppm - Perform the following: Check for obstructions in the simplex and inverted paper path.
Check tray 1 feed sensor, Q80-101. Refer to 08-101 Tray 1 Misfeed RAP. Make sure that all covers and paper guides are closed, and latch correctly.
Check tray 2 feed sensor, Q08-102. Refer to 08-102 Tray 2 Misfeed RAP. Procedure
Install new components as necessary. If the initial actions did not correct the problem, perform the following:
Check the registration sensor, Q08-150 and the wait sensor, Q08-100, refer to 08-150A, Switch off the machine, then switch on the machine, GP 14.
08-151A Registration Jam RAP (35-55 ppm).
If a fault code is displayed then go to the appropriate RAP.
Enter dC330, code 10-045 and check the operation of the inverter gate, PL 10.12 Item 7.
65-90 ppm - Perform the following: It should move freely without binding.
Check tray 1 feed sensor, Q80-101. Refer to 08-101 Tray 1 Misfeed RAP.
Check tray 2 feed sensor, Q08-102. Refer to 08-102 Tray 2 Misfeed RAP.
Check the registration sensor, Q08-150 and the wait sensor, Q08-100, refer to 08-150B,
08-151B Registration Jam RAP (65-90 ppm).

08-182 Unexpected Time Out in Duplex Mode RAP 08-190 Post Jam Clearance Initialization RAP
08-182 The IOT detected an unexpected time out for a known duplex sheet of paper. 08-190 A stray sheet has been detected in either the IOT or finisher device during the post jam
clearance initialization routine.
Initial Actions
Initial Actions
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 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
Enter the machine status mode and check for the active messages. Refer to OF4 Status death or injury. Moving parts can cause injury.
Codes and Message RAP for the jam clearance procedure. Enter the machine status mode and check for the active messages. Refer to OF4 Status
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Codes and Message RAP for the jam clearance procedure.
Check for obstructions in the duplex paper path. Check for paper in the machine paper path at all the sensor locations.
Check for paper in the finisher paper path at all the sensor locations. Use a flashlight to
Procedure check that the hole punch sensor is clear.:
2K LCSS punch sensor, PL 11.6 Item 7.
machine, GP 14. If a fault code is displayed then go to the appropriate RAP. HVF paper edge sensor, PL 11.153 Item 17.
Make sure that all the covers and paper guides are closed, and latched correctly.
Procedure
If the initial actions did not correct the problem. Switch off the machine, then switch on the
machine, GP 14. If a fault code is displayed then go to the appropriate RAP.

09-060 HVPS Fault RAP NOTE: The following are the only values that can be measured from the HVPS.
09-060 The HVPS fault sensor has detected a high voltage fault. Charge scorotron grid, -425V +/- 21V.
The two terminals identified as G are the same output.
The HVPS fault will occur when: Registration chute bias, -490V +/- 25V.
The (C) charge high voltage supply has a short or open circuit. The two terminals identified as CB are the same output.
The (G) charge grid high voltage supply has a short or open circuit. Developer bias, -370V +20V / -50V.
The (T) transfer high voltage supply has a short circuit. NOTE: The charge, transfer and detack corotron have 47k Ohms arc suppression resistors
The (DT) detack high voltage supply has a short circuit. within their harnesses.
The (DB) developer bias high voltage supply has a short circuit.
Check that the surface mounted fuse F1 on the IOT PWB is good. Refer to OF7 IOT PWB
The +24V supply to the HVPS has a short or open circuit. Diagnostics RAP, for the location of the F1 surface mounted fuse. The surface mounted
The 24 volt supply is momentarily overloaded. fuse is good.
The HVPS fault will deactivate within 100 milliseconds after the removal of the fault. Y N
Perform the procedures that follow:
NOTE: The following defects will NOT cause a 09-060 fault: 01G +24V Distribution RAP.
An open circuit or short circuit in the registration chute bias circuit (CB) 01B 0V Distribution RAP.
A poor contact of the registration/halo guide bias 01H Short Circuit and Overload RAP.
An open circuit in the developer bias circuit
An open circuit in the transfer corotron circuit Run the xerographic module cleaning routine from the UI tools menu.
Enter dC330. Select component code 09-060 HVPS fault and press save. Press start. The
An open circuit in the detack corotron circuit
display for code 09-060 is Low.
Initial Actions Y N
+24V is available at the bottom cap of fuse F1 on the IOT PWB.
Y N
WARNING Perform the 01G +24V Distribution RAP to troubleshoot the fault.
Install a new HVPS, PL 1.10 Item 5.
Add Component code 09-061 charge scorotron. Press start. Time out after 3 seconds. The
Switch off the machine, then switch on the machine, GP 14. display for code 09-060 is Low.
Clean the charge scorotron, ADJ 9.1. Y N
Clean the transfer / detack corotron and check the corotron wire, ADJ 9.1. Go to Flag 1. Check the charge scorotron harness for an open circuit or short circuit to
Reseat the high voltage connections on the HVPS, (40-90 ppm) Figure 1, (35 ppm) Figure ground, GP 7. The scorotron harness and connectors are good.
2. Y N
Install a new charge scorotron harness, (35-55 ppm) PL 4.17 Item 18, (65-90 ppm)
Check the registration transport bias contact, PL 8.15 Item 23, Figure 3.
PL 4.12 Item 20.
Check the bias connection, Figure 3.
Reseat the developer bias connection, Figure 4. Install a new xerographic module, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2.
If the machine is above 750 metres above sea level, check the transfer / detack assembly If the fault continues, install a new HVPS, PL 1.10 Item 5.
for arcing. If necessary go to dC131 NVM Read / Write location 09-098 and select the If the fault continues, there is a problem with the charge corotron harness/connector,
appropriate altitude. Install a new main drive module (35-55ppm), PL 4.15 Item 1, (65-90ppm), PL 4.10 Item 1.
Check for any cause of an overload to the 24V supply. For example, very thick multi-feeds
causing the main drive motor to stall. Add component code 09-062 charge grid. Press start. Time out after 3 seconds. The display
for code 09-060 is Low.
Y N
Procedure Go to the Flag 1. Check the charge grid harness for open circuit or short circuit to ground,
If you were directed from IQ8 Defect RAP, continue below. If the following checks do not GP 7. The grid harness and connectors are good.
resolve the image quality problem, return to IQ3 Xerographic RAP. Y N
Install a new charge grid harness, (35-55 ppm) PL 4.17 Item 19, (65-90 ppm) PL
4.12 Item 21.
A B

A B C
Install a new xerographic module, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2. Y N
If the fault continues, install a new HVPS, PL 1.10 Item 5. Repair the harness or install a new developer bias harness, (35-55 ppm) PL 9.17
If the fault continues, there is a problem with the charge corotron harness/connector, Item 6, (65-90 ppm) PL 9.15 Item 6. Secure the harness in position with adhesive
Install a new main drive module (35-55ppm), PL 4.15 Item 1, (65-90ppm), PL 4.10 Item 1. tape to prevent re-occurance of the fault.
Add component code 09-063 transfer corotron. Press start. Time out after 3 seconds. The Install a new HVPS PL 1.10 Item 5.
display for code 09-060 is Low.
Y N Make 10 copies. The 09-060 fault code occurs during making copies.
Go to the Flag 2. Check the transfer corotron harness for short circuit to ground, GP 7. Y N
The transfer corotron harness and connectors are good. Perform SCP 6 Final Actions.
Y N
Install a new transfer / detack harness, (35 ppm) PL 9.22 Item 9, (40-90 ppm) PL The problem may be caused by a +24V component pulling the +24V supply down below the
9.20 Item 9. lower limit of tolerance. Switch off the machine, then switch on the machine, GP 14. Monitor
the +24V interlocked supply at PJ27 pin 1 while copies are being made. The voltage drops
Install a new transfer / detack corotron, (35 ppm) PL 9.22 Item 8, (40-90 ppm) PL 9.20 below +23.28V.
Item 8. Y N
If the fault continues, install a new HVPS PL 1.10 Item 5. Perform SCP 6 Final Actions.
If the fault continues, there is a problem with the charge corotron harness/connector,
Install a new main drive module (35-55ppm), PL 4.15 Item 1, (65-90ppm), PL 4.10 Item 1. Perform the 01H Short Circuit and Overload RAP, check the +24V circuits to find the compo-
nent causing the voltage drop. Repair the fault or install a new component.
Add component code 09-064 detack corotron. Press start. Time out after 3 seconds. The dis-
play for code 09-060 is low. Transfer corotron
Y N connector
Go to Flag 2. Check the detack corotron harness for short circuit to ground, GP 7. The
detack corotron harness and connectors are good.
Y N Detack corotron
Install a new transfer / detack harness, (35 ppm), PL 9.22 Item 9, (40-90), PL 9.20 connector
Item 9.
On the 30 ppm machine, install a new transfer / detack corotron, PL 9.22 Item 8. On the Charge Grid connector. The
40-90 ppm machine, install a new transfer / detack corotron, PL 9.20 Item 8. two terminals identified as
If the fault continues, install a new HVPS PL 1.10 Item 5. G are the same output.
If the fault continues, there is a problem with the charge corotron harness/connector,
Install a new main drive module (35-55ppm), PL 4.15 Item 1, (65-90ppm), PL 4.10 Item 1.
Add component code 09-065 registration chute bias. Press start. Time out after 90 seconds. Charge scorotron
connector
The display for code 09-060 is low.
Y N
Install a new HVPS PL 1.10 Item 5. P/J55
Developer bias
Add component code 09-066 developer bias. Press start. Time out after 3 seconds. The dis- connector
play for code 09-060 is low.
Y N Registration and transfer
The high display indicates that the developer bias harness is shorted to ground. Confirm chute bias connector. The
this diagnosis by disconnecting the developer bias harness from the HVPS and make no two terminals identified as
more than ten copies. If copies can be made without the 09-060 fault occuring, the devel- CB are the same output.
oper bias harness is shorted to ground.
Switch off the machine, GP 14. Remove the input module and scanner. Go to Flag 3.
Check the developer bias harness for short circuit to ground, GP 7. The developer har-
ness and connectors are good.
Figure 1 Component location (40-90 ppm)
C
Transfer corotron
connector Registration guide
Detack corotron
connector
Halo guide
Charge Grid connector. The

two terminals identified as G
are the same output.
Charge scorotron
connector
P/J55
Developer bias
connector
Registration and transfer

chute bias connector. The
two terminals identified as
CB are the same output. Registration chute
bias connection
Bias contact
Figure 2 Component location (35 ppm) Figure 3 Component location

Developer bias connection

09-310, 09-390 Low Toner Sensor Failure RAP The display changes from high to low or low to high.
Y N
09-310 The toner cartridge motor continues to dispense toner for a period greater than 12 sec-
onds after the low toner sensor detects that the toner dispense module is full.
Figure 2.
09-390 The low toner sensor detects that the toner level is low for a period greater than 70 sec- P/J6, IOT PWB.
onds after toner cartridge motor start. 01B 0V Distribution RAP.
Initial Actions 01E +5V Distribution RAP.
Low toner sensor, (35-55 ppm) PL 9.17 Item 5, (65-90 ppm) PL 9.15 Item 5.
WARNING Developer module, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Item 2.
Ensure that the electricity to the machine is switched off while performing tasks that do Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Figure 1. Ensure the toner cartridge is not empty. If the toner cartridge is empty, install a new The fault may be intermittent, due to toner bridging inside the toner cartridge. Install a new
toner cartridge, (35-55 ppm) PL 9.17 Item 4, (65-90 ppm) PL 9.15 Item 4. toner cartridge, (35-55 ppm) PL 9.17 Item 4, (65-90 ppm) PL 9.15 Item 4.
Check the image quality and complete SCP 6 Final Actions.
Procedure
NOTE: The door interlock switch must be cheated when checking +24V components.
NOTE: The toner cartridge motor will time out after 5 seconds.
Cheat the door interlock switch. Enter dC330 code 09-045 toner cartridge motor, MOT09-045.
Press start. Observe the toner cartridge. The toner cartridge rotates.
Y N
The motor runs.
Y N
Figure 2.
P/J6, IOT PWB.
Toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL 9.15 Item
1.
Developer module, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Item 2.
PL 1.10 Item 2.
Check the toner dispense drive gears, Figure 1 and Figure 2.

If necessary install a new toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90
ppm) PL 9.15 Item 1. Toner cartridge PJ93
drive gears Toner cartridge
Enter dC330 code 09-040 toner dispense motor and add the code 09-310 low toner sensor,
Q09-310. Press Start.
NOTE: It may necessary to enter the codes several times to ensure that the toner dispense Figure 1 Component location
motor does actuate and deactuate the low toner sensor. It may be necessary to make several
copies to prevent over toning the developer.

Toner cartridge
drive gears
Toner cartridge motor

MOT 09-045
Toner dispense motor Low toner sensor

MOT 09-040 Q09-310 In-line connector PJ75

A
09-341, 09-342 Scorotron Cleaning Failure RAP The fault may be intermittent, perform the following:
09-341 The scorotron clean ing routine has failed to complete. Check the wiring, GP 7. Repair if necessary, REP 1.2.
Ensure that P/J64 is correctly and securely connected.
09-342 A scorotron cleaning warning detected.
Initial Actions
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Scorotron cleaner
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause motor
Check that the xerographic module is correctly installed.
Check the scorotron cleaner drive coupling, Figure 1.
Make sure that the scorotron cleaner home sensor bracket is correctly aligned.
Procedure
Enter dC330 code 09-071 or 09-072 scorotron cleaner motor. A clicking sound is heard.
Y N
GP 10 How to Check a motor. Drive
P/J64, IOT PWB. coupling
Main drive module, (35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.
1.10 Item 2.
Enter dC330 code 09-070 scorotron cleaner home sensor, Figure 2. Press Start. Enter dC330
code 09-071 or 09-072 scorotron motor. Actuate the sensor by entering the appropriate code.
Y N
NOTE: The scorotron cleaner home sensor is a magnetic reed switch.
P/J64, IOT PWB.

01B 0V Distribution RAP. Scorotron cleaner home sensor
Scorotron cleaner home sensor, (40-55 ppm) PL 4.17 Item 16, (65-90 ppm) PL 4.12
Item 19.
1.10 Item 2.

09-350 Erase Lamp Failure RAP
09-350 The photoreceptor erase lamp has failed.
Procedure
WARNING
NOTE: The xerographic module must be in the machine for the lamp to illuminate.
CAUTION
Do not illuminate the erase lamp for an extended length of time as this may cause damage to
the xerographic drum.
Cheat the door interlock switch. Enter dC330 code 09-022, photoreceptor erase lamp. Press
start. Figure 1. Observe the erase lamp. All the LEDs of the erase lamp are lit.
Y N
Some of the LEDs of the erase lamp are lit.
Y N
Go to Flag 1. +24V is available at P/J17 pin 1 on the LVPS.
Y N
Go to Flag 2. +24V is available at P/J41 pin 1.

Y N
Go to Flag 1. Check the inline fuse. The fuse is good.
Y N
Install a new fuse, GP 7, PL 1.10 Item 9.
If the fuse blows again, perform the 01G +24V Disribution RAP.
Go to:
Go to 01G +24V Distribution RAP.
Go to Flag 3. +13V is available at P/J5 pin 14.

Figure 2 Circuit diagram Y N
NOTE: To gain access to the erase lamp wiring, remove the main drive module,
(35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.
Check the wiring, GP 7, from the in-line fuse to P/J41, pin 2. The wiring is
good.
Y N
Repair the wiring.
A B C D
A B C D
Check that the connector PJ41 is located correctly in the IOT frame, Fig-
ure 1.
Install a new erase lamp, (35 ppm) PL 9.22 Item 1, (40-90 ppm) PL 9.20
Item 1.
1.10 Item 2.
Install a new erase lamp, (35 ppm) PL 9.22 Item 1, (40-90 ppm) PL 9.20 Item 1.
The fault may be intermittent. Perform the steps that follow:

Check the wiring, GP 7 between P/J41 and P/J17 on the LVPS.
Ensure that the P/Js are correctly and securely connected.
Malfunction of the following associated circuits can cause 09-350 faults.
P/J41 Erase lamp
The inverter paper path and Inverter nip solenoid, go to 10-120, 10-121, 10-126 IOT
Exit Sensor RAP.
The vacuum transport fan and Registration clutch, go to 10-101A, 10-102A, 10-103A
Lead Edge Late to Fuser Exit Sensor RAP.
Erase lamp

09-360, 09-361, 09-362, 09-363 Toner Concentration Sensor
Failure RAP
09-360 The toner concentration sensor has registered a reading outside the range, +0.75V to
+4.55V for three consecutive sheets.
09-361 The toner concentration sensor is reading high. This indicates that the toner concentra-
tion (TC) is low.
09-362 The toner concentration sensor is reading low. This indicates that the toner concentra-
tion (TC) is high.
09-363 This code is generated by the following factors:

The developer is not positioned correctly against the xerographic module.
The toner concentration is low.
The machine is being installed.
On the fifth consecutive occurrence.
GUI message - TONER CONTROL FAILURE
Initial Actions
WARNING
Check developer roll area for toner and bead contamination. If necessary, go to IQ1
Image Quality Entry RAP.
If 09-360 fault, enter dC131 location 09-115, sensor failure lockout flag. Check that it is
set to 0. If set at 1 the toner dispense motor will not run.
If 09-361 fault, enter dC131 location 09-001 TC lockout low. Check that it is set to 0. If
set at 1 the toner dispense motor will not run.
Check that when the xerographic module latch is in the locked position, the devel-
oper module is correctly installed, REP 9.2.
If 09-362 fault, enter dC131 location 09-276 TC lockout high. Check that it is set to 0. If
set at 1 the toner dispense motor will not run
Figure 2 Circuit diagram Initial Procedure

Make 20 prints. If the following three conditions apply, go to the 09-310, 09-390 Low Toner
Sensor Failure RAP. If not continue at the Procedure.
NOTE: If the machine is unable to make 20 prints, perform the TC Increase Adjustment.
1. The prints or copies are faint.

2. The toner cartridge is not rotating.
3. The low toner sensor, 09-310, reading is high.

A
Procedure NOTE: The routine 09-040 times out after 5 seconds.
NOTE: The door interlock switch must be cheated when checking +24V components. The toner dispense motor runs.
Y N
Enter dC330 code 04-010, to run the main drive motor. Go to Flag 1, read the voltage at P/J93 Go to Flag 2. Check MOT09-040. Refer to:
pin 8 while the main drive motor is running. The voltage is outside the range of +0.7V to GP 10 How to Check a Motor.
+4.5V. P/J6, IOT PWB.
Y N
Go to 01G +24V Distribution RAP.
Check the steps that follow:
Go to 01B 0V Distribution RAP.
Check the wiring, GP 7, between P/J93 to P/J6 on the IOT PWB.
Refer to the 01B 0V Distribution RAP.
Toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL 9.15 Item 1.
The developer module is correctly installed.
Check the toner dispense drive gears, Figure 1. The gears rotate.
The voltage at P/J93, pin 8, is less than +0.75V.
Y N
Y N
Install a new toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL
The voltage is greater than +4.5V. Check the wiring, GP 7. Go to Flag 3. +24V is 9.15 Item 1.
present at P/J93, pin 2.
Y N
Add the code 09-310, low toner sensor. Energize the components in the following order:
Disconnect P/J93, Figure 1. +24V is present at the harness end of P/J93, pin 2.
Y N 04-010, main drive motor.
Go to: 09-010, photoreceptor motor.
01G +24V Distribution RAP. 09-040, toner dispense motor.
01B 0V Distribution RAP. When the toner dispense motor stops, the toner level sensor display value is LOW.
Y N
Install a new developer module, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Go to the 09-310, 09-390 Low Toner Sensor Failure RAP.
Item 2. Perform dC905 TC Sensor Calibration.
Perform the TC Increase Adjustment.
Go to Flag 5. 0V is available at P/J93, pin 10.
Y N
Go to the 01B 0V Distribution RAP. Check the wiring, GP 7, between P/J6 on the IOT PWB and P/J93 on the developer module,
Figure 1. The wiring is good.
Enter dC131, 09-069, TC sensor control voltage, and record the displayed value. (100 Y N
displayed equals 1 volt). Go to Flag 4. Check the voltage at P/J93, pin 9. The dis- Repair the wiring.
played value is within 0.2V of the voltage checked at P/J93, pin 9.
Y N Go to Flag 3. +24V is present at P/J93, pin 2.
Disconnect P/J93. Check the voltage at pin 9. The recorded value is within 0.2V Y N
of the voltage checked at P/J93, pin 9. Disconnect P/J93, Figure 1. +24V is present at the harness end of P/J93, pin 2.
Y N Y N
Check the wiring, GP 7, between P/J93 and P/J6 on the IOT PWB. The wir- Go to:
ing is good. 01G +24V Distribution.
Repair the wiring, REP 1.2. Perform the TC Increase Adjustment.
Install a new developer module, PL 9.15 Item 2. Perform dC905 TC Sensor Calibration.
PL 1.10 Item 2.Perform the TC Increase Adjustment. Go to Flag 5. 0V is available at P/J93 pin 10.
Y N
Install a new developer module, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Go to the 01B 0V Distribution RAP.
Item 2. Perform dC905 TC Sensor Calibration.
Enter dC131, 09-069, TC sensor control voltage, and record the displayed value. (100 dis-
Enter dC330. Enter the code 04-010, main drive motor. Press start. Add the code 09-040, played equals 1 volt). Go to Flag 4. Check the voltage at P/J93, pin 9. The displayed value
toner dispense motor. Press Start. is within 0.2V of the voltage checked at P/J93 pin 9.
A

Y N
Disconnect P/J93. Check the voltage at pin 9. The displayed value is within 0.2V of
the voltage checked at P/J93 pin 9.
Y N
Check the wiring, GP 7, between P/J93 and P/J6 on the IOT PWB. The wiring is
good.
Y N
Repair the wiring, REP 1.2. Perform the TC Increase Adjustment
1.10 Item 2. Perform the TC Increase Adjustment
Install a new developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Item
2. Perform dC905 TC Sensor Calibration.
Perform the TC Reduction Adjustment.

If the 09-360 is intermittent and causes the message Machine unavailable. Perform OF7 IOT
PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item 2.
Perform the TC Reduction Adjustment.
TC Reduction Adjustment
1. Enter dC330, code 04-010, main drive motor; code 09-010, photoreceptor motor; 09-066,
developer bias.
2. Start the routine. The start will have to be pressed every 5 seconds to restart the devel-
oper bias routine.
3. Monitor the voltage output, Flag 1, at P/J6 pin 8 on the IOT PWB.
P/J93
NOTE: The toner concentration cannot be adjusted and maintained by making high area
coverage prints.
4. Run the routine until the monitored voltage is greater than 0.9 volts.
TC sensor Q09-360
5. Check the image quality.
TC Increase Adjustment
Toner dispense drive gears
1. Enter dC330, code 04-010, main drive motor; 09-040, toner dispense motor; 09-045,
toner cartridge motor. Toner dispense motor MOT09-040
2. Start the routine. The start will have to be pressed every 5 seconds to restart the toner
dispense motor and the toner cartridge routines.
3. Monitor the voltage output, Flag 1, at P/J6 pin 8 on the IOT PWB.
4. Run the routine until the monitored voltage is between 2.2 and 2.8 volts Figure 1 Component location
5. Check the image quality.

09-360, 09-361, 09-362, 09-363 2-272 Xerox WorkCentre 5790 Family
09-365 Relative Humidity Sensor Failure RAP
09-365 Average humidity reading is out of limits.
Also use this RAP if the relative humidity sensor is suspected of working incorrectly. A faulty
relative humidity sensor can cause image quality problems.
Initial Actions
WARNING
Procedure
Enter dC330 code 09-365, relative humidity sensor, Q09-365. Press start. Observe the dis-
played state of Q09-365. Figure 1. Open the bypass tray, gently blow on the relative humidity
sensor PWB. Observe again the displayed state of Q09-365. The displayed state has
changed.
Y N
Go to Flag 1. Check for +5V at P/J7 pin 3 on the IOT PWB. +5V is present.
Y N
Go to:
Go to Flag 1. Check for +5V at P/J46 pin 1. +5V is present.

Y N
Check the wiring between P/J7 on the IOT PWB and P/J46, GP 7. Repair wiring as
necessary, REP 1.2.
Install a new relative humidity sensor / ambient temperature sensor, (35 ppm) PL 9.22
Item 4, (40-90 ppm) PL 9.20 Item 4.
If the fault continues, perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
installed, PL 1.10 Item 2.
If possible, check the relative humidity of the external environment using a hygrometer. Com-
pare with a reading from the sensor Q09-365. Refer to the NOTE above Table 1. If a hygrome-
Figure 2 Circuit diagram ter is not available refer to Table 1 for the approximate expected humidity value. Compare the
expected values with Q09-365. If the value of Q09-365 is very different from the expected
reading.
Install a new relative humidity sensor / ambient temperature sensor, (35 ppm) PL 9.22 Item 4,
(40-90 ppm) PL 9.20 Item 4.
If the fault continues, perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
If the fault is intermittent, perform the steps that follow:
Check the wiring, GP 7. Repair if necessary, REP 1.2.
Make sure that the P/Js are correctly and securely connected.

NOTE: The actual value is not critical. If the reading from Q09-365 is approximately within the
range indicated in column 4, Table 1, the sensor is good.
Table 1 Relative humidity values

External Average relative Cold machine relative Warm machine relative
environment humidity humidity humidity
Wet 80% 80% 40% to 50%
Ambient 50% 50% 15% to 30%
Dry 10% 10% 1% to 7%
Relative humidity
sensor Q09-365 /
ambient temperature
sensor Q09-375
P/J46

09-370 Developer Temperature Sensor Failure RAP
09-370 The average developer temperature reading is out of limits.
Initial Actions
WARNING
Procedure
Enter dC330 code 09-370, developer temperature sensor Q09-370. Press start. Observe the
displayed state of Q09-370. Remove the xerographic module. Disconnect P/J47, Figure 1.
Cheat the front door interlock. Observe again the displayed state of Q09-370. The displayed
state has changed.
Y N
Y N
Go to:
Go to Flag 1. Check for +5V at P/J47 pin 3. +5V is present.

Y N Temperature sensor Q09-370
P/J47
NOTE: To gain access to the wiring, remove the main drive module, (35-55 ppm) PL
4.15 Item 1, (65-90 ppm) PL 4.10 Item 1 and the left hand cover, PL 8.10 Item 3. Figure 1 Component Location
Check the wiring between P/J7 on the IOT PWB and P/J47. Repair the wiring as
necessary, REP 1.2.
Install a new temperature sensor, (35 ppm) PL 9.22 Item 5, (40-90 ppm) PL 9.20 Item 5.
If the fault persists. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
Q09-370 is working correctly. Reconnect P/J47.

Make sure that the P/Js are correctly and securely connected.

A
09-375 Ambient Temperature Sensor Failure RAP Y N
Go to:
09-375 The average ambient temperature is out of limits.
Initial Actions 01B 0V Distribution RAP.
Go to Flag 1. Disconnect P/J46. Check for +5V at P/J46, pin 1. +5V is present.
Y N
WARNING
Check the wiring between P/J7 on the IOT PWB and P/J46, GP 7. Repair the wiring
Ensure that the electricity to the machine is switched off while performing tasks that do as necessary.
death or injury. Moving parts can cause injury. Install a new relative humidity sensor / ambient temperature sensor, (35 ppm) PL 9.22
Switch off the machine, then switch on the machine, GP 14. Item 4, (40-90 ppm) PL 9.20 Item 4.
If the fault persists, perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
Disconnect then re-connect P/J46 on the relative humidity sensor / ambient temperature sen- installed, PL 1.10 Item 2.
sor and P/J7 on the IOT PWB.
The ambient temperature sensor is working correctly.
Procedure If the fault is intermittent, perform the steps that follow:
Enter dC330, code 09-375 is available to use. Check the wiring, GP 7. Repair if necessary, REP 1.2.
Y N Make sure that the P/Js are correctly and securely connected, GP 11.
Connect a service meter between P/J7 and the machine frame and note the voltage
reading. Open the left hand door, gently blow on the temperature sensor PWB. The
meter reading has changed.
Y N
Y N
Go to:
Relative humidity
Go to Flag 1. Disconnect P/J46. Check for +5V at P/J46, pin 1. +5V is present. sensor Q09-365 /
Y N ambient temperature
Check the wiring between P/J7 on the IOT PWB and P/J46, GP 7. Repair the sensor Q09-375
wiring as necessary.
Install a new relative humidity sensor / ambient temperature sensor, (35 ppm) PL
9.22 Item 4, (40-90 ppm) PL 9.20 Item 4.
If the fault persists, perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB
is installed, PL 1.10 Item 2.
The ambient temperature sensor is working correctly.

Make sure that the P/Js are correctly and securely connected, GP 11.
Enter dC330 code 09-375, ambient temperature sensor, Q09-375. Press start. Observe the
displayed state of Q09-375. Figure 1. Open the left hand door, gently blow on the temperature
sensor PWB. Observe again the displayed state of Q09-375. The displayed state has P/J46
changed.
Y N Figure 1 Component location
A
09-380 Waste Toner Door Switch Failure RAP
09-380 The waste toner door switch has detected that the waste toner bottle is missing or the
door is open during run.
Initial Actions
WARNING
Figure 1. Ensure that the waste toner door is fully closed.
Procedure
Enter dC330 code 09-380 waste toner door switch, S09-380. Press start. Open and close the
waste toner door. The display changes.
Y N
Figure 2 Circuit diagram P/J7, IOT PWB.
Waste toner door switch, (35-55 ppm) PL 4.15 Item 8, (65-90 ppm) PL 4.10 Item 8.
1.10 Item 2.
Main drive module, (35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.
Make sure that S09-380 is mounted correctly. Install new components as necessary.

Waste toner door switch
S09-380
Waste toner Figure 2 Circuit diagram

door
Waste toner bottle

09-399 Incompatible Xerographic Module RAP NOTE: All new machines are configured to metered. A customer with an unmetered plan
should only have new sold xerographic module.
09-399 The xerographic module CRUM failed the authorization check.
Table 1 Service plan
The authorization check is performed to ensure that the xerographic module installed in the
system is compatible with the current machine configuration and the customer service plan. Service plan type Service plan description
A Sold - Xerox service agreement does not include the cost of
The message Replace Xerographic Module that may or may not be accombanied with the the xerographic module
message not compatible or incompatible, with an 09-587 status code in the event log.
B Meter - Xerox service agreement does include the cost of
the xerographic module
Initial Actions C Aftermarket -System will accept non-Xerox and OEM sup-
plied xerographic module with no CRUM
D Not used
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause NOTE: There is no communication with the CRUM when the system is configured to
death or injury. Moving parts can cause injury. aftermarket (3rd party).
5. If the fault persists, perform the following:

CAUTION a. Reset the machine configuration, perform GP 15 How to Set the Machine Configura-
tion.
Do not install a new sold xerographic module into a meter service plan machine. This will con-
vert the machine to a sold service plan. But this may not be noticed until the sold xerographic b. 03-371, 03-372 Fuser and Xerographic CRUM Communication Error RAP.
module has failed and is renewed with a meter xerographic module. To Change the Service Plan Type
Check that the xerographic module matches the customer service plan 1. Ensure a xerographic module to match the new service plan is installed in the machine.
Install a new xerographic module that matches the machine configuration and the cus- 2. Obtain the machine serial number.
tomer service plan, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2 3. Enter the Service Plan, refer to the Procedure.
NOTE: If a customers machine on a B - metered/non-sold plan, has a sold/non-metered xero- 4. Contact the market region technical specialist for a confirmation number.
graphic module inadvertantly installed, the customers billing plan will autamatically be set to A 5. Enter the confirmation number.
- sold/non-metered. From that point on, the machine will not accept the customers usual 6. Press Enter.
metered/non-sold xerographic modules.
7. Follow the message set to Exit.
Procedure 8. Check that the service plan is correct.
To check the chosen service plan: OpCo ID (Market Region) Validation Criteria
1. Enter Customer Administration Tools, GP 24. The xerographic module will be sold in the following market regions.
2. Select Consumables Management. NASG-N - North american solutions group.
3. Select Service Plan. NASG-S - North american solutions group.
4. The greyed out icon will indicate the chosen service plan. Refer to Table 1. ESG - European solutions group.
DMO-E - Developing markets east.
DMO-W - Developing markets west.
For each market region the system will support the xerographic modules configured as indi-
cated by Yes in Table 2. e.g. a xerographic module configured as NASG-S will function in the
following machine / market regions: NASG-N, NASG-S and DMO-W.
Xerographic modules configured to world wide are for all markets.

The system will not accept a xerographic module that does not match the OpCo ID (market 09A Photoreceptor Motor RAP
region) of the system. If there is a mismatch between the system configuration and the OpCo
ID then an incompatible xerographic module message will be displayed on the GUI. Procedure
Go to the 04A Main Drive Motor and Photoreceptor Motor RAP.
Table 2 OpCo ID (Market region)
Xerographic
module System configuration (Xerox OpCo ID)
NASG-N NASG-S DMO-W DMO-E ESG

NASG-N Yes Yes Yes No No
NASG-S Yes Yes Yes No No
DMO-W Yes Yes Yes No No
DMO-E No No No Yes Yes
ESG No No No Yes Yes
World wide Yes Yes Yes Yes Yes

09B Waste Toner Full Sensor RAP
Use this RAP if the message waste toner bottle nearly full appears, when the waste toner bot-
tle is empty.
The waste toner bottle has the capacity to hold the waste toner from over 100K prints at 6%
average area coverage.
The waste toner sensor is an infrared transmission sensor. The sensor consists of an infrared
emitter on one side of the bottle and an infrared detector on the other side of the bottle.
Initial Actions
WARNING
Check if the waste toner bottle is full, PL 9.10 Item 1.
Check for toner contamination around the waste toner full sensor, Figure 1.
Procedure
Use thick black card to manually actuate the sensor. Enter dC330 code 09-350 waste toner full
sensor, Q09-350. Pass the black card between the sensor transmitter and receiver. The dis-
play changes.
Y N
Figure 1.
P/J7, IOT PWB.
Waste toner full sensor, PL 9.10 Item 2.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL P/J48 Waste toner full sensor Q09-350
1.10 Item 2.
The fault may be intermittent. Check that the sensor is located correctly on the support bracket
and on the machine frame. Check for damaged components on the sensor, PL 9.10 Item 2. Figure 1 Component location

09C Photoreceptor Fan RAP
Use this RAP to check the photoreceptor fan.
NOTE: A faulty photoreceptor fan can cause image quality problems.
Procedure
WARNING
Switch off the machine GP 14. Remove the photoreceptor fan, PL 9.25 Item 7, from the photo-
receptor duct. Fans produced during March/April 2006 are known to have a reliability problem.
Check the serial number label on the top of the fan frame. The serial number is between
F09 to F21.
Y N
Switch on the machine, GP 14. Check the airflow by holding a piece of paper over the fan
intake, PL 9.25 Item 6. The fan is running.
Y N
Go to Flag 1. Check the photoreceptor fan motor. Refer to GP 10, How to Check a
Motor. Check the following:
+11V at P/J42 during standby, rising to +15V during run.
+11V at P/J17 during standby, rising to +15V during run.
Continuity between PJ42 and P/J17. If necessary repair the harness, REP 1.2.
Photoreceptor fan assembly, PL 9.25 Item 6.
Figure 2 Circuit diagram LVPS and base module, PL 1.10 Item 3.
Ensure that the fan is installed correctly. If the fan is installed correctly air will be drawn
into the air intake. Refer to the OF6 Ozone and Air Systems RAP.
Observe the fan, if the fan is exibiting any of the following symptoms, install a new photo-
receptor fan assembly, PL 9.25 Item 6 .
Running at low speed
Oscillating without turning
Runs for a few seconds, then stops for a few second repeatedly
The fault may be intermittent, go to Flag 1. Check the harness and the connectors, GP 7.
If necessary, install a new photoreceptor fan assembly, PL 9.25 Item 6 .
Install a new photoreceptor fan assembly, PL 9.25 Item 6 .

09B, 09C 2-282 Xerox WorkCentre 5790 Family

10-101, 10-102, 10-103 Lead Edge Late to Fuser Exit Switch 10-101A, 10-102A, 10-103A Lead Edge Late to Fuser Exit
Entry RAP Switch RAP (35-55 ppm)
10-101 The lead edge of the paper failed to actuate the fuser exit switch within the correct time 10-101 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
after the registration clutch was energized for a simplex sheet. after the registration clutch was energized for a simplex sheet.
after the registration clutch was energized for a duplex sheet side 1. after the registration clutch was energized for a duplex sheet side 1.
after the registration clutch was energized for a duplex sheet side 2. after the registration clutch was energized for a duplex sheet side 2.
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
Before performing this procedure, check that the paper is not being skewed at any point
between the paper tray and the fuser module. If skew is found, go to IQ8 Skew RAP.
WARNING
Procedure Do not touch the fuser while it is hot.
If the speed of the machine is 35-55 ppm, go to 10-101A, 10-102A, 10-103A Lead Edge Make sure that the correct RAP is used. To identify the correct RAP to use, go to 10-101,
Late to Fuser Exit Switch RAP. 10-102, 10-103 Lead Edge Late to Fuser Exit Switch Entry RAP.
If the speed of the machine is 65-90 ppm, go to 10-101B, 10-102B, 10-103B Lead Edge Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
Late to Fuser Exit Switch RAP. Check for obstructions in the registration transport, Figure 2.
Check for obstructions in the short paper path assembly, Figure 3.
Check the stripper fingers on the xerographic module.
Check for paper in the fuser module.
Check the fuser stripper fingers for contamination, (35-55 ppm) PL 10.8 Item 4.
If a 10-101 is caused by paper fed from the bypass tray, check for paper skew.
If a 10-103 is caused by a skewed sheet on side 2, check the inverter, PL 10.12 Item 1.
Also check the duplex paper path (35-55 ppm) PL 8.22 Item 1. Install new components as
necessary.
If 10-101 jams, check that all of the HT connectors are pushed fully home on the HVPS.
If the fault is 10-101 and the paper is fed from tray 1 or tray 2. Check if the paper has
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG
002 on the paper tray to constrain the effect of the curl.
Install the XRU skids kit to eliminate paper jams caused by curled copies between the
XRU and the fuser module, (35 ppm) PL 9.22 Item 21, (40-90 ppm) PL 9.20 Item 19.
If 10-101 jams are concurrent with feeding small size media e.g. A5, 8.5 x 5.5 inch paper,
ensure a W/O TAG 114 short paper path is installed.
If 10-101 jams are caused when paper is fed from tray 5, perform dC132 NVM Initializa-
tion.

Xerox WorkCentre 5790 Family 2-285 10-101, 10-102, 10-103, 10-101A, 10-102A, 10-103A
A
Procedure Install new components as necessary:
Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch 1.10 Item 2.
with a piece of paper, Figure 1. The display changes.
Y N Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Manually actuate the sen-
Go to Flag 1. Check S10-100. Refer to: sor Figure 2. The display changes.
GP 13 How to Check a Switch. Y N
Figure 1. Go to Flag 4. Check Q08-150. Refer to:
P/J35, IOT PWB. GP 11 How to Check a Sensor.
01D +3.3V Distribution RAP. Figure 2.
01B 0V Distribution RAP. P/J5, IOT PWB.
Install new components as necessary: 01D +3.3V Distribution RAP.
Fuser exit switch, (35-55 ppm) PL 10.8 Item 11. 01B 0V Distribution RAP.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL Install new components as necessary:
1.10 Item 2. Registration sensor, (35-55 ppm) PL 8.15 Item 3.
Enter dC330 code 10-065 vacuum transport fan, MOT10-065. Figure 3. Press Start, The fan 1.10 Item 2.
runs.
Y N Check the following components, refer to GP 7:
Go to Flag 2. Check MOT10-065. Refer to: Registration roll, PL 8.15 Item 9.
GP 10 How to Check a Motor. Roll assembly on the short paper path assembly, PL 10.25 Item 1.
Figure 3. Check the detack corotron and the connection to the HVPS. Refer to 09-060 HVPS Fault
P/J5, IOT PWB. RAP
P/J17, LVPS. The drive gear on the fuser module, (35-55 ppm) PL 10.8 Item 1.
Fuse, PL 1.10 Item 9, GP 7. The fuser drive gear on the main drives module, (35-55 ppm) PL 4.17 Item 10.
01G +24V Distribution RAP. Fuser web motor and the fuser web, 10A Fuser Web Motor RAP.
01B 0V Distribution RAP. Check the drives plate on the registration clutch for damage and contamination. Refer to
Install new components as necessary: the replacement procedure in REP 8.5.
Short paper path assembly, PL 10.25 Item 1. If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS,
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL PL 1.10 Item 3.
1.10 Item 2.
Enter dC330 code 04-010 main drive motor. Press Start. Add code 08-070 registration clutch,
CL08-070. Press Start.
NOTE: The clutch will switch off after 5 seconds.
The jam clearance knob 4c, PL 8.15 Item 10, rotates.

Y N
P/J5, IOT PWB.
P/J17, LVPS.
A
10-101A, 10-102A, 10-103A 2-286 Xerox WorkCentre 5790 Family
Registration rolls
Registration sensor
Q08-150
Fuser exit switch

S10-100
Registration clutch
CL08-070

Xerox WorkCentre 5790 Family 2-287 10-101A, 10-102A, 10-103A
Transfer / detack corotron
Transport rolls
Vacuum transport fan

MOT10-065

10-101A, 10-102A, 10-103A 2-288 Xerox WorkCentre 5790 Family
10-101B, 10-102B, 10-103B Lead Edge Late to Fuser Exit Procedure
Switch RAP (65-90 ppm) NOTE: The door interlock switch must be cheated when checking +24V components.
10-101 The lead edge of the paper failed to actuate the fuser exit switch within the correct time Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch
after the registration clutch was energized for a simplex sheet.
with a piece of paper, Figure 1. The display changes.
10-102 The lead edge of the paper failed to actuate the fuser exit switch within the correct time Y N
after the registration clutch was energized for a duplex sheet side 1. Go to Flag 1. Check S10-100. Refer to:
10-103 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
after the registration clutch was energized for a duplex sheet side 2. Figure 1.
P/J35, IOT PWB.
Initial Actions
WARNING Install new components as necessary:
Ensure that the electricity to the machine is switched off while performing tasks that do Fuser exit switch, (65-90 ppm) PL 10.10 Item 11
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
death or injury. Moving parts can cause injury. 1.10 Item 2.
Enter dC330 code 10-065 vacuum transport fan, MOT10-065. Figure 3. Press Start, The fan
WARNING runs.
Do not touch the fuser while it is hot. Y N
Make sure that the correct RAP is used. To identify the correct RAP to use, go to 10-101,
10-102, 10-103 Lead Edge Late to Fuser Exit Switch Entry RAP. GP 10 How to Check a Motor.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Figure 3.
Check for obstructions in the registration transport, Figure 2. P/J5, IOT PWB.
Check for obstructions in the short paper path assembly, Figure 3. P/J17, LVPS.
Check that the short paper path assembly latches without excessive force, PL 10.25 Item Fuse, PL 1.10 Item 9, GP 7.
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism. 01G +24V Distribution RAP.
Check the stripper fingers on the xerographic module. 01B 0V Distribution RAP.
Check for paper in the fuser module. Install new components as necessary:
Check the fuser stripper fingers for contamination, (65-90 ppm) PL 10.10 Item 4. Short paper path assembly, PL 10.25 Item 1.
If a 10-101 is caused by paper fed from the bypass tray, check for paper skew. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
If a 10-103 is caused by a skewed sheet on side 2, check the inverter PL 10.11 Item 23. 1.10 Item 2.
Also check the duplex paper path (65-90 ppm) PL 8.20 Item 1. Install new components as
necessary. Enter dC330 code 04-010 main drive motor. Press Start. Add code 08-070 registration clutch,
CL08-070. Press Start.
If 10-101 jams, check that all of the HT connectors are pushed fully home on the HVPS.
If the fault is 10-101 and the paper is fed from tray 1 or tray 2. Check if the paper has NOTE: The clutch will switch off after 5 seconds.
The jam clearance knob 4c, PL 8.17 Item 10, rotates.
002 on the paper tray to constrain the effect of the curl.
Y N
Install the XRU skids kit to eliminate paper jams caused by curled copies between the Go to Flag 3. Check CL08-070. Refer to:
XRU and the fuser module, (35 ppm) PL 9.22 Item 21, (40-90 ppm) PL 9.20 Item 19.
If the fault occurs only when paper is fed from tray 5 (HCF), perform an all machine NVM
P/J5, IOT PWB.
initialisation from dC132.
P/J17, LVPS.
If 10-101 jams are concurrent with feeding small size media e.g. A5, 8.5 x 5.5 inch paper,
ensure a W/O TAG 114 short paper path is installed. Fuse, PL 1.10 Item 9, GP 7.
If 10-101 jams are caused when paper is fed from tray 5, perform dC132 NVM Initializa- 01G +24V Distribution RAP.
tion. 01B 0V Distribution RAP.
A

Xerox WorkCentre 5790 Family 2-289 10-101B, 10-102B, 10-103B
A
1.10 Item 2.
Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Manually actuate the sen-
sor with a piece of paper, Figure 2. The display changes.
Y N
Figure 2.
P/J16, IOT PWB.
Registration sensor, PL 8.17 Item 3.
1.10 Item 2.
Check the following components, refer to GP 7:

Registration roll, (65-90 ppm) PL 8.17 Item 9.
Roll assembly on the short paper path assembly, PL 10.25 Item 1.
Check the detack corotron and the connection to the HVPS. Refer to 09-060 HVPS Fault
RAP
The drive gear on the fuser module, (65-90 ppm) PL 10.10 Item 1.
The fuser drive gear on the main drives module, (65-90 ppm) PL 4.12 Item 10.
Fuser web motor and the fuser web, 10A Fuser Web Motor RAP.
the replacement procedure in REP 8.5.
If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS,
PL 1.10 Item 3.
Fuser exit switch

S10-100

10-101B, 10-102B, 10-103B 2-290 Xerox WorkCentre 5790 Family
Transfer / detack corotron
Registration nip rolls
Transport rolls
Vacuum transport fan

MOT10-065

Registration clutch Registration sensor
CL08-070 Q08-150

Xerox WorkCentre 5790 Family 2-291 10-101B, 10-102B, 10-103B
10-107, 10-108, 10-109, 10-110 Trail Edge Late from Fuser
Exit Switch RAP
10-107 The trail edge of the paper failed to de-actuate the fuser exit switch within the correct
time after the trail edge at the registration sensor, for a simplex non inverted sheet.
time after the trail edge at the registration sensor, for a simplex inverted sheet.
time after the trail edge at the registration sensor, for a duplex sheet side 1.
time after the trail edge at the registration sensor, for a duplex sheet side 2.
Initial Actions
WARNING
WARNING
WARNING
Check that the paper size information in the UI matches the paper used in the paper trays
and the bypass tray.
Check the fuser stripper fingers for contamination, (35-55 ppm) PL 10.8 Item 4, (65-90
Check the inverter upper baffle assembly, (65-90 ppm) Figure 1, (35-55 ppm) Figure 2.
Check the entrance to the output device and the alignment of the device.
(35-55 ppm only) If a OCT is used, check for sticking fingers at the exit to the output tray,
REP 12.1.
(35-55 ppm 0nly) If the faults occur when feeding a transparency, install TAG 004 inverter
transparency feed kit.
Install the XRU skids kit to eliminate paper jams caused by curled copies between the
Figure 4 Circuit diagram XRU and the fuser module, (35 ppm) PL 9.22 Item 21, (40-90 ppm) PL 9.20 Item 19.

10-101B, 10-102B, 10-103B, 10-107, 10-108, 10-109, 2-292 Xerox WorkCentre 5790 Family
A B
Procedure 01B 0V Distribution RAP.
NOTE: The door interlock switch must be cheated when checking +24V components. Inverter motor, PL 10.11 Item 11.
Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch Inverter motor driver PWB, PL 10.11 Item 22.
with a piece of paper. The display changes. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
Y N PL 1.10 Item 2.
GP 13 How to Check a Switch. Install a new inverter motor driver PWB, PL 10.11 Item 22.
(35-55 ppm) Figure 2.
(65-90) Figure 1. Check the following components, refer to GP 7:
P/J35, IOT PWB. The drive gear on the fuser module, PL 10.10 Item 1.
01D +3.3V Distribution RAP. The fuser drive gear on the main drives module, (35-55 ppm) PL 4.17 Item 10, (65-90
Drives between inverter and the main drives module, PL 10.15.
Fuser exit switch, (35-55 ppm) PL 10.8 Item 11 or (65-90 ppm) PL 10.10 Item 11
Post fuser exit roller, PL 10.12 Item 9.
1.10 Item 2. NOTE: Excessive post fuser exit roll wear causes buckle between the fuser and the
inverter assembly. This can cause severe ripple on the trail edge of A3 (11x17 inch) sheet
Enter dC330 code 10-045 inverter path solenoid, SOL10-045. Press Start. The solenoid and paper jams.
energized.
Upper baffle, (35-55 ppm) PL 10.12 Item 23, (65-90 ppm) PL 10.12 Item 22.
Y N
Go to Flag 2. Check SOL10-045. Refer to: Baffle guide, PL 10.13 Item 3.
GP 12 How to Check a Solenoid or Clutch. If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS, PL
(35-55 ppm) Figure 2. 1.10 Item 3.
P/J5, IOT PWB
P/J17, LVPS.
1.10 Item 2.
Enter dC330 code 10-030 inverter motor, MOT 10-030. Press start. The jam clearance knob,
2B, PL 10.15 Item 13, is stationary and the motor can be heard.
Y N
The jam clearance knob, 2B, PL 10.15 Item 13, rotates counterclockwise.
Y N
P/J4, IOT PWB.
P/J45, P/J55 inverter motor driver PWB
A B

Fuser exit switch
S10-100
Fuser exit switch
S10-100
Inverter path solenoid

Upper baffle
SOL10-045
Upper baffle SOL10-045
Figure 1 Component location (65-90 ppm) Figure 2 Component location (35-55 ppm)


10-120, 10-121, 10-126 IOT Exit Sensor RAP For 10-126 faults. If the paper jam is at the entrance to the output device. Go to the rele-
vant output device copy damage RAP:
10-120 The lead edge of the paper failed to reach the IOT exit sensor within the correct time
11G-120 Copy Damage in the 1K LCSS RAP.
after the trail edge at the fuser exit switch for an inverted sheet.
11H-110 Copy Damage in the 2K LCSS RAP.
10-121 The lead edge of the paper failed to reach the IOT exit sensor within the correct time 11E-171 Copy Damage in the HVF BM RAP.
after the trail edge at the fuser exit switch for an non inverted sheet. For 10-126 faults. If the paper jam is at the entrance to the output device and the output
device fails to initialize after the front door is closed. Go to the relevant output device ini-
10-126 The trail edge of the paper failed to clear the IOT exit sensor within the correct time. tialization RAP.
11B-120 1K LCSS Initialization Failure RAP.
Initial Actions 11C-110 2K LCSS Initialization Failure RAP.
11K-171 HVF Initialization Failure RAP.
WARNING If the fault is caused by a multifeed of sheets, go to the OF8 Multifeed RAP.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Procedure
NOTE: Ensure that the door interlock switch is cheated when checking +24V components.
Enter dC330 code 10-120 IOT exit sensor, Q10-120. Press Start. Manually actuate the sensor.
WARNING The display changes.
Do not touch the fuser while it is hot. Y N
WARNING (35-55 ppm) Figure 1.
Take care during this procedure. Motors will become hot during normal operation. (65-90 ppm) Figure 2.
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. P/J5, IOT PWB.
NOTE: If the fault occurs only with heavy weight paper of 120gsm (32 lb.) or greater that 01D +3.3V Distribution RAP.
are being inverted. Then Enter the Tools Mode and Stock Settings. Change the stock type 01B 0V Distribution RAP.
to heavyweight for the respective tray. If the problem persists, perform the RAP. Install new components as necessary:
If the faults occur when feeding transparency, install TAG 004 inverter transparency feed IOT exit sensor, PL 10.11 Item 13.
kit. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
If the fault is 10-120 and the paper is fed from tray 1 or tray 2. Check if the paper has 1.10 Item 2.
002 on the paper tray to constrain the effect of the curl. Enter dC330 code 10-050 inverter nip solenoid, SOL10-050. Press Start. The solenoid ener-
gises.
If the fault is 10-120 and the paper is skewed with up-curl ensure a W/TAG 114 short
Y N
paper path assembly is installed.
Check for obstructions in the inverter area, (35-55 ppm) Figure 1, (65-90 ppm) Figure 2.
Check the upper and lower gravity fingers in the inverter, Figure 3, GP 7.
If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate mylar kit.
Check for obstructions in the exit area.
P/J5, IOT PWB.
Check that the output device is parallel to the machine. Refer to the appropriate adjust-
P/J17, LVPS.
ment:
ADJ 11.2-110 Machine to 2K LCSS Alignment.
ADJ 11.1-171 Machine to HVF/HVF BM, HVF BM to Tri-folder Alignment.
35-55 ppm Only. For 10-126 faults. If the machine has a OCT, make sure that the OCT
fingers are installed correctly. Refer to REP 12.1. Install new components as necessary:
Inverter nip solenoid, PL 10.11 Item 6.
A
A
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL The drive gear on the fuser module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10
1.10 Item 2. Item 1.
The fuser drive gear on the main drives module, (35-55 ppm) PL 4.17 Item 10, (65-90
Enter dC330 code 10-045 inverter path solenoid, SOL 10-045. Press Start. The solenoid ppm) PL 4.12 Item 10.
energizes.
Check the IOT exit sensor mounting bracket on the nip roll guide, PL 10.11 Item 10. The
Y N
bracket holds the IOT exit sensor in the correct position, PL 10.11 Item 13.
Go to Flag 3. Check SOL 10-045. Refer to:
GP 12 How to Check a Solenoid or Clutch. If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS, PL
1.10 Item 3.
P/J5, IOT PWB
P/J17, LVPS.
1.10 Item 2.
Enter dC330 code 10-030 inverter motor, MOT10-030. Press Start. The jam clearance knob,
2B, PL 10.15 Item 13, is stationary and the motor can be heard. Fuser exit switch
Y N S10-100
Y N
SOL10-045
IOT exit sensor
P/J4, IOT PWB
Q10-120
P/J45, P/J55 Inverter nip solenoid
01G +24V Distribution RAP SOL10-050
Figure 1 Component location 35-55 ppm
PL 1.10 Item 2.
Install a new inverter motor driver PWB, PL 10.11 Item 22.

Idler roll, PL 10.12 Item 15.
Upper baffle, (35-55 ppm) PL 10.12 Item 23, (65-90 ppm) PL 10.12 Item 22.
Double exit nip roll, PL 10.11 Item 8.
Exit shaft assembly, PL 10.13 Item 4.

Fuser exit switch
S10-100 Inverter path solenoid
SOL10-045
Inverter nip solenoid

IOT exit sensor SOL10-050
Q10-120
5 Upper gravity
fingers
4 Lower gravity fingers


A
10-132, 10-133, 10-134 Lead Edge Late to Inverter Sensor Install new components as necessary:
Fuser exit switch, PL 10.10 Item 11.
RAP (65-90 ppm)
10-132 The lead edge of the paper failed to actuate the inverter sensor within the correct time 1.10 Item 2.
after the fuser exit switch is made, for a simplex sheet.
Enter dC330 sensor code 10-105 inverter sensor, Q10-105. Press Start. Use a piece of paper
10-133 The lead edge of the paper failed to actuate the inverter sensor within the correct time to actuate the sensor. The display changes.
after the fuser exit switch is made, for a duplex 1 sheet.
Y N
10-134 The lead edge of the paper failed to actuate the inverter sensor within the correct time
after the fuser exit switch is made, for a duplex 2 sheet. GP 11. How to Check a Sensor.
Figure 2.
Initial Actions P/J61, IOT PWB
Ensure that the electricity to the machine is switched off while performing tasks that do Inverter sensor, PL 10.12 Item 19.
1.10 Item 2.

WARNING
The drive gear on the fuser module, PL 10.10 Item 1.
The fuser drive gear on the main drives module, PL 4.12 Item 10.
WARNING Drives between inverter and the main drives module, PL 10.15.
Take care during this procedure. Motors will become hot during normal operation. Post fuser exit roller, PL 10.12 Item 9.
Check that the paper size information in the UI matches the paper used in the paper trays NOTE: Excessive post fuser exit roll wear causes buckle between the fuser and the
and the bypass tray. inverter assembly. This can cause severe ripple on the trail edge of A3 (11x17 inch) sheet
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. and paper jams.
Upper baffle, PL 10.12 Item 22.
Baffle guide, PL 10.13 Item 3.
Check the fuser stripper fingers for contamination, PL 10.10 Item 4.
Check the inverter upper baffle assembly, Figure 1.
Procedure
Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch
with a piece of paper. The display changes.
Y N
Figure 1.
P/J35, IOT PWB.
A
Fuser exit switch
S10-100
Upper baffle
Inverter sensor
Q10-105
Inverter nip split solenoid

SOL10-055

A
10-135, 10-136, 10-137, 10-138 Trail Edge Late from Inverter Figure 3.
P/J61, IOT PWB.
Sensor RAP
10-135 The trail edge of the paper failed to de-actuate the inverter sensor within the correct
time, for a simplex non invert sheet. 01B 0V Distribution RAP.
10-136 The trail edge of the paper failed to de-actuate the inverter sensor within the correct Inverter sensor, PL 10.12 Item 19.
time, for a simplex inverted sheet. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
10-137 The trail edge of the paper failed to de-actuate the inverter sensor within the correct
time, for a duplex sheet side 1. Enter dC330 code 10-050 inverter nip solenoid, SOL10-050. Press Start. The solenoid ener-
gises.
10-138 The trail edge of the paper failed to de-actuate the inverter sensor within the correct Y N
time, for a duplex sheet side 2. Go to Flag 2. Check SOL10-050. Refer to:
P/J5, IOT PWB.
WARNING P/J17, LVPS.
Ensure that the electricity to the machine is switched off while performing tasks that do Fuse, PL 1.10 Item 9, GP 7.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 01G +24V Distribution RAP.
Inverter nip solenoid, PL 10.11 Item 6.
WARNING
Do not touch the fuser while it is hot. 1.10 Item 2.
Enter dC330 code 10-045 inverter path solenoid, SOL 10-045. Press Start. The solenoid
WARNING energizes.
Take care during this procedure. Motors will become hot during normal operation. Y N
Check the condition of the paper in all trays. Refer to IQ1 and GP 20. Go to Flag 3. Check SOL 10-045. Refer to:
NOTE: If the fault occurs only with heavy weight paper of 120gsm (32 lb.) or greater that
Figure 1.
are being inverted, enter the Tools Mode and Stock Settings. Change the stock type to
heavyweight for the appropriate tray. If the problem persists, perform the procedure in this P/J5, IOT PWB
RAP. P/J17, LVPS.
Check for obstructions in the inverter area, Figure 1.
Check the upper and lower gravity fingers in the inverter, Figure 3, GP 7.
Check for obstructions in the exit area.
If the fault is caused by a multifeed of sheets, go to OF8 Multifeed RAP.
Procedure
1.10 Item 2.
NOTE: Ensure that the door interlock switch is cheated when checking +24V components.
Enter dC330 code 10-055 tri-roll nip split solenoid, SOL 10-055. Press Start. The solenoid
Enter dC330 code 10-105 inverter sensor, Q10-105. Press Start. Manually actuate the sensor. energizes.
The display changes. Y N
Y N Go to Flag 5. Check SOL 10-055. Refer to:
Go to Flag 1. Check Q10-105. Refer to: GP 12 How to Check a Solenoid or Clutch.
A B
B
Figure 3.
P/J61, IOT PWB
P/J17, LVPS.
Tri-roll nip split solenoid, PL 10.14 Item 1.
1.10 Item 2.
Enter dC330 code 10-030 inverter motor, MOT10-030. Press Start. The jam clearance knob,
2B, PL 10.15 Item 13, is stationary and the motor can be heard.
Y N
Y N
GP 10 How to Check a Motor. SOL10-045
P/J4, IOT PWB
P/J45, P/J55
01G +24V Distribution RAP
Inverter nip solenoid
01E +5V Distribution RAP. SOL10-050
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, Figure 1 Component location
PL 1.10 Item 2.
Install a new inverter motor driver PWB, PL 10.11 Item 22.

Idler roll, PL 10.12 Item 15.
Upper baffle, (65-90ppm) PL 10.12 Item 22, (35-55ppm) PL 10.12 Item 23.
Double exit nip rolls, PL 10.11 Item 8.
Exit shaft assembly, PL 10.13 Item 4.
The drive gear on the fuser module, PL 10.10 Item 1.
The fuser drive gear on the main drives module, PL 4.12 Item 10.
If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS, PL
1.10 Item 3.

Inverter sensor
Q10-105
Inverter nip split solenoid

SOL10-055
Figure 3 Inverter assembly
5 Upper gravity
fingers
4 Lower gravity fingers


10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 10- Procedure
365, 10-380 Fuser Over Temperature RAP Switch off the machine, then switch on the machine, GP 14. The display shows Ready to
Copy.
10-315 The difference between 2 consecutive thermistor readings exceeds a given value. Y N
10-320 During standby or run mode, the thermistor reading is not within the target temperature Refer to Figure 5. Go to Flag 1. The voltage at the temperature sensors A and B should
range. be 2.9 volts when the sensors are cold. In standby mode the voltage should be 0.78 to
0.98 volts. Refer to:
10-321 Over temperature during standby mode, the thermistor reading is not within the target
P/J35, IOT PWB.
temperature range
10-323 Over temperature during run mode, the thermistor reading is not within the target tem-
perature range.
Before new components are installed, restore the NVM values to default.
10-340 Fuser temperature sensor A reading monitors above its normal operating temperature. Install new components as necessary:
10-350 The hardware comparator detects a fuser reading greater than 240 degrees centigrade Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
or a short circuit thermistor. 1.10 Item 2.
10-360 Fuser temperature sensor B reading is greater than the normal operating temperature. LVPS and base module, PL 1.10 Item 3.
Fuser Module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.
10-365 The fuser module is above the recommended operating temperature.
10-380 The fuser delta value between the temperature sensors A and B is to high. Perform SCP 6 Final Actions.
Initial Actions
Web drive gear Pin 1
Pin 5
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Pin 6
death or injury. Moving parts can cause injury. Pin 8
Pin 7
WARNING
If a number of 10-321 fault codes, are in the fault history. Check if the customer has been Pin 2 Pin 9
running transparency jobs of nominal papers at card stock settings. This fault can be gen-
erated when the temperature changes between the standby and run. This is a normal
function of the machine and should not effect the customer operation. Pin 3
Check that the fuser temperature NVM settings in dC131, are set to default. Refer to NVM Pin 10
location 10-028 though to 10-061 and location 08-282 through to 08-295. Ensure that the
values are set to the default level. If the values are not at default then, 10-320, 10-321,
10-340 and 10-360 may appear in the fault log. Pin 4
Check the fuser module connector, Figure 1. PJ100
Check the fuser connector assembly, Figure 2.
Check that the photorecptor fan, PL 9.25 Item 7 is working correctly and that the direction
of air flow is into the machine, refer to the 09C Photoreceptor Fan RAP. Check that the
intake grille at the rear of the machine is not blocked and there is not a heat source such
as a radiator immediately behind the machine. Check that the photoreceptor duct, PL CRUM
9.25 Item 5 and the lower duct, PL 9.25 Item 8 are correctly installed. Fuser drive
gear

10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 2-306 Xerox WorkCentre 5790 Family
Pin 5
Pin 6
Pin 8
LVPS
Pin 1 Pin 7
Pin 2
Pin 3 Pin 9
Pin 4
Pin 10
P/J100
IOT PWB
PJ24
HVPS
Figure 3 Component location 35 ppm

Xerox WorkCentre 5790 Family 2-307 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-
LVPS
IOT PWB
PJ24
HVPS

10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 2-308 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-309 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-
10-322, 10-324, 10-325, 10-330, 10-370 Fuser Under
Temperature RAP WARNING
10-322 Under temperature during standby mode, the thermistor reading is not within the target Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
temperature range
NOTE: The voltage will be 100% of the ACL voltage when the machine is switched on from
10-324 under temperature during run mode, the thermistor reading is not within the target tem- cold and pulse between 60% and 100% during standby.
perature range
Go to Flag 2 and check for ACL at PJ24. Switch on the machine, GP 14. ACL is available at
10-325 The fuser control task watchdog timer has not been reset within a specified period. PJ24 between pin 1 and 3, and between pin 4 and 6.
Y N
10-330 The initial fuser temperature rise was not achieved within 30 seconds from the start of Install new components as necessary.
warm up mode or the standby temperature was not reached within 150 seconds. Perform the OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
10-370 During power save mode, the thermistor reading is not within the target value, after the
If the fault still occurs, install a new LVPS and base module, PL 1.10 Item 3
fuser has cooled to the power save temperature.
Go to Flag 1. With the fuser cold, check for +2.9V at PJ 35 pin 1 and at pin 2. +2.9V is avail-
Initial Actions
able at both pins.
Y N
Go to Flag 1. Check the wiring and connectors.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do NOTE: Do not insert the service meter probes into the PJ100 terminals. This may dam-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause age the pins. Access the pins from the wire side of the connector.
death or injury. Moving parts can cause injury. Refer to:
P/J35, IOT PWB.
WARNING PJ100, Figure 2.
Do not touch the fuser while it is hot. 01D +3.3 V Distribution RAP.
Switch off the machine, then switch on the machine, GP 14. 01B 0V Distribution RAP.
If a number of 10-322 fault codes, are in the fault history. Check if the customer has been The wiring and connectors are good.
running transparency jobs of nominal papers at card stock settings. This fault can be gen- Y N
erated when the temperature changes between the standby and run. This is a normal As necessary, perform the actions that follow:
function of the machine and should not effect the customer operation. Repair the harness between P/J35 and PJ100, REP 1.2.
Check that the fuser temperature NVM settings in dC131, are set to default. If the fuser Install a new fuser connector assembly, (65-90 ppm) PL 4.10 Item 9 (35-55
temperatures are not set to default, 10-322 may appear in the fault log. ppm) PL 4.15 Item 9.
Perform the OF7 IOT PWB Diagnostics RAP. If the fault persists, install a new fuser mod-
Procedure
ule, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1.
Switch off the machine GP 14. Remove the fuser module and check the continuity between pin
1 and pin 2 and between pin 3 and pin 4 on the fuser module connector, Figure 1. There is If the fault persists, install a new fuser module, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL
continuity. 10.10 Item 1.
Y N
Install a new fuser module, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1.
Install the fuser module and disconnect PJ24, (35 ppm) Figure 3, (40-90 ppm) Figure 4. Go to
Flag 2 and check for continuity between pin 1 and 3 and between pins 4 and 6 at the harness
end. There is continuity.
Y N
Check the fuser connector assembly, Figure 2. If necessary, install a new fuser connector
assembly, (35-55 ppm) PL 4.15 Item 9, (65-90 ppm) PL 4.10 Item 9.
Connect PJ24, (35 ppm) Figure 3, (40-90 ppm) Figure 4.

Web drive gear Pin 1 Pin 5
Pin 5
Pin 6 Pin 6
Pin 8
Pin 8
Pin 7
Pin 7
Pin 2 Pin 1
Pin 9
Pin 2
Pin 9
Pin 3
Pin 10
Pin 3
Pin 4
Pin 4 Pin 10
P/J 100
P/J 100
CRUM
Fuser drive
gear

LVPS LVPS
IOT PWB
IOT PWB
P/J24
PJ24
HVPS HVPS
Figure 3 Component location 35 ppm Figure 4 Component location 40-90 ppm


10-399 Fuser Authorization Failure RAP 10A Fuser Web Motor RAP
10-399 The fuser CRUM failed the authorization check. Use this RAP when the fuser web motor is suspected of having failed. Indications of motor fail-
ure are contaminated stripper fingers and fuser roll. This fault may also cause paper jams in
The authorization check is performed to ensure that the fuser installed in the system is compat- the inverter.
ible with the machine configuration: 50Hz or 60Hz.
Initial Actions
Procedure
WARNING
WARNING
WARNING Do not touch the fuser while it is hot.
Do not touch the fuser while it is hot. Check the fuser web motor drive coupling, Figure 2.
Install a new Fuser module that matches the machine configuration. Check the fuser drawer connector, Figure 1.
Fuser module (35-55 ppm), PL 10.8 Item 1.
Fuser module (65-90 ppm), PL 10.10 Item 1. Procedure
The web motor does not run continuously. It is pulsed on for multiples of 0.9 seconds duration.
The pulsing of the motor is felt or heard during the print mode.
Enter dC330 code 10-010 fuser web motor, MOT10-010. The movement is very slow (approxi-
mately 0.1 rev per minute). The motor runs.
Y N
Figure 1.
P/J154, Main Drives PWB.
Fuser web motor assembly, (35-55 ppm) PL 4.17 Item 1.
Fuser web motor assembly, (65-90 ppm) PL 4.12 Item 1.
Main drives module, (35-55 ppm) PL 4.15 Item 1.
Main drives module, (65-90 ppm) PL 4.10 Item 1.
1.10 Item 2.

Drive coupling on the fuser web motor shaft, (65-90 ppm) PL 4.12 Item 1.
Drive coupling on the fuser web motor shaft, (35-55 ppm) PL 4.17 Item 1.
Drive coupling on the web assembly, Figure 2.

The life expectancy of the fuser web is the same as the Fuser module. Install new Fuser
module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.
Fuser
drawer
connector
P/J100
Drive coupling
for the web
assembly
Fuser
module
Fuser drawer
connector
Fuser web motor P/J100
assembly Fuser drive gear
(MOT10-010)

A
11-005-110, 11-006-110, 11-310-110, 11-311-110 Front Refer to:
Tamper Move Failure RAP
11-005-110 Front tamper fails to move to the front position.
P/J312, 2K LCSS PWB.
11-006-110 Front tamper fails to move to the rear position. 11D-110 2K LCSS Power Distribution RAP.
11-310-110 Front tamper not at the front home position. Repair or install new components as necessary:
11-311-110 Front tamper not at the rear home position. Tamper assembly, PL 11.16 Item 1.
Initial Actions
Enter dC330 code 11-310, actuate the front tamper home sensor. The display changes.
Y N
WARNING Go to Flag 1. Check the sensor.
Ensure that the electricity to the machine is switched off while performing tasks that do Refer to:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 11G-110 2K LCSS PWB Damage RAP.
death or injury. Moving parts can cause injury. GP 11 How to Check a Sensor.
Figure 1. Check for damage or obstructions that would prevent the tamper assembly from P/J312, 2K LCSS PWB.
operating correctly. If necessary, install a new tamper assembly, PL 11.16 Item 1.
11D-110 2K LCSS Power Distribution RAP.
Jams can be caused by removing prints from bin 1 before the machine has finished print-
Repair or install new components as necessary:
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 Front tamper home sensor, PL 11.16 Item 3.
and the tray 3 and tray 4 to paper path interface. 2K LCSS PWB, PL 11.26 Item 1.
Jams can also be caused if the tray settings do not match the paper in the trays. Make
sure the tray settings are correct. Perform SCP 6 Final Actions.
Check the condition and the tension of the front tamper drive belt. Tensioning is achieved
Front tamper home
by a spring on the motor, the motor should be free to move. sensor Q11-310
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 IQ1 Image Quality Entry RAP.
Check the operation of the paddle roll, refer to 11-024-110, 11-025-110 Paddle Roll
Failure RAP.
Check the operation of the bin 1 upper level sensor, refer to 11-030-110, 11-334-110,
11-335-110, 11-336-110 Bin 1 Movement Failure RAP.
Refer to the 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP
Switch Settings RAP.
Procedure
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
Front tamper motor
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state MOT-003 (located at
on the UI. Make sure that the correct sensor or switch is tested. the rear)
Enter dC330, codes 11-003 and 11-005 alternately The front tamper moves between the
home and inboard positions, Figure 1.
Y N
Go to Flag 2. Check the front tamper motor, MOT11-003.
A

Xerox WorkCentre 5790 Family 2-317 11-005-110, 11-006-110, 11-310-110, 11-311-110

11-005-110, 11-006-110, 11-310-110, 11-311-110 2-318 Xerox WorkCentre 5790 Family
11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-110 Procedure
Rear Tamper Move Failure RAP NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
11-007-110 Rear tamper fails to move to the front position. NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.
11-008-110 Rear tamper fails to move to the rear position.
Enter dC330, codes 11-004 and 11-006 alternately. The rear tamper moves between the
11-312-110 Rear tamper is not at the front home position. home and inboard positions, Figure 1.
Y N
11-313-110 Rear tamper is not at the rear home position. Go to Flag 3. Check the rear tamper motor, MOT11-004.
Refer to:
11-319-110 Rear tamper is not at the away home position. 11G-110 2K LCSS PWB Damage RAP.
GP 10, How to Check a Motor.
NOTE: The away home position is with the rear tamper approximately halfway along its travel.
Initial Actions 11D-110 2K LCSS Power Distribution RAP.
Tamper assembly, PL 11.16 Item 1.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Enter dC330 code 11-311, actuate the rear tamper home sensor Q11-311. The display
death or injury. Moving parts can cause injury. changes.
Figure 1. Check for damage or obstructions that would prevent the tamper assembly from Y N
operating correctly. If necessary, install a new tamper assembly, PL 11.16 Item 1. Go to Flag 1 and check Q11-311.
Jams can be caused by removing prints from bin 1 before the machine has finished print- Refer to:
ing. If the tampers are touched while they are moving, they may stall and cause the 11G-110 2K LCSS PWB Damage RAP.
machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher GP 11, How to Check a Sensor.
and the tray 3 and tray 4 to paper path interface.
sure the tray settings are correct.
Check the condition of the front 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. Rear tamper home sensor, PL 11.16 Item 3.
If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob- 2K LCSS PWB, PL 11.26 Item 1.
Perform the following: NOTE: The away home position is used for short edge feed small paper. This saves unneces-
sary rear tamper travel.
paper condition, buckling or paper type. Refer to IQ1 Image Quality Entry RAP. Enter dC330 code 11-319, actuate the rear tamper away home sensor Q11-319. The display
Check the operation of the paddle roll, refer to 11-024-110, 11-025-110 Paddle Roll changes.
Failure RAP. Y N
Check the operation of the bin 1 upper level sensor, refer to 11-030-110, 11-334-110, Go to Flag 2 and check Q11-319.
11-335-110, 11-336-110 Bin 1 Movement Failure RAP. Refer to:
Refer to the 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. 11G-110 2K LCSS PWB Damage RAP.
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP GP 11, How to Check a Sensor.
Switch Settings RAP. P/J312, 2K LCSS PWB.
Rear tamper away home sensor, PL 11.16 Item 3.

Xerox WorkCentre 5790 Family 2-319 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-
A
Rear tamper motor

MOT11-004 (located at
the front)
Rear tamper
away home
sensor
Q11-319
Rear tamper home

sensor
Q11-311

11-007-110, 11-008-110, 11-312-110, 11-313-110, 11- 2-320 Xerox WorkCentre 5790 Family

A
11-024-110, 11-025-110 Paddle Roll Failure RAP 2K LCSS PWB, PL 11.26 Item 1.
11-024-110 The paddle is not at the home position.
Enter dC330, code 11-025 and stack the code 11-326, to actuate the paddle roll position sen-
sor Q11-326. The display cycles high/low.
11-025-110 The paddle fails to rotate. Y N
NOTE: The paddle is in the home position when the sensor flag is located between the sensor
Refer to:
jaws. If a jam occurs in the compiler, bin 1 will not be available.
Initial Actions GP 11, How to Check a Sensor.
Figure 1.
WARNING
11D-110 2K LCSS Power Distribution RAP
death or injury. Moving parts can cause injury. Paddle roll position sensor, PL 11.8 Item 11.
Check the following: 2K LCSS PWB, PL 11.26 Item 1.
That there is no paper or other obstructions in the vicinity of the paddle.
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- Paddle roll
ponents. position sensor
Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, Q11-326
the compiler capacity can be exceeded. Refer to 11J-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 11.12-110 Paddle
Wheel Shaft Assembly. If any of the paddles are out of alignment to other paddles, install
a new paddle wheel shaft assembly, PL 11.8 Item 4.
2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Settings
RAP.
Procedure
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
Enter dC330, codes 11-024, paddle home position and 11-025, paddle run. The paddle
rotates correctly.
Y N
Go to Flag 2. Check the paddle motor, MOT 11-024.
Refer to:
GP 10, How to Check a Motor. Paddle motor
Figure 1. MOT11-024
Repair or install new components as necessary: Figure 1 Component location
Paddle motor, PL 11.8 Item 10.
A
11-024-110, 11-025-110 2-322 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-323 11-024-110, 11-025-110
11-030-110, 11-334-110, 11-335-110, 11-336-110 Bin 1 Procedure
Movement Failure RAP NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
11-030-110 Bin 1 fails to move. NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
11-334-110 Bin 1 has reached the upper limit of travel.
Remove the 2K LCSS rear cover. Enter dC330 code 11-336, bin 1 motor encoder sensor Q11-
11-335-110 Bin 1 has reached the lower limit of travel. 336, slowly rotate the encoder disk by hand. The display changes.
Y N
11-336-110 Bin 1 is not at the home position. Go to Flag 2. Check Q11-336.
Refer to:
NOTE: The home position of bin 1 is when bin 1 is actuating the bin 1 lower level sensor. See 11G-110 2K LCSS PWB Damage RAP.
the final actions at the end of the procedure. GP 11 How to Check a Sensor.
Three sensors and two switches monitor the level of paper in bin 1 and the position of the tray: P/J304, 2K LCSS PWB.
The bin 1 upper level sensor, the highest of two sensors that detect the top of the paper 11D-110 2K LCSS Power Distribution RAP.
stack in bin 1, or the empty bin 1, Figure 1.
The bin 1 90% full sensor detects when the tray has descended to a position where the
Bin 1 motor encoder sensor Q11-336, PL 11.10 Item 11.
tray is 90% full, Figure 2.
The bin 1 lower level sensor, the lowest of two sensors that detects when paper is
removed from bin 1, Figure 1.
Enter dC330 code 11-033, bin 1 elevator motor, MOT11-030. Bin 1 cycles down and up.
Bin 1 upper limit switch, S11-334, Figure 2. Y N
Bin 1 lower limit switch, S11-335, Figure 2. Go to Flag 1. Check MOT11-030.
Refer to:
Initial Actions
WARNING P/J318, 2K LCSS PWB.
Ensure that the electricity to the machine is switched off while performing tasks that do 11D-110 2K LCSS Power Distribution RAP.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Repair or install new components as necessary:
death or injury. Moving parts can cause injury. Bin 1 elevator motor MOT11-030, PL 11.10 Item 8
Perform the following: 2K LCSS PWB, PL 11.26 Item 1.
Check for a physical obstruction that would prevent bin 1 from moving, such as an item of
furniture. Figure 1, enter dC330, code 11-332. Actuate the bin 1 upper level sensor Q11-332. The dis-
Check that bin 1 is level front to back, if necessary perform ADJ 11.1-110 2K LCSS Bin 1 play changes.
Level. Y N
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Go to Flag 4. Check Q11-332.
Switch Settings RAP. Refer to:
Refer to the 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. 11G-110 2K 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, 2K LCSS PWB.
Perform the relevant check: 11D-110 2K LCSS Power Distribution RAP.
If paper is overflowing the tray when it is at the lower limit, check the tray 90% full sensor. REP 11.13-110 2K LCSS Un-docking.
If paper cannot be fed to bin 1 when it is at the highest position, check the bin 1 paper Repair or install new components as necessary:
sensor - low and bin 1 paper sensor - high. Bin 1 upper level sensor Q11-332, PL 11.12 Item 3.
Check the front and rear bin 1 drive belts. If necessary install new components, PL 11.10 Item 2K LCSS PWB, PL 11.26 Item 1.
1.
Figure 1, enter dC330, code 11-333. Actuate the bin 1 lower level sensor Q11-333. The dis-
play changes.

A
Y N 11D-110, 2K LCSS Power Distribution RAP.
Go to Flag 3. Check Q11-333. Repair or install new components as necessary:
Refer to:
Bin 1 90% full sensor Q11-331, PL 11.10 Item 5.
P/J314, 2K LCSS PWB. As final actions, check the following sequence of operation:
11D-110, 2K LCSS Power Distribution RAP. When bin 1 is empty and at the top, the bin 1 lower level sensor, Q11-333 is actuated by
REP 11.13-110 2K LCSS Un-docking. the edge of the tray and the bin 1 upper level sensor, Q11-332 is de-actuated.
Repair or install new components as necessary: Paper is delivered to the tray until the bin 1 upper level sensor, Q11-332 is actuated.
Bin 1 lower level sensor Q11-333, PL 11.12 Item 3. The motor lowers the tray until the bin 1 upper level sensor, Q11-332 is de-actuated.
2K LCSS PWB, PL 11.26 Item 1. As the tray is lowered to accommodate the increase in stack height, the Bin 1 lower level
sensor, Q11-333 is held actuated by the stack rear edge.
Figure 2. Enter dC330 code 11-334. Actuate the bin 1 upper limit switch, S11-334. The dis- When the tray is emptied, the tray returns to the home position; the bin 1 lower level sen-
play changes. sor, Q11-333 is de-actuated and the tray is elevated until both the bin 1 lower level sensor,
Y N Q11-333 and bin 1 upper level sensor, Q11-332 are made. The tray is then lowered until
Go to Flag 5. Check S11-334. the bin 1 upper level sensor, Q11-332 is just cleared. In the home position the bin one
Refer to: upper limit switch, S11-334 is also actuated.
Bin 1 lower level sensor
P/J315, 2K LCSS PWB. Q11-333
Bin 1 upper limit switch, PL 11.10 Item 3. Bin 1 upper level sensor
2K LCSS PWB, PL 11.26 Item 1. Q11-332
Enter dC330 code 11-335, actuate the bin 1 lower limit switch, S11-335. The display
changes.
Y N
Refer to:
11D-110 2K LCSS Power Generation RAP.
REP 11.13-110 2K LCSS Un-docking.
Bin 1 lower limit switch, PL 11.12 Item 1.
Enter dC330 code 11-331, actuate the bin 1 90% full sensor, Q11-331. The display changes.
Y N
Refer to:
GP 11 How to Check a Sensor. Figure 1 Component location

Bin 1 upper limit
switch, S11-334.
Bin 1 90%
full sensor
Q11-331
Bin 1 motor
encoder sensor
Q11-336
Bin 1 elevator
motor
MOT11-030
Bin 1 lower limit switch, S11-335.


A
11-043-110, 11-350-110 Hole Punch Operation Failure RAP GP 11 How to Check a Sensor.
11-043-110 The hole punch fails to perform a punch cycle. P/J307, 2K LCSS PWB.
11-350-110 The hole punch is not at the home position. Repair or install new components as necessary:
Punch head home sensor, PL 11.6 Item 1.
Initial Actions 2K LCSS PWB, PL 11.26 Item 1.
Enter dC330 code 11-043, hole punch motor MOT11-042. The punch cycles.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Go to Flag 3. Check MOT11-042.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Refer to:
death or injury. Moving parts can cause injury. 11G-110 2K LCSS PWB Damage RAP.
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP GP 10, How to Check a Motor.
Switch Settings RAP. P/J311, 2K LCSS PWB.
Check that the hole punch is present and correctly installed. 11D-110 2K LCSS Power Distribution RAP.
Check that the punch has not jammed in the down position. This can occur with transpar- Repair or install new components as necessary:
encies and labels.
Hole punch motor assembly, PL 11.6 Item 2.
NOTE: The home position of the punch unit is when the cut-out in the actuator is between 2K LCSS PWB, PL 11.26 Item 1.
the punch head home sensor jaws.
NOTE: The chad bin collects the pieces of paper cut out by the hole punch. The chad bin level
Procedure sensor will not operate if the tray is incorrectly installed. Ensure the chad bin is fully inserted
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state and the lever engages in the slot.
on the UI. Make sure that the correct sensor or switch is tested. Enter dC330, code 11-348 chad bin level sensor, Q11-348, Figure 2. Use a strip of paper actu-
Go to Flag 5. Check the link between P/J307 pins 10 and 11, 2K LCSS PWB. The link is ate Q11-348. The display changes.
good. Y N
Y N Go to Flag 4. Check Q11-340.
Repair the wiring or connector. Refer to:
Enter dC330, code 11-351, actuate the punch head present sensor, Q11-351, Figure 1. The GP 11 How to Check a Sensor.
display changes. P/J307, 2K LCSS PWB.
Y N
Refer to: Install new components as follows.
11G-110 2K LCSS PWB Damage RAP. Chad bin level sensor, PL 11.6 Item 7.
GP 11 How to Check a Sensor. 2K LCSS PWB, PL 11.26 Item 1.
Punch head present sensor, PL 11.6 Item 1.
Enter dC330 code 11-350, actuate the punch head home sensor, Q11-350, Figure 1. The dis-
play changes.
Y N
Refer to:
A
Hole punch motor
MOT11-042
Punch head
present sensor
Q11-351
Punch head home

sensor
Q11-350
Chad bin level sensor, Q11-348


11-050-110, 11-360-110 Staple Head Operation Failure RAP Y N
Go to Flag 1 and Flag 2. Check the wiring and connectors between the 2K LCSS PWB
11-050-110 The staple head fails to cycle.
and the staple head. The wiring is good.
Y N
11-360-110 The staple head is not at the home position. Repair the wiring.
NOTE: The home position is with the jaws of the staple head fully open.
Go to Flag 3. Check the SU1 safety gate switch, S11-365. Refer to:
NOTE: Staple head operation faults can be caused by offline stapling failures. The user may 11G-110 2K LCSS PWB Damage RAP.
be attempting to staple a set that exceeds the number of sheets/weight capacity. There may GP 13, How to Check a Switch.
also be an offline stapling problem, refer to 11A-110 Offline Stapling Fault RAP.
Figure 1.
Initial Actions P/J311, P/J308, 2K LCSS PWB
Ensure that the SU1 safety gate switch is correctly actuated by the switch actuator,
NOTE: The switch is closed and supplies +24V to the staple head when the cam is
positioned either fully counterclockwise or fully clockwise. During off line stapling
when the safety gate is partly down, the cam is in the mid position, the switch is open
and +24V is not supplied to the staple head.
CAUTION Install new components as necessary:
Do not run code 11-050 without two sheets of paper in the stapler jaws. Running this code with- Staple head unit, PL 11.20 Item 5.
out the paper in position can cause damage to the machine.
SU1 safety gate switch, PL 11.8 Item 1.
Refer to Figure 1. Check the following:
The spring and cam are correctly located.
The switch support bracket is correctly located.
The safety gate switch connector is fully seated on both sides of the frame.
The 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set-
tings RAP.
The staple head unit is correctly installed.
NOTE: Figure 1 shows the switch cam in the auto stapling position. To enable offline stapling,
the paddle motor is run in the reverse direction to lower the safety gate, this rotates the switch
cam in a counterclockwise direction, actuating the safety gate switch.
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 sheets of paper in the stapler jaws. Enter dC330, code 11-050 to cycle the staple
head once, and 11-051 to reverse the staple head to the home position. The staple head
operates as expected.

Safety gate
switch connector
Switch
support
bracket
Spring
Staple head including

MOT11-050 and staple
head 1 home sensor
Q11-360
Switch cam
SU1 safety gate
switch, S11-365


A
11-053-110, 11-370-110 Staple Head Unit Movement Failure 11D-110. 2K LCSS Power Distribution RAP.
RAP
Stapler traverse assembly, PL 11.20 Item 1.
11-053-110 The staple head unit fails to move.
11-370-110 The staple head unit is not at the home position.
Enter dC330, code 11-370. Actuate the SU1 home sensor, Q11-370, by moving the stapler unit
NOTE: The home position is when the staple head unit is at the corner stapling position (fully to and from the home position using the green thumb-wheel. The display changes.
Y N
to the front of the 2K LCSS and rotated through 45 degrees).
Initial Actions Refer to:
GP 11. How to check a sensor.
WARNING Figure 1.
Ensure that the electricity to the machine is switched off while performing tasks that do P/J308, 2K LCSS PWB.
SU1 home sensor, PL 11.20 Item 3.
WARNING 2K LCSS PWB, PL 11.26 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 11-021 to move the ejector assembly fully to the right. Enter code 11-371.
Actuate the SU1 front index sensor, Q11-371, by moving the stapler unit to and from the flag
position (approximately 115mm (4.5 inches) from the front of the track) using the green thumb-
wheel. The display changes.
Un-dock the 2K LCSS from the machine, REP 11.13-110, move the ejector assembly fully Y N
to the right, manually move the stapler unit along the full length of the track using the Go to Flag 2. Check Q11-371.
green thumb-wheel. Check the home sensor flag and the two dual position flags for dam- Refer to:
age, see NOTE. Check for damage or obstructions that would prevent the stapling unit
from moving. If necessary, install a new staple head unit, PL 11.20 Item 5 or a new stapler
traverse assembly, PL 11.20 Item 1. GP 11 How to Check a Sensor.
NOTE: For dual position stapling, the SU1 front index sensor uses two flags.
Dock the 2K LCSS to the machine. Repair or install new components as necessary:
SU1 front index sensor, PL 11.20 Item 3.
Procedure 2K LCSS PWB, PL 11.26 Item 1.
Enter dC330, code 11-021 to move the ejector assembly fully to the right. Enter code 11-055.
The stapling unit cycles back and forth along the track.
Y N
Go to Flag 3. Check MOT11-053.
Refer to:
Figure 1.
A
SU1 motor
MOT11-053
SU1 front index

sensor Q11-371
SU1 home sensor
Q11-370


11-100-110 2K LCSS Paper Entry RAP
11-100-110 The leading edge of the sheet is late to the entry sensor Q11-100, Figure 1.
Initial Actions
WARNING
Refer to the 11H-110 Copy Damage in the 2K LCSS RAP.

2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Settings
RAP.
Ensure the paper tray guides are set to the correct position for the size of paper in the
tray.
Check the input guide for damage or wear that could cause paper to jam.
Paper jam in the machine to 2K LCSS paper path, ADJ 11.2-110 Machine to 2K LCSS
Alignment.
IOT exit path and feed rolls.
Feeding performance from a paper tray loaded with a new ream of paper.
Procedure Entry sensor

Q11-100
Lower the paper entry guide assembly, PL 11.14 Item 8, to access the entry sensor. Enter Figure 1 Component location
dC330, code 11-100. Actuate the entry sensor, Q11-100. The display changes.
Y N
Refer to:
GP 11, How to Check a Sensor.
Entry sensor, PL 11.24 Item 3.

Xerox WorkCentre 5790 Family 2-337 11-100-110
11-110-110 Sheet Late to Hole Punch RAP
11-110-110 Sheet late at the punch sensor.
Initial Actions
WARNING
tings RAP.
tray.
For a paper jam at the entrance to the 2K LCSS. Check that there is no obstruction that
would prevent a sheet from arriving in position for punching, refer to the 11H-110 Copy
Damage in the 2K LCSS RAP.
The punch sensor, Q11-110 for chad debris, Figure 1.
Procedure
Figure 1. Enter dC330, code 11-110. Actuate the punch sensor, Q11-110. The display
changes.
Y N
Figure 2 Circuit diagram Refer to:
Punch sensor, PL 11.6 Item 7.

Punch sensor Q11-110

A
11-130-110, 11-132-110 Paper Exiting to Bin 0 RAP Refer to:
11-130-110 The leading edge of the sheet is late to the top exit sensor. 11G-110 2K LCSS PWB Damage RAP.
11-132-110 The trailing edge of the sheet is late from the top exit sensor. P/J309, 2K LCSS PWB.
Initial Actions Repair or install new components as necessary:
Transport motor 2, PL 11.22 Item 5.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Enter dC330, code 11-002 to energize the diverter gate solenoid, S11-002, Figure 1. The
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause diverter gate solenoid energizes.
Check the following: Go to Flag 2. Check SOL11-002.
2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Settings Refer to:
RAP. 11G-110 2K LCSS PWB Damage RAP.
Ensure the paper tray guides are set to the correct position for the size of paper in the GP 12, How to Check a Solenoid.
tray. P/J306, 2K LCSS PWB.
The tensioner on the intermediate paper drive belt. Check that the tensioner is free to 11D-110 2K LCSS Power Distribution RAP.
move and that the tensioner pulley is free to rotate. If necessary lubricate the tensioner
and tensioner pulley, REP 11.3-110. Refer to GP 18 Machine Lubrication.
Diverter gate solenoid, PL 11.22 Item 12.
The drive pulleys on both transport motor 1 and 2 are secure and do not slip on the motor
shaft. 2K LCSS PWB, PL 11.26 Item 1.
All the transport drive belts are correctly fitted, are in a good condition and are correctly
Enter dC330, code 11-130, actuate the top exit sensor, Q11-130, Figure 1. The display
tensioned, refer to REP 11.4-110.
changes.
All the transport rolls and idler pulleys are free to rotate. Y N
The diverter gate and linkage for free movement. Go to Flag 1. Check Q11-130.
A paper jam in the path to bin 0. Refer to:
Torn paper fragments from a previous jam clearance action. 11G-110 2K LCSS PWB Damage RAP.
A paper jam in the path to the top tray. If the jams occur shortly after install. Check the gap GP 11, How to Check a Sensor.
between the entry guide cover, PL 11.24 Item 5 and the paper guide PL 11.22 Item 10. If P/J313, 2K LCSS PWB.
the gap is less than 1mm, adjust or install a new entry guide cover. Refer to the replace- 11D-110 2K LCSS Power Distribution RAP.
ment procedure in REP 11.15-110.
Refer to the 11H-110 Copy Damage in the 2K LCSS RAP and the 11J-110 Mis-Registration in
Top exit sensor, PL 11.22 Item 11.
Stapled Sets and Non-Stapled Sets RAP.
NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized. Paper is fed to
bin 1 when the diverter gate solenoid is de-energized. Enter dC330, code 11-000 to energize the transport motor 1, MOT 11-000, Figure 1. The
motor energizes.
Procedure Y N
Go to Flag 4. Check MOT 11-000.
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors. Refer to:
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state 11G-110 2K LCSS PWB Damage RAP.
on the UI. Make sure that the correct sensor or switch is tested. GP 10, How to Check a Motor.
Enter dC330, code 11-001 to run transport motor 2, MOT11-001, Figure 1. The motor runs. P/J305, 2K LCSS PWB.
Y N 11D-110 2K LCSS Power Distribution RAP.
Go to Flag 3. Check MOT11-001. Repair or install new components as necessary:
A B
B
Top exit
sensor
Q11-130
Diverter gate
solenoid
S11-002
Transport motor 2
MOT11-001 Transport motor 1
MOT 11-000


11-140-110, 11-142-110 Sheet Late to Bin 1 RAP Procedure
11-140-110 The leading edge of the sheet is late to the 2nd to top exit sensor, Q11-140. NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
11-142-110 The trailing edge of the sheet is late to the 2nd to top exit sensor, Q11-140. NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
Initial Actions Figure 1. Enter dC330, code 11-001 to energize the transport motor 2, MOT11-001. The
motor energizes.
Y N
WARNING Go to Flag 3. Check MOT11-001.
Ensure that the electricity to the machine is switched off while performing tasks that do Refer to:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 11G-110 2K LCSS PWB Damage RAP.
death or injury. Moving parts can cause injury. GP 10, How to check a motor.
NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized. Paper is fed to P/J309, 2K LCSS PWB.
bin 1 when the diverter gate solenoid is de-energized. 11D-110 2K LCSS Power Distribution RAP.
Check the following: Repair or install new components as necessary:
2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Settings Transport motor 2, PL 11.22 Item 5.
RAP. 2K LCSS PWB, PL 11.26 Item 1.
Ensure the paper tray guides are set to the correct position for the size of paper in all
trays. Enter dC330, code 11-002 to energize the diverter solenoid, S11-002. Energize the solenoid.
The diverter solenoid energizes.
For trays 3 and 4, perform the following:
Y N
Select the systems settings button from the tools screen. Go to Flag 4. Check SOL11-002.
Select the tray management button and stock settings. Refer to:
From the list, select tray 3. Select the change stock size button. 11G-110 2K LCSS PWB Damage RAP.
Select the paper size loaded in the tray. Select the save button. GP 12, How to Check a Solenoid or Clutch.
Repeat for tray 4. P/J306, 2K LCSS PWB.
Save the stock setting and exit the tools mode. 11D-110 2K LCSS Power Distribution RAP.
The tensioner on the intermediate paper drive belt. Check that the tensioner is free to Repair or install new components as necessary:
move and that the tensioner pulley is free to rotate. If necessary re-lubricate the tensioner Diverter gate solenoid, PL 11.22 Item 12.
and tensioner pulley, REP 11.3-110. Refer to GP 18 Machine Lubrication.
NOTE: The tensioner arm and the tensioner pulley require different lubricants, refer to
REP 11.3-110 for details Figure 1. Enter dC330, code 11-140, actuate the 2nd to top exit sensor, Q11-140. The dis-
play changes.
That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the Y N
motor shaft. Go to Flag 1. Check Q11-140.
All the transport drive belts are correctly fitted and are in a good condition Refer to:
All the transport rolls and idler pulleys are free to rotate. 11G-110 2K LCSS PWB Damage RAP.
The diverter gate and linkage for free movement. GP 11, How to Check a sensor.
A paper jam in the path to bin 1, to the compiler, and for poor stacking on bin 1. P/J313, 2K LCSS PWB.
Ensure that the 2K LCSS is fully latched to the machine, refer to REP 11.13-110. 11D-110 2K LCSS Power Distribution RAP.
Torn paper fragments from a previous jam clearance action. Repair or install new components as necessary:
If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate mylar kit. 2nd to top exit sensor, PL 11.23 Item 4.
Refer to the 11H-110 Copy Damage in the 2K LCSS RAP and the 11J-110 Mis-Registration in 2K LCSS PWB, PL 11.26 Item 1.
Enter dC330, code 11-000 to energize the transport motor 1, MOT 11-000. The motor ener-
gizes.

Y N
Go to Flag 2. Check MOT 11-000.
Refer to:
If the fault is still present, perform 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-
110 Rear Tamper Move Failure RAP.
NOTE: A software problem can cause the machine to incorrectly display the fault code 11-142-
110.
2nd to top
exit sensor
Q11-140
Diverter gate
solenoid
S11-002
Transport motor 2
MOT11-001
Transport motor 1
MOT 11-000


11-300-110, 11-302-110, 11-303-110 Interlocks RAP 11-302-110 Top Cover Interlock RAP
11-300-110 The docking interlock is open during run mode. Check the top cover interlock switch, S11-302 as follows:
Check the switch actuator.
11-302-110 The top cover interlock is open during run mode.
Enter dC330, code 11-302. Actuate the switch, if the display does not change, refer to:
11-303-110 The front door interlock is open during run mode. GP 13, How to Check a switch
Go to Flag 3. Check the wiring between P/J315 and the switch.
WARNING
If necessary, install a new switch, PL 11.26 Item 6.
11-303-110 Front Door Interlock RAP
death or injury. Moving parts can cause injury. Check the front door interlock switch, S11-303 as follows:
Enter dC330, code 11-303. actuate the switch, if the display does not change, refer to:
WARNING GP 13, How to Check a switch
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Figure 1.
machine. Do not show the customer how to un-dock the LCSS.
If necessary, install a new switch, PL 11.26 Item 5.
The 2K LCSS is docked to the machine.
The 2K LCSS front door is closed.
The 2K LCSS top cover is closed.
Procedure
Go to Flag 1. Check for +24V on P/J302 pin 1. If the voltage is not present, refer to 11D-110 2K
LCSS Power Distribution RAP.
Go to the appropriate RAP:

Docking interlock switch
11-300-110 Docking Interlock RAP
S11-300
11-302-110 Top Cover Interlock RAP
Un-dock the 2K LCSS, REP 11.13-110, Check the docking interlock switch, S11-300 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 Top cover
this harness is not correctly positioned, the switch can be mis-located, giving intermittent interlock
docking interlock problems. switch
S11-302
Enter dC330, code 11-300. Actuate the switch, if the display does not change, refer to:
GP 13, How to Check a Switch
Figure 1.
P/J302, 2K LCSS PWB. Front door interlock
switch S11-303
If necessary, install a new switch, PL 11.4 Item 2. Figure 1 Component location

11-300-110, 11-302-110, 11-303-110 2-346 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-347 11-300-110, 11-302-110, 11-303-110
A
11-320-110, 11-322-110 Ejector Movement Failure RAP Refer to:
11-320-110 The ejector is not at the home position. 11G-110 2K LCSS PWB Damage RAP.
11-322-110 The ejector fails to perform a cycle of operation. Figure 1.
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.
Initial Actions Ejector home sensor, Q11-320, PL 11.18 Item 3.
WARNING Enter dC330, code 11-023 ejector cycle, check the operation of the ejector motor MOT11-020.
Ensure that the electricity to the machine is switched off while performing tasks that do The ejector motor runs.
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 Flag 3. Check the ejector motor, MOT11-020.
Refer to:
WARNING GP 10, How to Check a Motor.
Take care not to topple the LCSS. The LCSS is unstable when un-docked from the Figure 1.
machine. Do not show the customer how to un-dock the LCSS. P/J303, 2K LCSS PWB.
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP 11D-110 2K LCSS Power Distribution RAP.
Repair or Install new components as necessary:
Un-dock the 2K LCSS, REP 11.13-110, Check for any obstructions that would prevent the
Ejector assembly, PL 11.18 Item 1.
ejector from moving. Cheat the docking interlock switch.
Procedure Enter dC330, code 11-023 ejector cycle, check the ejector cycles. Stack the code 11-320 ejec-
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors. tor sensor home, then cycle the ejector. Stack the code 11-322 ejector sensor out, then cycle
the ejector. The ejector actuates the ejector home sensor and the ejector out sensor.
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state Y N
on the UI. Make sure that the correct sensor or switch is tested. Refer to GP 7, check the following components;
Figure 1. Pulley/drive gear, PL 11.18.
Enter dC330, code 11-322, actuate the ejector out sensor, Q11-322. The display changes.
Y N Ejector belt, PL 11.18 Item 5.
Refer to: Pulley/drive gear, PL 11.18.
11G-110 2K LCSS PWB Damage RAP. Ejector belt, PL 11.18 Item 5.
Figure 1. The ejector cycles noisily, colliding with the end stops.
Y N
Check the stapler to ensure the staples are correctly formed. Mis-formed staples can
11D-110 2K LCSS Power Distribution RAP. cause the set to hang in the stapler causing ejector movement failures. The staples are
Repair or install new components as necessary: correctly formed.
Ejector out sensor, Q11-322, PL 11.18 Item 3. Y N
2K LCSS PWB, PL 11.26 Item 1. 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 11.20 Item 5.
Enter dC330, code 11-320, actuate the ejector home sensor, Q11-320. The display changes.
Y N If the ejector is still not moving, install a new ejector assembly, PL 11.18 Item 1.
Go to Flag 1. Check Q11-320. Perform SCP 6 Final Actions.
Go to Flag 4. +5v is available at P/J304 between pins 7 and 8.

A
Y N
Go to the 11D-110 2K LCSS Power Distribution RAP.
Connect a service meter at P/J304 between pins 8 and 9. Slowly rotate the ejector motor
encoder. The voltage changes between +5V and 0V.
Y N
Go to Flag 4. Check the wiring and connectors between the ejector motor encoder sensor
and the 2K LCSS PWB. If necessary repair the wiring, REP 1.2. If the wiring is good,
install a new ejector motor encoder sensor, PL 11.18 Item 3.
Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K LCSS PWB,
PL 11.26 Item 1.
Pulley/drive
gear
Ejector
belt
Ejector out
sensor
Q11-322
Ejector motor
MOT11-020
Ejector motor
encoder sensor
Ejector home sensor
Q11-320


A
11-364-110 Stapling 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 2K LCSS interlocks
11-364-110 Staples in the stapling head are not primed.
are made.
Initial Actions Follow the customer instruction label inside the 2K LCSS front door to remove the staple car-
tridge, 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 car-
WARNING tridge 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, Fig-
ure 3. The first two staples have been partially formed.
Y N
Switch off the machine, then switch on the machine, GP 14. Install a new staple cartridge, PL 26.10 Item 11and repeat the check. If the first two sta-
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP ples are not partially formed, install a new staple head unit, PL 11.20 Item 5. Perform SCP
Switch Settings RAP. 6 Final Actions
The staple cartridge has staples in it and is correctly installed, Install a new staple head unit, PL 11.20 Item 5. Perform SCP 6 Final Actions.
The leading staples in the staple head have been primed, Figure 2.
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 11.
Refer to the 11A-110 Offline Stapling Fault RAP. Make sure the safety gate switch bulk-
head connector is connected.
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 2.
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 11-361, actuate the SH 1 paper sensor, Q11-361. The display
changes.
Y N
Refer to:
SH 1 paper
P/J308, 2K LCSS PWB. sensor Q11-361
Staple head unit
SH 1 paper sensor, PL 11.20 Item 4.
2K LCSS PWB, PL 11.26 Item 1. Figure 1 Component location

Forming plate open Primed staples Forming plate fully closed
Figure 2 Staple cartridge open Figure 3 Staple cartridge closed

11-364-110 2-352 Xerox WorkCentre 5790 Family

11A-110 Offline Stapling Fault RAP Procedure
Use this RAP when offline stapling fails to operate. NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
NOTE: Due to customer difficulty with the offline stapler feature, the feature is no longer pro-
moted. The button has had the staple symbol removed. Also the label that used to be on the Enter dC330, code 11-374 to illuminate the offline staple LED. The LED is illuminated.
front, showing how to put sets in for stapling has been removed. However a customer who Y N
knows about this feature may still use it. Go to Flag 4. Disconnect P/J312. +2V is available at P/J312 between pins B10 and
B12 when the code is entered.
The functionality is still present to allow the customer to lower bin 1 to remove documents.
Y N
Initial Actions Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K
LCSS PWB, PL 11.26 Item 1.
WARNING Check the wiring between the 2K LCSS PWB and the offline staple PWB. The wiring is
good.
Y N
Repair the wiring.
Switch off the machine, then switch on the machine, GP 14. Install a new offline staple PWB, PL 11.26 Item 3.
Refer Figure 2. Check the following: Enter dC330, code 11-373, actuate the offline staple switch, S11-373. The display changes.
The spring and cam are correctly located. Y N
The switch support bracket is correctly located. Go to Flag 5. Check the wiring between the 2K LCSS PWB and the offline staple PWB.
The safety gate switch connector is fully seated on both sides of the frame. The wiring is good.
Y N
Repair the wiring.
tings RAP.
The staple head unit is correctly installed. Refer to the 11G-110 2K LCSS PWB Damage RAP, Install new components as neces-
NOTE: Figure 2 shows the switch cam in the auto stapling position. To enable offline stapling, sary:
the paddle motor is run in the reverse direction to lower the safety gate, this rotates the switch Offline staple PWB, PL 11.26 Item 3.
cam in a counterclockwise direction, actuating the safety gate switch. 2K LCSS PWB, PL 11.26 Item 1.
Operation Enter dC330, code 11-367, actuate the edge registration sensor, Q11-367. The display
Offline stapling should follow the following sequence: changes.
The offline staple button is pressed. Y N
Bin 1 lowers to improve access to the stapler area. Go to Flag 2 and Flag 3. Check Q11-120. Refer to:
The front tamper moves into position to guide the set to be stapled.
The set to be stapled is inserted fully into the throat of the stapler.
The SH 1 paper sensor, Q11-361 detects the set in the throat of the stapler. The edge reg- NOTE: The edge registration sensor Q11-367 that detects paper in position for sta-
istration sensor, Q11-367 detects the set in the centre of the compiler. The set is correctly pling is an infrared device. It has two parts, the receiver is mounted on the staple
located for stapling when both sensors are made. traverse assembly and the LED is mounted on the sensor support assembly PL
The paddle motor drives in reverse to lower the safety gate until the safety gate interlock 11.12 Item 5.
switch is made. This process is a safety feature. Figure 1.
The stapler is then cycled once to staple the set. P/J308 and P/J314, 2K LCSS PWB.
Edge registration sensor, PL 11.20 Item 8.
A
11A-110 2-354 Xerox WorkCentre 5790 Family
A
Enter dC330, code 11-361, actuate the SH1 paper sensor, Q11-361. The display changes.
Y N Edge registration
Go to Flag 6. Check Q11-361. sensor Q11-367
Refer to:
Figure 2.
Repair or install new components as necessary: Stapler
traverse
SH 1 paper sensor, PL 11.12 Item 2. assembly Edge reg-
2K LCSS PWB, PL 11.26 Item 1. istration
sensor
Enter dC330, code 11-365, manually actuate the SU1 safety gate switch, S11-365. The dis- LED
play changes.
Y N
Figure 2.
Safety gate interlock switch, PL 11.8 Item 1. Ejector assembly
Enter dC330, code 11-026 to run the paddle motor in reverse. The switch cam is rotated
counter clockwise to its end stop.
Y N
Go to 11-024-110, 11-025-110 Paddle Roll Failure RAP.
If the stapler is still inoperative, install a new staple head unit, PL 11.20 Item 5.

Xerox WorkCentre 5790 Family 2-355 11A-110
Offline staple LED
Offline staple switch S11-373
Safety gate switch

connector
Switch support
bracket
SH1 paper
sensor
Q11-361
Staple head
Spring
Offline staple PWB
Switch cam
SU 1 safety gate
switch S11-365


11B-110 Bin 1 Overload RAP
Use this RAP to resolve a fault on the bin 1 90% full sensor.
Procedure
WARNING
Enter dC330, code 11-331, actuate the bin 1 90% full sensor, Q11-331. The display
changes.
Y N
Refer to:
11G-110 2K LCSS PWB Damage RAP. Bin 1 90% full sensor
Q11-331
GP 11, How to Check a sensor.
Figure 1.
P/J316 2K LCSS PWB.
11D-110 2K LCSS Power Generation RAP.
Bin 1 90% full sensor, PL 11.10 Item 5.

11B-110 2-358 Xerox WorkCentre 5790 Family
11C-110 2K LCSS Initialization Failure RAP Punch not at home, refer to 11-043-110, 11-350-110 Hole Punch Operation Failure RAP
When an initialization command is received from the machine, the units are initialized in two Staple head not at home, refer to 11-050-110, 11-360-110 Staple Head Operation Failure
RAP.
stages:
Stapling unit not at home, refer to 11-053-110, 11-370-110 Staple Head Unit Movement
The following units are initialized sequentially:
Failure RAP.
1. If the staple head is not at the home position, it is driven to the home position
Ejector not at home, refer to 11-320-110, 11-322-110 Compiler Ejector Movement Failure
2. If the stapling unit is not at the home position, it is driven to the home position
RAP.
3. If the ejector is not at the home position, it is driven to the home position
The following units are then initialized simultaneously:
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
4. If the paddle is not at the home position, it is driven to the home position
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.
Initial Actions
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Fuse
Check the fuse on the 2K LCSS PWB, If the fuse is good, continue at the procedure. If the fuse
not good, install a new 2K LCSS PWB, PL 11.26 Item 1.
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set-
tings RAP.
LED 1
Remove the 2K LCSS covers, REP 11.1-110, 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 11-300-110, 11-302-110,
11-303-110 Interlocks RAP.
LED 2
Procedure
Refer to Figure 1. Check that the software heartbeat is present on LED 1. The LED should Figure 1 LED location
flash twice per second if the 2K LCSS software is running. If necessary, re-load the 2K LCSS
software, refer to GP 4 Machine Software.
If the initialization sequence fails to place any unit at the home position, refer to the appropriate
RAPs:
Front tamper not at home, refer to 11-005-110, 11-006-110, 11-310-110, 11-311-110 Front
Rear tamper not at home, refer to 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-
319-110 Rear Tamper Move Failure RAP.
Paddle not at home, refer to 11-024-110, 11-025-110 Paddle Roll Failure RAP.
Bin 1 not at home, refer to 11-030-110, 11-334-110, 11-335-110, 11-336-110 Bin 1 Move-
ment Failures RAP.

Xerox WorkCentre 5790 Family 2-359 11C-110
A B C
11D-110 2K LCSS Power Distribution RAP +24V is available between all the checked pins on the end of the harness.
Y N
The 2K LCSS has an integral power supply providing +24V and +5V supplies to the 2K LCSS
Figure 1. Loosen the 4 screws and lift the power supply module away from
PWB. The AC power for the 2K LCSS power supply comes from the LVPS and base module of
the 2K LCSS frame. Go to Flag 1. ACL is available at CN1 between
the machine. pins 1 and 3.
Y N
Procedure Go to the 01C AC Power RAP and check the AC output voltages.
Check the wiring between CN2 and P/J300. The wiring is good.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Repair the wiring.
death or injury. Moving parts can cause injury. Install a new power supply module, PL 11.26 Item 2.
Check for a short circuit or an overload in the wiring or components connected

WARNING to the +24V on the 2K LCSS PWB. Refer to GP 7.
+24 V is available at PJ315 pin 5 on the 2K LCSS PWB.
Y N
CAUTION Go to the 11-300-110, 11-302-110, 11-303-110 Interlocks RAP.
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.
WARNING
Close or cheat all the 2K LCSS interlocks. LED 2 on the 2K LCSS PWB is illuminated.
Do not install a fuse of a different type or rating. Installing the wrong type or
Y N
rating of fuse can cause overheating and a risk of fire.
+24V is available at Fuse (F1) on the 2K LCSS PWB.
Y N Perform the following:
Go to Flag 2. Check for +24V between the following pins on P/J300: Switch off the machine, GP 14.
Pin 1 and pin 2 Go to Flag 3. Disconnect all the +24V harnesses to components.
Pin 1 and pin 3 Check each harness for short circuits and overheating, GP 7.
Pin 1 and pin 6 Repair or install new components as necessary.
Pin 1 and pin 7 Install a new fuse F1 on the 2K LCSS PWB, switch on the machine, GP 14.
Pin 5 and pin 2 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.
Pin 5 and pin 3
If the voltage drops below +22V, switch off the machine, GP 14. Re-check the
Pin 5 and pin 6
component and harness for overheating or short circuits. Repair or install new
Pin 5 and pin 7 components as necessary.
+24V is available between all the checked pins.
Y N Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K LCSS
Disconnect P/J300, check for +24V between the following pins on the end of PWB, PL 11.26 Item 1.
the harness:
Pin 1 and pin 2 Go to Flag 2. +5V is available at P/J300 between pins 4 and 6, also between pins 7 and 8.
Pin 1 and pin 3 Y N
Disconnect P/J300. +5V is available at P/J300 between pins 4 and 6, also between
Pin 1 and pin 6
pins 7 and 8 on the end of the harness.
Pin 1 and pin 7 Y N
Pin 5 and pin 2 Loosen the 4 screws and lift the power supply module away from the 2K LCSS
Pin 5 and pin 3 frame. Go to Flag 1. ACL is available at CN1 between pins 1 and 3.
Pin 5 and pin 6 Y N
Go to the 01C AC Power RAP and check the AC output voltages.
Pin 5 and pin 7
A B C D E F
11D-110 2-360 Xerox WorkCentre 5790 Family
D E F
Check the wiring between CN2 and P/J300. The wiring is good.
Y N
Repair the wiring.
Install a new power supply module, PL 11.26 Item 2.
Check for a short circuit or overload in the wiring or components connected to +5V on the
2K LCSS PWB. Refer to GP 7.
Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K LCSS PWB,
PL 11.26 Item 1.
Power Supply
Module

Xerox WorkCentre 5790 Family 2-361 11D-110

11E-110 2K LCSS to Machine Communications Interface 11F-110 2K LCSS PWB DIP Switch Settings RAP
RAP To show the correct settings for the DIP switches on the 2K LCSS PWB.
All communications between the machine and 2K LCSS are conducted through a single inter-
face cable. Procedure
Procedure
WARNING
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set-
tings RAP. If the settings are correct, go to 03-360, 03-408 to 03-410, 03-418 IOT to Output Ensure that the electricity to the machine is switched off while performing tasks that do
Device Error Rap. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Problems that can result from incorrect DIP switch settings are:
False jam clearance instructions for the 2K LCSS and/or the machine exit area.
Communication errors between the 2K LCSS and machine.
Erratic behavior of the 2K LCSS.
Check the DIP switch settings, Figure 1. If necessary, switch off the machine, GP 14. Correct
the DIP switch setting, then switch on the machine, GP 14.
NOTE: On later LCSS PWBs, the DPS2 and DPS3 DIP switches are no longer fitted. DPS1
remains on the later PWBs and should be set as shown in Figure 1.
Figure 1 DIP switch settings

Xerox WorkCentre 5790 Family 2-363 11E-110, 11F-110
11G-110 2K LCSS PWB Damage RAP
Use this RAP to determine the cause of damage to the 2K LCSS PWB, so that the cause can
be repaired before a new 2K LCSS PWB is installed.
Initial Actions
WARNING
Check the fuse on the 2K LCSS PWB, If the fuse is good, continue at the procedure. If the fuse
not good, install a new 2K LCSS PWB, PL 11.26 Item 1.
Procedure
The 2K LCSS PWB can be damaged by a component connected to it going short-circuit. If a
Fuse
new 2K LCSS PWB is installed and power applied to the machine, the new 2K LCSS PWB will
be damaged in the same way. The cause of the damage must be found by following this proce-
dure.
Remove the 2K LCSS PWB and inspect the components shown in Figure 1 for damage. The
damage 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 2K LCSS PWB.
Figure 1 2K LCSS PWB components

11G-110 2-364 Xerox WorkCentre 5790 Family
Table 1 2K LCSS PWB Drive Components Table 1 2K LCSS PWB Drive Components
2K LCSS 2K LCSS
PWB Driven Normal resistance Spared part and PWB Driven Normal resistance Spared part and
component component measurement +/- 10% references component component measurement +/- 10% references
U10 Rear tamper W/O Tag F-010 PJ312 Tamper assembly, PL 11.16 U23 Ejector motor PJ303 Ejector assembly, PL 11.18
motor pin A1 to A3 = 29 ohms Item 1. 11-007-110, 11-008- pin 1 to 2 = 8 ohms Item 1. 11-320-110, 11-322-
pin A1 to A4 = 29 ohms 110, 11-312-110, 11-313- 110 RAP
pin A2 to A5 = 29 ohms 110, 11-319-110 RAP Q1 Diverter gate PJ306 Diverter gate solenoid, PL
pin A2 to A6 = 29 ohms solenoid pin 1 to pin 2 = 74 ohms 11.22 Item 12. 11-130-110,
W/Tag F-010 PJ312 11-132-110 RAP
pin A1 to A3 = 20 ohms Q2, Q3, Q4, Bin 1 elevator PJ318 Bin 1 elevator motor, PL
pin A1 to A4 = 20 ohms
Q5 motor pin 1 to 2 = 7.7 ohms 11.10 Item 8. 11-030-110,
11-334-110, 11-335-110, 11-
pin A2 to A6 = 20 ohms 336-110 RAP
U11 Staple head PJ308 Staple head unit, PL 11.20
motor pin A8 to A10 = 20 ohms Item 5. 11-050-110, 11-360-
NOTE: If difficulty is found in connecting the service meter probes to the connector headers on
pin A9 to A11 = 20 ohms 110 RAP
the 2K LCSS PWB, refer to the RAP quoted in Table 1 and make the measurement at another
U12 Front tamper W/O TAg F-010 PJ312 Tamper assembly, PL 11.16 point in the harness to the driven component.
motor pin A7 to A9 = 29 ohms Item 1. 11-005-110, 11-006-
pin A7 to A10 = 29 ohms 110, 11-310-110, 11-311-110 If the defective driven component is found using the table checks, disconnect the connector
pin A8 to A11 = 29 ohms RAP closest to the driven component, then check the driven component again to identify any short
pin A8 to A12 = 29 ohms circuit in the wiring to the driven component. Repair the wiring or install new parts as neces-
W/Tag F-010 PJ312 sary.
pin A7 to A10 = 20 ohms If the defective driven component can not be found using the table checks, refer to GP 7, check
pin A8 to A11 = 20 ohms each driven component to ensure that it is not seized. Motors should rotate reasonably easily.
pin A8 to A12 = 20 ohms Solenoid armatures should slide easily in the coil. Also check the drive components to ensure
that they rotate easily, if necessary install new parts.
U14 Transport PJ305 Transport motor 1, PL 11.14
motor 1 pin 1 to 4 = 4 ohms Item 2. 11-130-110, 11-132-
pin 1 to 5 = infinity 110 RAP When the a new driven component has been installed or the defective drive components have
been repaired, install a new 2K LCSS PWB, PL 11.26 Item 1.
pin 2 to 6 = 4 ohms
pin 2 to 3 = infinity
U15 Transport PJ309 Transport motor 2, PL 11.22
motor 2 pin 1 to 4 = 1.3 ohms Item 5. 11-130-110, 11-132-
pin 1 to 5 = 1.3 ohms 110 RAP
pin 2 to 6 = 1.3 ohms
pin 2 to 7 = 1.3 ohms.
U16 Hole punch PJ311 Not spared. 11-043-110, 11-
motor pin 1 to 2 = 6 ohms 350-110 RAP
U17 Paddle motor PJ310 Paddle motor assembly, PL
pin 1 to 3 = 29 ohms 11.8 Item 10. 11-024-110,
pin 1 to 4 = 29 ohms 11-025-110 RAP
pin 2 to 5 = 29 ohms
pin 2 to 6 = 29 ohms.
U18 SU1 motor PJ308 Stapler traverse assembly,
(stapler index- pin B9 to B11 = 20 ohms PL 11.20 Item 1. 11-053-110,
ing) pin B9 to B12 = 20 ohms 11-370-110 RAP
pin B10 to B13 = 20 ohms
pin B10 to B14 = 20 ohms.

Xerox WorkCentre 5790 Family 2-365 11G-110
11H-110 Copy Damage in the 2K LCSS RAP
Use this RAP to identify and correct the causes of copy damage in the 2K LCSS.
Procedure Check that the end of the spring

clip is positioned on the inside of
the frame.
WARNING
Look for torn paper in the 2K LCSS paper path. Torn fragments can pass through the IOT
and 2K LCSS paper path without causing a problem until they finally wedge themselves at
some point. A likely place for a piece of paper to be wedged is at the hole punch assem-
bly, where the top and bottom guides form the narrowest part of the paper path.
Ensure that the shaft diverter assembly, PL 11.22 Item 13, operates correctly and has full
movement.
Ensure that the hole punches park at the fully open position. If they protrude even slightly,
a jam will occur in the narrow paper path of the hole punch.
Ensure that the jam clearance guide, PL 11.24 Item 6, closes and latches correctly. Check
that the magnet at the rear is located and functions correctly. Check the clip at the front is Figure 1 Position of the spring clip
positioned correctly, Figure 1.
Ensure that all idler rolls in the 2K LCSS paper path are free to rotate, particularly those
on the jam clearance guide, where the paper turns through 90 degrees.
Ensure that the paper path ribs of the jam clearance guide, PL 11.24 Item 6, and the entry
guide cover, PL 11.24 Item 5, are free of scores and nicks. Check also for contamina-
tion and glue from label stock.

11H-110 2-366 Xerox WorkCentre 5790 Family
11J-110 Mis-Registration in Stapled Sets and Non-Stapled 11K-110 2K LCSS Poor Stacking RAP
Sets RAP Use this RAP to find the cause of poor stacking in the 2K 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
The most likely cause of mis-registration is paper condition and/or damage such as curl, wrin- level sensors:
kle, creases, dog ears, etc. Large paper sizes should not be stacked on top of small paper sizes.
Ensure that the paper stack in each paper tray has been fanned.
Curl, wrinkle and creases are probably caused in the IOT, go to IQ1 Image Quality Entry RAP.
Turn over the paper stack in each paper tray.
For other copy/print damage and dog ears, go to the 11H-110 Copy Damage in the 2K LCSS 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.
RAP.
Try using a fresh ream of paper.
Check the following: Ensure that the edge guides of all paper trays are adjusted correctly for the paper
Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 11.2 size and that the trays are fully closed.
Item 13. Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL
Turn over the paper stack in the tray in use. 11.2 Item 13.
Use a new ream of paper in the tray in use. Labels must not be fed to bin 1, but to bin 0 only.
Paper type especially recycled paper can lead to registration problems. Try changing to a It is recommended that transparencies are fed to bin 0 whenever possible.
different brand or type of paper. Check that bin 1 is level front to back, if necessary perform ADJ 11.1-110 2K LCSS Bin 1
Ensure that the guides in the paper trays are correctly set and reported on the UI for the Level.
paper size loaded. Check that the bin 1 upper level sensor, Q11-332 and the bin 1 lower level sensor, Q11-
Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, 333 are working correctly. Refer to the 11-030-110, 11-334-110, 11-335-110, 11-336-110
the compiler capacity can be exceeded. Bin 1 Movement Failure RAP.
Check for obstructions in the compiler. Check the operation of the front and rear tampers. Refer to 11-005-110, 11-006-110, 11-
Ensure that the paddle roll operates correctly and that the paddles are not damaged. The 310-110, 11-311-110 Front Tamper Move Failure RAP and 11-007-110, 11-008-110, 11-
312-110, 11-313-110, 11-319-110 Rear Tamper Move Failure RAP.
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 Check that the output device is not near an air conditioning or ventilation output duct. Air
position sensor, PL 11.8 Item 11, the flag, PL 11.8 Item 7 and the paddle motor assembly, flow across the output bins can cause poor stacking.
PL 11.8 Item 10. If only one paddle is mis-aligned with the others, it can be re-positioned Check if Mod. TAG F-013 LCSS bin 1 kit is installed on the finisher.
by hand (they are not bonded to the shaft). Machine that regularly process large stacks of A4/8.5x11 inch LEF paper should
Make sure the paddles are clean. If necessary, use formula A cleaning fluid, PL 26.10 have the LCSS bin 1 W/TAG F-013 kit installed, PL 11.2 Item 16.
Item 2 to clean the paddles. Machines that regular process small stacks of A4/8.5x11 inch LEF, A3/11x17 inch
Ensure that the tampers operate correctly, i.e. are not stalling or losing position during the and A4/8.5x11 inch SEF paper should have the standard W/OTAG F-013 bin 1
job. Inspect the tampers for damage, if necessary install new parts. PL 11.16. installed, PL 11.2 Item 10.
Inspect the bin 1 entry nips for roll damage. The idlers should be held against the rubber Check the output copies for curl, refer to IQ5.
driving rolls and they should be free to rotate within their support springs. If necessary,
install new parts, PL 11.23.
Inspect the four spring loaded guides on the output cover, PL 11.2 Item 7. Ensure that
they are correctly located and are free to move up and down.

Xerox WorkCentre 5790 Family 2-367 11J-110, 11K-110
11J-110, 11K-110 2-368 Xerox WorkCentre 5790 Family
A
11-005-120, 11-006-120, 11-310-120, 11-311-120 Front Refer to:
11-005-120 Front tamper fails to move to the front position.
P/J9, 1K LCSS PWB.
11-006-120 Front tamper fails to move to the rear position. 11C-120 1K LCSS Power Distribution RAP.
11-310-120 Front tamper not at the front home position. Repair or install new components as necessary:
11-311-120 Front tamper not at the rear home position. Tamper assembly, PL 11.112 Item 1.
Initial Actions
Enter dC330 code 11-310. Actuate the front tamper home sensor, Q11-310. The display
changes.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Go to Flag 1. Check Q11-310.
death or injury. Moving parts can cause injury. 11F-120 1K LCSS PWB Damage RAP.
Figure 1. Check for damage or obstructions that would prevent the tamper assembly from GP 11 How to Check a Sensor.
operating correctly. If necessary, install a new tamper assembly, PL 11.112 Item 1. P/J16, 1K LCSS PWB.
Jams can be caused by removing prints from bin 1 before the machine has finished print- 11C-120 1K LCSS Power Distribution RAP.
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. Front tamper home sensor, PL 11.112 Item 3.
Jams can also be caused if the tray settings do not match the paper in the trays. Make 1K LCSS PWB, PL 11.124 Item 1.
Check the condition and tension of the front tamper drive belt. Tensioning is achieved by a
spring on the motor, the motor should be free to move.
Front tamper home
If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob-
sensor Q11-310
paper condition, buckling or paper type. Refer to the IQ1 Image Quality Entry RAP.
Check the operation of the paddle roll, refer to 11-024-120, 11-025-120 Paddle Roll
Failure RAP.
Check the operation of the bin 1 upper level sensor, refer to 11-030-120, 11-334-120,
11-335-120, 11-336-120 Bin 1 Movement Failure RAP.
Refer to the 11J-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP
Procedure
NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors. Front tamper motor
MOT11-003
(located at the rear)
Enter dC330, codes 11-003 and 11-005 alternately. The front tamper moves between the
home and inboard positions, Figure 1.
Y N
Go to Flag 2. Check the front tamper motor, MOT11-003. Figure 1 Component location
A


11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120 Procedure
Rear Tamper Move Failure RAP NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.
11-007-120 Rear tamper fails to move to the front position. NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
11-008-120 Rear tamper fails to move to the rear position.
Enter dC330, codes 11-004 and 11-006 alternately. The rear tamper moves between the
11-312-120 Rear tamper is not at the front home position. home and inboard positions, Figure 1.
Y N
11-313-120 Rear tamper is not at the rear home position. Go to Flag 3. Check the rear tamper motor, MOT11-004.
Refer to:
11-319-120 Rear tamper is not at the away home position. 11F-120 1K LCSS PWB Damage RAP.
NOTE: The away home position is with the rear tamper approximately halfway along its travel.
P/J9, 1K LCSS PWB.
Initial Actions 11C-120 1K LCSS Power Distribution RAP.
Tamper assembly, PL 11.112 Item 1.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Enter dC330 code 11-311. Actuate the rear tamper home sensor Q11-311. The display
death or injury. Moving parts can cause injury. changes.
Figure 1. Check for damage or obstructions that would prevent the tamper assembly from Y N
operating correctly. If necessary, install a new tamper assembly, PL 11.112 Item 1. Go to Flag 1. Check Q11-311.
Jams can be caused by removing prints from bin 1 before the machine has finished print- Refer to:
ing. If the tampers are touched while they are moving, may stall and cause the machine to 11F-120 1K LCSS PWB Damage RAP.
shutdown. The resulting shutdown can cause un-clearable jams in the finisher and the GP 11, How to Check a Sensor.
tray 3 and tray 4 to paper path interface.
P/J16, 1K LCSS PWB
Check the condition and tension of the front tamper drive belt. Tensioning is achieved by a
spring on the motor, the motor should be free to move. Rear tamper home sensor, PL 11.112 Item 3.
If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob- 1K LCSS PWB, PL 11.124 Item 1.
Perform the following: NOTE: The away home position is used for short edge feed small paper. This saves unneces-
sary rear tamper travel.
paper condition, buckling or paper type. Refer to the IQ1 Image Quality Entry RAP. Enter dC330. Actuate the rear tamper away home sensor Q11-319. The display changes.
Check the operation of the paddle roll, refer to 11-024-120, 11-025-120 Paddle Roll Y N
Failure RAP. Go to Flag 2. Check Q11-319.
Check the operation of the bin 1 upper level sensor, refer to 11-030-120, 11-334-120, Refer to:
11-335-120, 11-336-120 Bin 1 Movement Failure RAP. 11F-120 1K LCSS PWB Damage RAP.
Refer to the 11J-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. GP 11, How to Check a Sensor.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP P/J16, 1K LCSS PWB
Switch Settings RAP. 11C-120 1K LCSS Power Distribution RAP.
Rear tamper away home sensor, PL 11.112 Item 3.

Rear tamper motor
MOT11-004 (located
at the front)
Rear tamper away

home sensor
Q11-319
Rear tamper home

sensor
Q11-311

11-007-120, 11-008-120, 11-312-120, 11-313-120, 11- 2-372 Xerox WorkCentre 5790 Family

A
11-024-120, 11-025-120 Paddle Roll Failure RAP 1K LCSS PWB, PL 11.124 Item 1.
11-024-120 The paddle is not at the home position.
Enter dC330, code 11-025 and stack the code 11-326, to actuate the paddle roll position sen-
sor Q11-326. The display cycles high/low.
11-025-120 The paddle fails to rotate. Y N
NOTE: The home position of the paddle is when the sensor flag is located between the sensor
Refer to:
jaws. Jams will occur in the compiler and bin 1 cannot be used.
11F-120 1K LCSS PWB Damage RAP.
Initial Actions GP 11, How to Check a Sensor.
Figure 1.
P/J2, 1K LCSS PWB
WARNING
11C-120 1K LCSS Power Distribution RAP
death or injury. Moving parts can cause injury. Paddle roll position sensor, PL 11.104 Item 11.
Check the following: 1K LCSS PWB, PL 11.124 Item 1.
That there is no paper or other obstructions in the vicinity of the paddle.
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. Paddle roll position
sensor
Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
Q11-326
the compiler capacity can be exceeded. Refer to 11H-120 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 11.10-120 Paddle
Wheel Shaft Assembly. If any of the paddles are out of alignment to other paddles, install Paddle motor
a new paddle wheel shaft assembly, PL 11.104 Item 4. MOT11-024
1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings
RAP.
Procedure
Enter dC330, codes 11-024, paddle home position and 11-025, paddle run. The paddle
rotates correctly.
Y N
Go to Flag 2. Check the paddle motor, MOT 11-024.
Refer to:
Figure 1.
P/J14, 1K LCSS PWB.
11C-120 1K LCSS Power Distribution RAP
Repair or install new components as necessary: Figure 1 Component location
Paddle motor, PL 11.104 Item 10.
A

11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Procedure
Movement Failure RAP NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.
11-030-120 Bin 1 fails to move. NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
11-334-120 Bin 1 has reached the upper limit of travel.
Remove the 1K LCSS rear cover. Enter dC330 code 11-336, bin 1 motor encoder sensor Q11-
11-335-120 Bin 1 has reached the lower limit of travel. 336. Slowly rotate the encoder disk by hand. The display changes.
Y N
11-336-120 Bin 1 is not at the home position. Go to Flag 2. Check Q11-336.
Refer to:
NOTE: The home position of bin 1 is when bin 1 is actuating the bin 1 upper limit switch. See 11F-120 1K LCSS PWB Damage RAP.
the final actions at the end of the procedure. GP 11 How to Check a Sensor.
Two sensors and two switches monitor the level of paper in bin 1 and the position of the tray P/J8, 1K LCSS PWB
The bin 1 upper level sensor detects the top of the paper stack in bin 1, Figure 1. 11C-120 1K LCSS Power Distribution RAP.
The bin 1 90% full sensor detects when the tray has descended to a position where the Repair or install new components as necessary:
tray is 90% full, Figure 2.
Bin 1 motor encoder sensor Q11-336, PL 11.106 Item 11.
Bin 1 upper limit switch, S11-334, Figure 2.
Bin 1 lower limit switch, S11-335, Figure 2.
Initial Actions Enter dC330 code 11-033, bin 1 elevator motor, MOT11-030. Bin 1 cycles down and up.
Y N
Refer to:
WARNING
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. P/J12, 1K LCSS PWB
Perform the following: 11C-120 1K LCSS Power Distribution RAP.
Check for a physical obstruction that would prevent bin 1 from moving, such as an item of Repair or install new components as necessary:
furniture. Bin 1 elevator motor, PL 11.106 Item 8.
Check that bin 1 is level front to back, if necessary perform ADJ 11.1-120 1K LCSS Bin 1 1K LCSS PWB, PL 11.124 Item 1.
Level.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Figure 1. Enter dC330, code 11-332, bin 1 upper level sensor, Q11-332. Actuate Q11-332.
Switch Settings RAP. The display changes.
If the fault code is 11-030. Check that the screws to secure the motor damper and the Y N
motor bracket are not loose. This will cause the encoder disc to move away from the Go to Flag 3. Check Q11-332.
encoder sensor. Push the motor bracket towards the encoder sensor and tighten the Refer to:
screws. Refer to Figure 2. 11F-120 1K LCSS PWB Damage RAP.
Refer to the 11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. GP 11 How to Check a Sensor.
If there is a large jam of paper above bin 1, this has probably been caused by poorly P/J2, 1K LCSS PWB
stacked sets failing to actuate the bin 1 upper level sensor. 11C-120 1K LCSS Power Distribution RAP.
Perform the relevant check: Repair or install new components as necessary:
If paper is overflowing the tray when it is at the lower limit, check the tray 90% full sensor. Bin 1 upper level sensor Q11-332, PL 11.106 Item 5.
If paper cannot be fed to bin 1 when it is at the highest position, check the bin 1 paper 1K LCSS PWB, PL 11.124 Item 1.
sensor - low and bin 1 paper sensor - high.
Check the front and rear bin 1 drive belts. If necessary install new components, PL 11.106 Item 1.
A
A
Figure 2. Enter dC330 code 11-334, bin 1 upper limit switch, S11-334. Actuate S11-334. The When the tray is emptied, the tray returns to the home position. In the home position the
display changes. bin one upper limit switch, S11-334 is actuated.
Y N
Refer to:
P/J5, 1K LCSS PWB
Bin 1 upper limit switch, PL 11.106 Item 3.
Enter dC330 code 11-335, bin 1 lower limit switch, S11-335, actuate S11-335. The display
Bin 1 upper level
changes.
sensor Q11-332
Y N
Refer to:
P/J4, 1K LCSS PWB.
Bin 1 lower limit switch, PL 11.106 Item 11.
Enter dC330 code 11-331, bin 1 90% full sensor, Q11-331. Actuate Q11-331. The display
changes.
Y N
Go to Flag 6. Check Q11-331. Figure 1 Component location
Refer to:
P/J2, 1K LCSS PWB.
Bin 1 90% full sensor Q11-331, PL 11.106 Item 5.
As final actions, check the following sequence of operation:

When bin 1 is empty and at the top, bin 1 upper limit switch, S11-334 is actuated and the
bin 1 upper level sensor, Q11-332 is de-actuated.
Paper is delivered to the tray until the bin 1 upper level sensor, Q11-332 is actuated.
The motor lowers the tray until the bin 1 upper level sensor, Q11-332 is de-actuated.

Bin 1 upper limit
switch S11-334.
Bin 1 motor encoder

sensor Q11-336
Bin 1 elevator motor

MOT11-030
Bin 1 elevator motor

damper
Bin 1 lower limit switch

S11-335. Bin 1 90% full sensor
Q11-331


11-050-120, 11-360-120 Staple Head Operation Failure RAP
11-050-120 The staple head fails to cycle.
11-360-120 The staple head is not at the home position.
NOTE: The home position is with the jaws of the staple head fully open.
Initial Actions
WARNING
CAUTION
Do not run code 11-050 without two sheets of paper in the stapler jaws. Running this code with-
out the paper in position can cause damage to the machine.
Figure 1. Check the following:
The 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
Settings RAP.
The staple head unit is correctly installed.
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.
on the UI. Make sure that the correct sensor or switch is tested. Staple head including MOT11-050
Place two sheets of paper in the stapler jaws. Enter dC330, code 11-050, staple head motor 1, and staple head 1 home sensor
Q11-360
to cycle the staple head once. The staple head operates as expected.
Y N
Go to Flag 1 and Flag 2. Check the wiring and connectors between the 1K LCSS PWB
and the staple head. The wiring is good.
Y N
Repair the wiring.
Perform the following procedures:
Staple head unit, PL 11.116 Item 5.


11-100-120 1K LCSS Paper Entry RAP
11-100-110 The leading edge of the sheet is late to the entry sensor Q11-100.
Initial Actions
WARNING
Refer to the 11G-120 Copy Damage in the 1K LCSS RAP.

RAP.
tray.
Check the input guide for damage or wear that could cause paper to jam.
Paper jam in the machine to 1K LCSS paper path.
IOT exit path and feed rolls.
Feeding performance from a paper tray loaded with a new ream of paper.
Procedure
Figure 1. Lower the paper entry guide assembly, PL 11.110 Item 8, to access the entry sensor.
Enter dC330, code 11-100, entry sensor, Q11-100. Actuate Q11-100. The display changes.
Y N
Refer to:
11F-120 1K LCSS PWB Damage RAP. Entry sensor
GP 11 How to Check a Sensor. Q11-100
P/J8, 1K LCSS PWB
1K LCSS PWB, PL 11.124 Item 1. Figure 1 Component location

11-130-120, 11-132-120 Paper Exiting to Bin 0 RAP
11-130-120 The leading edge of the sheet is late to the top exit sensor.
11-132-120 The trailing edge of the sheet is late from the top exit sensor.
Initial Actions
WARNING
RAP.
tray.
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
and tensioner pulley. Refer to GP 18 Machine Lubrication.
That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the
motor shaft.
All the transport drive belts are correctly fitted, are in a good condition and correctly ten-
sioned, refer to ADJ 11.2-120.
All the 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.
Figure 2 Circuit diagram Paper fragments from a previous jam clearance action.
A paper jam in the path to the top tray. If the jams occur shortly after install. Check the gap
between the entry guide cover, PL 11.122 Item 5 and the paper guide PL 11.118 Item 10.
If the gap is less than 1mm, adjust or install a new entry guide cover. Refer to the replace-
ment procedure in REP 11.13-120.
Refer to the 11G-120 Copy Damage in the 1K LCSS RAP and the 11H-120 Mis-Registration in
bin 1 when the diverter gate solenoid is de-energized.
Procedure
Enter dC330, code 11-001 transport motor 2, MOT11-001, Figure 1. MOT11-001 runs.
Y N

A B
Refer to: 1K LCSS PWB, PL 11.124 Item 1.
P/J16, 1K LCSS PWB.
Top exit sensor
Repair or install new components as necessary: Q11-130
NOTE: The diverter gate solenoid remains energized for 5 seconds.
Enter dC330, code 11-002 diverter gate solenoid, SOL11-002. SOL11-002 energizes.
Y N
Go to Flag 2. Check SOL11-002. Transport motor 2
Refer to: MOT11-001
GP 12, How to Check a Solenoid.
P/J13, 1K LCSS PWB
11C-120 1K LCSS Power Distribution RAP. Diverter gate
Repair or install new components as necessary: solenoid S11-002
Diverter gate solenoid, PL 11.118 Item 12.
Enter dC330, code 11-130, top exit sensor, Q11-130. Actuate Q11-130. The display
changes.
Transport motor 1
Y N
MOT 11-000
Refer to:
P/J2, 1K LCSS PWB
Enter dC330, code 11-000, transport motor 1, MOT11-000. MOT11-000 runs.

Y N
Refer to:
GP 10, How to Check a Motor. Figure 1 Component location
P/J17, 1K LCSS PWB.
B

11-140-120, 11-142-120 Sheet Late to Bin 1 RAP NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.
11-140-120 The leading edge of the sheet is late to the 2nd to top exit sensor. Figure 1. Enter dC330, code 11-001 transport motor 2, MOT11-001. MOT11-001 runs.
Y N
11-142-120 The trailing edge of the sheet is late to the 2nd to top exit sensor. Go to Flag 3. Check MOT11-001.
Refer to:
Initial Actions 11F-120 1K LCSS PWB Damage RAP.
GP 10, How to check a motor.
P/J16, 1K LCSS PWB.
WARNING
death or injury. Moving parts can cause injury. Transport motor 2, PL 11.118 Item 5.
bin 1 when the diverter gate solenoid is de-energized. Enter dC330, code 11-002 diverter solenoid, SOL11-002. SOL11-002 energizes.
Check the following: Y N
Refer to:
RAP.
Ensure the paper tray guides are set to the correct position for the size of paper in all
trays. GP 12, How to Check a Solenoid.
For trays 3 and 4, perform the following: P/J13, 1K LCSS PWB
Select the systems settings button from the tools screen. 11C-120 1K LCSS Power Distribution RAP.
Select the tray management button and stock settings. Repair or install new components as necessary:
From the list, select tray 3. Select the change stock size button. Diverter gate solenoid, PL 11.22 Item 12.
Select the paper size loaded in the tray. Select the save button. 1K LCSS PWB, PL 11.26 Item 1.
Repeat for tray 4.
Enter dC330, code 11-140 2nd to top exit sensor, Q11-140. Actuate Q11-140. The display
Save the stock setting and exit the tools mode. changes.
The tensioner on the intermediate paper drive belt. Check that the tensioner is free to Y N
move and that the tensioner pulley is free to rotate. If necessary re-lubricate the tensioner Go to Flag 1. Check Q11-140.
and tensioner pulley. Refer to ADJ 4.1. Refer to:
That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the 11F-120 1K LCSS PWB Damage RAP.
motor shaft. GP 11, How to Check a sensor.
All the transport drive belts are correctly fitted and are in a good condition P/J2, 1K LCSS PWB
All the transport rolls and idler pulleys are free to rotate. 11C-120 1K LCSS Power Distribution RAP.
The diverter gate and linkage for free movement. Repair or install new components as necessary:
If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate mylar kit. 2nd to top exit sensor, PL 11.120 Item 4.
A paper jam in the path to bin 1, to the compiler, and for poor stacking on bin 1. 1K LCSS PWB, PL 11.124 Item 1.
Ensure that the 1K LCSS is fully latched to the machine, refer to REP 11.11-120.
Torn paper fragments from a previous jam clearance action. Enter dC330, code 11-000 transport motor 1, MOT11-000. MOT11-000 runs.
Refer to the 11G-120 Copy Damage in the 1K LCSS RAP and the 11H-120 Mis-Registration in Y N
Stapled Sets and Non-Stapled Sets RAP. Go to Flag 2. Check MOT11-000.
Refer to:
Procedure
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state P/J17, 1K LCSS PWB.
A
A
2nd to top exit

sensor Q11-140
Transport
motor 2
MOT11-001
Diverter
gate
solenoid
S11-002
Transport
motor 1
MOT11-000


11-300-120, 11-302-120, 11-303-120 Interlocks RAP Go to Flag 1. Check the wiring between P/J6 and S11-300.
11-300-120 The docking interlock is open during run mode. If necessary, install a new docking interlock switch, PL 11.102 Item 2.
11-302-120 The top cover interlock is open during run mode. Check the top cover interlock switch, S11-302 as follows:
11-303-120 The front door interlock is open during run mode.
Enter dC330, code 11-302, top cover interlock switch, S11-302. Actuate S11-302. If the
display does not change, refer to:
Initial Actions
GP 13, How to Check a switch
Figure 2.
WARNING P/J5, 1K LCSS PWB
Ensure that the electricity to the machine is switched off while performing tasks that do Go to Flag 3. Check the wiring between P/J5 and S11-302.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause If necessary, install a new top cover interlock switch, PL 11.124 Item 6.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
Check the front door interlock switch, S11-303 as follows:
Settings RAP.
Check the following: Enter dC330, code 11-303, front door interlock switch, S11-303. Actuate S11-303. If the
The 1K LCSS is installed correctly, refer to REP 11.13-120. display does not change, refer to:
The 1K LCSS front door is closed. GP 13, How to Check a switch
The 1K LCSS top cover is closed. Figure 2.
P/J51K LCSS PWB
Procedure Go to Flag 2. Check the wiring between P/J5 and S11-303.
If necessary, install a new front door interlock switch, PL 11.124 Item 5.
Go to Flag 1. Check for +24V on P/J6 pin 1. If the voltage is not present, refer to 11C-120 1K
LCSS Power Distribution RAP.

Undock the 1K LCSS, refer to REP 11.11-120. Figure 1, check the docking interlock switch,
S11-300 as follows:
While supporting the 1K LCSS, slide the 1K LCSS 5cm (2 inches) away from the
machine. 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 11-300, docking interlock switch, S11-300. While supporting the 1K
LCSS, slide the 1K LCSS 5cm (2 inches) away from the machine to de-actuate S11-300.
If the display does not change, refer to:
GP 13, How to Check a Switch
P/J6, 1K LCSS PWB

Top cover
interlock switch
S11-302
Front door interlock

switch S11-303
Docking interlock
switch S11-300


A
11-320-120, 11-322-120 Ejector Movement Failure RAP Refer to:
11-320-120 The ejector is not at the home position. 11F-120 1K LCSS PWB Damage RAP.
11-322-120 The ejector fails to perform a cycle of operation. P/J8, 1K LCSS PWB
NOTE: A cycle of operation for the ejector is to move from the home position to the out position
and back to the home position.
Ejector home sensor, Q11-320, PL 11.114 Item 3.
Initial Actions 1K LCSS PWB, PL 11.124 Item 1.
Enter dC330, code 11-023 to check the operation of the ejector motor, MOT11-020. MOT11-
WARNING 020 runs.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Go to Flag 3. Check MOT11-020.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP 11F-120 1K LCSS PWB Damage RAP.
Switch Settings RAP. GP 10, How to Check a Motor.
Check for any obstructions that would prevent the ejector from moving. P/J15, 1K LCSS PWB
If the fault code is 11-322. Check that the screws to secure the motor damper and the 11C-120 1K LCSS Power Distribution RAP.
motor bracket are not loose. This will cause the encoder disc to move away from the Repair or Install new components as necessary:
encoder sensor. Push the motor bracket towards the encoder sensor and tighten the Ejector assembly, PL 11.114 Item 1.
screws. Refer to Figure 1 and REP 11.8-120.
Procedure Enter dC330, code 11-023 ejector cycle, check the ejector cycles. Stack the code 11-320 ejec-
tor sensor home, then cycle the ejector. Stack the code 11-322 ejector sensor out, then cycle
the ejector. The ejector actuates the ejector home sensor and the ejector out sensor.
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state Y N
on the UI. Make sure that the correct sensor or switch is tested. Refer to GP 7, check the following components;
Pulley/drive gear.
NOTE: For clarity, the 1K LCSS is shown removed from the machine in Figure 1.
Ejector belt.
Refer to Figure 1. Enter dC330, code 11-322, ejector out sensor, Q11-322. Actuate Q11-322. Install new components as necessary:
The display changes. Pulley/drive gear, PL 11.114 Item 7.
Y N
Ejector belt, PL 11.114 Item 5.
Refer to:
The ejector cycles noisily, colliding with the end stops.
11F-120 1K LCSS PWB Damage RAP. Y N
GP 11 How to Check a Sensor. Check the stapler to ensure the staples are correctly formed, refer to the 11-364-120 Sta-
P/J8, 1K LCSS PWB pling Failure RAP. Mis-formed staples can cause the set to hang in the stapler causing
11C-120 1K LCSS Power Distribution RAP. ejector movement failures. The staples are correctly formed.
Y N
Clear the staple head of any mis-formed staples, then check the operation of the sta-
Ejector out sensor, Q11-322, PL 11.114 Item 3. pler. If necessary, install a new staple head unit, PL 11.116 Item 5.
If the ejector is still not moving, install a new ejector assembly, PL 11.114 Item 1.
Enter dC330, code 11-320, ejector home sensor, Q11-320. Actuate Q11-320. The display Perform SCP 6 Final Actions.
changes.
Y N Go to Flag 4. +5V is available at P/J8 between pins 7 and 8.
Go to Flag 1. Check Q11-320. Y N
Go to the 11C-120 1K LCSS Power Distribution RAP.
A B
B
Connect a service meter at P/J8 between pins 8 and 9. Slowly rotate the ejector motor
encoder. The voltage changes between +5V and 0V.
Y N
Go to Flag 4. Check the wiring and connectors between the ejector motor encoder sensor
and the 1K LCSS PWB. If necessary repair the wiring, REP 1.2. If the wiring is good,
install a new ejector motor encoder sensor, PL 11.114 Item 3.
Perform the 11F-120 1K LCSS PWB Damage RAP, if necessary install a new 1K LCSS PWB,
PL 11.124 Item 1.
Ejector out sensor

Q11-322
Pulley/drive gear
Ejector belt
Ejector motor
MOT11-020
Ejector motor
encoder sensor
Ejector home sensor
Q11-320
Ejector motor damper


A
11-364-120 Stapling 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 1K LCSS interlocks
11-364-120 Staples in the stapling head are not primed.
are made.
Initial Actions Follow the customer instruction label inside the 1K LCSS front door to remove the staple car-
tridge, 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 car-
WARNING tridge 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, Fig-
ure 3. The first two staples have been partially formed.
Y N
Switch off the machine, then switch on the machine, GP 14. Install a new staple cartridge, PL 26.10 Item 11 and repeat the check. If the first two sta-
ples are not partially formed, install a new stapler assembly, PL 11.116 Item 1. Perform
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch SCP 6 Final Actions
Settings RAP.
Install a new staple head unit, PL 11.116 Item 5. Perform SCP 6 Final Actions.
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 cartridge, PL 26.10
Item 11.
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 2.
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 and although they can be checked using
component control they cannot be exchanged as components.
Procedure
Figure 1. Enter dC330, code 11-361, SH 1 paper sensor, Q11-361. Actuate Q11-361. The
display changes.
Y N
Refer to:
P/J7, 1K LCSS PWB
Repair or install new components as necessary: SH 1 paper sensor
SH 1 paper sensor, PL 11.116 Item 4. Staple head unit Q11-361

Primed staples
Forming plate open Forming plate fully closed
Figure 2 Staple cartridge open Figure 3 Staple cartridge closed


11A-120 Bin 1 Overload RAP
Use this RAP to resolve a fault on the bin 1 90% full sensor.
Procedure
WARNING
Enter dC330, code 11-331, bin 1 90% full sensor, Q11-331. Actuate Q11-331. The display
changes.
Y N
Refer to:
GP 11, How to Check a sensor.
Figure 1. Bin 1 90% full sensor Q11-331
P/J2, 1K LCSS PWB
11C-120 1K LCSS Power Generation RAP. Figure 1 Component location
Bin 1 90% full sensor, PL 11.106 Item 5.

11B-120 Initialization Failure RAP
When an initialization command is received from the machine, the units are initialized in two
stages:
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 ejector is not at the home position, it is driven to the home position
The following units are then initialized simultaneously:
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 paddle is not at the home position, it is driven to the home position
4. If the stacker is not at the home position, it is driven to the home position
NOTE: The staple cartridge must be pushed fully home.
Initial Actions
WARNING
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
Settings RAP.
Remove the 1K LCSS covers, REP 11.1-120, 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 LED 1
LED 2
shows that all interlocks are made. If the LED fails to illuminate, go to 11-300-120, 11-302-120,
11-303-120 Interlocks RAP.
Figure 1 LED location
Procedure
Figure 1. Check that the software heartbeat is present on LED 1. The LED should flash twice
per second if the 1K LCSS software is running. If necessary, re-load the 1K LCSS software,
refer to GP 4 Machine Software.
If the initialization sequence fails to place any unit at the home position, refer to the appropriate
RAPs:
Front tamper not at home, refer to 11-005-120, 11-006-120, 11-310-120, 11-311-120 Front
Rear tamper not at home, refer to 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-
319-120 Rear Tamper Move Failure RAP.
Paddle not at home, refer to 11-024-120, 11-025-120 Paddle Roll Failure RAP.
Bin 1 not at home, refer to 11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Move-
ment Failures RAP.
Staple head not at home, refer to 11-050-120, 11-360-120 Staple Head Operation Failure
RAP.
Ejector not at home, refer to 11-320-120, 11-322-120 Compiler Ejector Movement Failure
RAP.

Xerox WorkCentre 5790 Family 2-399 11B-120
A B
11C-120 1K LCSS Power Distribution RAP +24 V is available at P/J5 pin 3 on the 1K LCSS PWB.
Y N
The 1K LCSS has an integral power supply providing +24V and +5V supplies to the 1K LCSS
Go to the 11-300-120, 11-302-120, 11-303-120 Interlocks RAP.
PWB. The AC power for the 1K LCSS power supply comes from the LVPS and base module of
the machine. Perform the steps that follow:
Switch off the machine, GP 14.
Procedure Go to Flag 3. Disconnect all the +24V harnesses to components.
Check each harness for short circuits and overheating, GP 7.
WARNING Repair or install new components as necessary.
Ensure that the electricity to the machine is switched off while performing tasks that do Monitor the voltage at P/J6 pin 1. Re-connect the circuits one at a time. Energize the
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause re-connected components using dC330 control codes.
death or injury. Moving parts can cause injury. If the voltage drops below +22V, switch off the machine, GP 14. Re-check the com-
ponent and harness for overheating or short circuits. Repair or install new compo-
nents as necessary.
WARNING
+5V is available between TP3 and TP4 on the 1K LCSS PWB.
Y N
Go to Flag 2. +5V is available at P/J1 between pins 4 and 6, also between pins 7 and
CAUTION 8.
Do not connect the finisher power cord directly to the AC wall outlet. The finisher cannot oper- Y N
ate without the machine. The machine controls the distribution of electricity to the finisher for Disconnect P/J1. +5V is available at P/J1 between pins 4 and 6, also between
correct power on and power off sequencing. pins 7 and 8 on the end of the harness.
Y N
Close or cheat all the 1K LCSS interlocks. LED 2 on the 1K LCSS PWB is illuminated.
Go to Flag 1. Disconnect the 1K LCSS power cord from PJ22. ACL is avail-
Y N
able at PJ22 between pins 1 and 3 on the LVPS and base module.
Go to Flag 2. +24V is available at P/J1 between pins 1 and 2, also between pins 5
Y N
and 3.
Go to the 01C AC Power RAP.
Y N
Disconnect P/J1. +24V is available at P/J1 between pins 1 and 2, also between
Remove the 1K LCSS, REP 11.12-120. Loosen the 2 screws and lift the power
pins 5 and 3 on the end of the harness.
supply module away from the 1K LCSS frame. Go to Flag 2. Check the wiring
Y N
between CN2 and P/J1. The wiring is good.
Go to Flag 1. Disconnect the 1K LCSS power cord from PJ22 on the Power and
Y N
Control Assembly. ACL is available at PJ22 between pins 1 and 3 on the
Repair the wiring.
LVPS and base module.
Y N
Install a new power supply module, PL 11.124 Item 2.
Go to the 01C AC Power RAP.
Remove the 1K LCSS, REP 11.12-120. Loosen the 2 screws and lift the power
supply module away from the 1K LCSS frame. Go to Flag 1. Check the wiring Check for a short circuit or an overload in the wiring or components connected
between PJ22 and CN1. The wiring is good. to the +24V on the 1K LCSS PWB. Refer to GP 7.
Y N Perform the 11F-120 1K LCSS PWB Damage RAP. If necessary install a new
Repair the wiring. 1K LCSS PWB, PL 11.124 Item 1.
Install a new power supply module, PL 11.124 Item 2. Perform the 11F-120 1K LCSS PWB Damage RAP. If necessary install a new 1K LCSS
PWB, PL 11.124 Item 1.
Check for a short circuit or an overload in the wiring or components connected The +24V and +5V supplies on the 1K LCSS PWB are good.
to the +24V on the 1K LCSS PWB. Refer to GP 7.
Perform the 11F-120 1K LCSS PWB Damage RAP. If necessary install a new
A B
11C-120 2-400 Xerox WorkCentre 5790 Family
Power Supply
Module


11D-120 1K LCSS to Machine Communications Interface 11E-120 1K LCSS PWB DIP Switch Settings RAP
RAP To show the correct settings for the DIP switches on the 1K LCSS PWB.
All communications between the machine and 1K LCSS are conducted through a single inter-
face cable. Procedure
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Problems that can result from incorrect DIP switch settings are:
death or injury. Moving parts can cause injury. False jam clearance instructions for the 1K LCSS and/or the machine exit area.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Communication errors between the 1K LCSS and machine.
Settings RAP. Erratic behavior of the 1K LCSS.
Check the DIP switch settings, Figure 1. If necessary, switch off the machine, GP 14. Correct
Go to 03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error Rap.
the DIP switch setting, then switch on the machine, GP 14.
Figure 1 DIP switch settings

Xerox WorkCentre 5790 Family 2-403 11D-120, 11E-120
11F-120 1K LCSS PWB Damage RAP
Use this RAP to determine the cause of damage to the 1K LCSS PWB, so that the cause can
Table 1 1K LCSS PWB Drive Components
be repaired before a new 1K LCSS PWB is installed.
1K LCSS
Procedure PWB Driven Normal resistance Spared part and
component component measurement +/- 10% references
U5 Paddle motor At PJ14: Paddle motor assembly, PL
WARNING (MOT11024) Pin 1 to 3 = 28 ohms. 11.104 Item 10.
Ensure that the electricity to the machine is switched off while performing tasks that do Pin 1 to 4 = 28 ohms. 11-024-120, 11-025-120
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Pin 2 to 5 = 28 ohms. RAP
death or injury. Moving parts can cause injury. Pin 2 to 6 = 28 ohms.
The 1K LCSS PWB can be damaged by a component connected to it going short-circuit. If a U10 Staple head At PJ7: Staple head unit, PL 11.116
new 1K LCSS PWB is installed and power applied to the machine, the new 1K LCSS PWB will motor (MOT11- Pin 8 to 10 = 12.6 ohms. Item 5.
be damaged in the same way. The cause of the damage must be found by following this proce- 050) Pin 9 to 11 = 12.6 ohms 11-050-120, 11-360-120
dure. RAP
U11 Bin 1 elevator At PJ12: Bin 1 elevator motor, PL
Remove the 1K LCSS PWB and inspect the components shown in Figure 1 for damage. The motor (MOT11- Pin 1 to 2 = 6.4 ohms 11.10 Item 8.
damage to the component may be in the form of a crack, a small crater or a burnt patch. Refer 030) 11-030-120, 11-334-120, 11-
to Table 1 to locate the component causing the damage to the 1K LCSS PWB. 335-120, 11-336-120 RAP
U12 Front tamper At PJ9: Tamper assembly, PL 11.16
motor (MOT11- Pin 1 to 3 = 20 ohms. Item 1.
003) Pin 1 to 4 = 20 ohms. 11-005-120, 11-006-120, 11-
Pin 2 to 5 = 20 ohms. 310-120, 11-311-120 RAP
Pin 2 to 6 = 20 ohms.
U13 Rear tamper At PJ9: Tamper assembly, PL 11.112
motor (MOT11- Pin 7 to 9 = 20 ohms. Item 1.
004) Pin 7 to 10 = 20 ohms. 11-007-120, 11-008-120, 11-
Pin 8 to 11 = 20 ohms. 312-120, 11-313-120, 11-
Pin 8 to 12 = 20 ohms. 319-120 RAP
U14 Transport At PJ17: Transport motor 1, PL
motor 1 Pin 1 to 3 = 2.2 ohms. 11.110 Item 2.
(MOT11-000) Pin 1 to 4 = 2.2 ohms. 11-130-120, 11-132-120
Pin 2 to 5 = 2.2 ohms. RAP
Pin 2 to 6 = 2.2 ohms.
U15 Ejector motor At PJ15: Ejector assembly, PL 11.114
(MOT11-020) Pin 1 to 2 = 6.6 ohms Item 1.
11-320-120, 11-322-120
RAP
U16 Transport At PJ16: transport motor 2, PL 11.118
motor 2 Pin 10 to 12 = 0.8 ohms. Item 5.
(MOT11-001) Pin 10 to 13 = 0.8 ohms. 11-130-120, 11-132-120
Pin 11 to 14 = 0.8 ohms. RAP
Pin 11 to 15 = 0.8 ohms.
Q1 Diverter gate At PJ13: Diverter gate solenoid, PL
solenoid (S11- Pin 1 to pin 2 = 74 ohms 11.118 Item 12.
002) 11-130-120, 11-132-120
RAP
Figure 1 1K LCSS PWB components

11F-120 2-404 Xerox WorkCentre 5790 Family
NOTE: If difficulty is found in connecting the service meter probes to the connector headers on 11G-120 Copy Damage in the 1K LCSS RAP
the 1K LCSS PWB, refer to the RAP quoted in Table 1 and make the measurement at another
Use this RAP to identify and correct the causes of copy damage in the 1K LCSS.
point in the harness to the driven component.
If the defective driven component is found using the table checks, disconnect the connector Procedure
closest to the driven component, then check the driven component again to identify any short
circuit in the wiring to the driven component. Repair the wiring or install new parts as neces-
sary. WARNING
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 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. Check the following:
Look for torn paper in the 1K LCSS paper path. Torn fragments can pass through the IOT
When the a new driven component has been installed or the defective drive components have and 1K LCSS paper path without causing a problem until they finally wedge themselves at
been repaired, install a new 1K LCSS PWB, PL 11.124 Item 1. some point.
Ensure that the shaft diverter assembly, PL 11.118 Item 13, operates correctly and has its
full movement.
Ensure that the jam clearance guide, PL 11.122 Item 6, closes and latches correctly.
Check that the magnet at the rear is located and functions correctly. Check the clip at the
front is positioned correctly, Figure 1.
Ensure that all idler rolls in the 1K LCSS paper path are free to rotate, particularly those
on the jam clearance guide, where the paper turns through 90 degrees.
Ensure that the paper path ribs of the jam clearance guide, PL 11.122 Item 6, and the
entry guide cover, PL 11.122 Item 5, are free of scores and nicks. Check also for con-
tamination and glue from label stock.
Check that the end of the spring

clip is positioned on the inside of
the frame.
Figure 1 Position of the spring clip

Xerox WorkCentre 5790 Family 2-405 11F-120, 11G-120
11H-120 Mis-Registration in Stapled Sets and Non-Stapled 11J-120 1K LCSS Poor Stacking RAP
Sets RAP Use this RAP to find the cause of poor stacking in the 1K LCSS.
Procedure
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 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
The most likely cause of mis-registration is paper condition and/or damage such as curl, wrin- level sensors:
kle, creases, dog ears, etc.
Large paper sizes should not be stacked on top of small paper sizes.
Curl, wrinkle and creases are probably caused in the IOT, go to the IQ1 Image Quality Entry Ensure that the paper stack in each paper tray has been fanned.
RAP. 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
For other copy / print damage and dog ears, go to the 11G-120 Copy Damage in the 1K LCSS specifications. Refer to GP 20 Paper and Media Size Specifications.
RAP. 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.
Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 11.100
Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL
Item 13.
11.100 Item 13.
Turn over the paper stack in the tray in use.
Labels must not be fed to bin 1, but to bin 0 only.
Use a new ream of paper in the tray in use.
It is recommended that transparencies are fed to bin 0 whenever possible.
Paper type, especially recycled paper, can lead to registration problems. Try changing to
Check that bin 1 is level front to back, if necessary perform ADJ 11.1-120 1K LCSS Bin 1
a different brand or type of paper.
Level.
Ensure that the guides in the paper trays are correctly set and reported on the UI for the
Check that the bin 1 upper level sensor, Q11-332 is working correctly. Refer to the 11-030-
paper size loaded.
120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP.
Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
Check the operation of the front and rear tampers. Refer to 11-005-120, 11-006-120, 11-
the compiler capacity can be exceeded.
310-120, 11-311-120 Front Tamper Move Failure RAP and 11-007-120, 11-008-120, 11-
Check for obstructions in the compiler. 312-120, 11-313-120, 11-319-120 Rear Tamper Move Failure RAP.
Ensure that the paddle roll operates correctly and that the paddles are not damaged. The Check that the output device is not near an air conditioning or ventilation output duct. Air
paddles should park completely inside the top section of the compiler, with the shorter flow across the output bins can cause poor stacking.
paddle in a vertical position. If all of the paddles are out of position, check the paddle roll
Check if Mod. TAG L-013 LCSS bin 1 kit is installed on the finisher.
position sensor, PL 11.104 Item 11, the flag, PL 11.104 Item 7 and the paddle motor
assembly, PL 11.104 Item 10. If only one paddle is mis-aligned with the others, it can be Machine that regularly process large stacks of A4/8.5x11 inch LEF paper should
re-positioned by hand (they are not bonded to the shaft). have the LCSS bin 1 W/TAG L-013 kit installed, PL 11.100 Item 10.
Make sure the paddles are clean. If necessary, use formula A cleaning fluid, PL 26.10 Machines that regular process small stacks of A4/8.5x11 inch LEF, A3/11x17 inch
Item 2 to clean the paddles. and A4/8.5x11 inch SEF paper should have the standard W/OTAG L-013 bin 1
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 11.112. Check the output copies for curl, refer to IQ5.
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 11.120.
Inspect the four spring loaded guides on the output cover, PL 11.100 Item 7. Ensure that
they are correctly located and are free to move up and down.

11H-120, 11J-120 2-406 Xerox WorkCentre 5790 Family
11-024-171, 11-026-171 Paddle Roller Position RAP
11-024-171 The paddle roller has failed to return to the home position.
11-026-171 The paddle roller has failed to move from the home position.
Initial Actions Paddle

roller
home
Pusher
sensor
WARNING Q11-326
Check for damage or any obstruction that would prevent paddle movement. If necessary,
install new components.
Procedure
Figure 1 shows the location of the components.
Enter dC330, code 11-025 Paddle Roll Motor Run, to check the movement of the paddle, Fig-
ure 1. The paddle turns.
Y N
Go to Flag 2. Check the wiring and repair as necessary, REP 1.2. Check the paddle roller Paddle
motor, MOT11-025. Refer to: roller motor
GP 10 How to Check a Motor. MOT11-025
P/J202, HVF Control PWB
11A-171 HVF Power Distribution RAP.
Install new components ad necessary:
Paddle module assembly, PL 11.145 Item 2
HVF control PWB, PL 11.157 Item 2.
Stack the code 11-326, paddle roller home sensor, Q11-326, Figure 1. The display changes
as the paddle rotates.
Y N
Go to Flag 1. Check the wiring and repair as necessary, REP 1.2. Check the paddle roller
home sensor, Q11-326. Refer to:
Install new components as necessary: Figure 1 Component location
Paddle module assembly, PL 11.145 Item 2.


A
11-044-171 to 11-047-171 Punch Unit Head and Position RAP Install new components as necessary:
11-044-171 The punch head has failed to return to the home position. HVF hole punch assembly, PL 11.153 Item 1
11-045-171 The punch head has failed to move from the home position.
11-046-171 The punch unit has failed to return to the home position. Enter dC330, code 11-044 for the punch unit home sensor and stack the code 11-045 or 11-
046 to take the punch unit motor into, and out of, the home position. Observe the condition of
11-047-171 The punch unit has failed to move from the home position. the sensor on the UI. The display changes.
Initial Actions Y N
Go to Flag 3. Check the wiring from the sensor to the PWB. Repair as necessary, REP
1.2. Check the punch unit home sensor, Q11-044. Refer to:
WARNING GP 11 How to Check a Sensor.
Ensure that the electricity to the machine is switched off while performing tasks that do P/J501, HVF Control PWB
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 11A-171 HVF Power Distribution RAP.
Check the punch head area for any obstruction or damage that could prevent the free move- HVF hole punch assembly, PL 11.153 Item 1
ment of the head or the unit. If necessary, install new components. HVF control PWB, PL 11.157 Item 2.
Procedure
Enter dC330, code 11-043 for the punch head motor. The motor operates.
Y N
Punch head motor
Go to Flag 2. Check the wiring from the motor to the PWB. Repair as necessary, REP 1.2. MOT11-043
Check the punch head motor, MOT11-043. Refer to:
Install new components as necessary: Punch head home
HVF hole punch assembly, PL 11.153 Item 1 sensor Q11-350
Enter dC330, code 11-350 for the punch head home sensor and stack the code 11-043 for the Punch unit home
punch head motor. Observe the condition of the sensor on the UI. The display changes. sensor Q11-044
Y N
Go to Flag 1. Check the wiring from the sensor to the PWB. Repair as necessary, REP
1.2. Check the punch head home sensor, Q11-350. Refer to: Punch unit motor
GP 11 How to Check a Sensor. MOT11-045
HVF hole punch assembly, PL 11.153 Item 1
Enter dC330, code 11-045 for the motor to travel in the forward direction, or enter the code 11-
046 for the motor to travel in the reverse direction. The motor operates.
Y N
Go to Flag 4. Check the wiring from the motor to the PWB. Repair as necessary, REP 1.2.
Check the punch unit motor, MOT11-045. Refer to: Hole punch assembly
A

Xerox WorkCentre 5790 Family 2-409 11-044-171 to 11-047-171

11-044-171 to 11-047-171 2-410 Xerox WorkCentre 5790 Family
11-056-171, 11-057-171 Inserter Bottom Plate RAP Install new components as necessary:
11-056-171 The inserter bottom plate has failed to return to the home position. IDG Pickup sensor, PL 11.179 Item 10.
11-057-171 The inserter bottom plate has failed to lift. Perform SCP 6 Final Actions.
Initial Actions
WARNING
Check that the bottom plate area is clear and that there is no damage or obstructions. Install IDG Pickup Sen-
new components as necessary. sor
Procedure
Enter dC330, code 11-078 for the inserter motor. The motor runs.
Y N
Go to Flag 5 and Flag 6. Check the wiring from the motor to the HVF control PWB. Repair
as necessary, REP 1.2. Check the Inserter motor, MOT-078. Refer to:
Inserter motor
P/J701, HVF Control PWB MOT11-078
P/J4, P/J12, Inserter PWB
Install new components as necessary: Inserter bottom plate sen-
sor Q11-156
Inserter Motor, MOT 11-078, PL 11.181 Item 1.
Enter dC330, code 11-156 for the inserter bottom plate sensor and actuate the sensor. The
display changes.
Go to Flag 1 and Flag 2. Check the wiring from the sensor to the HVF control PWB.
Repair as necessary, REP 1.2. Check the bottom plate sensor, Q11-156. Refer to:
Bottom plate sensor, Q11-156, PL 11.175 Item 16.
Go to Flag 3 and Flag 4. Check the wiring from the IDG Pickup Sensor to the Inserter PWB.
Check the IDG Pickup Sensor. Refer to:


A
11-061-171, 11-416-171 HVF BM Creasing RAP Refer to:
11-061-171 The crease blade has failed to clear the crease blade home sensor. GP 11, How to Check a Sensor.
P/J552, BM PWB.
11-416-171 The crease blade has failed to return to the home position. 11A-171 HVF Power Distribution RAP.
Initial Actions BM PWB, PL 11.166 Item 10.
BM crease blade motor encoder sensor, PL 11.165 Item 1.
WARNING Enter dC330, code 11-061 to run the BM crease blade motor, MOT 11-061, Figure 1. The
Ensure that the electricity to the machine is switched off while performing tasks that do motor runs.
death or injury. Moving parts can cause injury. Go to Flag 3. Check the BM crease blade motor, MOT 11-061.
Refer to:
WARNING P/J557, BM PWB.
Keep away from the crease blade mechanism when working in close proximity to the 11A-171 HVF Power Distribution RAP.
booklet maker when the machine is powered on. The crease blade mechanism activates
quickly and with great force.
BM crease blade motor, PL 11.165 Item 3.
Refer to Figure 1. Turn the crease blade knob to ensure that the crease blade mechanism
is free to move. If necessary, clear any paper jam in the area of the blade. BM PWB, PL 11.166 Item 10.
Ensure that the crease roll is level front to back and is installed correctly, refer to REP
The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
11.59-171.
sary install new components:
Check the following parts for damage:
Crease blade assembly, PL 11.165 Item 13.
Drive gear, PL 11.165 Item 6.
Connecting rods, PL 11.165 Item 9.
Crank, PL 11.165 Item 8.
Procedure
Enter dC330 code 11-416. Actuate the BM crease blade home sensor, Figure 1, by rotating the
crease blade knob, so that the actuator moves into and out of the home sensor. The display
changes.
Y N
Go to Flag 1. Check the BM crease blade home sensor, Q11-416.
Refer to:
P/J552, BM PWB.
BM PWB, PL 11.166 Item 10.
Crease blade home sensor, PL 11.165 Item 1.
Enter dC330 code 11-418. Actuate the BM crease blade motor encoder sensor, Figure 1, by
slowly rotating the crease blade knob. The display changes.
Y N
Go to Flag 2. Check the BM crease blade motor encoder sensor, Q11-418.

BM crease blade BM crease BM crease blade
motor encoder sensor, blade motor, Crease blade home sensor,
Q11-418 MOT 11-061 knob Q11-416


A
11-062-171 HVF BM Crease Roll Failure RAP The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
11-062-171 The HVF BM crease roll motor has failed to run.
BM crease roll motor encoder sensor, PL 11.166 Item 9.
Initial Actions BM crease roll motor, PL 11.166 Item 12.
BM PWB, PL 11.166 Item 10
Clear any paper jam in the area of the crease rolls.
Procedure
WARNING
WARNING
Keep away from the crease blade mechanism when working in close proximity to the
booklet maker when the machine is powered on. The crease blade mechanism activates
quickly and with great force.
Release the crease roll nip pressure by moving the crease roll handle, PL 11.161 Item 5, fully
counter clockwise. Remove the BM right hand cover, PL 11.168 Item 15, to access the crease
rolls. Enter dC330 code 11-419. Actuate the BM crease roll motor encoder sensor by rotating
the crease rolls slowly by hand. The display changes.
Y N
Go to Flag 1. Check the BM crease roll motor encoder sensor, Q11-419, Figure 1.
Refer to:
P/J552, BM PWB.
Enter dC330, code 11-062 to run the BM crease roll motor, MOT 11-062, Figure 1. The motor
BM crease roll motor,
runs.
MOT11-062
Y N
Go to Flag 2. Check the BM crease roll motor, MOT 11-062.
Refer to:
GP 10 How to Check a Motor. BM crease roll motor encoder sensor,
P/J557, BM PWB. Q11-419
BM crease roll motor, PL 11.166 Item 12. Figure 1 Component location
A

A
11-063-171, 11-411-171 HVF BM Staple Unit 1 Failure RAP Enter dC330 code 11-063 to run the BM SH1 motor, Figure 1. The staple head cycled.
Y N
11-063-171 The HVF BM staple unit 1 has failed to leave the home position.
Go to Flag 3. Check the wiring and connectors between P/J560 and P/J585. The wir-
ing and connectors are good.
11-411-171 The HVF BM staple unit 1 has failed to return to the home position. Y N
Repair the wiring or connectors, REP 1.2.
Initial Actions
Install a new BM staple head 1, PL 11.168 Item 7.
WARNING The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. 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 1, PL 11.168 Item 7.
death or injury. Moving parts can cause injury. BM PWB, PL 11.166 Item 10.
Check that there is no damage or obstruction that would prevent the stapling unit from
cycling.
overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, PL 26.10
Item 11.
Check for jammed staples in the stapler head.
Ensure that the customer job does not exceed the capacity of the booklet maker. Refer to
11D-171 Booklet Quality RAP for booklet maker quality specifications.
Procedure
Enter dC330, code 11-421 to check the BM staple head carrier closed sensor, Q11-421, Figure
1. Open and close the staple head carrier. The display changes.
Y N
Go to Flag 1. Check the BM staple head carrier closed sensor, Q11-421.
Refer to:
P/J552, BM PWB.
BM staple head carrier closed sensor, PL 11.168 Item 18.
BM staple head carrier
Remove the HVF front door and door support, refer to REP 11.1-171 HVF Covers. Pull out the closed sensor, Q11-421
BM staple head 1
BM module. Remove the staple head 1 cover, PL 11.168 Item 14. Enter dC330, code 11-411 to
check the BM SH1 home switch. Manually rotate the staple head to actuate the BM SH1 home
switch. The display changes.
Y N
Go to Flag 2. Check the BM SH1 home switch, S11-411.
Refer to:
P/J551, BM PWB.
BM staple head 1, PL 11.168 Item 7.
A

11-065-171, 11-383-171 HVF BM Backstop Failure RAP Refer to:
11-065-171 The HVF BM staple unit 1 has failed to leave the home position. GP 12, How to Check a Solenoid or Clutch.
P/J555, BM PWB.
11-383-171 The HVF BM staple unit 1 has failed to return to the home position.
Initial Actions Install new components as necessary:
Back stop assembly, PL 11.164 Item 17.
WARNING
BM backstop guide home sensor, PL 11.163 Item 18.
BM backstop motor,PL 11.163 Item 4.
Check for a jam or other obstruction that could prevent the backstop mechanism from
moving. BM PWB, PL 11.166 Item 10.
Check the following items:
Damaged BM back stop drive belt, PL 11.163 Item 7.
Damaged BM back stop belt, PL 11.164 Item 15.
Damaged pulley, PL 11.163 Item 5.
Damaged pulley on the BM back stop drive shaft, PL 11.164 Item 14.
Damaged pulley on the BM back stop idler shaft, PL 11.163 Item 13.
The BM back stop drive belt is tensioned correctly. Refer to REP 11.20-171.
The BM back stop belt is tensioned correctly. Refer to REP 11.26-171.
Procedure
Enter dC330 code 11-383. Actuate the BM backstop guide home sensor, Figure 1. The dis-
play changes.
Y N
Go to Flag 1. Check the sensor, Q11-383.
Refer to:
P/J556, BM PWB.
BM backstop guide home sensor, PL 11.163 Item 18.
Enter dC330, code 11-065 to run the BM backstop motor, MOT 11-065, Figure 1. The motor
runs.
Y N
Go to Flag 2 and Flag 3. Check the motor, MOT 11-065.
Refer to:
BM backstop motor,
GP 10 How to Check a Motor. MOT 11-065
P/J554, BM PWB.
BM backstop guide BM stack hold solenoid,
Install new components as necessary: SOL11-076
home sensor, Q11-383
BM backstop motor, PL 11.163 Item 4.
Note: For clarity, the BM base plate is not shown
Go to Flag 4. Check the BM stack hold solenoid SOL 11-076. Figure 1 Component location


11-066-171, 11-384-171 HVF BM Tamper Failure RAP
11-066-171 The HVF tamper has failed to clear the home sensor.
11-384-171 The HVF tamper is not at the home sensor.
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 11.162.
Procedure
BM tamper 1 motor,
Enter dC330 code 11-384 Actuate the BM tamper 1 home sensor, Figure 1. The display MOT11-066
changes.
Y N
Refer to:
GP 11, How to Check a Sensor. BM tamper 1 home sensor, Q11-384
P/J556, BM PWB.
BM tamper 1 home sensor, PL 11.162 Item 1.
Enter dC330, code 11-066, to run the BM tamper 1 motor, MOT 11-066, Figure 1. The motor
runs.
Y N
Refer to:
P/J554, BM PWB.
BM tamper 1 motor, PL 11.162 Item 3.
BM tamper 1 home sensor, PL 11.162 Item 1.


A
11-083-171, 11-440-171 to 11-443-171 Paper Pusher RAP Enter dC330, code 11-171. Manually operate the paper pusher upper sensor, Q11-171, The
display changes.
11-083-171 The paper pusher motor has stalled.
Y N
Go to Flag 1. Check the sensor, Q11-171
11-440-171 The paper pusher has failed to return to the home, (upper) position. Refer to:
11-441-171 The paper pusher has failed to move from the home, (upper) position.
11-442-171 The paper pusher has failed to return to the away, (lower) position. 11A-171 HVF Power Distribution RAP
11-443-171 The paper pusher has failed to move from the away, (lower) position. Paper pusher upper sensor, PL 11.145 Item 16.
HVF Control PWB PL 11.157 Item 2
Initial Actions
Enter dC330, code 11-173. Manually actuate the paper pusher lower sensor, Q11-173. The
display changes.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Go to Flag 3. Check the sensor, Q11-173.
Check for a jam or other obstruction that could prevent the paper pusher from moving. P/J201, HVF Control PWB
Check for damaged paper pusher components. 11A-171 HVF Power Distribution RAP
Procedure Paper pusher lower sensor, PL 11.145 Item 16.
Figure 1. shows the location of the components. HVF Control PWB PL 11.157 Item 2.
Enter dC330, code 11-083 to run the paper pusher motor, MOT 11-083, Figure 1. The motor
runs. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
Y N sary install new components:
Go to Flag 2. Check the motor, MOT 11-083.
Paper pusher upper sensor, PL 11.145 Item 22.
Refer to:
Paper pusher lower sensor, PL 11.145 Item 22.
Paper pusher motor, PL 11.145 Item 13.
11A-171 HVF Power Distribution RAP
Stapler gate safety switch, PL 11.145 Item 17.
Paper pusher motor, PL 11.145 Item 13.
HVF control PWB, PL 11.157 Item 2
Go to Flag 4. Check the stapler gate safety switch S11-365.

Refer to:
GP 13 How to check a switch
The switch is good.
Y N
Sensor assembly, PL 11.145 Item 22.
HVF Control PWB PL 11.157 Item 2.
A
11-083-171, 11-440-171 to 11-443-171 2-424 Xerox WorkCentre 5790 Family
Paper pusher motor
(MOT11-083)
Paper pusher upper

sensor (Q11-171)
Stapler gate
safety switch
(S11-365)
Paper pusher
lower sensor
(Q11-173)

Xerox WorkCentre 5790 Family 2-425 11-083-171, 11-440-171 to 11-443-171

A
11-100-171, 11-101-171 HVF Entry Sensor RAP The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
11-100-171 The paper leading edge is late arriving at the entry sensor.
11-101-171 The paper trailing edge is late leaving the entry sensor. Entry feed motor 1, PL 11.150 Item 2.
Initial Actions Check if the HVF module has the W/TAG V-006 modifications installed. If the modifica-
tions have not been installed perform ADJ 11.13-171 HVF Performance Improvements W/
TAG V-006.
WARNING
Check for a jam or other obstruction in the entrance guide.
Check the entrance guide for damage.
If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate mylar kit.
Check if the HVF module has had the W/TAG V-006 modifications installed. If necessary
perform ADJ 11.13-171 HVF Performance Improvement (W/TAG V-006).
Procedure
Enter dC330, code 11-100. Manually operate the entry sensor, Q11-100, Figure 1. The dis-
play changes.
Y N
Go to Flag 1. Check the sensor, Q11-100. Entry feed motor 1
(MOT11-000)
Refer to:
Entry sensor, PL 11.156 Item 2. Entry sensor
HVF Control PWB, PL 11.157 Item 2. (Q11-100)
Enter dC330, code 11-000 to run the Entry feed motor 1, MOT 11-000, Figure 1. The motor
runs.
Y N
Go to Flag 2. Check the entry feed motor 1, MOT 11-000. Figure 1 Component location
Refer to:
Entry feed motor 1, PL 11.150 Item 2.
Check the drive belt on the motor. The drive belt is good.
Y N
Install a new drive belt, PL 11.150 Item 7.
A


A
11-130-171, 11-132-171 HVF Top Exit Sensor RAP P/J102, HVF Control PWB
11-130-171 The paper leading edge is late arriving at the top exit sensor. 11A-171 HVF Power Distribution RAP
11-132-171 The paper trailing edge is late leaving the top exit sensor. Exit feed motor 2, PL 11.150 Item 1.
Initial Actions
Y N
WARNING Install a new drive belt, PL 11.150 Item 7.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
death or injury. Moving parts can cause injury. sary install new components:
Check for a jam or other obstruction in the paper guide. Top exit sensor, PL 11.156 Item 3.
Check the paper guide for damage. Exit diverter solenoid, PL 11.150 Item 4.
Diverter gate, PL 11.153 Item 9.
Procedure Exit feed motor 2, PL 11.150 Item 1.
Figure 1 shows the location of the components. HVF control PWB, PL 11.157 Item 2.
Enter dC330, code 11-130. Manually operate the top exit sensor, Q11-130, Figure 1. The dis-
play changes. Exit diverter solenoid
Y N (SOL11-002)
Refer to: Top exit sensor
GP 11 How to Check a Sensor. (Q11-130)
HVF Control PWB, PL 11.157 Item 2
Enter dC330, code 11-002. Energize the exit diverter solenoid SOL 11-002, Figure 1. The
solenoid energizes.
Y N
Go to Flag 2. Check the solenoid, SOL 11-002.
Refer to:
GP 12, How to Check a Solenoid or Clutch.
Exit feed motor 2
Exit diverter solenoid, PL 11.150 Item 4.
(MOT11-001)
Enter dC330, code 11-001 to run the exit feed motor 2, MOT 11-001, Figure 1. The motor
runs.
Y N
Go to Flag 3. Check the exit feed motor 2, MOT 11-001. Figure 1 Component location
Refer to:
A


A
11-140-171, 11-142-171 HVF 2nd to Top Exit Sensor RAP Refer to:
11-140-171 The paper leading edge is late arriving at the 2nd to top exit sensor. GP 10 How to Check a Motor.
11-142-171 The paper trailing edge is late leaving the 2nd to top exit sensor. 11A-171 HVF Power Distribution RAP
Initial Actions Exit feed motor 2, PL 11.150 Item 1.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Install a new drive belt, PL 11.150 Item 10.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
death or injury. Moving parts can cause injury. sary install new components:
Check for a jam or other obstruction in the paper guide. 2nd to top exit sensor, PL 11.156 Item 2.
Check the paper guide for damage. Exit diverter solenoid, PL 11.150 Item 4.
If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate finger kit. Diverter gate, PL 11.153 Item 9.
Check the buffer guide assembly (5b), PL 11.153 Item 13 for damage. Exit feed motor 2, PL 11.150 Item 1.
Procedure
Check if the HVF module has the W/TAG V-006 modifications installed. If the modifica-
Figure 1 shows the location of the components. tions have not been installed perform ADJ 11.13-171 HVF Performance Improvements W/
Enter dC330, code 11-140. Manually activate the 2nd to top exit sensor, Q11-140, Figure 1. TAG V-006.
Y N
Go to Flag 1. Check the sensor, Q11-140. Exit diverter solenoid
Refer to: (SOL11-002)
2nd to top exit sensor
P/J101, HVF Control PWB (Q11-140)
2nd to top exit sensor, PL 11.156 Item 2.
Enter dC330, code 11-002. Energize the exit diverter solenoid SOL 11-002, Figure 1. The
solenoid energizes.
Y N
Refer to:
GP 12, How to Check a Solenoid or Clutch.
Exit diverter solenoid, PL 11.150 Item 4.
HVF control PWB, PL 11.157 Item 2 Exit feed motor 2
(MOT11-001)
Enter dC330, code 11-001 to run the exit feed motor 2, MOT 11-001, Figure 1. The motor
runs.
Go to Flag 3. Check the exit feed motor 2, MOT 11-001.


A
11-157-171, 11-161-171 HVF Buffer Position Sensor RAP Remove the hole punch assembly. Check the mechanical operation of the hole punch. The
hole punch rotates unimpeded.
11-157-171 The paper leading edge is late arriving at the buffer position sensor.
Y N
Install a new hole punch assembly, PL 11.153 Item 1.
11-161-171 The paper trailing edge is late leaving the buffer position sensor.
Check the punch head motor, MOT 11-043 and the Punch head home sensor, Q11-350, refer
Initial Actions to RAP 11-044-171 to 11-047-171Punch Unit Head and Position.
WARNING Buffer position sensor, PL 11.156 Item 2.
Ensure that the electricity to the machine is switched off while performing tasks that do Entry feed motor 1, PL 11.150 Item 2.
Hole punch assembly, PL 11.153 Item 1.
Check for a jam or other obstruction in inserter transport.
Check the paper guide for damage.
Check the paper path of the hole punch assembly for obstructions
Check if the HVF module has had the W/TAG V-006 modifications installed. If necessary Inserter transport
Procedure
Enter dC330, code 11-157. Manually activate the buffer position sensor, Q11-157, Figure 1.
Y N
Refer to: Buffer position sensor
GP 11 How to Check a Sensor. Q11-157
Buffer position sensor, PL 11.156 Item 2.
Enter dC330, code 11-000 to run the entry feed motor 1, MOT 11-000, Figure 1. The motor
Entry Feed motor 1
runs.
MOT11-000
Y N
Go to Flag 2. Check the entry feed motor 1, MOT 11-000.
Refer to:
11A-171 HVF Power Distribution RAP Figure 1 Component location
Entry feed motor 1, PL 11.150 Item 2.
Y N
A


A
11-158-171, 11-160-171, 162-171, 163-171 HVF BM Entry Enter dC330, code 11-080 to run the bypass feed motor, MOT 11-080, Figure 1. The motor
runs.
RAP Y N
11-158-171 The paper leading edge is late leaving the HVF booklet exit sensor to enter into the Go to Flag 3. Check the bypass feed motor, MOT 11-080.
booklet maker. Refer to:
11-160-171 The paper leading edge is late arriving at the booklet maker entry sensor. P/J103, HVF Control PWB
11-162-171 The paper trailing edge is late leaving the booklet maker entry sensor.
11-163-171 The paper trailing edge is late leaving the HVF booklet exit sensor to enter into the Bypass feed motor, PL 11.150 Item 2.
booklet maker. HVF control PWB, PL 11.157 Item 2.
Initial Actions Check the drive belt on the motor. The drive belt is good.
Y N
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Enter dC330, code 11-160. Manually activate the BM entry sensor, Q11-160, Figure 2. The
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause display changes.
Check for a jam or other obstruction in bypass transport.
Refer to:
Check or a jam or other obstruction in the BM paper entry guide.
P/J551, BM PWB.
Procedure
Figure 1 and Figure 2 show the location of the components.
Enter dC330, code 11-158. Manually activate the HVF booklet exit sensor, Q11-158, Figure 1.
The display changes. BM entry sensor, PL 11.161 Item 16.
Y N HVF Control PWB, PL 11.157 Item 2.
Refer to: Enter dC330, code 11-060 to run the BM compiler motor, MOT 11-060, Figure 2. The motor
GP 11 How to Check a Sensor. runs.
Y N
P/J101, HVF Control PWB.
Go to Flag 5. Check the BM compiler motor, MOT 11-060.
11A-171 HVF Power Distribution RAP Refer to:
Install new components as necessary: GP 10 How to Check a Motor.
HVF booklet exit sensor, PL 11.156 Item 3. P/J554, BM PWB
HVF Control PWB, PL 11.157 Item 2. 11A-171 HVF Power Distribution RAP
Enter dC330, code 11-074. Energize the BM diverter solenoid SOL 11-074, Figure 1. The
solenoid energizes. BM compiler motor, PL 11.166 Item 1.
Y N HVF control PWB, PL 11.157 Item 2.
Refer to: Lower the stapler bracket assembly, Figure 2. Enter dC330 code 11-190 BM paper present
GP 12, How to Check a Solenoid or Clutch. sensor, Q11-190. Actuate Q11-190. The display changes.
Y N
11A-171 HVF Power Distribution RAP. Refer to:
Install new components as necessary: GP 11, How to Check a Sensor.
BM diverter solenoid, PL 11.150 Item 4. P/J556, BM PWB.
A B

Xerox WorkCentre 5790 Family 2-435 11-158-171, 11-160-171, 162-171, 163-171
B
BM paper present sensor, PL 11.168 Item 5. BM entry sensor
Q11-160
BM compiler
Check the drive belt on the motor. The drive belt is good. motor
Y N MOT11-060
HVF booklet exit sensor, PL 11.156 Item 3.
BM diverter solenoid, PL 11.150 Item 4.
BM diverter gate, PL 11.153 Item 9.
BM compiler motor, PL 11.166 Item 1.
Bypass feed motor 2, PL 11.150 Item 2.
HVF control PWB, PL 11.157.
BM diverter solenoid
SOL11-074
BM paper present
sensor
Q11-190
HVF booklet exit sensor

Q11-158
Stapler bracket
assembly
Bypass feed motor
MOT11-080

11-158-171, 11-160-171, 162-171, 163-171 2-436 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-437 11-158-171, 11-160-171, 162-171, 163-171
11-164-171, 11-165-171 HVF Buffer Path RAP
11-164-171 The paper trailing edge is late leaving the buffer path sensor.
11-165-171 The paper leading edge is late arriving at the buffer path sensor.
Initial Actions
WARNING
Check for a jam or other obstruction in buffer path transport.
Check the paper guide for damage.
Procedure
Enter dC330, code 11-164. Manually activate the buffer path sensor, Q11-164, Figure 1. The
display changes.
Y N
Refer to:
Figure 4 Circuit diagram Buffer path sensor, PL 11.156 Item 2.
HVF Control PWB, PL 11.157 Item 2.
Enter dC330, code 11-079 to run the Buffer feed motor 1, MOT 11-079, Figure 1. The motor
runs.
Y N
Go to Flag 2. Check the entry feed motor 1, MOT 11-079.
Refer to:
Buffer feed motor, PL 11.150 Item 1.
Y N
A
11-158-171, 11-160-171, 162-171, 163-171, 11-164-171, 2-438 Xerox WorkCentre 5790 Family
A
Buffer path sensor, PL 11.156 Item 2.
Buffer feed motor, PL 11.150 Item 1.
Buffer path sensor

Q11-164
Buffer feed motor

MOT11-079


A
11-172-171 HVF BM Compiler Exit Jam RAP Unlatch the entrance baffle assembly, PL 11.161 Item 22. Run again MOT11-060. The BM
entry roll rotates.
11-172-171 The trail edge is late leaving the BM compiler exit sensor.
Y N
Check the following components:
Initial Actions BM compiler motor belt, PL 11.166 Item 15.
BM entry roll pulley, PL 11.161 Item 14.
WARNING BM entry roll, PL 11.161 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 BM.
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 11.52-171 BM Crease Rolls,
Check that the stapler bracket assembly, PL 11.168 Item 10, is correctly latched. Gears and Bearings.
Check the operation of the BM tampers, refer to the 11-066-171, 11-384-171 HVF BM
Tamper Failure RAP. If the tampers are operating correctly, go to ADJ 11.5-171 Booklet Perform SCP 6 Final Actions.
Tamping and check the tampers are correctly adjusted.
Procedure
Lower the stapler bracket assembly, Figure 1. Enter dC330 code 11-190 BM paper present
sensor, Q11-190. Actuate Q11-190. The display changes.
Y N
Refer to:
P/J556, BM PWB.
BM paper present sensor, PL 11.168 Item 5.
Go to Flag 1. Check the connectors and harness between PJ568 and P/J556. Refer to GP 7.
The wiring and connectors are good.
Y N
Repair the wiring, REP 1.2 or install new components as necessary.
Enter dC330 code 11-060 BM compiler motor, MOT11-060. MOT11-060 runs.

Y N
Refer to:
P/J554, BM PWB.
Install new components as necessary
BM compiler motor, PL 11.166 Item 1.

BM entry roll
BM compiler motor,
MOT11-060
BM paper present sensor,

Q11-190
Stapler bracket assembly


A
11-173-171 to 11-177-171 HVF Offset Unit RAP Refer to:
GP 11 How to Check a Sensor
11-173-171 The offset unit has failed to find its initialization point.
11-174-171 The offset unit has failed to return the home position. 11A-171 HVF Power Distribution RAP
11-175-171 The offset unit has failed to move from the home position. Install new components as necessary:
Offset away sensor, PL 11.140 Item 15
11-176-171 The offset unit has failed to return to the away position.
Ejector assembly, PL 11.140 Item 2
11-177-171 The offset unit has failed to move from the away position. HVF Control PWB PL 11.157 Item 2
Initial Actions Enter dC330, code 11-034 to run the bin 1 offset motor, MOT 11-034, Figure 1.. The motor
runs.
Y N
Go to Flag 4. Check the bin 1 offset motor, MOT 11-034.
WARNING
Refer to:
Check for a jam or other obstruction in the offset unit.
Check the offset unit for damage.
Bin 1 offset motor, PL 11.140 Item 19
Procedure HVF control PWB, PL 11.157 Item 2
Figure 1 shows the location of the components. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
Enter dC330, code 11-337. Manually activate the bin 1 offset sensor, Q11-337, Figure 1. The sary install new components:
display changes. Bin 1 offset sensor, PL 11.140 Item 15
Y N Offset index sensor, PL 11.140 Item 15
Go to Flag 1. Check the sensor, Q11-337. Offset away sensor, PL 11.140 Item 15
Refer to: Bin 1 offset motor, PL 11.140 Item 19
GP 11 How to Check a Sensor HVF control PWB, PL 11.157 Item 2
Bin 1 offset sensor, PL 11.140 Item 15
Enter dC330, code 11-187. Manually activate the offset index sensor, Q11-187, Figure 1. .
Y N
Refer to:
GP 11 How to Check a Sensor. Bin 1 offset sensor
P/J302, HVF Control PWB Q11-337
Offset index sensor, PL 11.140 Item 15
Ejector assembly, PL 11.140 Item 2
Enter dC330, code 11-176. Manually activate the offset away sensor, Q11-176, Figure 1. . The
Offset index sensor
display changes. Bin 1 offset motor
Q11-187 Offset away sensor
Y N Q11-176 MOT11-034
A

A
11-180-171, 11-182-171 HVF BM Exit Jam RAP Refer to:
11-180-171 The lead edge is late arriving at the BM exit sensor. GP 11, How to Check a Sensor.
P/J556, BM PWB.
11-182-171 The trail edge is late leaving the BM exit sensor. 11A-171 HVF Power Distribution RAP.
Initial Actions BM PWB, PL 11.166 Item 10.
BM exit sensor, PL 11.168 Item 17.
WARNING Enter dC330, code 11-062 to run the BM crease roll motor, MOT 11-062. The motor runs.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Go to Flag 4. Check the motor, MOT 11-062.
Turn the crease blade knob (6d) to ensure that the crease blade mechanism is free to move. If GP 10 How to Check a Motor.
necessary, clear any paper jam in the exit area. P/J557, BM PWB.
Enter dC330 code 11-418. Actuate the BM crease blade motor encoder sensor, Q11-418, Fig- BM crease roll motor, PL 11.166 Item 12.
ure 1 by rotating the crease blade knob (6d). The display changes.
Y N
Enter dC330, code 11-061 to run the BM crease blade motor, MOT 11-061. The motor runs.
Refer to:
Y N
GP 11, How to Check a Sensor. Go to Flag 5. Check the motor, MOT 11-061.
P/J552, BM PWB. Refer to:
11A-171 HVF Power Distribution RAP. GP 10 How to Check a Motor.
Install new components as necessary: P/J557, BM PWB.
BM PWB, PL 11.166 Item 10. 11A-171 HVF Power Distribution RAP.
BM crease blade motor encoder sensor, PL 11.165 Item 1. Install new components as necessary:
Release the crease roll nip pressure by moving the crease roll handle fully counter clockwise.
Remove the BM right hand cover, PL 11.168 Item 15, to access the crease rolls. Enter dC330
code 11-419. Actuate the BM crease roll motor encoder sensor by rotating the crease rolls
Enter dC330, code 11-401 to run the BM crease roll gate motor, MOT 11-401. The motor
slowly by hand. The display changes.
runs.
Y N
Y N
Refer to:
Refer to:
P/J552, BM PWB.
P/J555, BM PWB.
BM crease roll gate motor, PL 11.166 Item 8.
Enter dC330 code 11-409. Actuate the BM exit sensor, Q11-409, Figure 2. The display
changes.
sary install a new BM PWB, PL 11.166 Item 10.
Y N
Go to Flag 3. Check sensor, Q11-409.
A
BM crease roll gate motor, MOT11-401
BM crease blade
motor encoder
sensor, Q11-418
BM exit sensor, Q11-409
BM crease blade motor,

MOT11-061
BM crease roll motor, MOT11-062
BM crease roll motor encoder sensor, Q11-419


A
11-183-171, 11-184-171 HVF BM Paper Jam RAP Refer to:
11-183-171 The BM control PWB has detected an unexpected sheet in the booklet maker GP 11 How to Check a Sensor.
paper path. P/J551, BM PWB.
11-184-171 The BM control PWB has detected a stray sheet in the booklet maker paper path Install new components as necessary:
after jam clearance.
BM entry sensor, PL 11.161 Item 16.
Initial Actions
Enter dC330 code 11-183. Manually actuate the tri-folder entry sensor, Q11-183, Figure 3.
WARNING Y N
Check for a jam or other obstruction in the booklet maker paper path. P/J604, Tri Folder Control PWB.
Check the paper path for damage. 11A-171 HVF Power Distribution RAP.
Procedure Tri-folder control PWB, PL 11.193 Item 16.
Figure 3 shows the location of the components. Tri-folder entry sensor, PL 11.197 Item 11.
Enter dC330 code 11-190. Manually actuate the BM paper present sensor, Q11-190, Figure 1.
The display changes. Enter dC330 code 11-183. Manually actuate the tri-folder entry sensor Q11-183. The display
Y N changes.
Go to Flag 1. Check the sensor, Q11-190. Y N
Refer to: Go to Flag 5. Check between P/J602 pin 10 on the tri-folder control PWB and P/J563 pin
GP 11 How to Check a Sensor. 1 on the BM PWB.
P/J556, BM PWB. Refer to:
11A-171 HVF Power Distribution RAP. P/J563, BM PWB.
Install new components as necessary: P/J602, Tri-folder Control PWB
BM PWB, PL 11.166 Item 10. 11A-171 HVF Power Distribution RAP.
BM paper present sensor, PL 11.168 Item 5. Install new components as necessary:
Enter dC330 code 11-409. Manually actuate the BM exit sensor, Figure 2. The display Tri-folder control PWB, PL 11.193 Item 16.
changes.
Y N The fault may be intermittent, check the wiring REP 1.2. If necessary, install a new BM PWB,
Go to Flag 2. Check the sensor, Q11-409. PL 11.166 Item 10.
Refer to:
P/J556, BM PWB.
BM exit sensor, PL 11.168 Item 17.
Enter dC330 code 11-160. Manually actuate the BM entry sensor, Q11-160, Figure 1. The dis-
play changes.
Y N
Go to Flag 3. Check sensor, Q11-160.
A

BM entry sensor,
Q11-160
BM exit sensor, Q11-409
BM paper present sensor,

Q11-190
Tri folder entry sensor Q11-183


A
11-185-171 to 11-187-171 Tri-Folder Exit Sensor and Assist BM PWB, PL 11.166 Item 10.
Sensor RAP Enter dC330 code 11-085 to energize the tri folder diverter solenoid, SOL 11-085. The sole-
11-185-171 The lead edge is late arriving at the folder exit sensor. noid energizes.
Y N
11-186-171 The trail edge is late leaving the folder exit sensor. Go to Flag 5 and Flag 6. Check the solenoid, SOL 11-085.
Refer to:
11-187-171 The lead edge is late arriving at the tri folder assist sensor. GP 12, How to Check a Solenoid or Clutch.
P/J602, P/J603, Tri Folder Control PWB.
Initial Actions P/J563, BM PWB.
Ensure that the electricity to the machine is switched off while performing tasks that do Diverter solenoid, PL 11.197 Item 16.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Tri-folder control PWB, PL 11.193 Item 16.
death or injury. Moving parts can cause injury. BM PWB, PL 11.166 Item 10.
Check for a jam or other obstruction in the tri-folder.
Check the tri-folder for damage. Enter dC330 code 11-086 to energize the tri folder assist gate solenoid, SOL 11-086, Figure 1.
The solenoid energizes.
Y N
Procedure Go to Flag 7 and Flag 8. Check the solenoid, SOL 11-086.
Figure 1, Figure 2 and Figure 3 show the location of the components. Refer to:
Enter dC330 code 11-184. Manually actuate the tri folder assist sensor, Q11-184, Figure 1. GP 12, How to Check a Solenoid or Clutch.
P/J563, BM PWB.
Y N
Go to Flag 1 and Flag 2. Check the sensor, Q11-184. P/J602, P/J603, Tri Folder Control PWB.
Refer to: 11A-171 HVF Power Distribution RAP.
GP 11, How to Check a Sensor. Install new components as necessary:
P/J604, P/J602, Tri Folder Control PWB Tri-folder assist solenoid, PL 11.197 Item 8.
P/J563, BM PWB. Tri-folder control PWB, PL 11.193 Item 16.
11A-171 HVF Power Distribution RAP. BM PWB, PL 11.166 Item 10.
Enter dC330 code 11-087 to energize the drive clutch, CL 11-087, Figure 1. The clutch ener-
Tri folder assist gate sensor, PL 11.197 Item 6.
gizes.
Tri-folder control PWB, PL 11.193 Item 16. Y N
BM PWB, PL 11.166 Item 10. Go to Flag 9 and Flag 10. Check the clutch, CL 11-087.
Refer to:
Enter dC330 code 11-185. Manually actuate the folder exit sensor, Figure 2. The display GP 12, How to Check a Solenoid or Clutch.
changes.
P/J563, BM PWB.
Y N
Go to Flag 3 and Flag 4. Check the sensor, Q11-185. P/J602, P/J603, Tri Folder Control PWB.
Refer to: 11A-171 HVF Power Distribution RAP.
GP 11, How to Check a Sensor. Install new components as necessary:
P/J604, P/J602, Tri Folder Control PWB. Drive clutch, PL 11.193 Item 9.
P/J563, BM PWB. Tri-folder control PWB, PL 11.193 Item 16.
11A-171 HVF Power Distribution RAP. BM PWB, PL 11.166 Item 10.
Enter dC330, code 11-062 to run the BM crease roll motor, MOT 11-062, Figure 3. The motor
Folder exit sensor, PL 11.197 Item 12.
runs.
Tri-folder control PWB, PL 11.193 Item 16.
A
Y N
Refer to: TF Exit sensor,
Q11-185
P/J557, BM PWB.
BM crease roll motor, PL 11.166 Item 8.
Drive clutch,
CL11-087
TF Assist sensor,
Q11-184
TF Assist gate solenoid, TF diverter solenoid,

SOL11-086 SOL11-085

BM crease roll motor,
MOT11-062



A
11-188-171, 11-189-171 HVF Nip Split RAP P/J101, P/J102HVF Control PWB.
11-188-171 The nip split has failed to operate. 11A-171 HVF Power Distribution RAP.
11-189-171 The nip split has failed to return to the home position. Nip split sensor, PL 11.156 Item 1.
Initial Actions
Perform SCP 6, Final Actions.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Nip split motor, MOT11-081
Check for a jam or other obstruction in the nip split.
Check the nip split for damage.
Procedure
Enter dC330, code 11-081 to run the nip split motor, MOT 11-081. The nip-split mechanism
can be heard.
Y N Nip home sensor,
Nip split sensor,
Go to Flag 3. Check the motor, MOT 11-081. Q11-170 Q11-159
Refer to:
GP 10 How to Check a Motor. REAR VIEW
Nip split motor, PL 11.153 Item 15.
Enter dC330 code 11-159. Manually actuate the Nip home sensor, Q11-159, Figure 1. The
display changes.
Y N
Refer to:
GP 11, How to Check a Sensor. Figure 1 Component location
Nip home sensor, PL 11.156 Item 1.
Enter dC330 code 11-170. Manually actuate the nip split sensor, Q11-170. The display
changes.
Y N
Refer to:
A


A
11-191-171, 11-193-171, 11-194-171, 11-196-171 Inserter Install new components as necessary:
Acceleration sensor, PL 11.175 Item 10.
Paper Jam RAP
Inserter PWB, PL 11.179 Item 9.
11-191-171 The leading edge is late arriving at the inserter standby sensor.
11-193-171 The trailing edge is late leaving the inserter standby sensor.
Measure the voltage at pin 2 of P/J702 on the HVF PWB. Open the front door and open 8a
11-194-171 The leading edge is late arriving at the inserter TE sensor. jam clearance guide. Manually actuate the inserter standby sensor with a sheet of paper. The
voltage changes.
Y N
11-196-171 The trailing edge is late leaving the inserter TE sensor.
Go to Flag 5. Check the sensor.
Refer to:
Fault code 11-191 may also be generated where a fault in the inserter causes jamming in the
IOT. GP 11, How to Check a Sensor.
Initial Actions 11A-171 HVF Power Distribution RAP.
Inserter standby sensor, PL 11.156 Item 2.
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Enter dC330 code 11-077. Energize the inserter, CL 11-077. The clutch energizes.
Check for a jam or other obstruction in the inserter. Go to Flag 6 (W/O TAG V-001) or Flag 10 (With TAG V-001) and Flag 7. Check the clutch,
Check the inserter for damage. CL 11-077.
Refer to:
Procedure GP 12, How to Check a Solenoid or Clutch.
Figure 1 shows the location of the components. P/J12, P/J5, Inserter PWB.
Enter dC330 code 11-155. Manually actuate the inserter TE sensor, Q11-155, Figure 1. The P/J703, HVF Control PWB
display changes. 11A-171 HVF Power Distribution RAP.
Go to Flag 1 and Flag 2. Check the sensor, Q11-155.
Inserter clutch, PL 11.179 Item 3.
Refer to:
Inserter control PWB, PL 11.179 Item 9.
P/J6, P/J4, Inserter PWB.
P/J701, HVF Control PWB Enter dC330, code 11-078 to run the inserter motor, MOT 11-078. The motor runs.
11A-171 HVF Power Distribution RAP. Y N
Install new components as necessary: Go to Flag 8 and Flag 9. Check the motor, MOT 11-078.
Inserter TE sensor, PL 11.179 Item 11. Refer to:
Inserter PWB, PL 11.179 Item 9. GP 10 How to Check a Motor.
HVF control PWB, PL 11.157 Item 2. P/J701, HVF Control PWB
P/J4, Inserter PWB.
Measure the voltage of pin 2 of P/J11. Manually actuate the acceleration sensor, Figure 1. 11A-171 HVF Power Distribution RAP.
The voltage changes. Install new components as necessary:
Y N
Inserter motor, PL 11.181 Item 1.
Go to Flag 3 and Flag 4. Check the sensor.
Refer to: Inserter control PWB, PL 11.179 Item 9.
GP 11, How to Check a Sensor. HVF control PWB, PL 11.157 Item 2.
A

Inserter TE sen-
sor Q11-155
Inserter LE sensor
Q11-154
Acceleration sensor
Inserter clutch, Inserter motor,

CL11-077 MOT11-078
Inserter standby
sensor



A
11-198-171, 11-199-171 HVF Paper Jam RAP P/J101, HVF Control PWB.
11-198-171 A stray sheet was detected in the finisher, after a jam clearance. 11A-171 HVF Power Distribution RAP
11-199-171 An unexpected sheet has been detected in the finisher. Buffer path sensor, PL 11.156 Item 2.
Initial Actions
Enter dC330, code 11-140. Manually activate the stacker exit sensor, Q11-140, Figure 1. The
display changes.
WARNING Y N
Check for a jam or other obstruction in the HVF paper path. P/J101, HVF Control PWB.
Check the paper path for damage. 11A-171 HVF Power Distribution RAP
Procedure Stacker exit sensor, PL 11.156 Item 2.
Figure 1 shows the location of the components. HVF Control PWB, PL 11.157 Item 2.
Enter dC330, code 11-100. Manually activate the entry sensor, Q11-100, Figure 1. The dis-
play changes. Enter dC330, code 11-130. Manually activate the top exit sensor, Q11-130, Figure 1. The dis-
Y N play changes.
Refer to: Go to Flag 5. Check the sensor, Q11-130.
GP 11 How to Check a Sensor. Refer to:
P/J101, HVF Control PWB. GP 11 How to Check a Sensor.
11A-171 HVF Power Distribution RAP P/J101, HVF Control PWB.
Install new components as necessary: 11A-171 HVF Power Distribution RAP
Entry sensor, PL 11.156 Item 2. Install new components as necessary:
HVF Control PWB, PL 11.157 Item 2. Top exit sensor, PL 11.156 Item 3.
Enter dC330, code 11-157. Manually activate the buffer position sensor, Q11-157, Figure 1.
The display changes. HVF BM machines only, enter dC330, code 11-158. Manually activate the HVF booklet exit
Y N sensor, Q11-158, Figure 1. The display changes.
Refer to: Go to Flag 6. Check the sensor, Q11-158.
GP 11 How to Check a Sensor. Refer to:
11A-171 HVF Power Distribution RAP P/J101, HVF Control PWB.
Install new components as necessary: 11A-171 HVF Power Distribution RAP
Buffer position sensor, PL 11.156 Item 2. Install new components as necessary:
HVF Control PWB, PL 11.157 Item 2. HVF booklet exit sensor, PL 11.156 Item 3.
Enter dC330, code 11-164. Manually activate the buffer path sensor, Q11-164, Figure 1. The
display changes. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If
Y N necessary install new components.
Refer to:
A

Top exit sensor
Q11-130
Stacker sensor
Q11-140
Buffer path sensor

Q11-164
Entry sensor
Q11-100 HVF booklet exit sensor
Q11-158
Buffer position sensor
Q11-157


11-300-171, 11-302-171, 11-303-171 HVF Docking and 11-303-171 Front Door Interlock RAP
Interlock RAP Check the front door interlock switch, S11-303, Figure 1.
Check the switch actuator on the inside of the front door is not damaged.
11-300-171 The finisher was detected to be undocked in the run mode.
Enter dC330, code 11-303 actuate the switch and check the display.
11-302-171 The top cover interlock was detected open during a run. Refer to:
11-303-171 The finisher front door interlock was detected open during a run.
Figure 1, Flag 2.
Initial Actions
Check the wiring, GP 7.
If necessary, install a new front door interlock switch, PL 11.145 Item 29.
WARNING
Ensure the HVF is correctly docked to the machine and all interlocks are closed.
Procedure
Check the docking interlock switch, S11-300, Figure 1.
Check the switch actuator mounted on the machine is correctly installed and un-broken.
Enter dC330, code 11-300, actuate the switch and check the display.
Refer to:
Figure 1, Flag 3.
If necessary, install new components:
Docking interlock switch, PL 11.130 Item 16.
Check the top cover interlock switch, S11-302, Figure 1.
Check the switch actuator is not damaged.
Enter dC330, code 11-302 actuate the switch and check the display.
Refer to:
Figure 1, Flag 1.
If necessary, install a new top cover interlock switch, PL 11.145 Item 24.
.

S11-302
Front door interlock switch,

Docking interlock switch, S11- S11-303
300


A
11-306-171, 11-309-171 HVF Inserter Interlock RAP The fault may be intermittent. Check the wiring and the routing of the harness. Refer to GP 7.
11-306-171 The inserter top cover interlock was detected open in the run mode.
11-309 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 inter-
locks are operated. Remove any obstruction as necessary.
Check the actuator on the top cover is not damaged, PL 11.179 Item 17.
Check the actuator on the top left door is not damaged, PL 11.175 Item 7.
Procedure
Enter dC330, code 11-306. Open and close the top cover to actuate the switch, Figure 1. The
display changes
Y N
Refer to:
Figure 1, Flag 1 and Flag 2. Inserter left hand door Inter- Inserter top cover interlock
P/J1, P/J5, P/J4, Inserter PWB. lock switch, S11-431 switch, S11-306
P/J701, P/J703, HVF Control PWB.
If necessary install new components:
Inserter top cover interlock switch, PL 11.177 Item 8. Figure 1 Component location
Open the top cover. Enter dC330, code 11-431, open and close the left hand door to actuate
the switch. The display changes.
Y N
Refer to:
Figure 1, Flag 3 and Flag 4.
If necessary install new components:
Inserter left door interlock switch, PL 11.175 Item 18.


A
11-307-171, 11-308-171 Tri-folder Interlock RAP Install new components as necessary:
11-307-171 The Tri-folder top cover interlock was detected open during a run. Tri-folder front door interlock switch, PL 11.197 Item 3.
Tri-folder PWB, PL 11.193 Item 16.
11-308-171 The Tri-folder front door interlock was detected open during a run. BM PWB, PL 11.166 Item 10.
Initial Actions Enter dC330, code 11-394. Open the tri-folder top cover door assembly. The display
changes.
Y N
WARNING Go to Flag 6 and Flag 7. Check the wiring and repair as necessary, REP 1.2. Check the
Tri-folder top cover interlock sensor, Q11-394. Refer to:
death or injury. Moving parts can cause injury. P/J605, P/J602, Tri Folder Control PWB.
Check that the tri-folder top cover and front door can be fully closed and that the interlocks are P/J563, BM PWB.
operated. Remove any obstruction as necessary. 11A-171 HVF Power Distribution RAP.
Procedure Top cover interlock sensor, Q11-394, PL 11.190 Item 10.
NOTE: The two yellow, +24V interlock LEDs on the BM PWB will extinguish if a tri-folder inter-
lock is open. BM PWB, PL 11.166 Item 10.
Figure 1 shows the location of the components. Perform SCP 6 Final Actions.
Check that the yellow, +24V interlock LED on the BM PWB is lit. The LED is lit.
Y N
TF top cover interlock TF top cover sensor
Go to Flag 1, Flag 2 and Flag 3. Check the wiring and repair as necessary, REP 1.2.
switch Q11-394
Check the TF top cover interlock switch and the TF front door interlock switch, S11-393.
Refer to:
P/J601, Tri Folder Control PWB.
P/J553, BM PWB.
P/J559, BM PWB.
Top cover interlock switch, PL 11.197 Item 3.
Front door interlock switch, PL 11.197 Item 2.
HVF PWB, PL 11.157 Item 2.
Enter dC330, code 11-393. Open the tri-folder front door. The display changes.
Y N
Go to Flag 4 and Flag 5. Check the wiring and repair as necessary, REP 1.2. Check the TF front door interlock
tri-folder front door interlock, S11-393. Refer to: switch, S11-393
P/J605, P/J602, Tri Folder Control PWB.
P/J563, BM PWB.
11A-171 HVF Power Distribution RAP. Figure 1 Component location


A
11-371-171 to 11-377-171 HVF Stapler Position and Priming P/J801, HVF Control PWB.
RAP
11-371-171 The stapler did not move from the home position.
Stapler assembly, PL 11.140 Item 14.
11-372-171 The stapler did not return to the home position. HVF control PWB, PL 11.157 Item 2.
11-373-171 The stapler did not enter the mid home position. With the stapler unit still at the inboard end, enter dC330, code 11-360, stapler home sensor.
Manually activate the stapler home sensor, Q11-360, Figure 2. The display changes.
11-374-171 The stapler did not leave the mid home position. Y N
11-375-171 The stapler jaw did not enter the home position. Refer to:
11-376-171 The stapler jaw did not leave the home position. P/J301, HVF Control PWB.
11-377-171 A stapler priming failure was detected.
Initial Actions Stapler assembly, PL 11.140 Item 14.
WARNING Enter dC330, code 11-054 to send the stapler unit to the outboard end of the machine. Enter
code 11-175, stapler unit mid home sensor. Manually activate the stapler unit mid home sen-
sor, Q11-175, Figure 2. The display changes.
Y N
Refer to:
CAUTION GP 11 How to Check a Sensor.
Do not run code 11-050 without two sheets of paper in the stapler jaws. Running this code with- P/J301, HVF Control PWB.
out the paper in position can cause damage to the machine. 11A-171 HVF Power Distribution RAP
If stapling has failed, perform the following: Install new components as necessary:
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. Place two sheets of paper in the stapler jaws. Raise the finisher top cover. Figure 1, lower the
Check that the leading staples in the staple head have been primed. paper pusher fully down and lower the top cover. Enter dC330, code 11-050 to run the staple
Check that the sheets of staples in the cartridge are feeding one at a time. If staples head motor, MOT 11-050. The motor runs.
sheets overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, Y N
PL 11.140 Item 33 Go to Flag 6. Check the wiring and repair as necessary, REP 1.2. Check the stapler gate
safety switch.
Procedure Refer to:
NOTE: The sensors Q11-364, Q11-363, Q11-360 and Q11-362 are integral to the staple head P/J304, HVF Control PWB.
unit and although they can be checked they are not separately spared.
Figure 1 and Figure 2 show the locations of the components. Install new components as necessary:
Enter dC330, code 11-053 to run the stapler unit motor, MOT 11-053 and send it to the inboard Sensor assembly, PL 11.145 Item 22.
end of its travel. The motor runs.
Y N
Go to Flag 5. Check the motor, MOT 11-053. HVF control PWB, PL 11.157 Item 2.
Refer to: With the paper still in place, re-enter the code 11-050 to run the staple head motor, MOT
GP 10 How to Check a Motor. 11-050. The motor runs.
A B

B C D E
Y N Install a new stapler assembly, PL 11.140 Item 14.
Refer to: Install a new HVF Control PWB, PL 11.157 Item 2.
Enter dC330, code 11-360 to monitor the staple home sensor Q11-360, stack the code 11-050
to cycle the staple head. The display changes.
Y N
Install new components as necessary: Go to Flag 3. Check for a change in signal level at P/J301 pin 12, while code 11-050 is
Stapler assembly, PL 11.140 Item 14. running. The signal level changes.
HVF control PWB, PL 11.157 Item 2. Y N
Check the wiring between P/J301 pin 12 and the staple head unit. The wiring is
If the stapler is now working satisfactorily, perform SCP 6 Final Actions. If necessary, con- good.
tinue with this RAP. Y N
Repair the wiring, REP 1.2 or install a new stapler harness and P-clip assembly,
Remove the stapled paper and raise the paper pusher fully upwards. Go to Flag 3. +5V is PL 11.140 Item 25 as necessary.
available at T502 between pins 1 and 4, also between pin 1 and 7 on the staple head.
Check the wiring between P/J T502 and P/J301. The wiring is good.
Y N Install a new HVF Control PWB, PL 11.157 Item 2.
Repair the wiring, REP 1.2 or install a new stapler harness and P-clip assembly, PL
11.140 Item 25. Enter dC330, code 11-362, actuate the low staples sensor, Q11-362, by removing and install-
ing the staple cartridge. The display changes.
Install a new HVF control PWB, PL 11.157 Item 2. Y N
Go to Flag 3. Check for a change in signal level at P/J301 pin 13 when Q11-362 is being
Enter dC330, code 11-364 actuate the stapler priming sensor, Q11-364, by removing and actuated. The signal level changes.
installing the staple cartridge. The display changes. Y N
Y N Check the wiring between P/J301 pin 13 and the staple head unit. The wiring is
Check for a change in signal level at P/J301 pin 9 when Q11-364 is being actuated. The good.
signal level changes. Y N
Y N Repair the wiring, REP 1.2 or install a new stapler harness and P-clip assembly,
Check the wiring between P/J301 pin 9 and the staple head unit. The wiring is PL 11.140 Item 25 as necessary.
good.
PL 11.140 Item 25 as necessary. Install a new HVF Control PWB, PL 11.157 Item 2.
Install a new stapler assembly, PL 11.140 Item 14. Check the fault history for 11-341 faults. 11-341 faults are in the fault history.
Y N
Install a new HVF Control PWB, PL 11.157 Item 2. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If
necessary install new components.
Enter dC330, code 11-363 actuate the stapler cartridge sensor, Q11-363, by removing and
installing the staple cartridge. The display changes. Switch off the machine, GP 14. Disconnect PJ131, PJ132 and PJ133 from the HVF Control
Y N PWB. Switch on the machine, GP 14. The fault is still present.
Check for a change in signal level at P/J301 pin 10 when Q11-363 is being actuated. Y N
The signal level changes. Switch off the machine, GP 14. Re-connect PJ131, PJ132 and PJ133. Go to the 11-403-
Y N 171, 11-413-171, 11-414-171 HVF BM Staple Head 2 and Stapler Module RAP.
Check the wiring between P/J301 pin 10 and the staple head unit. The wiring is
good. The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
Y N sary install new components.
PL 11.140 Item 25 as necessary.
C D E
Stapler unit mid home sensor,
Q11-175
Paper pusher
Stapler gate safety

switch, S11-365
Stapler home sensor,

Q11-360



11-380-171 HVF Punch Unit Paper Edge Detect RAP
11-380-171 The punch unit failed to detect the edge of the paper.
Initial Actions
WARNING
Check that the paper path through the punch is clear, Figure 1. Check the punch module
is seated at the rear or the machine.
Procedure
Go to Flag 1. Check the wiring and repair as necessary, REP 1.2. Check the paper edge sen- Entry Feed
sor, Figure 1 and Figure 2. Refer to: motor 1,
GP 11 How to Check a Sensor. MOT11-000
Paper edge sensor
HVF hole punch assembly, PL 11.153 Item 1.
REAR VIEW
Enter dC330, code 11-000, entry feed motor 1, to check that the motor runs. The motor runs.
Y N
Go to Flag 2. Check the wiring and repair as necessary, REP 1.2. Check entry feed motor Figure 1 Component location
1, MOT11-000. Refer to:
Entry Feed motor, MOT11-000, PL 11.150 Item 2.

For machines W/TAG 046 or W/TAG 047, decrease the downcurl on prints. Refer to ADJ
10.1.
Check the tension of the entry feed motor 1 belt, PL 11.150 Item 7. Refer to ADJ 11.10-
171.
If the fault only occurs when paper is fed from tray 5, check the tray 5 alignment. Refer to
ADJ 7.4.
Reload the software, GP 4.


A
11-392-171 to 11-395-171 HVF Front Tamper Tray RAP Stack the dC330 code 11-174, front tamper away sensor. Move the motor using its control code
11-003 or 11-005. The display changes.
11-392-171 The front tamper tray did not move from the home position.
Y N
Go to Flag 3. Check the wiring and repair as necessary, REP 1.2. Check the front tamper
11-393-171 The front tamper tray did not return to the home position. away sensor, Q11-174. Refer to:
11-394-171 The front tamper tray did not enter the away position.
11-395-171 The front tamper tray did not move from the away position. 11A-171 HVF Power Distribution RAP.
Initial Actions Front tamper away sensor, Q11-174, PL 11.156 Item 1.
WARNING Perform SCP 6 Final Actions.

Check for damage or obstructions that would prevent the front tamper tray from operating
correctly.
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 dC330, code 11-003 to move the tamper inboard, and enter 11-005 to move the tamper
outboard. The tamper moves.
Y N
motor, MOT11-003. Refer to:
Front tamper motor, MOT11-003, PL 11.153 Item 6.
Stack the dC330 code 11-310, front tamper home sensor. Move the motor using its control Front tamper home Front tamper away Front Tamper Motor,
sensor, Q11-310 sensor, Q11-174 MOT 11-003
code 11-003 or 11-005. The display changes.
Y N
Front tamper home sensor, Q11-310, PL 11.156 Item 1.
A

A
11-396-171 to 11-399-171 HVF Rear Tamper Tray RAP Enter the dC330 code, 11-319, rear tamper away sensor. Actuate the rear tamper away sensor,
using a piece of paper inserted from the rear of the machine. The display changes.
11-396-171 The rear tamper tray did not move from the home position.
Y N
Go to Flag 3. Check the wiring and repair as necessary, REP 1.2. Check the rear tamper
11-397-171 The rear tamper tray did not return to the home position. away sensor, Q11-319. Refer to:
GP 11 How to check a sensor.
11-398-171 The rear tamper tray did not move from the away position.
11-399-171 The rear tamper tray did not return to the away position. 11A-171 HVF Power Distribution RAP.
Initial Actions Rear tamper, PL 11.140 Item 13.
WARNING Perform SCP 6 Final Actions.

Check for damage or obstructions that would prevent the rear tamper tray from operating
correctly.
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, 11-006, move rear tamper inboard. The tamper moves.
Y N
motor, MOT11-004. Refer to: Rear tamper motor, Rear tamper Rear tamper
GP 10 How to Check a Motor. MOT11-004 away sensor, home sensor,
Q11-319 Q11-311
Rear tamper, PL 11.140 Item 13.
Stack the dC330 code, 11-311, rear tamper home sensor. Move the tamper motor using the
code 11-006, move motor inboard. The display changes.
Y N
Rear tamper, PL 11.140 Item 13.

A

A
11-403-171, 11-413-171, 11-414-171 HVF BM Staple Head 2 Install new components as necessary:
BM staple head 2, PL 11.168 Item 7.
and Stapler Module RAP
11-403-171 The booklet maker staple head 2 motor has failed to move.
Enter dC330, code 11-403 to run the BM SH2 motor, Figure 1. The staple head cycled.
11-413-171 The booklet maker staple head 2 is not detected in the home position.
Y N
Go to Flag 3. Check the wiring and connectors between P/J560 and P/J585. The wir-
11-414-171 The booklet maker stapler module is not detected in the home (staple head closed)
ing and connectors are good.
position during hard / soft initialize, or at set boundary.
Y N
Repair the wiring or connectors, REP 1.2.
Initial Actions
Install a new BM staple head 2, PL 11.168 Item 7.
WARNING The fault may be intermittent, check for damaged wiring or bad connectors, REP 1.2. If neces-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause BM staple head carrier closed sensor, PL 11.168 Item 18.
death or injury. Moving parts can cause injury. BM staple head 2, PL 11.168 Item 7.
Check that there is no damage or obstruction that would prevent the stapling unit from BM PWB, PL 11.166 Item 10.
cycling.
overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, PL
11.168 Item 8.
Ensure that the customer job does not exceed the capacity of the booklet maker. Refer to
11D-171 Booklet Quality RAP for booklet maker quality specifications.
Procedure
Enter dC330, code 11-421 to check the BM staple head carrier closed sensor, Q11-421. Open
and close the staple head carrier. The display changes.
Y N
Go to Flag 1. Check the staple head carrier closed sensor, Q11-421.
Refer to:
P/J552, BM PWB.
BM staple head carrier closed sensor, PL 11.168 Item 18.
Staple head carrier closed
Remove the HVF front door and door support, refer to REP 11.1-171 HVF Covers. Pull out the sensor, Q11-421
BM module. Remove the staple head 2 cover, PL 11.168 Item 14. Enter dC330, code 11-413 to
check the BM SH2 home switch. Manually rotate the staple head to actuate the BM SH2 home
switch. The display changes.
Y N BM staple head 2
Go to Flag 2. Check the BM SH2 home switch, S11-413.
Refer to:
P/J551, BM PWB.
A

11-415-171 HVF BM Crease Roll Gate Home RAP
11-415-171 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 roll gate home sensor,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Q11-415
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 11.167 Item 8. BM crease roll gate motor,
Crease roll gate racks, PL 11.167 Item 14. MOT 11-401
Procedure
Enter dC330 code 11-415. Actuate the BM crease roll gate home sensor, Q11-415. The dis-
play changes.
Y N
Go to Flag 1. Check the BM crease roll gate home sensor, Q11-415.
Refer to:
P/J552, BM PWB.
BM PWB, PL 11.166 Item 10. Figure 1 Component location
BM crease roll gate home sensor PL 11.166 Item 9.
Enter dC330, code 11-401 to run the BM crease roll gate motor, MOT 11-401. The motor
runs.
Y N
Go to Flag 2 and Flag 3. Check the BM crease roll gate motor, MOT 11-401.
Refer to:
P/J555, BM PWB.
BM crease roll gate motor, PL 11.166 Item 8.
sary install a new BM PWB, PL 11.166 Item 10.


11-417-171, 11-418-171 HVF BM Flapper RAP
11-417-171 The booklet maker flapper did not return to the home position.
11-418-171 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 11-390 to check the BM flapper motor, MOT11-390, Figure 1. The BM
flapper rotates.
Y N
Refer to:
P/J560, BM PWB.
11A-171, HVF Power Distribution RAP.
BM flapper motor, PL 11.166 Item 1.
Flapper home
BM flapper, PL 11.161 Item 23. BM Flapper motor,
sensor, Q11-391.
MOT11-390.
Enter dC330, code 11-391. Actuate the flapper home sensor, Q11-391. The display changes.
Y N
Refer to:
P/J551, BM PWB.
Flapper home sensor, PL 11.161 Item 12.


A
11-450-171, 11-456-171 to 11-459-171 HVF Ejector Module Exit the diagnostics mode, selecting the Re-boot option. This returns the ejector module to the
home position. Enter the dC330 code, 11-322, ejector unit out sensor. Stack the dC330 code,
RAP 11-053 to move the stapler unit inboard. The display changes.
11-450-171 The ejector module motor has stalled Y N
Go to Flag 3. Check the wiring and repair as necessary, REP 1.2. Check the ejector unit
11-456-171 The ejector module did not return to the home position. out sensor, Q11-322. Refer to:
11-457-171 The ejector module did not move from the home position. P/J401, HVF Control PWB.
11-458-171 The ejector module did not return to the out position.
11-459-171 The ejector module did not move from the out position. Ejector assembly, PL 11.140 Item 2.
Initial Actions
Exit the diagnostics mode, selecting the Re-boot option. This returns the ejector module to the
home position. Enter the dC330 code 11-177, ejector motor encoder. Stack the dC330 code,
WARNING 11-053 to move the stapler unit inboard. The display changes condition for a few seconds.
Y N
Go to Flag 4. Check the wiring and repair as necessary, REP 1.2. Check the ejector motor
encoder, Q11-177. Refer to:
Check for damage or obstructions that would prevent the ejector module from operating cor-
rectly.
Procedure
Enter the dC330 code 11-320, ejector home sensor. Stack the dC330 code 11-053 to move the HVF control PWB, PL 11.157 Item 2.
stapler unit inboard, and observe the display. This action moves the stapler unit inboard, and
moves the ejector module to the out position. The display changes. Perform SCP 6 Final Actions.
Y N
The ejector module moved to the out position.
Y N
Go to Flag 2. Check the wiring and repair as necessary, REP 1.2. Check the ejector
unit motor, MOT11-023. Refer to:
Go to Flag 1. Check the wiring and repair as necessary, REP 1.2. Check the ejector home
sensor, Q11-320. Refer to:
A
Left view of ejector
Ejector Unit Motor,
MOT11-023.
Ejector Motor Encoder Ejector Home Sensor, Ejector Unit Out

Sensor, Q11-177 Q11-320. Sensor, Q11-322.

Xerox WorkCentre 5790 Family 2-491 11-450-171, 11-456-171 to 11-459-171

A B
11-451-171 to 11-455-171 HVF Ejector Roll and Lower GP 10 How to Check a Motor.
Paddle RAP
11-451-171 The ejector roll motor has stalled.
11-452-171 The ejector roll did not return to the home position. Ejector assembly, PL 11.140 Item 2.
11-453-171 The ejector roll did not move from the home position.
Go to Flag 3. Check the wiring and repair as necessary, REP 1.2. Check the ejector plate
11-454-171 The lower paddle has failed to return to the home position. encoder sensor, Q11-178. Refer to:
11-455-171 The lower paddle has failed to move from the home position. P/J401, HVF Control PWB.
Initial Actions Install new components as necessary:
WARNING HVF control PWB, PL 11.157 Item 2.
Measure the voltage at P/J401, pin B4. Figure 3, rotate the lower home paddle upwards and
inwards for one full rotation. The voltage changes from a logic high to a low, and then
back to high.
Check for any damage or obstructions that would prevent the ejector roll and lower paddle Y N
from operating correctly. Damaged or mis-positioned fingers can catch on the ejector tee Go to Flag 4. Check the wiring and repair as necessary, REP 1.2. Check the ejector lower
bar, causing 11-452-171 faults. paddle switch, S11-180. Refer to:
Check that the curl suppressor solenoid SOL11-084 is operating correctly. If necessary, GP 13 How to Check a Switch.
go to 11M-171 Curl Suppressor RAP. P/J401, HVF Control PWB.
Figure 1, Figure 2 and Figure 3 show the component locations. Ejector assembly, PL 11.140 Item 2.
Enter dC330 code, 11-032 to take the bin 1 stacker tray down. Enter code 11-053, staple unit 1
forward to move the ejector module to the out position. Enter code 11-179, ejector plate home
sensor. Manually turn the ejector belts a few centimetres. The display changes.
Measure the voltage at P/J401, pin B12. Actuate the ejector paper present sensor by placing a
Y N
sheet of paper on the ejector module. The voltage changes.
Go to Flag 1. Check the wiring and repair as necessary, REP 1.2. Check the ejector plate
Y N
Go to Flag 5. Check the wiring and repair as necessary, REP 1.2. Check the ejector paper
present sensor. Refer to:
11A-171 HVF Power Distribution RAP. P/J401, HVF Control PWB.
Install new components as necessary: 11A-171 HVF Power Distribution RAP.
Ejector assembly, PL 11.140 Item 2. Install new components as necessary:
HVF control PWB, PL 11.157 Item 2. Ejector assembly, PL 11.140 Item 2.
Enter the dC330 code 11-178, ejector plater encoder sensor. Enter the code, 11-088 to rotate
the ejector roll motor one cycle of the ejector plates in the forward direction. The display
changes.
Y N
The ejector roll motor turned.
Y N
Go to Flag 2. Check the wiring and repair as necessary, REP 1.2. Check the ejector
roll motor, MOT 11-088. Refer to:
A B

Ejector roll motor MOT11-088
Ejector lower
paddle home
switch, S11-180
Ejector plate encoder Ejector plate home

sensor Q11-178 sensor Q11-179
LEFT SIDE VIEW OF EJETOR
RIGHT UNDER-SIDE VIEW OF EJECTOR

Rotate paddle 1 Ejector paper
complete turn present sensor


A B
11-460-171 to 11-462-171 HVF Bin 1 Position RAP HVF control PWB, PL 11.157 Item 2.
11-460-171 Bin 1 motor has stalled.

If the tray is not at the lower limit, enter the dC330 code 11-335, bin 1 lower limit switch.
Manually actuate the switch. The display changes.
11-461-171 Bin 1 did not actuate the bin 1 upper level sensor during stacking. Y N
Go to Flag 6. Check the wiring and repair as necessary, REP 1.2. Check the bin 1
11-462-171 Bin 1 did not leave the bin 1 upper level sensor during stacking.
lower limit switch, S11-335. Refer to:
Initial Actions P/J602, HVF Control PWB.
Ensure that the electricity to the machine is switched off while performing tasks that do Bin 1 lower limit switch, PL 11.135 Item 7.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause HVF control PWB, PL 11.157 Item 2.
Check that bin1 is not damaged and there are no obstructions that would prevent bin 1 Go to Flag 1. Check the wiring and repair as necessary, REP 1.2. Check the bin 1 eleva-
from moving. tor motor, 11-030. Refer to:
Remove any obstructions that could prevent the full descent and elevation of bin 1.
Press the pause to unload button to lower bin 1. Press again the pause to unload button
to raise bin 1. 11A-171 HVF Power Distribution RAP.
Poor operation of the inboard and outboard pressing plate fingers can cause poor stack- Install new components as necessary:
ing in bin 1, leading to 11-462 faults. Check the pressing plate fingers move from and Bin 1 elevator motor, PL 11.135 Item 10.
return to their home positions correctly. Check the operation of the other mechanical com- HVF control PWB, PL 11.157 Item 2.
ponents in the bin 1 and ejector assembly area.
Enter the dC330 code, 11-182, bin 1 encoder sensor. Turn the bin 1 encoder wheel. The dis-
Procedure play changes.
Y N
NOTE: The bin 1 90% full sensor, Q11-331, and the bin 1 lower limit switch are mounted on the Go to Flag 2. Check the wiring and repair as necessary. Check the bin 1 encoder sensor,
same bracket. This bracket can be in either of two positions. It is in the upper position, only Q11-182. Refer to:
when a tri-folder module is installed. GP 11 How to Check a Sensor.
NOTE: The bin 1 upper level sensor controls the height of the tray during normal use. The sen- P/J601, HVF Control PWB.
sor is in two parts: the transmitter at the front of the tray and the receiver at the rear of the tray. 11A-171 HVF Power Distribution RAP.
Only the LED of the front sensor is used and only the light sensitive transistor of the rear sen- Install new components as necessary:
sor is used. Refer to Flag 3 and Flag 4. Bin 1 encoder sensor, Q11-182, PL 11.135 Item 3.
Figure 1 shows the location of the components. HVF control PWB, PL 11.157 Item 2.
Place about one centimeter thickness of paper on the bin 1 tray. Switch off, then switch on the
machine, GP 14. The bin 1 tray moves during initialization. Enter the dC330 code 11-332, bin 1 upper level sensor. Remove the paper from the tray. Actu-
Y N ate the sensor by breaking the light beam from the front transmitter to the rear receiver. The
If the tray is not at the upper limit, enter the dC330 code 11-334, bin 1 upper limit switch. display changes.
Manually actuate the switch. The display changes. Y N
Y N Go to Flag 3 and Flag 4. Check the wiring and repair as necessary. Check the two parts of
Go to Flag 5. Check the wiring and repair as necessary, REP 1.2. Check the bin 1 the bin 1 upper level sensor, Q11-332. Refer to:
upper limit switch, S11-334. Refer to: GP 11 How to Check a Sensor.
GP 13 How to Check a Switch. P/J601 and P/J901, HVF Control PWB.
P/J602, HVF Control PWB. 11A-171 HVF Power Distribution RAP.
11A-171 HVF Power Distribution RAP. Install new components as necessary:
Install new components as necessary: Bin 1 upper level sensor (transmitter), PL 11.140 Item 20.
Bin 1 upper limit switch, PL 11.135 Item 7. Bin 1 upper level sensor (receiver), PL 11.140 Item 16.
A B C

C
Enter the dC330 code 11-331, bin 1 90% full sensor. Actuate the sensor using a piece of
paper. The display changes.
Y N
Go to Flag 7. Check the wiring and repair as necessary. Check the bin 1 90% full sensor,
Q11-331. Refer to:
Bin 1 encoder
P/J601, HVF Control PWB. sensor, Q11-182 Bin 1 eleva-
tor motor,
11A-171 HVF Power Distribution RAP. Bin 1 rear wall sensor, MOT11-030
Install new components as necessary: Q11-196
Bin1 90% full sensor, PL 11.135 Item 3.
Lower the bin 1 tray by pressing the PTU switch, or by entering the dC330 code 11-032, bin1
elevator motor down. Enter the dC330 code 11-196, bin 1 rear wall sensor. Actuate the bin 1
rear wall sensor using a sheet of paper. The display changes.
Y N
Go to Flag 8. Check the wiring and repair as necessary, REP 1.2. Check the bin 1 rear Bin 1 upper level sensor,
wall sensor, Q11-196. Refer to: (transmitter) Q11-332
11A-171 HVF Power Distribution RAP. Bin 1 upper level sensor,
Install new components as necessary: (receiver)
Bin 1 rear wall sensor, PL 11.140 Item 17.
HVF control PWB, PL 11.157 Item 2. Bin 1 upper limit
switch, S11-334
If the fault is random and Bin 1 has an erratic up / down movement and poor stacking. Check
that the Bin 1 rear wall sensor is clean. The sensor is clean.
Y N
Bin 1 90% full sensor, Q11-331
Clean the Bin 1 rear wall sensor. Use a brush to remove paper dust from the sensor and
the plastic surround. Then use a damp cloth to clean the sensor and plastic surround.
Bin 1 lower limit

switch, S11-335



A
11-463-171, 11-464-171 HVF BM +24V Failure RAP Y N
Go to 11-306-171, 11-309-171 HVF Inserter Interlock RAP
11-463-171 The booklet maker control PWB has failed to detect +24V at the input from the HVF.
Go to Flag 5. +24V is available at P/J601 between pins 1 and pin 4.
11-464-171 The booklet maker control PWB has detected an internal +24V failure, such as
Y N
over current, short circuit or under voltage. Install a new BM PWB, PL 11.166 Item 10.
Initial Actions Go to Flag 6. +24V is available at P/J601 between pins 4 and 6.
Y N
Go to the 11-300-171, 11-302-171, 11-303-171 Docking and Interlocks RAP.
WARNING
The +24V supply are good. Go to SCP 6 Final actions.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause The +24V supply are good. Go to SCP 6 Final actions.
WARNING
Ensure the HVF BM is correctly docked to the machine and all interlocks are closed.
Procedure
Close or cheat all the HVF BM interlocks. The HVF BM performs a mechanical reset.
Y N
Go to Flag 1. ACL is available at PJ22 on the LVPS and base module between pins 1
and 2.
Y N
Go to Flag 2. +24V is available at P/J111 between pins 1 and 4.

Y N
Refer to 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 11.157 Item 1.
Check the connectors and harness between T001 and PJ111. Repair the harness as
necessary, REP 1.2.
Go to Flag 3. +24V is available at P/J111 between pins 1 and 4, between pins 2 and 5
and between pins 3 and 6.
Y N
Go to the 11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlock RAP.
Go to Flag 4. +24V is available at P/J559 between pins 1 and 2. Tri-folder unit

Y N
+24V is available at P/J131 between pins 1 and 2.
Y N
Install a new HVF control PWB, PL 11.157 Item 2.
HVF power
Check the connectors and harness between P/J559 and P/J131. Repair the har- supply module
HVF control
ness as necessary, REP 1.2. BM PWB PWB
If an inserter is installed, go to P/J703. +24V is available between P/J703 pin 1 and P/ Figure 1 Component location
J111 pin 1.
A


A
11-465-171 to 11-468-171 Paddle Unit Position RAP Enter dC330, code 11-195 paddle unit lower sensor, Q11-195. Select code 11-195 and press
Start. Select code 11-027 and press Start. The sensor status changes.
11-465-171 The paddle unit has failed to return to the upper position.
Y N
11-466-171 The paddle unit has failed to move from the upper position. Go to Flag 3. Check Q11-195.
Refer to:
11-467-171 The paddle unit has failed to return to the lower position.
11-468-171 The paddle unit has failed to move from the lower position. P/J201, HVF Control PWB.
Initial Actions 11A-171 HVF Power Distribution RAP.
WARNING HVF control PWB, PL 11.157 Item 2.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform SCP 6 Final Actions.
Check for damage or obstructions that would prevent the paddle unit from operating correctly. Paddle Unit Upper Paddle Unit Lower
Sensor, Q11-194. Sensor, Q11-195.
Procedure
NOTE: All HVF BM interlocks must be made to supply +24V to the motors.
Enter dC330, code 11-027 paddle unit motor, MOT11-027, Figure 1. Select code 11-027 and
press Start. The motor runs.
Y N
Refer to:
Paddle module driving motor assembly, PL 11.150 Item 6.
Enter dC330, code 11-027 to check the paddle unit motor, MOT11-027, Figure 1. The paddle
unit moves.
Y N
Check the drive gears on the paddle unit. Install new components as necessary. PL
11.145 Item 2.
Enter dC330, code 11-194 paddle unit upper sensor, Q11-194. Select code 11-194 and press
Start. Select code 11-027 and press Start. The sensor status changes.
Y N
Refer to:
GP 11 How to Check a Sensor. Paddle Unit Motor,
P/J201, HVF Control PWB MOT11-027
A


A
11-473-171 to 11-478-171 Support Finger Position RAP Install new components as necessary:
11-473-171 The support finger has failed to return to the initial position. Rear tamper assembly, PL 11.140 Item 13.
11-474-171 The support finger has failed to move from the initial position. HVF control PWB, PL 11.157 Item 2.
11-475-171 The support finger has failed to return to the home position. Enter the dC330 code 11-193, support finger out sensor, Q11-193 and continue turning the
gear wheel. When the support fingers have extended by about 105mm, the support finger out
11-476-171 The support finger has failed to move from the home position. sensor changes state. The display changes from High to Low.
Y N
11-477-171 The support finger has failed to return to the out position. Go to Flag 3. Check the support finger out sensor, Q11-193. Refer to:
11-478-171 The support finger has failed to move from the out position. P/J402, HVF Control PWB
Rear tamper assembly, PL 11.140 Item 13.
WARNING Ejector assembly, PL 11.140 Item 2.
Ensure that the electricity to the machine is switched off while performing tasks that do HVF control PWB, PL 11.157 Item 2.
death or injury. Moving parts can cause injury. Make several small sets of copies and observe that the support fingers are extended between
each set.
NOTE: When manually extending the fingers to check the sensors, the home sensor operates
first, followed by the init sensor. The away sensor operates when the fingers are fully extended. NOTE: If copies can not be made, go to the check of the support finger motor encoder.
All three sensors are spared as part of the rear tamper assembly. The support fingers are extended.
Figure 1 shows the component locations. Y N
Enter dC330 code 11-192, support finger home sensor. Note the position of the support fingers Remove the HVF top cover and rear cover, REP 11.1-171. Enter the dC330 code 11-172,
at rest. Using a screwdriver, or with a finger, turn the gear wheel shown in Figure 1, down- support finger motor encoder. Figure 1. Manually turn the support motor encoder disc.
wards. The support fingers extend to the right as the gear is turned. When the support fingers The encoder sensor changes state.
have extended by about six millimetres, the support finger home sensor changes state. The Y N
display changes from High to Low. Go to Flag 4. Check the support finger motor encoder sensor, Q11-172. Refer to:
Y N GP 11 How to Check a Sensor.
Go to Flag 1. Check the support finger home sensor, Q11-192. Refer to: P/J402, HVF Control PWB.
GP 11 How to Check a Sensor. 11A-171 HVF Power Distribution RAP.
P/J402, HVF Control PWB. Install new components as necessary:
11A-171 HVF Power Distribution RAP. Support finger motor encoder sensor, PL 11.140 Item 15.
Install new components as necessary: HVF control PWB, PL 11.157 Item 2.
Rear tamper assembly, PL 11.140 Item 13.
Ejector assembly, PL 11.140 Item 2. Go to Flag 5. Check the wiring between P/J802 and the support finger motor. Repair as
necessary, REP 1.2. Install new components as necessary:
Motor encoder assembly, PL 11.140 Item 18.
Enter the dC330 code 11-191 and continue turning the gear wheel. When the support fingers HVF control PWB, PL 11.157 Item 2.
have extended by about 25mm, the support finger init sensor changes state. The display
changes from High to Low. Perform SCP 6 Final Actions.
Y N
Go to Flag 2. Check the support finger init sensor, Q11-191. Refer to:

Support Finger Home Sensor, Q11-192. Support Finger Out
Sensor, Q11-193
Gear wheel
Support Finger Init Support Finger Motor Support Finger Motor

Sensor, Q11-191. Encoder Sensor.



A
11-479-171 Inserter Paper Length Fault RAP P/J701, HVF Control PWB.
11-479-171 A shorter than expected sheet has been fed from the inserter. 11A-171, HVF Power Distribution RAP.
Initial Actions TE sensor, PL 11.179 Item 11.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Enter the dC330 code 11-154, LE sensor. Use a piece of paper to actuate the sensor. The
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause sensor display changes state.
Check that the inserter paper path is clear of obstructions and the sensors are clean. Go to Flag 7 and Flag 8. Check Q11-154. Refer to:
Procedure
Figure 1 shows the component locations.
Enter the dC330 code 11-150, sheet size detector 1 sensor. Use a piece of paper to actuate 11A-171 HVF Power Distribution RAP.
the sensor. The sensor display changes state. Install new components as necessary:
Y N LE sensor, PL 11.179 Item 11.
Go to Flag 1 and Flag 2. Check Q11-150. Refer to: Inserter PWB, PL 11.179 Item 9.
P/J701, HVF Control PWB. Enter the dC330 code 11-077, to energize the inserter clutch. The inserter clutch is ener-
11A-171 HVF Power Distribution RAP. gised.
Go to Flag 9 (W/O TAG V-001) or Flag 13 (With TAG V-001) and Flag 10 and check the
Sheet size detector 1 sensor, PL 11.175 Item 12.
inserter clutch, CL11-077. Refer to:
Inserter PWB, PL 11.179 Item 9. GP 12 How to Check a Solenoid or Clutch.
HVF control PWB, PL 11.157 Item 2. P/J703, HVF Control PWB.
Enter the dC330 code 11-151, sheet size 2 sensor. Use a piece of paper to actuate the sensor.
The sensor display changes state. 11A-171 HVF Power Distribution RAP.
Go to Flag 3 and Flag 4. Check Q11-151. Refer to: Inserter clutch, PL 11.179 Item 3.
GP 11 How to Check a Sensor. Inserter PWB, PL 11.179 Item 9.
P/J9, P/J4, Inserter PWB. HVF control PWB, PL 11.157 Item 2.
11A-171 HVF Power Distribution RAP. Enter the dC330 code 11-078, to run the inserter motor. The inserter motor runs.
Go to Flag 11 and Flag 12. Check the inserter motor, MOT11-078. Refer to:
Sheet size detector 2 sensor, PL 11.175 Item 12.
Enter the dC330 code 11-155, TE sensor. Use a piece of paper to actuate the sensor. The 11A-171, HVF Power Distribution RAP.
sensor display changes state. Install new components as necessary:
Y N Inserter motor, PL 11.181 Item 1.
Go to Flag 5 and Flag 6. Check Q11-155. Refer to: Inserter PWB, PL 11.179 Item 9.
A

Sheet size detector 1 sensor,
Q11-150
Sheet size detector 2
sensor, Q11-151 TE sensor,
Q11-155
LE sensor,
Q11-154
Inserter clutch,
CL11-077
Inserter motor,
MOT11-078



A B C D
11A-171 HVF Power Distribution RAP NOTE: Before each PJ is reconnected, switch off the machine, GP 14.
The HVF has an integral power supply providing +24V and +5V supplies to the HVF PWB and The HVF has a short circuit. Reconnect each PJ one at a time until short circuit
HVF BM PWB. The AC power for the HVF power supply comes from the LVPS and base mod- is found. When the short circuit is found, repair the harness, REP 1.2 or install
ule of the machine. new components as necessary.
Disconnect P/J113. Go to Flag 2. +5V is available at the harness end of P/J113

between pins 1 and 2.
CAUTION
Y N
Do not connect the HVF power cord directly to the AC wall outlet. The HVF cannot operate Check the connectors and harness between T001 and P/J113. Repair the har-
without the machine. The machine controls the distribution of electricity to the HVF/HVF BM for ness as necessary, REP 1.2.
correct power on and power off sequencing.
Initial Actions Install a new HVF control PWB, PL 11.157 Item 2.

WARNING Y N
+24V is available at T001 between pins 1 and 6.
Y N
Install a new HVF power supply module, PL 11.157 Item 1
Figure 3. Check the in-line fuse (10A), and as necessary install a new fuse PL
11.157 Item 5.
WARNING
Check the connectors and harness between T001 and PJ111. Repair the harness as
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. necessary, REP 1.2.
Ensure the HVF/HVF BM is correctly docked to the machine and all interlocks are closed.
Go to Flag 3. +24V is available at P/J111 between pins 1 and 4, between pins 2 and 5
Procedure and between pins 3 and 6.
Y N
Refer to Figure 3 for the location of components.
Go to the 11-300-171, 11-302-171, 11-303-171 Docking and Interlocks RAP.
Refer to HVF Control PWB and BM PWB LEDs to identify the status of the PWBs.
Close or cheat all the HVF BM interlocks. The HVF BM performs a mechanical reset.
Y N
Y N
Y N
Y N
Go to Flag 2. +5V is available at T001 on the HVF power supply module
Y N
Check the connectors and harness between P/J132 and P/J559. Repair the har-
Go to Flag 1. ACL is available at PJ22 on the LVPS and base module
ness as necessary.
Y N
Y N
Switch off the machine, GP 14. Disconnect all PJs on the HVF Control PWB
Y N
except P/J111 and P/J113. Switch on the machine, GP 14. Go to Flag 2. +5V
is available at T001 on the HVF power supply module between pins 4 and
8.
Check the connectors and harness between P/J559 and P/J131. Repair the har-
Y N
ness as necessary, REP 1.2.
Install a new HVF power supply module, PL 11.157 Item 1.
If an inserter is installed, go to P/J703. +24V is available between P/J703 pin 1 and P/
J111 pin 1.
Y N
Go to 11-306-171, 11-309-171 HVF Inserter Interlock RAP
A B C D A E

A E
Go to Flag 5. +5V is available at P/J601 between pins 3 and 4. HVF Control PWB and BM PWB LEDs
Y N
Figure 1 shows the LED s on the HVF PWB. These are:
Y N LED 1 - red. Not used.
LED 2 - red. Not used.
Check the connectors and harness between P/J553 and P/J601. Repair the har- LED 3 - red, flashing. This indicates the functioning of the CPU. When flashing at 2Hz,
ness as necessary, REP 1.2. (every 1/2 second), the software is running normally. When flashing at about 1/4Hz,
(every 4 seconds), this indicates that the software is encountering a code problem and a
Go to Flag 5. +24V is available at P/J601 between pins 1 and pin 4. possible software upgrade is needed. If this LED is OFF, the CPU does not function and a
Y N new HVF control PWB is needed.
Install a new BM PWB, PL 11.166 Item 10. LED 4 - red. Not used.
LED 5 - red, toggling. This changes state whenever the paper is accelerated to 1,300 m/s.
Go to Flag 6 +24V is available at P/J601 between pins 4 and 6. It is only used for paper that is longer than 220mm.
Y N
LED 6 - red, steady. When this is ON, a paper jam has been detected. It remains ON until
Go to the 11-300-171, 11-302-171, 11-303-171 Docking and Interlocks RAP. the HVF successfully initializes. In all other cases this LED is OFF.
LED 7 - red. This LED is used during the machine production and is connected with the
The +24V and +5V supplies are good. Go to SCP 6 Final actions.
activity of the stacker nearly full sensor.
The +24V and +5V supplies are good. Go to SCP 6 Final actions. 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 1 LEDs on the HVF control PWB

Figure 2 shows the LEDs on the BM PWB. These are:
LED 1 - red, steady. This indicates a fault or other abnormal status.

LED 2 - yellow, flashing at about 1Hz. This indicates that the software is operating in nor-
mal mode. In other modes, e.g., software downloading, the flashing rate is higher.
LED 3 - orange, steady. This indicates either:
that the tri-folder front door and top cover interlocks are closed, and +24V is avail-
able to the BM module or, if the tri-folder in not installed;
that the interlock cheater is present in PJ553 on the BM control PWB the logic
cheater is present in PJ563 on the BM control PWB.
LED 19 - orange, steady. This indicates that the +24V supply is within voltage and current
limits, and that the power limiting circuit has not been active for over a set time limit.
LED 5 - blue, steady. this indicates that the +5V supply is present in the BM module.
Figure 2 LEDs on the BM PWB

Tri-folder unit
In-line fuse
HVF power
supply module
HVF control
BM PWB PWB


11B-171 HVF BM to Machine Communications Interface
and BM Present RAP
A communication fault exists between the HVF BM and the machine.
Procedure
WARNING
Figure 1 shows the communications between the booklet maker and the HVF control PWB. For
communications between the HVF control PWB and the machine, go to the 03-360, 03-408 to
03-410, 03-418 IOT to Output Device Error RAP.
The pulses on the connections at Flag 1 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 1.2. Refer to:

P/J562, BM PWB.
If necessary, install new components:
If the machine indicates that the booklet maker is not present, check that P/J133, pin 6 is held
at zero. If necessary, repair the wiring, REP 1.2 or install a new HVF control PWB, PL 11.157
Item 2.

Xerox WorkCentre 5790 Family 2-517 11B-171
A
11C-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 11.169 Item 4.
Initial Actions
sary install new conveyor belts, PL 11.169 Item 1.
WARNING
Check for a jam or any other obstruction that could prevent the conveyor belt mechanism from
moving.
Procedure
Enter dC330 code 11-389. Actuate the BM bin 2 90% full sensor, Q11-389, Figure 1. The dis-
play changes.
Y N
If a tri-folder is installed, go to Flag 4. 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 1.2.

Refer to:
P/J556, BM PWB. BM bin 2 90% full
11A-171 HVF Power Distribution RAP. sensor Q11-389 BM conveyor belts drive
Install new components as necessary: motor, MOT11-402
BM bin 2 90% full sensor PL 11.169 Item 5.
NOTE: The BM conveyor belts drive motor stops after 10 seconds.

Enter dC330, code 11-402 to run the BM conveyor belts drive motor, MOT11-402. MOT11-402
runs.
Y N
If a tri-folder is installed, go to Flag 5. 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 1.2.
Go to Flag 3 or Flag 2. Check MOT 11-402.

Refer to:
P/J555, BM PWB.
A

11D-171 Booklet Quality RAP Examine the booklets for defects. Refer to the following:
Use this RAP to identify and correct the causes of poor booklet quality in the HVF BM. Top and Bottom Edge Alignment.
Open Side Edge Alignment.
The following booklet quality problems are covered in this RAP: Badly Formed Booklet Staples
The alignment of the top and bottom edges of the booklet are not within specification. Booklet Compiler is Not Correct
The alignment of the open side edges of the booklet are not within specification. Skewed Booklet Crease.
The booklet staples are badly formed. Booklet Crease is Off Centre.
The booklet compiling is not correct (page order is wrong). Booklet Staple Position is Not On The Fold.
The booklet crease is skewed greater than the specification. The Booklet is Not Sufficiently Creased.
The booklet crease is off-centre, greater than the specification. Top and Bottom Edge Alignment
The booklet staple position is not within the specification. Figure 1, open out the booklet at the centre page and press it onto a flat surface. Measure the
The booklet is not sufficiently creased. mis-alignment of the top and bottom edges of the booklet.
Initial Actions
WARNING
Check that the paper loaded in the paper trays matches the paper size displayed on the
UI, refer to 07E Tray 1 and 2 Wrong Size Paper RAP.
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 80gsm (16 to 21lb bond) 14 including 56 -
with heavy- with 160gsm (43lb bond) cover 1 cover
weight cover
Check the machine and HVF BM paper paths for any obstruction that could cause mis-
alignment of the paper fed to the BM compiling area. Figure 1 Top and bottom alignment
Procedure
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.

Table 2 Top and bottom edge alignment
Paper weight 95% of booklets 99.7% of booklets
80gsm (20lb) 1mm 2mm Measure the total scatter
All other BM approved weights in GP 20 2mm 3mm
If the top and bottom edge alignment does not conform to the specification in Table 2, check
the operation of the BM tampers, refer to the 11-066-171, 11-384-171 HVF BM Tamper Failure
RAP. If the tampers are operating correctly, go to ADJ 11.5-171 Booklet Tamping and check the
tampers are correctly adjusted.
If the booklet skew does not conform to the specification in Table 4. Perform the following:
Check the operation of the BM stack hold solenoids, refer to 11-065-171, 11-383-171 HVF
Booklet Back Stop failure RAP.
If the stack hold solenoids are operating correctly, check for contamination or debris in the
compiling area of the BM that could cause the mis-alignment.
Perform ADJ 11.4-171 Crease Blade Position.
Open Side Edge Alignment
Figure 2, open out the booklet at the centre page and press it onto a flat surface. Measure the
mis-alignment of the open side edges of the booklet.
Figure 2 Open side edge alignment
Table 3 Open side edge alignment

Paper weight 95% of booklets 99.7% of booklets
80gsm (20lb) 1mm 2mm
All other BM approved weights in GP 20 2mm 3mm
If the open side edge alignment does not conform to the specification in Table 3, check the
operation of the BM stack hold solenoids, refer to the 11-065-171, 11-383-171 HVF Booklet
Back Stop Failure RAP. If the stack hold solenoids are operating correctly, check carefully for
any contamination or debris in the compiling area of the BM, that could cause the mis-align-
ment.
Badly Formed Booklet Staples

If the booklet staples are not formed correctly, perform ADJ 11.3-171 Staple Anvil Alignment.
Booklet Compiler is Not Correct

If the page order of the booklets is not correct, perform ADJ 11.6-171 Booklet Compiling Posi-
tion.

Skewed Booklet Crease Table 4 Skew tolerance
Figure 3, open out the booklet at the centre page and press it onto a flat surface. Measure the Paper size A4, Paper size A4,
amount of booklet skew. 8.5x11in, 8.5x11in,
8.5x13in or 8.5x13in or Paper size A3 Paper size A3
Paper weight 8.5x14in 8.5x14in or 11x17in or 11x17in
95% of 99.7% of 95% of 99.7% of
- 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 11-065-171, 11-383-171
HVF Booklet Back Stop Failure RAP. If the stack hold solenoids are operating correctly,
check for any contamination or debris in the compiling area of the BM, that could cause
the mis-alignment.
2. ADJ 11.9-171 Booklet Maker Skew.
3. Check the BM back stop assembly for damage. If necessary, install a new BM back stop
assembly, PL 11.164 Item 17.
The amount of skew is the difference

between the two measurements
Figure 3 Booklet skew

Booklet Crease is Off Centre Booklet Staple Position is Not On The Fold
Figure 4, open out the booklet at the centre page and press it onto a flat surface. Measure the Figure 5, open out the booklet at the centre page and press it onto a flat surface. Measure the
position of the booklet crease. position of the booklet staple from the crease line.
Measure from the booklet

edge to the crease
Staple position
must align with the
crease +/-1.5mm
Figure 4 Booklet crease position Figure 5 Booklet staple position
Table 5 Crease position and tolerance If the booklet staple position does not conform to the specification in Figure 5, perform ADJ
11.8-171 Booklet Staple Position.
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
11.7-171 Booklet Crease Position.

The Booklet is Not Sufficiently Creased 11E-171 Copy Damage in the HVF BM RAP
Figure 6, Measure the open dimension of the booklets. Use this RAP to identify and correct the causes of copy damage in the HVF BM.
Procedure
WARNING
Check the alignment between the IOT and the HVF BM, ADJ 11.1-171.
Look for paper fragments in the HVF BM paper path. Paper fragments can move through
the IOT and HVF BM paper path without causing a problem until they finally wedge them-
selves at some point. A likely place for a fragment of paper to be wedged is at the hole
punch assembly, where the top and bottom guides form the narrowest part of the paper
path.
Ensure that the exit diverter gate solenoid, PL 11.150 Item 4, operates correctly and has
its full movement.
Ensure that the hole punches park at the fully open position. If they protrude, even
slightly, a jam will occur in the narrow paper path of the hole punch. Refer to the 11-044-
171 to 11-047-171 Punch Head Position RAP.
Check that all the idler rolls in the HVF BM paper path are free to rotate, particularly those
on the jam clearance guides. Refer to ADJ 4.1 Machine Lubrication.
Make sure that the jam clearance guides 5a, 5b and 5c close and latch correctly.
Check that the paper path ribs of the jam clearance guide 5b, PL 11.161 Item 7 and the
exit path PL 11.168 are free of scores and nicks. Check also for contamination and glue
from label stock.
Make sure that the compiler carriage tampers move to the correct paper size.
Check that the paper size reported on the user interface corresponds to the actual paper
size loaded in the trays, refer to the 07E Tray 1 and 2 Wrong Size Paper RAP.
Figure 6 Booklet creasing
Make sure that the BM tampers move to the correct paper size, refer to the 11-066-171,
11-384-171 HVF BM Tamper Failure RAP.
Table 6 Creasing tolerance
Ensure that the BM paper guide, PL 11.161 Item 7, closes and latches correctly.
Paper size A4,
If the top sheet of paper is being been torn from booklets, check that the components in
8.5x11in, Paper size A4,
the lower crease roll gear and clutch assembly are correctly installed. Refer to the
8.5x13in or 8.5x11in, 8.5x13in Paper size A3 or Paper size A3 or
replacement procedure in REP 11.52-171 BM Crease Rolls, Gears and Bearings.
Paper weight 8.5x14in or 8.5x14in 11x17in 11x17in
If heavy-weight paper is used, the paper can stop in the vertical transport and cause a 10-
- 95% of booklets 99.7% of booklets 95% of booklets 99.7% of booklets 126 fault. The fault is caused when the vertical transport motor is over loaded. Check the
80gsm (20lb) Less than 30mm Less than 35mm Less than 22mm Less than 25mm position of the jam clearance guides 5a, 5b and 5c. Check the vertical transport rolls and
bearings for contamination. If necessary remove and clean the drive shaft and the bear-
ings. If the problem continues then install a new transport motor,.
If the open dimension of the booklets does not conform to the specification in Table 6, install
new crease nip springs, PL 11.165 Item 12.

11D-171, 11E-171 2-524 Xerox WorkCentre 5790 Family
11F-171 Mis-Registration in Stapled and Unstapled Sets 11G-171 HVF BM Poor Stacking RAP
RAP Use this RAP to find the cause of poor stacking in the HVF BM.
Procedure
WARNING
death or injury. Moving parts can cause injury. Look for sets that are not dropping back fully in the bin 1 tray and therefore not being
A probable cause of mis-registration is the condition of the paper and/or damage such as, curl, detected by the kicker fingers and sensors:
wrinkle, creases, dog ears, etc. Large paper sizes should not be stacked on top of small paper sizes.
Curl, wrinkle and creases are probably caused in the IOT, go to the IQ1 Image Quality Ensure that the paper stack in each paper tray has been fanned.
Entry RAP. Turn over the paper stack in each paper tray.
For other copy / print damage and dog ears, go to the 11E-171 Copy Damage in the HVF Ensure that all paper or other copy stock being used is within the size and weight
BM RAP. specifications. Refer to GP 20 Paper and Media Size Specifications.
Check the following: Try using a fresh ream of paper.
Check the alignment between the IOT and the HVF BM, ADJ 11.1-171. Ensure that the edge guides of all paper trays are adjusted correctly for the paper
Turn over the paper stack in the tray in use. size and that the trays are fully closed.
Use a new ream of paper in the tray in use. Labels must not be fed to bin1, but to bin 0 only.
Paper type, especially recycled paper, can lead to registration problems. Try changing to It is recommended that transparencies are fed to bin 0 whenever possible.
a different brand or type of paper. Check that the bin 1 upper limit switch, S11-334 and the bin 1 lower limit switch, S11-335
Ensure that the guides in the paper trays are correctly set and reported on the UI for the are working correctly. Refer to the 11-460-171 to 11-462-171 Bin 1 Position RAP.
paper size loaded, refer to the 07E Tray 1 and 2 Wrong Size Paper RAP. Make sure that the compiler carriage tampers move to the correct paper size.
Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, Check that the HVF BM is not positioned near an air conditioning or ventilation output
the compiler capacity can be exceeded. duct. Air flow across the output bins can cause poor stacking.
Check for obstructions in the compiler. Check the output copies for curl, refer to IQ5.
Ensure the paddle roll mechanism in the eject housing operating correctly, refer to the 11-
024-171, 11-026-171 Paddle Roll Position RAP.
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 11-066-171, 11-
384-171 HVF BM Tamper Failure RAP.

Xerox WorkCentre 5790 Family 2-525 11F-171, 11G-171
11H-171 Pause to Unload (PTU) RAP
Use this RAP to diagnose Pause to Unload (PTU) problems.
Procedure
WARNING
Figure 1 shows the component locations. Go to Flag 1. Check the wiring and the voltages.
Refer to P/J901. Repair the wiring as necessary, REP 1.2. Install new components as neces-
sary:
Pause to unload PWB, PL 11.157 Item 3.

PTU PWB
PTU Switch, PTU LED

S11-392

11H-171 2-526 Xerox WorkCentre 5790 Family
11J-171 Inserter Paper Sensing and +5V Supply RAP Y N
Check the inserter paper width sensor 2, Q11-152. Refer to:
Use this RAP to find the cause of inserter empty, inserter paper width and +5v supply prob-
lems.
P/J8 and P/J4, Inserter PWB.
Procedure 11A-171 HVF Power Distribution RAP.
Inserter paper width sensor 2, PL 11.175 Item 13.
WARNING Inserter PWB, PL 11.179 Item 9.
Ensure that the electricity to the machine is switched off while performing tasks that do HVF control PWB, PL 11.157 Item 2.
death or injury. Moving parts can cause injury. Go to Flag 7 and Flag 8. Measure the voltage from the acceleration sensor, while actuating the
Figure 1 and Figure 2 show the component locations. sensor with paper. The voltage changes.
If a +5V supply problem is suspected, perform the following: Y N
Go to 11A-171 and check the 0V and +5V supply from the HVF control PWB to the inserter Check the acceleration sensor. Refer To:
control PWB. Repair the wiring as necessary, REP 1.2, or refer to 11A-171 HVF Power Distri- GP 11 How to check a Sensor.
bution RAP. P/J11 and P/J4, Inserter PWB.
Install new components as necessary: 11A-171 HVF Power Distribution RAP.
Inserter PWB, PL 11.179 Item 9. Install new components as necessary:
HVF control PWB, PL 11.157 Item 2. Acceleration sensor, PL 11.175 Item 10.
To diagnose inserter paper sensing and paper width problems, perform the following: Inserter PWB, PL 11.179 Item 9.
Enter the dC330 code 11-153, inserter unit empty sensor. Actuate the sensor using a sheet of
paper. The sensor display changes.
Y N
Got to Flag 9 and Flag 10. Measure the voltage from the IDG pickup sensor while actuating the
Go to Flag 1 and Flag 2. Check the inserter unit empty sensor Q11-153. Refer to:
sensor with paper. The voltage changes.
Y N
P/J8 and P/J4, Inserter PWB. Check the IDG Pickup sensor. Refer to:
11A-171 HVF Power Distribution RAP GP 11 How to check a Sensor.
Install new component as necessary: P/J7 and P/J4, Inserter PWB.
Unit empty sensor, PL 11.175 Item 11. 11A-171 HVF Power Distribution RAP.
Inserter PWB, PL 11.179 Item 9. Install new components as necessary:
HVF control PWB, PL 11.157 Item 2. IDG pickup sensor, PL 11.179 Item 10.
Go to Flag 3 and Flag 4. Measure the voltage from the inserter paper width sensor 1, Q11-152,
while sliding paper width guide. The voltage changes.
Y N
Check the inserter paper width sensor 1, Q11-152. Refer to:
P/J8 and P/J4, Inserter PWB.
Inserter paper width sensor 1, PL 11.175 Item 13.
Go to Flag 5 and Flag 6. Measure the voltage from the inserter paper width sensor 2, Q11-152
while sliding paper width guide. The voltage changes.

Xerox WorkCentre 5790 Family 2-527 11J-171
inserter paper width
Inserter unit empty sensor, sensor 1, Q11-152
Q11-153
inserter paper width

sensor 2
IDG pickup sensor

Acceleration sensor

11J-171 2-528 Xerox WorkCentre 5790 Family

Xerox WorkCentre 5790 Family 2-529 11J-171

11J-171 2-530 Xerox WorkCentre 5790 Family
11K-171 HVF Initialization Failure RAP 5. The BM staple heads are driven to their home position, unless already home.
When an initialization command is received from the machine, the HCF polls all of the relevant Initial Actions
sensors to check if the various HCF modules are in their home positions. If any sensor reports
that a module is not in the home position, the HCF attempts to drive that module to the home
position. If unsuccessful, a fault status is raised and that module is disabled. If all modules are WARNING
reported in their home position, the HVF is initialized with the following actions: Ensure that the electricity to the machine is switched off while performing tasks that do
1. Bin 1 lowers then raises. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
2. The ejector assembly paddle performs two revolutions. death or injury. Moving parts can cause injury.
3. The curl suppression solenoid energises and raises the paddle modules centre flap. Open the HVF front door. Cheat the front door interlock switch. Fully pull out the BM module
4. The paddle module moves to the up position.
5. The paper pusher moves to the down position. Procedure
6. The ejector assembly travels to the out position. If the initialization sequence fails to place any unit at the home position, refer to the appropriate
RAPs:
7. The curl suppression solenoid de-energises and the paddle modules centre flap drops
down. The front tamper is not at the home position, refer to 11-392-171 to 11-395-171 HVF Front
tamper Tray RAP
8. The stapler module travels to the inboard position.
The rear tamper is not at the home position, refer to 11-396-171 to 11-399-171 HVF Rear
9. The stapler module returns to the outboard position
Tamper Tray RAP.
10. The curl suppression solenoid energises and raises the paddle modules centre flap. The paddle roll is not at the home position, refer to 11-024-171, 11-026-171 Paddle Roll
11. The paper pusher moves to the up position. Position RAP.
12. The ejector assembly returns to the home position. Bin 1 is not at the home position, refer to 11-460-171 to 11-462-171 HVF Bin 1 Position
13. The support finger motor turns on and drives the support fingers to the initialisation posi- RAP.
tion, which in turn pushes the pressing plate fingers down onto bin 1. The punch head is not at the home position, refer to 11-044-171 to 11-047-171 Punch
14. The support finger motor reverses and drives the support fingers to the home position, head Position RAP
which in turn retracts the pressing plate fingers. The staple head not at the home position, refer to 11-371-171 to 11-377-171 HVF stapler
15. The the front tamper moves to the away position then moves to the home position. Position and Priming RAP.
The ejector is not at the home position, refer to 11-450-171, 11-456-171 to 11-459-171
16. The bin 1 offset motor turns on and moves the ejector assembly, front taper and rear
HVF Ejector Module RAP.
tamper to the away position and then to the home position.
The buffer motor fails to start, refer to 11-164-171, 11-165-171 HVF Buffer Path RAP.
17. The paddle module moves to the down position.
The entry feed motor 1 fails to start, refer to 11-100-171, 11-101-171 HVF Entry Sensor
18. The entry feed motor 1, bypass feed motor, buffer feed motor and the exit feed motor 2 RAP.
turn on.
The exit feed motor 2 fails to start, refer to 11-130-171, 11-132-171 HVF Top Exit Sensor
19. The booklet maker diverter solenoid actuates, if applicable. RAP.
20. The exit diverter solenoid actuates. Bin 1 fails to offset, refer to 11-173-171 to 11-177-171 HVF Offset Unit RAP.
21. The booklet maker diverter solenoid de-actuates, if applicable. The booklet maker diverter solenoid fails to operate, refer to 11-158-171, 11-160-171,
22. The exit diverter solenoid de-actuates. 162-171, 163-171 HVF BM Entry RAP.
23. The hole punch unit motor and hole punch head motor turn on momentarily, if applicable. The exit diverter solenoid fails to operate, refer to 11-130-171, 11-132-171 HVF Top Exit
Sensor RAP.
24. The entry feed motor 1, bypass feed motor, buffer feed motor and the exit feed motor 2
turn off. Either of the BM staple heads are not at the home position, refer to 11-063-171, 11-411-
171 HVF BM Stapler Unit 1 Failure RAP or 11-403-171, 11-413-171, 11-414-171 HVF BM
NOTE: The HVF initialization procedure can be triggered by opening and closing the HVF front Stapler Head 2 and Stapler Module RAP.
door, or by raising and lowering the top tray. When this is done the tray will not lower com- The BM tampers are not at the home position, refer to 11-066-171, 11-384-171 HVF BM
pletely, but will adjust its position. Tamper Failure RAP.
The booklet maker is initialized as follows: The BM backstop is not at the home position, refer to 11-065-171, 11-383-171 HVF BM
Backstop Failure RAP.
1. The BM tampers are driven to their home position, unless already home.
The BM crease roll gate is not at the home position, refer to 11-415-171 HVF BM Crease
2. The BM backstop is driven to the home position, unless already home Roll Gate Home RAP.
3. The BM crease roll gate is driven to the home position, unless already home The BM crease blade is not at the home position, refer to 11-061-171, 11-416-171 HVF
4. The BM crease blade is driven to the home position, unless already home BM Creasing RAP.

Xerox WorkCentre 5790 Family 2-531 11K-171
11L-171 Tri-Folder Not Detected RAP
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 Flag 1. Check the wiring of the tri-folder present link, and repair as necessary, REP 1.2.
Check for 0V at P/J563 pin 7. Refer to:
P/J563, BM PWB.

11L-171 2-532 Xerox WorkCentre 5790 Family
11M-171 Curl Suppressor RAP
Use this RAP to fix curl suppressor problems.
Procedure
WARNING
Enter dC330, code 11-084 curl suppressor solenoid, SOL11-084, Figure 1. The solenoid
energizes.
Y N
Go to Flag 1. Check the curl suppressor solenoid, SOL 11-084.
Refer to:
11A-171, HVF Power Distribution RAP. Curl suppressor
solenoid, SOL11-084

Xerox WorkCentre 5790 Family 2-533 11M-171
11N-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
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 11-112, chad bin present sensor. Remove the chad bin and operate the sen-
sor manually. The display changes.
Y N
Go to Flag 1. Check the wiring. Repair as necessary, REP 1.2. Check the chad bin
present sensor, Q11-112. Refer to:
As necessary, install new components:
Chad bin present sensor, PL 11.153 Item 18.
Enter the dC330 code, 11-348, chad bin full sensor. Remove the chad bin and activate the sen-
sor with paper. The display changes.
Y N
Go to Flag 2. Check the wiring. Repair as necessary, REP 1.2. Refer to:
Chad bin full sensor, PL 11.153 Item 17.

11M-171, 11N-171 2-534 Xerox WorkCentre 5790 Family
Chad bin full sensor,
Q11-348
Chad bin present

sensor, Q11-112
UNDERSIDE VIEW

Xerox WorkCentre 5790 Family 2-535 11N-171

11N-171 2-536 Xerox WorkCentre 5790 Family
11P-171 Buffer Clamp RAP
Use this RAP when having problems with the buffer 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 11-082, buffer clamp solenoid. The solenoid actuates.
Y N
Go to Flag 1. Check the wiring. Repair as necessary, REP 1.2. Check the buffer clamp
solenoid, SOL 11-082. Refer to:
Buffer clamp solenoid, PL 11.150 Item 4. Buffer clamp solenoid,
HVF control PWB, PL 11.157 Item 2. SOL 11-082
REAR VIEW

Xerox WorkCentre 5790 Family 2-537 11P-171

11P-171 2-538 Xerox WorkCentre 5790 Family
12-301 Offset Catch Tray Failure RAP
12-301 The offset catch tray has not made an index position within 450 ms of the last index
position being made.
Initial Actions
WARNING
OCT index sensor
Ensure that the electricity to the machine is switched off while performing tasks that do Q12-301
Check that the offset catch tray is correctly installed and there is no obstruction to prevent OCT motor
movement between offset positions. If the tray is damaged, install a new OCT PL 12.10 MOT12-005
Item 1.
35-55 ppm Only. Make sure that the OCT fingers are installed correctly. Refer to REP
12.1.
Procedure
Figure 1. Go to Flag 1 and Flag 2. Check the OCT wiring, GP 7. The wiring is good.
Y N
Repair the wiring or install a new OCT, PL 12.10 Item 1.
Enter dC330, code 12-005 to check the OCT motor, MOT12-005. MOT12-005 runs.
Y N
Install a new OCT, PL 12.10 Item 1.
Enter dC330, code 12-005 and stack code 12-301 to check the OCT index sensor, Q12-301.
The display changes as the motor runs.
Y N
Install a new OCT, PL 12.10 Item 1.
Enter dC330, code 12-300 to check the OCT tray 90% full sensor, Q12-300. Actuate the sen-
Y N
Check the sensor actuator. If necessary install a new OCT, PL 12.10 Item 1. OCT tray 90% full sensor
Q12-300
Perform SCP 6 Final Actions RAP.


14-110 Scan Carriage Home Sensor Entry RAP 14-110A Scan Carriage Home Sensor RAP (W/O TAG 150)
14-110. The scanner PWB has not detected the scan carriage in the home position. Initial Actions
Procedure
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 14-
death or injury. Moving parts can cause injury. 110 Scan Carriage Home Sensor Entry RAP.
Perform the following: Check that the scan cables are correctly positioned, Figure 2.
(W/O TAG 150), go to the 14-110A Scan Carriage Home Sensor RAP (W/O TAG 150). Visually check the alignment of the scan motor through the document glass, the rubber
(W/TAG 150), go to the 14-110B Scan Carriage Home Sensor RAP (W/TAG 150). element of the motor bracket can fail. If necessary, install a new scan motor bracket, PL
14.25 Item 18. Refer to REP 14.11 Scan Motor.
Check that the harness from PJ152 is not routed under the single board controller PWB. If
the harness was under the PWB, examine the harness sleeving for punctures or other
damage. If necessary, install a new DADH/power distribution PWB harness, PL 3.24 Item
6. Route the new harness to the right, away from the single board controller PWB. If this
has caused a blown fuse F1 on the power distribution PWB, install a new power distribu-
tion PWB, PL 3.24 Item 5.
NOTE: This fault has been caused on a number of machines by bad routing of the DADH/
power distribution PWB harness PL 3.24 Item 6.
Procedure
Go to Flag 3. Check for +24V on P/J135 between pins 1 to 3 and 2 to 4 on the power distribu-
tion PWB. The voltage is good.
Y N
As necessary, perform the steps that follow:
Go to the 01G +24V Distribution RAP.
Go to the 01B 0V Distribution RAP, refer to the 24V return.
Go to Flag 3. Check for +12V on P/J135 between pins 6 to 8 on the power distribution PWB.
The voltage is good.
Y N
Go to 01F +12V Distribution RAP.
Go to 01B 0V Distribution RAP, refer to the 12V return.
Check that +24V is available in the scanner by entering the dC330 output code 14-005. The
exposure lamp illuminates.
Y N
Go to Flag 3. Check for +24V on P/J455 between pins 1 to 2 and 3 to 4 on the scanner
PWB. Also check for +12V on P/J450 between pins 1 and 2 on the CCD PWB. The volt-
ages are good.

A
Y N Y N
Check the harnesses between the power distribution PWB, the scanner PWB and Go to Flag 2. Check the wiring and P/J457. The wiring and connector are good.
the CCD PWB. If necessary, install a new single board controller module/scanner Y N
driver PWB/CCD PWB harness PL 14.25 Item 13, CCD PWB/Scanner PWB har- Repair the wiring and connector, REP 1.2. If necessary, install a new scan motor, PL
ness PL 14.25 Item 23. 14.25 Item 2.
Go to the 14D Exposure Lamp Failure RAP. Perform the following:

Check the scan motor bracket, the rubber component can fail, allowing the motor to
Check that +5V is available in the scanner by entering the dC330 input code 14-310, actuate move out of position. If necessary, install a new scan motor bracket, PL 14.25 Item
the input module angle sensor by opening and closing the DADH. The display changes. 18.
Y N
If necessary install a new scan motor, PL 14.25 Item 2.
Go to Flag 4. Check for +5V on P/J451 pins 1 to 2 on the CCD PWB right side. The
If necessary install a new scanner, PL 14.25 Item 1.
voltage is good.
Y N
The sensor and scan motor are working correctly, the fault may be intermittent. Check the fol-
lowing:
Check all harness connectors on the scanner PWB and CCD PWB are
The connectors are fully seated and the wiring is not damaged.
securely connected.
Q14-100 is mounted correctly.
Check the CCD PWB for damaged components. Install new components as
necessary: Check that the scanner drive belt is not loose, causing the belt to slip, refer to REP 14.11.
Scanner PWB, PL 14.25 Item 4. If necessary, go to REP 14.11 Scan Motor and re-position the scan motor so that the belt
does not slip.
Go to the 14A Scanning Document Size RAP and check the input module angle sensor, Check the scan motor bracket, the rubber component can fail, allowing the motor to move
Q14-310. out of position. If necessary, install a new scan motor bracket, PL 14.25 Item 18.
Go to Flag 4. Check for +5V on P/J452 pins 17 to 18 on the scanner PWB. The voltage is
good.
Y N
Check the harness between P/J451 and P/J452. If necessary, install a new harness, PL
14.25 Item 23.
Enter dC330 code 14-100 to check the scan carriage home sensor, Q14-100. Activate Q14-
100, Figure 1. The display changes.
Y N
Go to Flag 1. Check the scan carriage home sensor, Q14-100. Refer to:
P/J454, scanner PWB.
01B 0V Distribution RAP, refer to the 3.3V and 5V return.
Sensor harness, REP 1.2.
Scan carriage home sensor, PL 14.25 Item 16.
Scanner, PL 14.20 Item 1.
Perform ADJ 14.1 Optics Cleaning Procedure.
Switch off the machine, GP 14. Open the DADH or document cover. Switch on the machine,
GP 14. Observe the scan carriage as the machine initializes. The scan carriage moves
away from and back to the scan carriage home sensor.

The scan cable upper run must
Scan carriage home sensor (Q14-100) not go through cable anchor
slot
Cable anchor slot
Figure 2 Correct position of the scan cable
Scanner PWB
Figure 1 Carriage home sensor


A
14-110B Scan Carriage Home Sensor RAP (W/TAG 150) Check that +5V is available in the scanner by entering the dC330 input code 14-310, actuate
the input module angle sensor by opening and closing the DADH. The display changes.
Initial Actions Y N
Go to Flag 4. Check for +5V on P/J136 between pins 1 to 4 on the PDB PWB. Also check
for +3.3V on P/J136 between pins 2 and 3 on the PDB PWB. The voltages are good.
WARNING Y N
Ensure that the electricity to the machine is switched off while performing tasks that do lnstall new components as necessary:
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause PDB PWB, PL 3.24 Item 5.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 14- Go to the 14A Scanning Document Size RAP and check the input module angle sensor,
110 Scan Carriage Home Sensor Entry RAP. Q14-310.
Check that the scan cables are correctly positioned, Figure 2.
Go to Flag 4. Check for +5V on P/J920 between pins 7 to 8 on the scanner PWB. Also check
Check that the harness from PJ152 is not routed under the single board controller PWB. If
for +3.3V on P/J920 between pins 15 and 16 on the scanner PWB. The voltages are good.
Y N
Check the harness between P/J136 and P/J920. If necessary, install a new SBC PWB/
DADH comms/scanner power harness, PL 14.15 Item 5.
Enter dC330 code 14-100 to check the scan carriage home sensor, Q14-100. Activate Q14-
NOTE: This fault has been caused on a number of machines by bad routing of the DADH/ 100. The display changes.
power distribution PWB harness PL 3.24 Item 6. Y N
Check Q14-100. Refer to:
Procedure GP 11 How to Check a Sensor.
Go to Flag 3. Check for +24V on P/J135 between pins 1 to 3 and 2 to 4 on the power distribu- P/J924, Scanner PWB.
tion PWB. The voltage is good.
Y N
As necessary, perform the steps that follow: 01B 0V Distribution RAP, refer to the 3.3V and 5V return.
Go to the 01G +24V Distribution RAP. Repair or install new components as necessary:
Go to the 01B 0V Distribution RAP, refer to the 24V return. Sensor harness, REP 1.2.
Scan carriage home sensor, PL 14.15 Item 16.
Go to Flag 3. Check for +12V on P/J135 between pins 6 to 8 on the power distribution PWB. Scanner PWB, PL 14.15 Item 4.
The voltage is good. Scanner, PL 14.10 Item 1.
Y N
Go to 01F +12V Distribution RAP. Switch off the machine, GP 14. Open the DADH or document cover. Switch on the machine,
Go to 01B 0V Distribution RAP, refer to the 12V return. GP 14. Observe the scan carriage as the machine initializes. The scan carriage moves
away from and back to the scan carriage home sensor.
Check that +24V is available in the scanner by entering the dC330 output code 14-005. The Y N
exposure lamp illuminates. Go to Flag 2. Check the wiring and P/J929. The wiring and connector are good.
Y N Y N
Go to Flag 3. Check for +24V on P/J920 between pins 1 to 2 and 3 to 4 on the scanner Repair the wiring and connector, REP 1.2.
PWB. Also check for +12V on P/J920 between pins 1 and 2 on the scanner PWB. The
voltages are good. Perform the following:
Y N If necessary install a new scan motor, PL 14.15 Item 2.
Check the harnesses between the power distribution PWB and the scanner PWB. If
If necessary install a new scanner, PL 14.10 Item 1.
necessary, install a new single board controller PWB/DADH comms/scanner power
harness PL 14.15 Item 5.
The sensor and carriage motor are working correctly, the fault may be intermittent. Check the
following:
Go to the 14D Exposure Lamp Failure RAP.
The connectors are fully seated and the wiring is not damaged.
Q14-100 is mounted correctly.
A

Check that the scanner drive belt is not loose, causing the belt to slip. If necessary re-
position the scan motor so that the belt does not slip.
The scan cable upper run must
not go through cable anchor
slot.
Scan carriage home sensor (Q14-100).
Cable anchor slot.
Figure 2 Correct position of the scan cable
Scanner PWB
Figure 1 Carriage home sensor


14-310 CCD PWB Not Detected RAP (W/O TAG 150) The voltages are good.
Y N
14-310 The scanner PWB detects an abnormal power supply voltage or a CCD PWB failure.
Disconnect P/J135. Check the voltages again at the connector on the power distribution
PWB. The voltages are good.
NOTE: This fault code only applies to machines W/O TAG 150. Y N
Procedure Go to the relevant RAP:
01B 0V Distribution RAP, refer to the 12V return and 3.3V return.
WARNING 01D +3.3V Distribution RAP.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Check for a short circuit on the harness between P/J135 and P/J450. Repair the har-
death or injury. Moving parts can cause injury. ness, REP 1.2, or install a new harness, PL 14.25 Item 13. Perform ADJ 14.1 Optics
Go to Flag 1. Check the following voltages at P/J135 on the power distribution PWB: Cleaning Procedure.
Go to Flag 2. Check the following voltages at P/J450 on the CCD PWB, Figure 1:
+3.3V between pins 3 and 4.
Y N
Disconnect P/J135. Check the voltages again at P/J135 on the power distribution PWB. The voltages are good.
The voltages are good. Y N
Y N Check for an open circuit in the harness between P/J135 and P/J450. Repair the har-
Go to the following RAPs: ness, REP 1.2, or install a new harness, PL 14.25 Item 13. Perform ADJ 14.1 Optics
Cleaning Procedure.
01G +24V Distribution RAP. Install new components in the following order:
CCD harness, PL 14.25 Item 5.
Check for a short circuit in the harness between P/J135 and P/J455. Repair the harness,
REP 1.2, or install a new harness, PL 14.25 Item 13. If the harness is good, install a new Scanner PWB, PL 14.25 Item 4.
scanner PWB, PL 14.25 Item 4. Scanner, PL 14.20 Item 1.
Check that +24V is available in the scanner by entering the dC330 output code 14-005. The
exposure lamp illuminates.
Y N
Remove the CVT glass and document glass, REP 14.6.
Remove the PWB cover, 3 screws, PL 14.25 Item 1.
Re-install the scanner top cover and GUI, but do not install the screws. Re-connect the
power cord and switch on the machine, GP 14.
Go to Flag 1. Check the following voltages at P/J455 on the scanner PWB, Figure 1:
Y N
Check for a open circuit on the harness between P/J135 and P/J455. Repair the
harness, REP 1.2, or install a new harness, PL 14.25 Item 13. Perform ADJ 14.1
Optics Cleaning Procedure.
Go to the 14D Exposure Lamp Failure RAP.
Go to Flag 2. Check the following voltages at P/J135 on the power distribution PWB:
+3.3V between pins 7 and 5.

Scanner PWB CCD PWB

14-320 CVT Active Hot Line in Wrong State RAP 14-322 Platen Active Hot Line in Wrong State RAP (W/O
14-320 The CVT active hot line (DADH) is in the wrong state before a scan calibration or scan. TAG 150)
14-322 The platen active hot line is in the wrong state before a scan calibration or scan.
Procedure
Procedure
WARNING
Switch off the machine, then switch on the machine, GP 14. The fault code is still present. death or injury. Moving parts can cause injury.
Y N Switch off the machine, then switch on the machine, GP 14. The fault code is still present.
Y N
Check the leads and the connections that follow:
(W/O TAG 150) Check between PJ188 pin 5 on the DADH PWB and PJ102 pin 1 on the Check between PJ452 pin 5 and pin 6 on the scanner PWB W/O TAG 150 and PJ451 pin 13
single board controller PWB. Refer to wiring diagram WD 12 and pin 14 on the CCD PWB. Refer to WD 15.
a. (W/TAG 150) Check between PJ921 pin 5 on the Scanner PWB (W/TAG 150), inline
connector PJ102, PJ152 pin 17 and PJ188 pin 5 on the DADH PWB. Refer to wiring
diagrams WD 13 and WD 16.

14-340 Scanner AGC Failure RAP 14-703 to 14-706, 712, 714, 716, 718 Failure To Calibrate
14-340 The scanner AGC (automatic gain control) failure has been detected during calibration Entry RAP
or before the start of scan.
14-703. The scanner PWB failed to calibrate as the pixel gain is too high.
Procedure 14-704. The scanner PWB failed to calibrate as the pixel gain is too low.
14-705. The scanner PWB failed to calibrate as one or more pixels are offset higher than the
WARNING required level.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause 14-706. The scanner PWB failed to calibrate as one or more pixels are offset lower than the
death or injury. Moving parts can cause injury. required level.
Switch off the machine, then switch on the machine, GP 14. The fault code is still present.
Y N 14-712. The scanner PWB failed to calibrate due as overall gain is at maximum and fails to
Perform SCP 6 Final Actions. raise the brightest pixel to an acceptable level.
Check that the lamp illuminates correctly. 14-714. The scanner PWB failed to calibrate as the dark gain is at minimum and fails to lower
Install new components as required. the darkest pixel to an acceptable level.
(W/O TAG 150) Exposure lamp, PL 14.25 Item 9.
14-716. The scanner PWB failed to calibrate due to an abnormal CCD level.
(W/TAG 150) Exposure lamp, PL 14.15 Item 9.
14-718. The scanner PWB failed to auto-calibrate.
NOTE: The fault code 14-716 only applies to machines W/O TAG 150.
Procedure
Identify the speed of the machine, refer to SCP 7 Machine Features. Go to the relevant proce-
dure:
(W/O TAG 150), go to the 14-703A to 14-706A, 712A, 714A, 716A, 718A Failure to Cali-
brate RAP (W/O TAG 150).
(W/TAG 150), go to the 14-703B to 14-706B, 712B, 714B, 718B Failure to Calibrate RAP
(W/TAG 150).

Xerox WorkCentre 5790 Family 2-551 14-340, 14-703 to 14-706, 712, 714, 716, 718
14-703A to 14-706A, 712A, 714A, 716A, 718A Failure To Y N
Repair the wiring, REP 1.2.
Calibrate RAP (W/O TAG 150)
Initial Actions Check the tension of the scanner drive belt, refer to REP 14.11. A loose drive belt can cause
the belt to slip. The scanner drive belt is good.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 14-703 to
Y N
14-706, 712, 714, 716, 718 Failure to Calibrate Entry RAP.
Refer to REP 14.11 Scan Motor. Re-position the scan motor so that the belt does not slip.
Procedure
Inspect the calibration strips on the front underside of the CVT glass and document glass. The
calibration strips are undamaged.
WARNING Y N
Install a new CVT glass, PL 14.20 Item 4 and / or a new document glass, PL 14.20 Item 5.
Clean the calibration strips, using a cleaning cloth dampened with water. Re-assemble the
parts. Turn on the machine, GP 14. The fault is still present.
Switch off the machine, then switch on the machine, GP 14. The fault is still present. Y N
Y N Perform SCP 6 Final Actions.
Install new parts in the following order:
Go to Flag 1 and Flag 2. Check for the following voltages at P/J135 on the power distribution
Exposure lamp, PL 14.25 Item 9.
PWB:
Single board controller PWB module / CCD PWB harness, PL 14.25 Item 5.
+24V between pins 1 and 3, Flag 1.
+3.3V between pins 5 and 7, Flag 2.
Y N CVT glass Document glass Full rate carriage mirror Exposure lamp
Refer to the following:
Go to 01B 0V Distribution RAP, refer to the 24V return and 12V return.
Remove the CVT glass and document glass REP 14.6. Check that all optics mirrors are
securely attached and correctly aligned, Figure 1. Check that the light path to the CCD array is
clear of obstructions. The optical path is good.
Y N
Correct the mirror alignment, clear the light path or install a new scanner, PL 14.20 Item 1.
Check the CCD assembly for loose electrical connections or misalignment of the assembly,
Figure 2. The CCD assembly is good.
Y N
Correct the problem or install a new scanner, PL 14.20 Item 1.
Check the scanner PWB for loose connections or damage, Figure 2. The scanner PWB is
good.
Y N
Install a new scanner PWB, PL 14.25 Item 4.
Half rate carriage mirrors
Check the wiring between P/J135 and P/J455, also between P/J135 and P/J450, refer to GP CCD array Lens
7. The wiring is good.
Figure 1 Optical path

14-703A to 14-706A, 712A, 714A, 716A, 718A 2-552 Xerox WorkCentre 5790 Family
Scanner PWB CCD PWB

Xerox WorkCentre 5790 Family 2-553 14-703A to 14-706A, 712A, 714A, 716A, 718A
A
14-703B to 14-706B, 712B, 714B, 718B Failure To Calibrate Clean the white CVT strips, under the front edges of the document glass and the CVT glass,
using a cleaning cloth dampened with film remover, PL 26.10 Item 4. Re-assemble the parts.
RAP (W/TAG 150) If the fault persists, install new components as necessary:
Initial Actions Scan carriage ribbon cable, PL 14.15 Item 10.
WARNING
W/O TAG 157 Exposure Lamp Check
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Procedure
CAUTION
WARNING When measuring voltages of the scanner PWB, take special care not to short any two pins
together.
Take care, a hazardous voltage is present at the output of the exposure lamp inverter.
Electricity can cause death or injury. Remove the document size sensor cover REP 14.20. +24V is available at P/J926 between
pins 5 and 3, also between pins 6 and 1, Flag 2.
Y N
703 to 14-706, 712, 714, 716, 718 Failure to Calibrate Entry RAP.
Go to Flag 3, disconnect P/J1 at the exposure lamp inverter PWB. +24V is available at
Check that the exposure lamp illuminates when the machine is performing the set up pro- P/J926 between pins 5 and 3, also between pins 6 and 1, Flag 2.
cedure. If necessary, enter the dC330 output code, 14-005. If the lamp does not illumi- Y N
nate, go to the W/O TAG 157 Exposure Lamp Check or the W/TAG 157 Exposure Lamp Go to Flag 2, disconnect P/J926 at the scanner PWB +24V is available at P/J926
Check. between pins 5 and 3, also between pins 6 and 1.
Y N
Procedure Install a new Scanner PWB, PL 14.15 Item 4.
Figure 1 shows the component location. Switch off the machine, then switch on the machine,
GP 14. The fault is still present. Check for a short circuit on the ribbon harness. Repair the harness or install a new
Y N scan carriage ribbon harness, PL 14.15 Item 10.
Install a new exposure lamp inverter PWB, PL 14.15 Item 12.
+24V is available at P/J1 between pins 5 and 3, also between pins 6 and 1, Flag 3.
Remove the DADH, REP 5.19.
Y N
Remove the scanner top cover, REP 14.14. Install a new scan carriage ribbon harness, PL 14.15 Item 10.
Reinstall the DADH, REP 5.19.
Go to Flag 1. Check the voltages at P/J135 on the power distribution PWB. As necessary, Measure the lamp enable signal at P/J926 pin 4 on the scanner PWB (W/TAG 150), Flag 3.
refer to: enter the dC330 output code 14-005. The signal voltage changes from +24V to 0V when
01D +3.3V Distribution RAP. the code is active.
Y N
Install a new scanner PWB W/TAG 150, PL 14.15 Item 4.
01G +24V Distribution RAP. Measure the lamp enable signal at P/J1 pin 4. enter the dC330 output code 14-005. The sig-
01B 0V Distribution RAP. nal voltage changes from +24V to 0V when the code is active.
Check that the CCD PWB/Scanner PWB ribbon cable 1, PL 14.15 Item 15 and CCD PWB/ Y N
Scanner PWB ribbon cable 2, PL 14.15 Item 23 are undamaged and correctly connected. Go Install a new scan carriage ribbon harness, PL 14.15 Item 10.
to Flag 1. Check the wiring between P/J135 and P/J136 on the power distribution PWB in the
SBC PWB module, and P/J920 on the scanner PWB. Repair as necessary, REP 1.2 or install Switch off the machine, GP 14. Go to Flag 4, check the wiring and connectors between P/J2
a new SBC PWB/DADH comms/scanner power harness, PL 14.15 Item 5. and the exposure lamp. The wiring and connectors are good.
Inspect the calibration strips on the front underside of the CVT glass and document glass. The Y N
calibration strips are undamaged. Install a new exposure lamp, PL 14.15 Item 9.
Y N
Install a new CVT glass, PL 14.20 Item 4 and/or a new document glass, PL 14.20 Item 5. Install a new exposure lamp inverter PWB, PL 14.15 Item 12.
A
14-703B to 14-706B, 712B, 714B, 718B 2-554 Xerox WorkCentre 5790 Family
W/TAG 157 Exposure Lamp Check
Exposure lamp inverter
Procedure (W/O TAG 157)
CAUTION
When measuring voltages of the scanner PWB, take special care not to short any two pins
together.
Remove the document size sensor cover REP 14.20. +24V is available at P/J926 between
pins 5 and 3, also between pins 6 and 1, Flag 2.
Y N
Go to Flag 3, disconnect P/J1 at the LED driver PWB. +24V is available at P/J926 Scan carriage
assembly
between pins 5 and 3, also between pins 6 and 1, Flag 2.
Y N
Go to Flag 2, disconnect P/J926 at the scanner PWB +24V is available at P/J926
between pins 5 and 3, also between pins 6 and 1.
Y N
Install a new Scanner PWB, PL 14.15 Item 4. Scan carriage
ribbon cable
Check for a short circuit on the ribbon harness. Repair the harness or install a new
scan carriage ribbon harness, PL 14.15 Item 10.
Exposure lamp
Install a new LED scan carriage assembly, PL 14.15 Item 26.
+24V is available at P/J1 between pins 5 and 3, also between pins 6 and 1, Flag 3.
Y N Scanner PWB
Install a new scan carriage ribbon harness, PL 14.15 Item 10.
Measure the lamp enable signal at P/J926 pin 4 on the scanner PWB (W/TAG 150). enter the
dC330 output code 14-005. The signal voltage changes from +24V to 0V when the code is
active.
Install a new scanner PWB W/TAG 150, PL 14.15 Item 4.
Measure the lamp enable signal at P/J1 pin 4. enter the dC330 output code 14-005. The sig-
nal voltage changes from +24V to 0V when the code is active.
Y N
Install a new scan carriage ribbon harness, PL 14.15 Item 10.
Switch off the machine, GP 14. Go to Flag 6, check the wiring and connectors between P/J2
and the LED exposure lamp. The wiring and connectors are good.
Y N
Repair the wiring or install a new LED scan carriage assembly, PL 14.15 Item 26.
Install a new LED scan carriage assembly, PL 14.15 Item 26.

Xerox WorkCentre 5790 Family 2-555 14-703B to 14-706B, 712B, 714B, 718B

14-703B to 14-706B, 712B, 714B, 718B 2-556 Xerox WorkCentre 5790 Family
14-710 NVM Value Out Of Range RAP 14-720 Scan Length Out Of Range RAP
14-710 The scanner PWB has received an NVM value from the single board controller PWB 14-720 The scan length request from the single board controller PWB exceeds the physical
that is out of range, high or low. limits of the scan carriage.
Procedure Procedure
WARNING
Switch off the machine, then switch on the machine, GP 14. The fault is still present.
Y N
Perform dC132 NVM Initialization, copier NVM initialization.

14-730 Scanner Application Card Failure RAP 14A Scanning Document Size Entry RAP
14-730 There is no response or an incorrect response to the command issued by the scan ser- The scanner has encountered a document that is larger than expected.
vice.
The scanner has encountered a document of unknown size. The document size sensors have
Procedure incorrectly determined the size of the original.
Procedure
WARNING Go to the relevant procedure:
Ensure that the electricity to the machine is switched off while performing tasks that do (W/O TAG 150), go to the 14B Scanning Document Size RAP (W/O TAG 150).
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause (W/TAG 150), go to the 14C Scanning Document Size RAP (W/TAG 150).
2. Check that the harness from PJ152 is not routed under the single board controller PWB. If
NOTE: This fault has been caused on a number of machines by bad routing of the DADH/
power distribution PWB harness PL 3.24 Item 6.

A B
14B Scanning Document Size RAP (W/O TAG 150) Y N
Install a new scanner drive PWB, PL 14.25 Item 4.
Initial Actions
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 14A Check the wiring between P/J454 and Q14-310 for an open circuit.
Scanning Document Size Entry RAP
Go to Flag 4. Check the input module angle sensor, refer to:
Procedure P/J454, scanner PWB.
Ensure that the electricity to the machine is switched off while performing tasks that do Repair or install new components as necessary:
Input module angle sensor, PL 14.25 Item 16.
Check that the input module angle sensor actuator is not damaged, if necessary, install a new
input module angle sensor actuator, PL 14.25 Item 21. Scanner, PL 14.20 Item 1.
Enter the dC330 input code 14-310. Actuate the input module angle sensor, Q14-310 by open-
ing and closing the DADH. The display changes. Raise the DADH. Enter the dC330 input code 14-315. Actuate the document size sensor 1 by
Y N placing a piece of paper on the document glass above the sensor, Figure 1. Enter the dC330
Go to Flag 2. Check for +12V on P/J135 between pins 6 and 8 on the power distribution input code 14-320 and repeat the test for document size sensor 2. The display changes for
PWB. The voltage is good. both sensors.
Y N Y N
Go to the following RAPs: Go to Flag 1. Check the document size sensors 1 and 2, refer to:
01B 0V Distribution RAP, refer to the 12V return. GP 11 How to Check a Sensor.
01F +12V Distribution RAP. NOTE: If necessary, temporarily install the document glass when checking the size
sensors, to ensure that the document is the correct distance from the sensor.
Go to Flag 4. +5V is available at pin 3 on Q14-310 connector (yellow wire).
Y N 01D +3.3V Distribution RAP.
Remove the CVT glass and document glass, REP 14.6. 01B 0V Distribution RAP, refer to the 3.3V return.
Remove the PWB cover, 3 screws, PL 14.25 Item 1. Repair or install new components as necessary:
Re-install the scanner top cover and GUI, but do not install the screws. Re-connect Document size sensor, PL 14.25 Item 3.
the power cord and switch on the machine, GP 14.
Go to Flag 2. Check for +12V on P/J450 between pins 1 and 2 on the CCD PWB.
The voltage is good. Scanner, PL 14.20 Item 1.
Y N
Check the harness between P/J135 and P/J450 for an open or short circuit. The scanner is working correctly, perform dC604 Registration Setup.
Repair the wiring, REP 1.2, or install a new harness, PL 14.25 Item 13.
Go to Flag 3. Check for +5V on P/J451 between pins 1 and 2 on the scanner PWB.
The voltage is good.
Y N
Install a new scanner, PL 14.20 Item 1.
Go to Flag 3. Check for +5V on P/J452 between pins 17 and 18. The voltage is
good.
Y N
Check the connectors on the ribbon cable between P/J451 and P/J452 are
correctly installed. If necessary install a new harness, PL 14.25 Item 5.
+5V is available at P/J458 pins 1 and 4, also on P/J454 pin 4.
A B

Document size Document size
sensor 2 sensor 1
Q14-320 Q14-315
Input module angle sensor Q14-310


14C Scanning Document Size RAP (W/TAG 150) Y N
Go to Flag 3. Check the document size sensors 1 and 2, refer to:
Initial Actions GP 11 How to Check a Sensor.
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 14A
Scanning Document Size Entry RAP NOTE: If necessary, temporarily install the document glass when checking the size
sensors, to ensure that the document is the correct distance from the sensor.
Procedure Repair or install new components as necessary:
Document size sensor, PL 14.15 Item 3.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do Reassemble the scanner, then perform dC604 Registration Setup.
Figure 1 shows the component location. Go to Flag 1. Check the voltages at P/J136 on the
power distribution PWB. As necessary, refer to:
Remove the following components,
DADH, REP 5.19.
Document glass, REP 14.6.
Document size
Document size sensor cover, REP 14.20. sensor 2
Check the wiring between P/J136 on the power distribution PWB in the single board controller
PWB module and P/J920 on the scanner PWB. Repair as necessary, REP 1.2 or install a new
single board controller PWB/DADH comms/scanner power harness, PL 14.15 Item 5. Document size
Check that the input module angle sensor actuator is not damaged, if necessary, install a new sensor 1
actuator, PL 14.15 Item 21.
Switch the machine off, then switch the machine on GP 14. The fault is still present
Y N
Perform SCP 6 final actions.
Reinstall the DADH, REP 5.19. Enter the dC330 input code 14-310, Document Handler Angle
Sensor and actuate the input module angle sensor, Q14-310 by opening and closing the
DADH.
Y N
Go to Flag 2. Check the input module angle sensor, Q14-310. Refer to GP 11, How to
Check a Sensor.
Input module angle sensor, PL 14.15 Item 16.
Reinstall the document size sensor cover, REP 14.20. Raise the DADH, enter the dC330 input
code 14-315, actuate the document size sensor 1, Q14-315 by placing a piece of paper above
the sensor, Figure 1. Enter the dC330 input code 14-320 and repeat the test for document size
sensor 2, Q14-320. The display changes for both sensors.


A B
14D Exposure Lamp Failure RAP Y N
The lamp is lit.
(W/O TAG 150), use this RAP when the exposure lamp does not light, and there is no auto-
Y N
matic gain control signal.
Go to Flag 1. Check the lamp ribbon harness between P/J456 and P/
J463 for open or short circuits. The lamp ribbon harness is good.
NOTE: For W/TAG 150 machines, go to the 14-703B to 14-706B, 712B, 714B, 718B Failure to
Y N
Calibrate RAP (W/TAG 150).
Install a new lamp ribbon harness, PL 14.25 Item 10.
Install new components in the following order:

WARNING Exposure lamp, PL 14.25 Item 9.
Ensure that the electricity to the machine is switched off while performing tasks that do Exposure lamp inverter, PL 14.25 Item 12.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Perform ADJ 14.1 Optics Cleaning Procedure.
WARNING Install new components in the following order:

Take care, a hazardous voltage is present at the output of the exposure lamp inverter. Exposure lamp, PL 14.25 Item 9 and exposure lamp fuse, PL 14.25 Item 11.
Electricity can cause death or injury. Exposure lamp inverter, PL 14.25 Item 12 and exposure lamp fuse, PL 14.25
Procedure Item 11.
Go to Flag 2. Check the following voltages at P/J135 on the power distribution PWB. Perform ADJ 14.1 Optics Cleaning Procedure.
Switch on the copier. Go to Flag 1. Disconnect P/J456 and check the following voltages
at P/J456 on the scanner PWB:
Y N
Go to 01B 0V distribution RAP, refer to the 24V return and 01G +24V Distribution RAP. +24V between pins 2 and 8.
Remove the CVT glass and document glass, REP 14.6. Remove the PWB cover, 3 screws, PL The voltages are good.
14.25 Item 1. Re-install the scanner top cover and GUI, but do not install the screws. Re-con- Y N
nect the power cord, switch on the machine, GP 14. Install a new scanner PWB, PL 14.25 Item 4.
Go to Flag 2. Check for the following voltages at P/J455 on the scanner PWB.
+24V between pins 1 and 2. Re-connect P/J456. Disconnect P/J463. Check the following voltages on the inverter
+24V between pins 3 and 4. end of the harness.
The voltages are good. +24V between pins 1 and 7.
Y N +24V between pins 2 and 8.
Check the harness between P/J135 and P/J455. Repair the harness, REP 1.2, or install +24V between pins 3 and 9.
a new harness, PL 14.25 Item 13. The voltages are good.
Y N
Enter the dC330 output code 14-005. The exposure lamp illuminates. Install a new lamp ribbon harness, PL 14.25 Item 10.
Y N
Re-connect P/J463. +10V is available at PJ/463 pin 4.
Y N
WARNING
Install a new exposure lamp inverter, PL 14.25 Item 12.
Do not install a fuse of a different type or rating. Installing the wrong type or rating
of fuse can cause overheating and a risk of fire. +10V is available at PJ/456 pin 6.
Check the fuse, Figure 1. Refer to REP 14.2, to remove the fuse. The fuse is good. Y N
Y N Install a new lamp ribbon harness, PL 14.25 Item 10.
Install a new fuse, PL 14.25 Item 11. Re-install the scanner top cover and GUI, but
do not install the screws. Switch on the machine, GP 14. Enter the dC330 output
code 14-005. The new fuse fails.
A B A C
A C
Go to Flag 1. Connect a test meter between pins 6 and 1 of P/J456 on the scanner PWB.
Enter the dC330 output code 14-005. The voltage changes from +10V to 0V when the Exposure lamp
code is entered.
Y N
Fuse
Check the lamp ribbon harness between P/J456 and P/J463. The lamp ribbon har-
ness is good.
Y N
Install a new lamp ribbon harness, PL 14.25 Item 10.

Exposure lamp, PL 14.25 Item 9.
Exposure lamp inverter, PL 14.25 Item 12.
The automatic gain control circuit does not see the light from the exposure lamp. Check for
misplaced optics mirrors or an obstruction in the light path. If necessary, install a new scanner,
PL 14.20 Item 1.
Scanner PWB Exposure lamp inverter
Figure 1 Exposure lamp, inverter and fuse.


16A Network Error Entry RAP 16B FTP or SMB Unable to Connect to Remote Server RAP
Use this RAP when the customer reports network failures. e.g. Cannot connect to the scan Either the machine cannot connect, find or login to the scan server.
server when using the FPT or SMB protocols, or when a folder on the scan server cannot be
opened. Procedure
NOTE: The fault message will be printed on the confirmation report. The report may take sev-
eral minutes to print after scanning the document. WARNING
Initial Actions Ensure that the electricity to the machine is switched off while performing tasks that do
Consult your manager before troubleshooting the customers network, as the policy varies
according to region.
NOTE: The FTP/SMB protocol will be followed by a colon and port number, :21 is for FTP and
Procedure :139 is for SMB.
NOTE: If it is possible to log into the web UI by entering the IP address of the machine, then Scan the document using the default template and one other template. The fault is present
the network controller on the single board controller PWB is good. on both templates.
Y N
Perform the following: The template that failed is incorrectly configured. Ask the customer or system administra-
1. Check that the machines date and time are correctly set, refer to GP 31. tor to verify the settings of the web template that failed, including the login password.
2. Print a configuration report.
Ask the customer to open the machines CWIS page. The machines CWIS page can be
3. Check with customer that the printing of the confirmation report is enabled. If necessary,
opened.
ask the customer to enable printing of the confirmation report.
Y N
4. Ensure that the machine is configured for scan to file: Look at the front of the configuration report. Make sure that HTTP is enabled and set to
a. Check the back of the configuration report under the heading Workflow Scanning port 80. The settings are correct.
(Default Repository). Y N
b. If a IP address or name is not listed next to Protocol, ask the customer to configure Enable HTTP, GP 32 and set the port to 80 on the UI. Restart this RAP from the
the machine before continuing. beginning. If this path has been followed previously, escalate the fault to the system
5. Go to the relevant procedure: Administrator. If the customer does not have a System Administrator, they should
contact the Customer Support Centre or request a Xerox analyst troubleshoot their
16B FTP or SMB Unable to Connect to Remote Server RAP.
network which will be subject to a charge.
16C Remote Directory Lock Failed RAP.
Disconnect the network cable from the machine. Make sure the PWS network adaptor
settings are set to Auto. Use a crossover cable, PL 26.10 Item 6 to connect the PWS to
the machine. Either the two LEDs on the SBC PWB or the PWS are lit, indicating a
connection.
Y N
1. Change the network speed setting of the machine, GP 35.
2. If either the two LEDs on the SBC PWB or the PWS are not lit, repeat the steps
in GP 35.
3. If the LEDs light, use the new network speed setting. Inform the customer that
the network speed has been changed then follow the Yes path from this step.
4. If the LEDs do not light, install a new single board controller PWB, PL 3.24 Item 3.
Correctly configure the IP address of the PWS, GP 34. Make sure the firewall of the PWS
is disabled, GP 36. Ping the machine from the PWS, GP 33.
NOTE: Re-enable the PWS firewall after completion of this procedure.
The machine responds to the ping request.

A

A B
Y N Y N
Perform an Altboot, GP 4. Perform the Customers Settings Check. Changes were made to the customers
settings.
The machine software is up to date. Y N
Y N Escalate the fault to the system Administrator. If the customer does not have a
Upgrade the software, GP 4. The fault persists. System Administrator, they should contact the Customer Support Centre or
Y N request a Xerox analyst troubleshoot their network which will be subject to a
Perform SCP 6 Final Actions. charge.
Perform the Customers Settings Check. Changes were made to the customers Retry the job. The job was successful.
settings. Y N
Y N Escalate the fault to the system Administrator. If the customer does not have a
Escalate the fault to the system Administrator. If the customer does not have a System Administrator, they should contact the Customer Support Centre or
System Administrator, they should contact the Customer Support Centre or request a Xerox analyst troubleshoot their network which will be subject to a
request a Xerox analyst troubleshoot their network which will be subject to a charge.
charge.
Retry the job. The job was successful.
Y N The customer can ping the default gateway IP address.
Escalate the fault to the system Administrator. If the customer does not have a Y N
System Administrator, they should contact the Customer Support Centre or Escalate the fault to the system Administrator. If the customer does not have a Sys-
request a Xerox analyst troubleshoot their network which will be subject to a tem Administrator, they should contact the Customer Support Centre or request a
charge. Xerox analyst troubleshoot their network which will be subject to a charge.
Perform SCP 6 Final Actions. Perform the Customers Settings Check. Changes were made to the customers set-
tings.
Perform the Customers Settings Check. Changes were made to the customers set- Y N
tings. 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
Escalate the fault to the system Administrator. If the customer does not have a Sys- Xerox analyst troubleshoot their network which will be subject to a charge.
tem Administrator, they should contact the Customer Support Centre or request a
Xerox analyst troubleshoot their network which will be subject to a charge. Retry the job. The job was successful.
Y N
Retry the job. The job was successful. 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
Escalate the fault to the system Administrator. If the customer does not have a Sys- Xerox analyst troubleshoot their network which will be subject to a charge.
tem Administrator, they should contact the Customer Support Centre or request a
Xerox analyst troubleshoot their network which will be subject to a charge. Perform SCP 6 Final Actions.
Perform SCP 6 Final Actions. Perform the Customers Settings Check. Changes were made to the customers settings.
Y N
Ask the customer to ping the scan servers IP address or name. 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-
NOTE: The scan server is the computer that the job is being sent. The scan servers IP address lyst troubleshoot their network which will be subject to a charge.
or name is displayed on the confirmation report.
The customer can ping the scan server. Retry the job. The job was successful.
Y N Y N
Check the configuration report for default gateway IP address listed under TCP/IPv4 Set- Escalate the fault to the system Administrator. If the customer does not have a System
tings. A default gateway IP address is listed. Administrator, they should contact the Customer Support Centre or request a Xerox ana-
lyst troubleshoot their network which will be subject to a charge.

B
Customers Settings Check 16C Remote Directory Lock Failed RAP
NOTE: Both the configuration and confirmation reports are required to check the customers Use this RAP when the customer reports that the machine has logged onto the scan server,
settings. Corrections must be made through the machines CWIS page. 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.
Check the following with the customer, ask the customer to correct any errors:
1. That the scan server is switched on and online. NOTE: The scan server is the computer that the job is being sent.
NOTE: The scan server is the computer that the job is being sent. Procedure
2. That the scan servers IP address or name is correct. The machines login name that it is using to log onto the scan server, for this file repository,
3. That the path and user name are correct. 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
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 request a Xerox
configuration report.
analyst troubleshoot their network which will be subject to a charge.
5. Check with System Administrator that the correct password has been entered on the
machines CWIS page.
NOTE: The password is not printed on the configuration or confirmation reports.

Xerox WorkCentre 5790 Family 2-569 16B, 16C
16B, 16C 2-570 Xerox WorkCentre 5790 Family
19-401, 19-402, 19-403 Out of Memory Resources RAP 19-404 Compressor Time-out RAP
19-401 Out of memory - stress document. 19-404 Video compressor DVMA time-out
19-402 Out of memory - stress job. Initial Actions

19-403 Out of memory with greater than one job in EPC.
WARNING
Also use this RAP when a fault code is not displayed but the machine fails to complete com-
plex jobs.
Also use this RAP when memory related messages appear e.g.:
Check for DADH misfeed.
Resources low, will start shortly. Check for jammed paper before the fuser.
Please wait your job will start shortly. If the job has mixed originals, make sure that Mixed Size Originals is selected on the UI.
System memory is full. Please wait while memory resources are made available to con- Switch off, then switch on the machine, GP 14.
tinue your job. Do not press the start button again the scanner will start automatically. Or
touch Cancel Job to cancel your job. Procedure
Initial Actions Perform the following:
1. Check the history files for DADH 05-XX faults and if necessary perform the appropriate
RAP.
WARNING 2. (W/TAG 150 Only) perform the following:
a. Re-seat PJ922 on the scanner PWB.
death or injury. Moving parts can cause injury. b. Re-seat the scanner daughter PWB, PL 3.24 Item 20.
Switch off, then switch on the machine, GP 14. c. Install new components as necessary:
Procedure Scanner daughter PWB/scanner PWB video harness, PL 14.15 Item 13.
Perform the following: 3. Perform the 03-315, 325, 347, 348, 349, 355, 400 Single Board Controller PWB Failure
RAP.
1. Re-seat the memory module, PL 3.24 Item 12.
4. If prints are mostly black, fuzzy or scrambled make sure that all grounding straps are
2. If the fault remains, install a new components as necessary:
secure. If necessary perform the 01A Ground Distribution RAP.
SBC PWB, PL 3.24 Item 3.

19-406 Loopback DVMA Time-out RAP 19-407, 19-408 Middle Function DVMA Time-out RAP
19-406 Video loop back DVMA time-out detected. 19-407 Video middle function DVMA input time-out.
Initial Actions 19-408 Video middle function DVMA output time-out.
Initial Actions
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
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 Switch off the machine, then switch on the machine, GP 14.
Go to the 03-315, 325, 347, 348, 349, 355, 400 Single Board Controller PWB Failure RAP.
Procedure

19-409 Video Job Integrity Fault RAP
19-409 Video determines that it cannot guarantee the integrity of the job being processed.
Initial Actions
WARNING
If the job has mixed originals, make sure that Mixed Size Originals is selected on the UI.
Procedure

20-302, 20-303 Fax Reset Failure RAP 20-305 Fax System Low Memory Unrecoverable RAP
The embedded fax PWB will automatically reset itself. The embedded fax PWB will automatically reset itself.
20-302 Unexpected reset on the embedded fax PWB due to hardware or software error. 20-305 Unrecoverable fax system low memory due to hardware or software error
20-303 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, using the NVM save and restore
death or injury. Moving parts can cause injury. tool on the PWS. Refer to Portable Work Station and Tools, GP 5.
Make a backup of the phone book and the customer settings, using the NVM save and restore
tool on the PWS. Refer to Portable Work Station and Tools, GP 5. 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. Perform SCP 6 Final Actions.
Y N
Perform SCP 6 Final Actions. (W/O TAG X-001) The compact flash, PL 20.10 Item 3 is installed correctly.
Y N
Clear the fax card NVM. Go to dC132, select Embedded Fax NVM initialization and perform Remove, then re-install the compact flash memory, PL 20.10 Item 3. If necessary install a
the routine, Reformat. The fault is cleared. new compact flash memory, PL 20.10 Item 3.
Y N
Reload the software, GP 4. The fault is cleared. Clear the images from the embedded fax PWB. Go to dC132 NVM Initialization. Select Embed-
Y N ded Fax NVM Initialization. Perform the routine, Reformat. The fault is cleared.
Go to the 20G Embedded Fax Checkout RAP. Y N
Go to dC132 fax card NVM initialization. Perform the routine Reformat. The fault is
Perform SCP 6 Final Actions. cleared.
Y N
Perform SCP 6 Final Actions. Reload the software GP 4. If the fault remains, install a new embedded fax PWB, PL
20.10 Item 4.

20-320 Fax Fault Not Cleared RAP 20-322 Fax Non-Volatile Device not Present RAP
20-320 After five instances of an unrecoverable fax fault and has not been cleared by a card 20-322 The non-volatile device has not been installed on the embedded fax PWB.
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, using the NVM save and restore
Make a backup of the phone book and the customer settings, using the NVM save and restore tool on the PWS. Refer to Portable Work Station and Tools, GP 5.
tool on the PWS. Refer to Portable Work Station and Tools, GP 5.
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
(W/O TAG X-001) The compact flash, PL 20.10 Item 3 is installed correctly.
(W/O TAG X-001) The compact flash, PL 20.10 Item 3 is installed correctly. Y N
Y N Remove, then re-install the compact flash memory, PL 20.10 Item 3. If necessary install a
Remove, then re-install the compact flash memory, PL 20.10 Item 3. If necessary install a new compact flash memory, PL 20.10 Item 3.
new compact flash memory, PL 20.10 Item 3.
Clear the fax card NVM. Go to dC132, NVM Initialization. Select Embedded Fax NVM initialisa-
Clear the fax card NVM. Go to dC132 NVM Initialization. Select Embedded Fax NVM initialisation. Perform the routine, Reformat. The fault still occurs.
tion. Perform the routine, Reformat. The fault is cleared. Y N
Perform SCP 6 Final Actions. (W/O TAG X-001) Compact flash memory, PL 20.10 Item 3.

20-323, 20-324 Fax System Memory Low RAP 20-327 Extended Fax PWB Failure RAP
20-323 The fax system memory is low, less than 6Mb. 20-327 The registers cannot be accessed on the extended fax PWB.
20-324 There is not enough memory to use the fax service. Initial Actions
Initial Actions
WARNING
tool on the PWS. Refer to Portable Work Station and Tools, GP 5. Procedure
Procedure 1. Switch off the machine, then switch on the machine, GP 14.
Switch off the machine, then switch on the machine, GP 14. The fault still occurs. 2. Check if the extended fax PWB is installed, PL 20.10 Item 2.
Y N
3. Check that the extended fax PWB is connected correctly to the embedded fax PWB.
4. Check that the embedded fax PWB is connected correctly in the riser PWB.
(W/O TAG X-001) The compact flash, PL 20.10 Item 3 is installed correctly. 5. If an extended fax PWB has just been installed and the Fax continues to reset with an
Y N error message. Perform the following:
Remove, then re-install the compact flash memory, PL 20.10 Item 3. If necessary install a a. Remove the extended fax PWB from the embedded fax PWB and install the embed-
new compact flash memory, PL 20.10 Item 3. ded fax PWB back into the machine.
b. Complete the removal procedure in 22-417 Embedded Fax Remove Failure RAP.
tion. Perform the routine, Reformat. The fault still occurs. c. Remove the embedded fax PWB and install the extended fax PWB onto it.
Y N d. Install the embedded fax PWB and extended fax PWB and complete the install pro-
Perform SCP 6 Final Actions. cedure.
6. If necessary, install a new extended fax PWB, PL 20.10 Item 2.
(W/O TAG X-001) Compact flash memory, PL 20.10 Item 3.

20-331, 20-339, 20-341 Fax Network Line 1 Fault RAP 20-332, 20-340 Fax Network Line 2 Fault RAP
20-331 No communication via the PSTN 1 port. 20-332 No communication via the PSTN 2 port.
20-339 Fault at fax port 1 on the fax card. 20-340 Fault at port 2 on the extender fax PWB.
20-341 Miscellaneous faults on the embedded fax PWB. Initial Actions
Initial Actions
WARNING
Procedure
WARNING
Do not touch the test pads on the embedded fax PWB while the machine is switched on.
Dangerous voltages may be present that could cause death or injury.
Y N
Make a backup of the phone book and the customer settings, using the NVM save and restore Perform SCP 6 Final Actions.
Check the connection pins on the extended fax PWB, GP 7. The pins are good.
Procedure Y N
Install a new extended fax PWB, PL 20.10 Item 2.
Y N Check that the customer line is operational, plug a phone into the line and check for a dial tone.
Perform SCP 6 Final Actions. If a phone is not available then use a line test tool, PL 26.10 Item 3. The phone line connec-
tion is good.
(W/O TAG X-001) Check the connection pins on the extended Fax PWB, GP 7. The pins are Y N
good. The telephone line has a fault, advise the customer to have the line checked by the tele-
Y N phone company.
Install a new extended fax PWB, PL 20.10 Item 2.
Check that the customer line is operational, plug a phone into the line and check for a dial tone. Telephone cable, PL 20.10 Item 8.
If a phone is not available then use a line test tool, PL 26.10 Item 3. The phone line connec- Embedded fax PWB, PL 20.10 Item 4.
tion is good.
Y N
The telephone line has a fault, inform the customer to have the line checked by the tele-
phone company.

Telephone cable, PL 20.10 Item 8.

20-342 Fax File Integrity Fault RAP 20-701 Fax Phone Book Download Failed Entry RAP
20-342 An error has occur when accessing the file on a non-volatile device. 20-701 The fax phone book down load failed.
Initial Actions Procedure

(W/O TAG X-001) 20-701A Fax Phone Book Download Failed RAP (W/O TAG X-001).
WARNING
(W/TAG X-001) 20-701B Fax Phone Book Download Failed RAP (W/TAG X-001).
Procedure
Y N
Y N
Remove, then re-install the compact flash memory, PL 20.10 Item 3. If necessary install a
Clear the fax card NVM. Go to dC132 NVM Initialization. Select Embedded Fax NVM initialisa-
tion. Perform the routine, Reformat. The fault is cleared.
Y N

20-701A Fax Phone Book Download Failed RAP (W/O TAG 20-701B Fax Phone Book Download Failed RAP (W/TAG X-
X-001) 001)
WARNING WARNING
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 20- Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 20-
701 Fax Phone Book Download Failed Entry RAP. 701 Fax Phone Book Download Failed Entry RAP.
Check that the embedded fax PWB is correctly grounded. Ensure that the grounding strip, Check that the embedded fax PWB is correctly grounded. Ensure that the grounding strip,
PL 20.10 Item 7 is securely attached to the bracket of the embedded fax PWB. PL 20.10 Item 7 is securely attached to the bracket of the embedded fax PWB.
Make a backup of the phone book and the customer settings, using the NVM save and Make a backup of the phone book and the customer settings, using the NVM save and
restore tool on the PWS. Refer to Portable Work Station and Tools, GP 5. restore tool on the PWS. Refer to Portable Work Station and Tools, GP 5.
Procedure Procedure
Switch off the machine, then switch on the machine, GP 14. The fault still occurs. Perform the following:
Y N 1. Reload the machine software, GP 4.
2. Install a new single board controller, PL 3.24 Item 3.
Retry to download the fax phone book. The phone book downloads.
Y N
Check the connection between the embedded fax PWB, PL 20.10 Item 4 and the riser
PWB, PL 3.22 Item 3. The connections are good.
Y N
The fault still occurs.

Y N
Install a new compact flash memory, PL 20.10 Item 3. If the fault remains, reload the
machine software, GP 4.

20-710, 20-711 Image Overwrite Error Entry RAP 20-710A, 20-711A Image Overwrite Error RAP (W/O TAG X-
20-710 Immediate image overwrite error has occurred on the fax card when overwriting the 001)
job.
Initial Actions
20-711 On demand image overwrite error has occurred on the fax card when overwriting the
compact flash memory.
WARNING
(W/O TAG X-001) 20-710A, 20-711A Image Overwrite Error RAP (W/O TAG X-001).
(W/TAG X-001) 20-710B, 20-711B Image Overwrite Error RAP (W/TAG X-001). 710, 20-711 Image Overwrite Error Entry RAP.
Make a backup of the phone book and the customer settings, using the NVM save and
restore tool on the PWS. Refer to Portable Work Station and Tools, GP 5.
Procedure
Y N
Y N
Remove, then re-install the compact flash memory, PL 20.10 Item 3. If necessary install a
tion. Perform the routine, Reformat. The fault still occurs.
Y N

Compact flash memory, PL 20.10 Item 3.

20-710B, 20-711B Image Overwrite Error RAP (W/TAG X- 20A Fax Entry RAP
001) Use this RAP to isolate components which contribute to Fax communications failure.
WARNING WARNING
Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 20- Check that the telephone line cables are properly connected. Fax line 1 from the tele-
710, 20-711 Image Overwrite Error Entry RAP. phone line outlet connects to line 1 socket on the machine. If fitted, fax line 2 from the
Make a backup of the phone book and the customer settings, using the NVM save and telephone line outlet connects to line 2 socket on the machine, Figure 1.
restore tool on the PWS. Refer to Portable Work Station and Tools, GP 5. Use a hand set to dial remote number and listen to dial type, (tone / pulse)
(W/O TAG X-001 machines only) Perform 20H Embedded Fax PWB Voltage Checkout.
Procedure Check the ground connection on the embedded fax PWB. Go to the 01A Ground Distribu-
Switch off the machine, then switch on the machine, GP 14. The fault still occurs. tion RAP and refer to figure 16 and figure 17.
Y N Check the Fault History. If the fault codes are 20-331, 20-339, 20-341 or 20-332, 20-340,
Perform SCP 6 Final Actions. then go to the appropriate RAP.
Check the Fax setup for any active feature that would inhibit the sending of a fax, such as:
Clear the fax card NVM. Go to dC132, NVM Initialization. Select Embedded Fax NVM initialisa- Delayed start time, Local name and ID are set, Dialing type or junk fax prevention.
tion. Perform the routine, Reformat. The fault still occurs.
Enter Tools / Fax Setup and check the following:
Y N
Perform SCP 6 Final Actions. Country setting
Line Selection
Perform an Altboot, GP 4. The fault still occurs. Line Configuration
Y N Dial type setting, tone / pulse.
Enter dC109 Embedded Fax Protocol Report and check for error codes.
Install new components as necessary: Enter Tools / Fax Setups / Fax Reports. Print a Activity Report and check for error codes.
Embedded fax PWB, PL 20.10 Item 4. Procedure
Single board controller PWB, PL 3.24 Item 3. The Fax tab is available
Y N
Go to the 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 the 20B Unable To Send A Fax RAP.
Go to the 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.

20-710B, 20-711B, 20A 2-582 Xerox WorkCentre 5790 Family
Y N 20B Unable To Send A Fax RAP
Go to the 20E Fax Will Not Print RAP.
Use this RAP to isolate components which contribute to a send failure.
The fault is cleared.
Y N Initial Actions
Go to the 20G Embedded Fax Checkout RAP.
The fax is working correctly. Send a three page test fax to a known good fax machine. Print a WARNING
Protocol Report and check for errors. Ensure that the electricity to the machine is switched off while performing tasks that do
Line 1 socket
WARNING
Do not touch the test pads on the embedded fax PWB while the fax cable is connected
to the machine. Dangerous voltages may be present that could cause death or injury.
Go to the 20A Fax Entry RAP and complete all of the initial actions.
Procedure
Line 2 socket
(W/O Tag X-001 only) NOTE: Refer to the Fax NVM Document for the fax NVM values.
Verify with the customer that PSTN / PABX (Public Switched Telephone Network / Private
Automatic Branch Exchange) line is operational. Connect a telephone handset into line outlet
and listen for a dial tone. Use a known good telephone handset. The dial tone is present.
Y N
Use the line test tool, PL 26.10 Item 3 to check the telephone line. The green normal
indicator light is on.
Y N
Ask the customer to request a line check by the telephone company.
Figure 1 Line 1 and line 2 sockets Use a telephone handset to dial a known good number. The ring back is heard.
Y N
Ask the customer to request a line check by the telephone company.
Enable audio line monitor (Enter Tools / Fax setups / Fax Transmission defaults / audio
line monitor) and set to ON 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) Reset the NVM value at the following locations:
20-281 Line1CurrentDetect = 0
20-282 Line2CurrentDetect = 0 A Fax tone is present.
Y N
Go to the 20G Embedded Fax Checkout.
The fax is working correctly. Send a three page test fax to a known good fax
machine. Print a Protocol Report and check for errors.
A B

A B C
The dial tone and dialling answer tones are present. Reset the values at location 20-230 FaxLine1DialTypeDef and at location 20-231
Y N FaxLine2DialTypeDef set to 0 = Tone or 1 = Pulse.
The exchange is receiving the digits too quickly or is not processing the digits cor- Insert a pause (,) between the first and second digit of the dial string. In the Dialling
rectly. Ask the customer if the exchange is DTMF (Dual Tone Multiple Frequency) or Options select Dialling Characters / Pause / Add Character / Save.
pulse dialing.
Set NVM Location 20-621 FaxTimeBeforeDial to 13.
Ensure that the machine is set for the correct dialing tone. The fax only dials once and hangs up or the busy tone has unusual timing, frequency or level.
Reset the values at location 20-230 FaxLine1DialTypeDef and at location 20- Are the busy tones recognized.
231 FaxLine2DialTypeDef set to 0 = Tone or 1 = Pulse. Y N
Insert a pause (,) between the first and second digit of the dial string. In the Check the number for a voice or tone answer.
Dialling Options select Dialling Characters / Pause / Add Character / Save. Check that the values at location 20-461 to 20-466 are set to the correct defaults to
match the appropriate country setting.
The fax only dials once and hangs up or the busy tone has unusual timing, frequency or
level. The busy tones are recognized. The fax is working correctly. Send a three page test fax to a known good fax machine. Print a
Y N Protocol Report and check for errors. Re-enter the details from the fax options
Check the number for a voice or tone answer.
Check that the values at location 20-461 to 20-466 are set to the correct defaults to
match the appropriate country setting.
The fax is working correctly. Send a three page test fax to a known good fax machine.
Print a Protocol Report and check for errors. Re-enter the details from the fax options
Check that the customer is dialing the correct number. The number is correct.
Y N
Ask the customer to dial the number using the appropriate access codes.
Enable audio line monitor (Enter Tools / Fax setups / Fax Transmission defaults / audio line
monitor) and set to ON max time 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) Reset the value at the following locations:
20-281 Line1CurrentDetect = 0
20-282 Line2CurrentDetect = 0 A Fax tone is present.
Y N
Go to the 20G Embedded Fax Checkout.
Print a Protocol Report and check for errors.
The dial tone and dialling answer tones are present.

Y N
The exchange is receiving the digits too quickly or is not processing the digits correctly.
Ask the customer if the exchange is DTMF (Dual Tone Multiple Frequency) or pulse dial-
ing.
Ensure that the machine is set for the correct dialing tone.
C
A
20C Unable To Send A Fax To Some Machines RAP The Protocol Report shows MCF (Message Confirmation) is not sent by the remote Fax (last
page), only DCN (Disconnect). The failure report printed out but the remote fax prints mul-
Use this RAP to isolate components which contribute to a failure to send a Fax to some
tiple copies of the job or failed page.
machines.
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 Tools / Fax Setups / Fax Transmission Defaults / Automatic Resend. Set Auto Resend
Ensure that the electricity to the machine is switched off while performing tasks that do Attempts to 1 or 2.
Procedure
NOTE: Refer to the Fax NVM Document for the fax NVM values.
The correct number is being dialled to make the connection. The connection is made.
Y N
The exchange is not processing the digits correctly, the machine needs longer pause
between digits.
Insert a pause (,) between the first and second digit of the dial string. In the Dialling
Options select Dialling Characters / Pause / Add Character / Save.
Change the setting at location 20-640 FaxDTMFInterdigitTime 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 dC109 and print a Protocol 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). Reset the value at the following locations:
20-287 T30MaxSpeedL1Tx = 11 (14400).
20-288 T30MaxSpeed2Tx = 11 (14400).
(W/O TAG X-001) If mains noise, install and use line 2 instead of line 1.
(W/O TAG X-001) When sending to a PC fax or fax server that has an ISDN card,
need to customize the CEQ values. Set the value at location 20-832 and 20-833 to 0.

A
20D Unable To Receive A Fax RAP 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.
Use this RAP to isolate components which contribute to the fax not received from the machine.
Y N
Print Activity Report. Check for receive calls on the Activity Report. Machine probably
Initial Actions does not bleep to indicate incoming call.
Check that the NVM values at location 20-222 and at location 20-654 to 20-658 are set to
the correct defaults to match the appropriate country setting. The machine answers and
WARNING a Fax tone is heard.
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Go to the 20G Embedded Fax Checkout
(W/O TAG X-001) Compact flash memory, PL 20.10 Item 3.
WARNING
Do not touch the test pads on the embedded fax PWB while the fax cable is connected The Fax is working correctly. Send a three page test Fax to a known good Fax machine.
to the machine. Dangerous voltages may be present that could cause death or injury. Print a Protocol Report and check for errors.
Receive a three page test Fax from the original Fax machine. Enter dC109 and print a Protocol
Report and check for errors. The Protocol Report shows communication failure after CSI /
Procedure DIS (Called Subscriber Identified / Digital Identification Signal) or DCS / TCF (Digital
NOTE: Refer to the Fax NVM Document for the fax NVM values. Command Signal / Training Check) or (W/O TAG X-001) after V34-PH2 / V34-PH3 or EQM
(Eye Quality Monitor) value greater than 5000.
Verify with the customer that PSTN / PABX (public switched telephone network / private auto- Y N
matic branch exchange) line is operational. Use a known good telephone handset or use the The problem may be intermittent, inform the operator of the remote machine, they should
line test tool, PL 26.10 Item 3 to check the telephone line. The dial tone is present. report the problem to the telephone company.
Y N
Ask the customer to request a line check by the telephone company. Perform the following:
Ensure Fax service is enabled and supported on that line by a PBX administrator. Confirm line is standard PSTN / PBX analogue line
Line quality too poor for Super G3 or G3 to function correctly. Possible mains interference
Call the handset from another telephone. The phone rings.
on line. Possible DSL line, not properly filtered.
Y N
Ask the customer to request a line check by the telephone company. Ask customer to request Fax capable service from telephone company.
Ensure Fax service is enabled and supported on that line by a PBX administrator. If mains noise, install a (W/O TAG X-001) embedded fax PWB, PL 20.10 Item 4 and an
extended fax PWB, PL 20.10 Item 2. Use line 1.
Enable audio line monitor (Enter Tools / Fax Setups / Fax Transmission defaults / audio line Disable the advanced fax features. Login to Customer Administration Tools, GP 24.
monitor) and set to ON and High volume. Select Fax Setups / Receive Defaults / Advanced Capabilities / Disable.
Dial the Fax number and listen for a dial tone or dialing and answer tones. A Fax tone is Disable V34 (Super G3). Reset the value at the following locations:
present.
20-289 T30MaxSpeedL1Rx = 11 (14400)
Y N
(W/O TAG X-001) Reset the value at the following location: 20-290 T30MaxSpeedL2Rx = 11 (14400)
20-281 Line1CurrentDetect = 0 If the problem still exists try a lower line receive (Rx) speed: 12 = 12000, 13 = 9600, 14 =
20-282 Line2CurrentDetect = 0 A Fax tone is present. 7200, 15 = 4800, 16 = 2400
Y N Send a three page test Fax from a known good fax machine. Enter dC109 and print a Pro-
Go to 20G Embedded Fax Checkout tocol Report and check for errors.
Enter dC109 and print a Protocol Report and check for errors.
A
20E Fax Will Not Print RAP 20F Fax Tab Not Available RAP
Use this RAP to solve fax printing problems. Use this RAP to isolate the problem when the Fax tab is not available or greyed out.
Initial Actions
Initial Actions
WARNING
WARNING
Check for the correct installation of the embedded fax option. Refer to the system admin-
Check that the paper trays are loaded with the appropriate paper sizes for printing the istration guide CD1, for the install instruction. Follow the screen prompts.
Fax.
Procedure
Procedure The Fax tab is displayed on the user interface screen.
Y N
If the received fax has mixed size documents (example, the first prints are 8.5 x 11 and
then followed by 8.5 x 14 prints). Check in the All Incomplete Jobs queue, the job will The fax installation was not completed.
Go to Tools / Options services / Embedded Fax. Select Enable and Save. Switch off the
print 8.5 x 11 pages without printing 8.5 x 14 pages and then the job will be deleted.
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. If the procedure fails to
In Tools menu, go to Fax setup and select: result in the Fax tab being displayed, perform a forced AltBoot.
Receive Defaults.
The Fax tab is displayed after installation.
Receive Printing mode and change to Manual. Y N
In paper sizes, select correct page for each size to match the paper in the tray. Check that the embedded fax PWB and the (W/O TAG X-001) compact flash memory are
Save and then change back to Auto. Save and Exit. installed correctly. Perform the following:
If the User Interface is asking for a size paper that is not loaded in trays. 1. Switch off the machine, GP 14.
Perform the following: 2. (W/O TAG X-001) Remove, then install the compact flash card.
In Tools menu, go to Fax setup and select: 3. Check the following connections:
Receive Defaults. Between the embedded fax PWB, PL 20.10 Item 4 and the riser PWB, PL 3.22
Item 1.
Receive Printing mode.
Between the single board controller PWB, PL 3.24 Item 3 and the riser PWB,
Select manual, change small paper setting to None and Save.
PL 3.22 Item 1.
NOTE: For small, long and large paper sizes select NONE if the corresponding 4. Switch on the machine, GP 14.
paper is not loaded in the paper trays.
The super fine tab is displayed.
Change setting to Auto and Save. Y N
The Server Fax may be enabled.
Go to Tools / Optional Services / Embedded Fax and press enable Embedded Fax. 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 fitted).
Y N
The fax is installed correctly. Send a three page test fax to a known good fax machine.
Print a Protocol Report and check for errors.
Perform an AltBoot, GP 4.
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.

Xerox WorkCentre 5790 Family 2-587 20E , 20F
20G Embedded Fax Checkout Y N
Return to the original fault code RAP and perform the remaining actions in the procedure.
Use this RAP to check for problems with the embedded Fax PWB.
Initial Actions
Single board controller

WARNING PWB
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Riser PWB
Embedded fax
PWB
WARNING
Check that the embedded fax PWB is located correctly, Figure 1.
Check that the embedded fax PWB is correctly grounded. Ensure that the grounding strip,
PL 20.10 Item 7 is securely attached to the bracket of the embedded fax PWB.
(W/O TAG X-001) If an extended fax PWB has just been installed and the fax continues to
reset with an error message. Refer to 20-327 Extended Fax PWB failure RAP
For copy quality defects, go to the IQ9 Unacceptable Received Facsimile Image Quality
RAP.
Procedure
Go to Flag 1. Check the voltages at P/J155. The voltages are good.
Y N
Refer to the following:
01D +3.3V Distribution RAP
If necessary install a new riser PWB, PL 3.22 Item 3.
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.
Check that the connectors are clean and not damaged. If the connectors are damaged then
install new components as necessary:
Reconnect the following:
The riser PWB to the single board controller PWB.
The embedded fax PWB to the riser PWB.
Switch on the machine, GP 14. The fault is cleared.

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
image quality defects are caused by electrical noise on the line.
Procedure
WARNING
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 a fax.
2. Disconnect the fax cable from the single board controller PWB.
3. Remove the embedded fax PWB, PL 20.10 Item 4.
4. Remove the safety cover, PL 20.10 Item 1 and the lower cover, PL 20.10 Item 5.
5. If installed, remove the extended fax PWB, PL 20.10 Item 2.
6. Install the embedded fax PWB.
7. Connect the fax cable.
8. Switch on the machine, GP 14.
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.
a. For line 1. Measure between test pad 1 and test pad 2 and between test pad 2 and
test pad 3, Figure 1.
b. 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 01A Ground Distribution RAP.
If the machine ground connections are good, request that the customer has the power
outlet socket checked.

Xerox WorkCentre 5790 Family 2-589 20G, 20H
20J Fax Problems on Digital Networks RAP
Use this RAP to isolate the problem when using digital networks.
Line 1 test pads 1, 2 and 3 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
Line 2 test pads 4, 5 and 6
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
Figure 1 Line 1 and line 2 test pads
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

1. Perform the 20A Fax Entry RAP.
2. Request the latest SPAR release.
3. If a communication fault occurred while sending the fax, decrease the transmission speed
by disabling V34 (Super G3).
4.Reset the value at the following locations:
20-287 T30MaxSpeedL1Tx = 11 (14400)
20-288 T30MaxSpeedL2Tx = 11 (14400)
20-289 T30MaxSpeedL1Rx = 11 (14400)
20-290 T30MaxSpeedL2Rx = 11 (14400)
5. If problems are still not resolved after these actions, then escalate the problem using the
normal escalation process.

20H, 20J 2-590 Xerox WorkCentre 5790 Family
22-300 AHA End of Record Error RAP
22-300 AHA end of record error (Advanced Hardware Architecture). Registration
guide
Initial Actions
WARNING
Halo guide
Clear obstructions from the paper path.
Re-seat all connectors on the single board controller PWB, PL 3.24 Item 3. Re-seat the
software module, PL 3.24 Item 8 and memory module, PL 3.24 Item 12.
Procedure
2. Figure 1. Check the conductive path between the transfer / detack corotron halo guide
and the bias contact, PL 8.15 Item 23. A bad contact can cause a corrupted image on the
print.
3. Measure the resistance between the registration chute and the halo guide. If more than
10 ohms is measured, install a new bias contact, PL 8.15 Item 23.
4. Clean the transfer / detack corotron and check for signs of arcing, ADJ 9.1.
5. Check and if necessary clean the area of the halo guide, registration guide.
Check the bias contact, connection.
Check that the bias is available at the halo guide while the machine is in run mode.
For the voltage range of the registration chute bias, refer to 09-060 HVPS Fault RAP.
6. Xerographic contamination may be caused by the failure of the scorotron cleaner, go to
the 09-341, 09-342 Scorotron Cleaning Failure RAP.
NOTE: If the fault has been caused by contamination and showing a CQ defect of band-
ing on the prints. Check the fuser module stripper fingers for contamination. If necessary
clean the stripper fingers or install a new stripper fingers (35-55 ppm) PL 10.8 Item 4, (65- Registration chute
Transfer/detack
90 ppm) PL 10.10 Item 4. bias connection
corotron
7. Check the machine fault history for other fault codes that occurs around the same time as Bias contact
the 22-300 fault code and follow the related RAP.
8. If 22-300 codes persist, the jobs may be beyond the capabilities of the machine. Request
the customer to select job parameters that are within the capabilities of the machine. Figure 1 Component location
9. If a 22-300 fault code occurs. There are paper jams on the short paper path and the cop-
ies have half the print and black lines on them. The cause can be because of the ROS
corrupting the video data lines. Install a new ROS, PL 6.10 Item 4.

22-306 to 22-315, 22-801, 22-814 System Error RAP 22-316, 22-810, 22-820 Capability That Does Not Exist RAP
22-306 No proposal for rejection. 22-316 Job requires a paper tray that does not exist. Job terminated.
22-307 Reschedule Error. Can not find reschedule point for rejection. 22-810 Job required IOT capability that does not exist. Job terminated.
22-309 No accept time out error. Consecutive no accepts received from a module exceeds the 22-820 Job required finishing capability that does not exist. Job terminated.
threshold value (20). Five consecutive 22-309s will cause a 22-819.
Procedure
22-310 Image sequence error. Job terminated. Perform the following:
1. Resend the job with acceptable instructions that are within the capabilities of the machine.
22-315 Module completion no response fault. One or more modules did not respond with com-
pletion message. 2. If the error recurs, switch off the machine, then switch on the machine, GP 14.
22-801 Module completion message received after IOT returned to standby.
22-814 Module registration late error. Module registration message received beyond required
time window.
Initial Actions
WARNING
Check for and clear any obstructions in the paper path.
Procedure
1. If a 22-315 fault code is displayed, go to the 06-340 ROS Laser Failure RAP.
2. If the problem persists, the jobs may be beyond the capabilities of the machine. Request
the customer select job parameters that are within the capabilities of the machine.

22-306 to 22-315, 22-801, 22-814, 22-316, 22-810, 22- 2-592 Xerox WorkCentre 5790 Family
22-370 Cannot Communicate to the XSA Database RAP 22-400 to 22-403, 22-423, 22-426, 22-427, 22-775 Option
22-370 A loss of data communications on the single board controller. Install Failure RAP
22-400 The system manager failed to install the network scanning (scan to file) option.
The Xerox Standard Accounting (XSA) feature will only be available on a System Terminal (ST)
devices. The administrator enables the feature through the machine user Interface or by a Web
22-401 The system manager failed to install the server fax option.
user interface.
22-402 The system manager failed to install the E-mail (scan to E-mail) option.
Procedure
Perform the following: 22-403 The system manager failed to install the internet fax option.
2. Perform an Altboot, GP 4. 22-423 The system manager failed to install the searchable fire format option.
22-426 The system manager failed to install the common access card (CAC) option.
22-427 The system manager failed to install the colour scan option.
22-775 The system manager failed to install the CPSR file cabinet option.
Procedure
2. Reinstall the failed option. Refer to the system administration guide CD1, for the install
instruction. Enter the kit option number found in the software options kit.

Xerox WorkCentre 5790 Family 2-593 22-370, 22-400 to 22-403, 22-423, 22-426, 22-427, 22-
22-404 to 22-406 Option Install Failure RAP 22-407 Embedded Fax Install Failure RAP
22-404 The system manager failed to install the network accounting (JBA) option. 22-407 The system manager failed to install the embedded fax option.
22-405 The system manager failed to install the on demand image overwrite option. Initial Actions
22-406 The system manager failed to install the immediate image overwrite option.
WARNING
Perform the following: 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. death or injury. Moving parts can cause injury.
2. Reinstall the failed option. Refer to the system administration guide CD1, for the install Check if the Fax tab is greyed out.
instruction. Enter the kit option number found in the software options kit. Check that the compact flash is installed correctly.
Procedure
3. Reinstall the embedded fax option. Refer to the system administration guide, CD1 for the
installation instructions. Follow the screen prompts.

22-404 to 22-406, 22-407 2-594 Xerox WorkCentre 5790 Family
22-410 to 22-416, 22-423, 22-425, 22-428, 22-777 Option 22-417 Embedded Fax Remove Failure RAP
Remove Failure RAP 22-417 The system manager failed to remove the embedded fax option.
22-410 The system manager failed to remove the network scanning (scan to file) option. Procedure
22-411 The system manager failed to remove the server fax option.
WARNING
22-412 The system manager failed to remove the E-mail (scan to E-mail) option.
22-413 The system manager failed to remove the internet fax option. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
22-414 The system manager failed to remove the network accounting (JBA) option. Perform the following:
22-415 The system manager failed to remove the on demand image overwrite option. 2. To remove the option perform the following:
a. Enter Customer Administration Tools, GP 24.
22-416 The system manager failed to remove the immediate image overwrite option.
b. Select Optional Services.
22-424 The system manager failed to remove the searchable fire format option. c. Select the option to be disabled.
d. Select Disable.
22-425 The system manager failed to remove the common access card (CAC) option.
NOTE: An option must be disabled before it can be removed.
22-428 The system manager failed to remove the colour scan option. e. Select Save.
f. Wait for the screen to refresh and select the failed option.
22-777 The system manager failed to remove, disable and delete CPSR file cabinet option.
g. Select Remove.
Procedure h. Select Save.
Perform the following: i. Select Confirm.
1. Switch off the machine, then switch on the machine, GP 14. j. Select Exit Tools.
2. To remove the option perform the following: k. The machine system reboots.
a. Enter Customer Administration Tools, GP 24. After the machine system reboot. A Fax Install window appears and the options are
to View Install Information, Install now or Install later. Select the option required.
l. The machine will reset with the new configuration. When complete the optional fea-
c. Select the option to be disabled.
ture removed will not appear in the machine user interface screen.
d. Select Disable.
3. If the embedded fax remove failure still occurs, go to dC132 NVM initialization and select
NOTE: An option must be disabled before it can be removed. All Copier NVM and reset the NVM.
4. If the embedded fax PWB is to be removed from the machine. Switch off the machine, GP
e. Select Save
14. Remove the embedded fax PWB. Switch the machine on, GP 14.
f. Wait for the screen to refresh and select the failed option.
g. Select Remove
a. An Options not detected window appears.
h. Select Save
b. Select SA confirm.
i. Select Confirm
c. Enter password (1111).
j. Select Exit Tools
d. Select Enter.
k. The machine system reboots.
e. Select line 1 fax card.
l. The machine will reset with the new configuration. When complete the optional fea-
f. Select Confirm removal of selected option.
g. Repeat for line 2 fax card.
3. If the fault persists, reload the software, GP 4.
h. Select Confirm removal of selected option.
i. Select Confirm.
j. Select Save.

Xerox WorkCentre 5790 Family 2-595 22-410 to 22-416, 22-423, 22-425, 22-428, 22-777, 22-
22-419 Embedded Fax Enable Failure RAP 22-421 Embedded Fax Disable Failure RAP
22-419 The system manager failed to enable embedded fax option. 22-421 The system manager failed to disable embedded fax option.
Procedure Procedure
WARNING
2. To disable the option perform the following:
death or injury. Moving parts can cause injury. b. Select Optional Services.
Perform the following: c. Select the Embedded fax.
1. Switch off the machine, then switch on the machine, GP 14. d. Select Disable.
2. Go to 20G Embedded Fax Checkout. e. Select Save
3. To enable the option perform the following: f. Select Exit Tools
a. Enter Customer Administration Tools, GP 24. g. The machine will reset with the new configuration. When complete the optional fea-
3. If the embedded fax disable failure still occurs. Go to dC132 NVM initialization and select
c. Select the Embedded fax.
All Copier NVM and reset the NVM.
d. Select Enable.
e. Select Save
f. Select Exit Tools
g. The machine will reset with the new configuration. When complete the optional fea-

22-450 Test Pattern Standard Grey Level Too High RAP 22-451 Test Pattern Average Grey Level Too Low RAP
22-450 The image quality adjustment routine has determined that the test pattern standard 22-451 The image quality adjustment routine has determined that the average grey level of the
deviation is too high. The standard deviation of the grey levels of the test pattern as scanned test pattern is too low. The grey part of the test pattern as measured by the scanner is too dark
by the scanner is too high. (i.e. low grey levels = dark). If this fault occurs the (IQA) image quality adjustment factor will not
be readjusted and stay as it is.
Initial Actions
Load A4 (8.5x11 inch) white paper LEF in the bypass tray. Initial Actions
Load A4 (8.5x11 inch) white paper LEF in the bypass tray.
Procedure
Run print samples using a test pattern and inspect the copy quality. All copy quality defects Procedure
must be rectified before running the image quality adjustment routine. Streaks and non-uniform Perform the following:
halftone prints can cause the code to be shown. 1. Make print samples and if the images are dark or black refer to IQ1 Image Quality Entry
RAP to resolve image quality defects for dark or black images.
Take print samples to check image quality. Refer to IQ1 Image Quality Entry RAP to resolve 2. Check that the image quality adjustment factor in the NVM is not too high causing the
image quality defects.
ROS to have a high level output and very dark test pattern. Enter dC131 location 06-04
image quality adjustment factor and reset value to 100. Reboot the machine and repeat
the ADJ 9.2 Image Quality Adjustment Routine.
3. Check in dC131 location 06-01 ROS light level, is correct and not set high. Enter dC131
location 06-01 ROS light level and reset value to default. Reboot the machine and repeat
4. Check that the developer bias is not set high. Enter dC131 location 09-021 developer bias
print level and reset value to default.
5. If the fault still occurs the ROS output level may be too high. Go to the RAP 03-395, 396,
852, 853 IOT PWB Fault RAP.

22-452 Test Pattern Average Grey Level Too High RAP 22-760 IQA Factor Set to Maximum RAP
22-452 The image quality adjustment routine has determined that the average grey level of the 22-760 The (IQA) image quality adjustment factor has been set to the maximum value (dark).
test pattern is too high. The grey part of the test pattern as measured by the scanner is too light The fault will occur if the test pattern is light, but not light enough to create a 22-452 fault. This
(i.e. high greys levels = light). If this fault occurs the (IQA) image quality adjustment factor will may result in subsequent image quality being too dark, as the ROS output level may be too
not be re-adjusted and will stay as it is. Subsequent IQ will not be altered. high. Check in fault history to find a 22-760 failure.

Load A4 (8.5x11 inch) white paper LEF in the Bypass Tray. Load A4 (8.5x11 inch) white paper LEF in the Bypass Tray.
Procedure Procedure
Perform the following: Perform the following:
1. Check that the test pattern was fed through the document handler the correct way up. 1. Check that the test pattern was fed through the document handler the correct way up.
2. Make print samples and if the images are light or white refer to IQ1 Image Quality Entry 2. Make print samples and if the images are light or white refer to the IQ1 Image Quality
RAP to resolve image quality defects for light or white images. Entry RAP to resolve image quality defects for light or white images.
3. Check that the image quality adjustment factor in the NVM is not too low causing a high 3. Check that the image quality adjustment factor in the NVM is not too, low causing high
ROS light level output, and very light test pattern. Enter dC131 location 06-04 (IQA) ROS light level output, and very light test pattern. Enter dC131 location 06-04 (IQA)
image quality adjustment factor, reset value to 100. Reboot the machine and repeat the image quality adjustment factor, reset value to 100. Reboot the machine and repeat the
ADJ 9.2 Image Quality Adjustment Routine. ADJ 9.2 Image Quality Adjustment Routine.
4. Check in dC131 location 06-01 ROS light level, is correct and not set low. Enter dC131 4. Check in dC131 location 06-01 ROS light level, is correct and not set low. Enter dC131
location 06-01 ROS light level, reset value to default. Reboot the machine and repeat the location 06-01 ROS light level, reset value to default. Reboot the machine and repeat the
ADJ 9.2 Image Quality Adjustment Routine. ADJ 9.2 Image Quality Adjustment Routine.
5. Check that the developer bias is not set low. Enter dC131 location 09-021 developer bias 5. Check that the developer bias is not set low. Enter dC131 location 09-021 developer bias
print level and reset value to default. print level and reset value to default.
6. If the fault still occurs the ROS output level may be too low. Go to the RAP 03-395, 396, 6. If the fault still occurs the ROS output level may be too low. Go to the RAP 03-395, 396,
852, 853 IOT PWB Fault RAP. 852, 853 IOT PWB Fault RAP.

22-761 IQA Factor Set to Minimum RAP 22-774 CPSR File Cabinet Enable Failure RAP
22-761 The (IQA) image quality adjustment factor has been set to the minimum value (light). 22-774 The system manager failed to enable the CPSR file cabinet option.
The fault will occur if the test pattern is dark, but not dark enough to create a 22-451 fault. This
may result in subsequent image quality being too light, as the ROS output level may be too Procedure
low. Check in fault history to find a 22-761 failure.
Initial Actions
2. To enable the option perform the following:
Load A4 (8.5x11 inch) white paper LEF in the Bypass Tray.
Procedure
c. Select the CPSR File Cabinet.
d. Select Enable.
1. Make print samples and if the images are dark or black refer to the IQ1 Image Quality
Entry RAP to resolve image quality defects for dark or black images. e. Select Save
2. Check that the image quality adjustment factor in the NVM is not too high causing high f. Select Exit Tools
ROS light level output and very dark test pattern. Enter dC131 location 06-04 (IQA) image g. The machine will reset with the new configuration. When complete the optional fea-
quality adjustment factor and reset value to 100. Reboot the machine and repeat the ADJ ture removed will not appear in the machine user interface screen.
9.2 Image Quality Adjustment Routine.
3. Check in dC131 location 06-01 ROS light level, is correct and not set high. Enter dC131
location 06-01 ROS light level and reset value to default. Reboot the machine and repeat
4. Check that the developer bias is not set high. Enter dC131 location 09-021 developer bias
print level and reset value to default.
5. If the fault still occurs the ROS output level may be too high. Go to the RAP 03-395, 396,
852, 853 IOT PWB Fault RAP.

22-776 CPSR File Cabinet Disabled Failure RAP 22-819, 22-831 to 22-837 Time Out Error RAP
22-776 The system manager failed to disable the CPSR file cabinet option. The 22-83x faults occur when the service fails to respond to the job queue request. This is
either because it is busy processing a previous job request, or has failed or locked up.
Procedure
22-819 Cycle up / cycle down loop failure. Job terminated. Can be caused by five consecutive
22-309s.
2. To disable the option perform the following: 22-831 List jobs request timed out between single board controller PWB and user interface.
b. Select Optional Services. 22-832 List jobs request timed out between single board controller PWB and network controller
print service.
c. Select the CPSR File Cabinet.
d. Select Disable. 22-833 List jobs request timed out between single board controller PWB and network controller
e. Select Save scan to file.
f. Select Exit Tools
g. The machine will reset with the new configuration. When complete the optional fea- 22-834 List jobs request timed out between single board controller PWB and network controller
ture removed will not appear in the machine user interface screen. scan to fax / server fax service.
22-835 List jobs request timed out between queue utility and either DC job service or the
embedded fax services.
22-836 Network controller scan to distribution service not responding to List jobs RPC call for
scan to E-mail or for internet fax.
22-837 List jobs request time out between the single board controller PWB and file 2 E-Fax
services.
Initial Actions
WARNING
Check for and clear any obstructions in the paper path.
Check for other fault codes generated about the same time, in case a more relevant fault
code has been generated.
Procedure
2. Go to the fault history, GP 2 and perform the relevant RAP for the fault that occurred prior
to any of the above faults occurring.
3. If the problem persists, the jobs may be beyond the capabilities of the machine. Request
the customer select job parameters that are within the capabilities of the machine.

22-776, 22-819, 22-831 to 22-837 2-600 Xerox WorkCentre 5790 Family
OF1 Audible Noise RAP Main Drives and Paper Transport
Use this RAP to isolate unusual noises in the machine. Enter dC330 code 04-010 main drive motor, to run the main drives.
The following components will be run:
NOTE: Due to the intermittent nature of unusual noises, this RAP can only give guidance on
Registration transport PL 8.15 Item 1.
how to isolate noises. This RAP will not find all possible causes. When machines become old
and worn, unusual noises may arise that are not covered in this RAP. Developer module (35-55 ppm), PL 9.17 Item 2 or (65-90 ppm), PL 9.15 Item 2.
Short paper path assembly, W/O TAG 114, PL 10.25 Item 1.
Procedure Fuser module (35-55 ppm), PL 10.8 Item 1 or (65-90 ppm), PL 10.10 Item 1.
Inverter post fuser and exit rolls and the jam clearance knob 3C rotate.
To isolate the developer module:
WARNING Unlatch the xerographic module to separate the developer from the main drives. If
Ensure that the electricity to the machine is switched off while performing tasks that do the source of the noise is the developer assembly, check the developer drive gear,
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause PL 9.15 Item 16.
death or injury. Moving parts can cause injury. Remove the fuser module to eliminate the noise caused by the fuser. If the source of the
1. Ask the customer if there are any specific machine functions that are noisy. noise is the fuser, go to the Fuser checkout.
2. Ask the customer to demonstrate the function of the machine that generates the unusual To isolate the fuser module:
noise. Release the jam clearance latch 3b4a on the fuser module, to separate the pressure
3. Check the Fault and Error logs. roll from the fuser roll.
4. Switch off the machine, GP 14. Wait for two minutes, switch on the machine. Allow the Enter dC330 code 04-010 and add code 08-070 to energize the registration clutch. The
machine to perform a normal initialization and warm-up. registration rolls and the jam clearance knob 4c rotate.
5. Run the machine in all modes. Also use the diagnostics to run individual components. Go Enter dC330 code 10-065 Vac. transport fan, to run the vacuum transport fan, PL 10.25.
to the relevant subsection: Enter dC330 code 08-060 motor slow or code 08-062 motor fast, to run the duplex trans-
Main Drives and Paper Transport port motor. The duplex transport rolls rotate, (35-55 ppm), PL 8.22 or (65-90 ppm), PL
DADH 8.20.
ROS Enter dC330 code 10-030 Invert Mot Fwd Slow, to rotate the nip split shaft, PL 10.11 Item
Tray 1 and 2 Assembly 4.
Tray 3 and 4 Assembly (W/O TAG 151) Enter dC330 code 10-035 Invert Mot Rev Slow, to rotate the nip split shaft and the jam
Tray 3 and 4 Assembly (W/TAG 151) clearance knob 2b rotates, PL 10.11 Item 4.
Tray 5 Assembly Enter dC330 code 10-040 Invert Mot Rev Duplex, to rotate the nip split shaft and the jam
clearance knob 2b rotates fast, PL 10.11 Item 4.
Xerographics
Enter dC330 code 10-045 Invert Path solenoid, energizes the solenoid and moves the
Fuser
inverter gate, PL 10.11 Item 14.
1K LCSS
Enter dC330 code 10-050 Invert Nip solenoid, energizes the solenoid and moves the nip
2K LCSS
split shaft, PL 10.11 Item 4.
HVF and HVF BM
Possible causes and potential solutions are:
Scanner
Squeaks.
Possible causes are:
Contamination of the drive shafts and the bearings.
Bearings in cooling fans.
Incorrectly adjusted or worn drive belts.
Incorrectly aligned or damaged parts.
Solution:
Clean the components.
Remove and clean the drive shafts, bearings and then lubricate. Refer to ADJ 4.1
Machine Lubrication.
Adjust the components if necessary.
Check for parts that are damaged or out of position.
Install new parts as necessary.

Xerox WorkCentre 5790 Family 2-601 OF1
Squeaks from the duplex tray (65-90 ppm) Solution:
Possible causes are: Install a new the feed assembly, (35 ppm) PL 5.15 Item 18 or (40-90 ppm) PL 5.17
The metal stiffener bracket on the bottom of the duplex tray vibrates against the Item 18.
plastic frame moulding. Noise from the DADH input tray.
Solution: Possible causes are:
Remove the duplex transport, REP 8.7. Document guides.
Remove the metal stiffener bracket and reform the securing edge with the two loca- Solution:
tion holes by 5 degrees. Refit the metal stiffener bracket and ensure that the metal Clean the DADH input tray in the area below the input guides with antistatic fluid, PL
bracket is tight against the plastic frame moulding. 26.10 Item 19.
Clicking. Squeaks from the DADH.
Possible causes are: Possible causes are:
The waste toner auger clutch slipping. This clutch is designed to slip to prevent dam- DADH exit roll assembly or takeaway roll assembly, PL 5.35 Item 6.
age to the auger gear box if toner backs up in the waste pipe.
Solution:
Drive belt slipping on gear/pulley of the short paper path, W/O TAG 114.
Remove and clean the shafts and plastic bushes with antistatic fluid, PL 26.10 Item
Solution: 19.
Remove the waste toner bottle and clean the toner from the waste pipe and the Knocking noise.
auger system. Refer to REP 9.10 Auger Damper.
Install a new drives module, (35-55 ppm), PL 4.15 Item 1, (65-90 ppm), PL 4.10 Item
The feed motor and CVT motor are not tensioned correctly, causing the drive belts to
1. slip.
Install a new intermediate drive belt, PL 10.25 Item 10. Solution:
DADH Adjust the DADH drive belts, ADJ 5.1.
Run the following components: Gear rattle.
Enter dC330 code 05-030 DADH CVT motor to rotate the DADH CVT roll, PL 5.25 Item 5. Possible causes are:
Enter dC330 code 05-020 feed motor, to run the DADH takeaway rolls, PL 5.35 Item 6. A loose meshing of the feed clutch and motor gears (35 ppm) PL 5.15 Item 9 and PL
Enter dC330 code 05-020 and add code 05-025 feed solenoid, to energize the feed 5.15 Item 16 or (40-90 ppm) PL 5.17 Item 9 and PL 5.17 Item 16.
clutch, (35 ppm) PL 5.15 Item 9 or (40-90 ppm) PL 5.17 Item 9. Solution:
Possible causes and potential solutions are: Adjust the DADH drive belts, ADJ 5.1.
Excessive noise from the DADH when duplex documents are being recirculated for ROS
copying the second side.
Run the following components:
Enter dC330 code 06-020 ROS motor, to drive the ROS motor at normal run speed, PL
The DADH speeds up during second side recirculation when in duplex mode.
6.10 Item 4.
Solution:
Enter dC330 code 06-025 ROS motor, to drive the ROS motor at standby speed, PL 6.10
Switch off the acceleration in duplex mode. Set dC131 NVM location 05-012 DADH Item 4.
Dup Motor Spd to 1.
The ROS gives out a whining noise of a ascending frequency for a duration between 5 and 6
NOTE: The default value for dC131 NVM location 05-012 DADH Dup Motor Spd is seconds. The whining noise is the normal sound of the ROS motor accelerating.
0.
Grinding noise.
The intermediate feed bearing, (35 ppm) PL 5.15 Item 22 or (40-90 ppm) PL 5.17
Item 22 can stick, preventing the feed roll from free wheeling as the document is
transported by takeaway roll.
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.

OF1 2-602 Xerox WorkCentre 5790 Family
Tray 1 and 2 Assembly Tray 3 and 4 Assembly (W/TAG 151)
Remove tray 1 and tray 2 and run the following components: Run the following components:
Enter code dC330 code 08-010 T1 Feed Motor, to run the tray 1 feed motor, PL 8.26 Item Open the left hand door. Enter dC330 code 08-045 HCF transport motor, to run the tray 3
6. and 4 transport roll and tray 3 transport drives, PL 8.36 and PL 8.32 Item 4.
Enter code dC330 code 08-020 T2 Feed Motor, to run the tray 2 feed motor, PL 8.26 Item Pull out tray 3 and let the tray drop, then push the tray back in. Enter dC330 code 07-030
6. Tray 3 elevator motor, to elevate tray 3, PL 7.21 Item 1.
Open left hand door. Pull out tray 4 and let the tray drop, then push the tray back in. Enter dC330 code 07-040
Enter dC330 code 08-025 Tray 1 and 2 Transport Motor, to run tray 1 and tray 2 transport Tray 4 elevator motor to elevate tray 4, PL 7.21 Item 1.
rolls, PL 8.25 Item 8. Possible causes and potential solutions are:
Possible causes and potential solutions are: Knocking noise, no drive or a knocking noise from the HCF transport motor.
Squeaks. Possible causes are:
Possible causes are: The HCF transport motor.
Contamination of the drive shafts and bearings. Tray 3 transport drives.
Incorrectly adjusted or worn drive belts. Worn or stretched tray 3 elevator cables.
Incorrectly aligned or damaged parts. Worn or stretched tray 4 elevator cables.
Solution: Solution:
Remove and clean the drive shafts, bearings and then lubricate. Refer to ADJ 4.1 Check the tray 3 transport drives, PL 8.36.
Machine Lubrication. Adjust and install new components as necessary, PL 7.18.
Check for parts that are damaged or out of position. Check that the paper trays are correctly positioned and that the tray moves freely
Adjust the components if necessary. inside the tray assembly.
Install new parts as necessary. Install new components as necessary, PL 7.18.
Tray 3 and 4 Assembly (W/O TAG 151) Tray 5 Assembly
Run the following components: Run the components as follows:
Open the left hand door. Enter dC330 code 08-045 tray 3 and 4 transport motor, to run the Open the tray 5 door to lower the elevator.
tray 3 and 4 transport roll, PL 8.30 Item 18. Close the door or actuate the interlock.
Pull out tray 3 and let the tray drop, then push the tray back in. Enter dC330 code 07-030 Enter the dC330 code 07-373 to drive the tray up.
Tray 3 elevator motor, to elevate tray 3, PL 7.20 Item 1.
Enter the dC330 code 07-374 to drive the tray down.
Pull out tray 4 and let the tray drop, then push the tray back in. Enter dC330 code 07-040
Enter the dC330 code 08-046 to operate the tray 5 transport motor, PL 8.40 Item 2.
Tray 4 elevator motor to elevate tray 4, PL 7.20 Item 1.
Enter the dC330 code 08-117 to operate the tray 5 feed motor, PL 8.40 Item 3.
Check the associated belts, rollers, bearings, sensors and encoders for possible noise
Knocking noise, no drive or a knocking noise from the tray 3 and 4 transport motor.
sources.
The tray 3 and 4 transport motor.
Worn or stretched tray 3 elevator cables.
Worn or stretched tray 4 elevator cables.
Solution:
Check the drive belt and gears, PL 8.30 Item 8.
Adjust and install new components as necessary, PL 7.15.
Check that the paper trays are correctly positioned and that the tray moves freely
inside the tray assembly.
Install new components as necessary, PL 7.15.

Xerographics Fuser
Run the following components: Possible causes and potential solutions are:
Enter dC330 code 09-010 P/R motor, to run the photoreceptor drive motor, (35-55 ppm) Grinding noise.
PL 4.15 Item 17 or (65-90 ppm) PL 4.10 Item 17. Possible causes are:
Enter dC330 code 09-071 Scorotron Cleaner Motor Forward or 09-072 scorotron cleaner The fuser web motor not turning the fuser web, causing excessive loading on the
motor Reverse, to run the scorotron cleaner motor. fuser drives. This will also cause toner contamination on the stripper fingers and
Possible causes and potential solutions are: paper jams in the inverter.
A high pitched noise when the corotron is switched on. The fuser web drive dog, 35-55 ppm PL 10.8 Item 2 or 65-90 ppm PL 10.10 Item 2.
Possible causes are: Solution:
The detack corotron. Go to 10A Fuser Web Motor RAP.
Solution:
NOTE: Do not change the fuser module, because of the appearance of wrinkles on
None, this is normal behavior.
the pressure roll. This is normal for the pressure roll, caused by the conductive
A clicking noise from the Xerographic module.
sleeve that stretches as the silicon rubber base of the roll expands. The pressure
Possible causes are: rolls are more wrinkled due to the higher run temperatures on the 65-90 ppm
The scorotron cleaning mechanism. A clicking noise is made when the scorotron machines.
cleaning brush reaches the end of its travel.
Solution: 1K LCSS
None, this is normal behavior. If the scorotron cleaning mechanism is the cause of Run the following components:
the noise, inform the customer. Enter dC330 code 11-000 Transport Motor 1, to run the entry transport rolls, PL 11.110
A Knocking or clicking noise. Item 2 and PL 11.110 Item 9, PL 11.110 Item 6.
Possible causes are: Enter dC330 code 11-001 Transport Motor 2, to run the entry rolls, PL 11.120 Item 13.
Xerographic module drive gear is not correctly engaged, PL 9.20 Item 2. Enter dC330 code 11-024 Paddle Wheel Motor Run, rotates the paddle wheel, PL 11.104
Item 4.
Developer module drive gear is not correctly engaged, PL 9.15 Item 2.
Enter dC330 code 11-009 Tamp Mot Cycle, cycles the front and rear tampers, PL 11.112
Cooling fan blades catching on a harness, component or cover.
Item 1.
Solution:
Enter dC330 code 11-023 Eject Mot Cycle, cycles the eject assembly, PL 11.114 Item 1.
Remove the xerographic module. Re-install the module.
Enter dC330 code 11-033 Bin 1 Elevator Motor Cycle, to move bin 1 up and down, PL
Remove and lubricate the developer module support pins, REP 9.2. Refer to ADJ 11.106 Item 8.
4.1 Machine Lubrication.
Ensure that the fan is secured correctly and the area around the fan is clear. NOTE: . The bin will move down and then move up to the home position.
Install a new fan: Possible causes and potential solutions are:
Cooling fan, PL 9.25 Item 7. 2 knocks for each stapled set.
Ozone fan, PL 9.25 Item 1. Possible causes are:
Photoreceptor fan assembly, PL 9.25 Item 6. LCSS set ejector.
A mooing, grunting or moaning noise at the machine cycle down/end of run cycle. Solution:
Cause: Go to the 11-320-120, 11-322-120 Ejector Movement Failure RAP.
The noise occurs when the drum moves slowly under the cleaning blade as the Clicking Noise from the LCSS.
drives come to a stop.
The environment (temperature, humidity, type of media, print density, etc.) will also
effect the coefficient of friction between the cleaning blade and the drum, directly The staple head continually operating for approximately 15 seconds. This occurs
every time the LCSS top cover or front door is opened then closed, because the sta-
effecting the noise.
pler is attempting to prime the staple head, by indexing the staple stick forward and
Solution:
pre-forming two staples.
Dusting the drum with Kynar or zinc stearate will quiet the noise temporarily, but as
Solution:
these lubricants wear off the noise will return.
Check the staple cartridge for jammed staples and remove any that are found.
A new xerographic module, PL 9.20 Item 2 (40-90 ppm) or PL 9.22 Item 2 (35 ppm)
Ensure the staple cartridge is fully seated.
may be less noisy than the xerographic module currently in the machine, at a noise
sensitive customers site this may provide a solution, but the old xerographic module Ensure that the correct staple cartridge is installed.
should be kept for use in a more noise tolerant environment. Perform 11-364-120 Stapling Failure RAP.

2K LCSS HVF and HVF BM
Run the following components: Run the following components:
Enter dC330 code 11-000 Transport Motor 1, to run the entry transport rolls, PL 11.14
Item 6.
CAUTION
Enter dC330 code 11-001 Transport Motor 2, to run the entry rolls, PL 11.22 Item 5.
Make sure that the first tamper in the compiler carriage is returned to the home position before
Enter dC330 code 11-024 Paddle wheel Motor run, rotates the paddle wheel, PL 11.8 the second tamper is checked in diagnostics.
Item 4.
Enter dC330 code 11-000 Transport Motor 1, to run the input transport roll, PL 11.150
Enter dC330 code 11-009 Tamp Mot Cycle, cycles the front and rear tampers, PL 11.16 Item 2.
Item 1.
Enter dC330 code 11-001 Transport Motor 2, to run the exit drive shafts to feed paper to
Enter dC330 code 11-023 Eject Mot Cycle, cycles the eject assembly, PL 11.18 Item 1. the top tray or to the stacker tray, PL 11.150 Item 1.
Enter dC330 code 11-033 Bin 1 Elevator Motor Cycle, to move bin 1 up and down, PL Enter dC330 code 11-003 Tamp. Mot. Front Home, to move the front tamper to the home
11.10 Item 8. position PL 11.153 Item 6.
NOTE: The bin will move down and then move up to the home position. Enter dC330 code 11-004 Tamp. Mot. Rear Home, to move the rear tamper to the home
position, PL 11.153 Item 6.
Enter dC330 code 11-043 Punch Head run, rotates the punch head, PL 11.6 Item 3.
Enter dC330 code 11-005 Tamp. Mot. Front Move, to move the front tamper to the centre
Enter dC330 code 11-055 SU1 index Mot Cycle, cycles the stapler from the front to the of the compiler, PL 11.153 Item 6.
rear, PL 11.20 Item 5.
Enter dC330 code 11-006 Tamp. Mot. Rear Move, to move the rear tamper to the centre
Possible causes and potential solutions are: of the compiler tray, PL 11.153 Item 6.
2 knocks for each stapled set. Enter dC330 code 11-025 Paddle Roll Motor Run, to lift the paddle unit and rotate the
Solution: paddle rolls, PL 11.145 Item 2.
Go to the 11-320-110, 11-322-110 Ejector Movement Failure RAP. Enter dC330 code 11-027 Paddle Unit Mot. Home, to lift the paddle unit to the up position,
Noise from the right hand side of the machine. PL 11.145 Item 2.
Possible causes are: Enter dC330 code 11-030 Bin 1 Elevator Motor Home, to move Bin 1 up to the home posi-
The LCSS is not aligned correctly. tion, PL 11.135 Item 10.
Solution: Enter dC330 code 11-031 Bin 1 Elevator Motor Up, to move Bin 1 down, PL 11.135 Item 10.
Check the machine to LCSS alignment, ADJ 11.2-110. NOTE: The tray moves up for 15 seconds and then stops.
Adjust the components if appropriate.
Enter dC330 code 11-032 Bin 1 Elevator Motor Down, to move Bin 1 down, PL 11.135
Install new parts as necessary. Item 10.
Clicking Noise from the LCSS
NOTE: The tray moves down for 15 seconds and then stops.
The staple head continually operating for approximately 15 seconds. This occurs Enter dC330 code 11-034 Bin 1 Offset Motor, to offset sets and fed to Bin 1, PL 11.140
every time the LCSS top cover or front door is opened then closed, because the sta- Item 19.
pler is attempting to prime the staple head, by indexing the staple stick forward and Enter dC330 code 11-053 SU1 Motor Forward, to move the stapler unit to the rear, PL
pre-forming two staples. 11.140 Item 12.
Solution: Enter dC330 code 11-054 SU1 Motor Reverse, to move the stapler unit to the rear, PL
Check the staple cartridge for jammed staples and remove any that are found. 11.140 Item 12.
Ensure the staple cartridge is fully seated. Enter dC330 code 11-060 BM Compiler Motor, runs the compiler BM entry roll, PL 11.161
Ensure that the correct staple cartridge is installed. Item 15.
Perform 11-364-110 Stapling Failure RAP. NOTE: The tray moves down for 15 seconds and then stops.
Enter dC330 code 11-061 BM Blade motor, to move the crease blade assembly, PL
11.165 and the crease roll gate, PL 11.167.
Enter dC330 code 11-062 BM Crease Motor, to rotate the two crease rolls, PL 11.167 Item 7.
Enter dC330 code 11-065 BM Back Stop Motor, to move the back stop assembly, PL
11.164 Item 17.

Enter dC330 code 11-066 BM Tamper 1 Motor, to move the tamper rack and fingers, PL Scanner
11.162 Item 3.
Enter dC330 code 11-402 BM conveyor drive motor, to run the output tray conveyor belts,
Knocking.
PL 11.169 Item 1.
Enter dC330 code 11-390 BM flapper Motor, to run the BM flapper, PL 11.161 Item 23.
If the scan carriage moves to the right and repeatedly knocks against the frame
Enter dC330 code 11-401 BM Crease roll, to move the crease roll gate up and down, PL
together with the UI screen remaining blank.
11.166 Item 8.
Solution.
Enter dC330 code 11-078 Inserter unit motor, to run inserter main drives, PL 11.181 Item 1
Check the condition of CR15 on the IOT PWB. Refer to the OF7 IOT PWB Diagnos-
Enter dC330 code 11-062 BM crease roll motor, to run the tri-roller drives, PL 11.166 Item 12. tics RAP.
Noise from the right hand side of the machine.
The HVF / HVF BM is not aligned correctly.
Bin 1 not aligned correctly on the main drive belts, PL 11.135 Item 6.
Solution:
Check the machine to HVF or HVF BM alignment, ADJ 11.1-171
Check that the Bin 1 is level, refer to REP 11.38-171 HVF Stacker Drive Belts.
Adjust the components if appropriate.
Knocking.
Mis-adjusted or worn drive belts.
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.
Squeak.
The transport drive shaft or bearings.PL 11.150.
Check that the paper guides are closed and located correctly.
Solution:
Clicking Noise from the HVF / HVF BM.
The noise is caused by the transport motor 2, dC330 code 11-001, continually oper-
ating for approximately 15 seconds. This occurs every time the top tray, PL 11.130
Item 9, or the front door, PL 11.130 Item 3, is opened then closed.
Solution:
Ensure the staple cartridge is fully seated and that the correct cartridge is installed.
NOTE: When a new staple cartridge is installed the stapler makes a repeating noise.
This is normal it is the stapler performing a priming cycle.
Perform 11-371-171 to 11-377-171 HVF Stapler Position and Priming RAP.

OF2 Touch Screen Failure RAP The wiring is good.
Y N
Use this RAP to solve UI touch screen problems when the machine has power but either the
Repair the wiring, REP 1.2 or install a new single board controller PWB module/UI har-
display is missing, is too dark or the UI screen responds incorrectly or does not refresh.
ness, PL 2.10 Item 3.
Initial Actions Go to Flag 4. Check the harness and wiring, GP 7. Check between PJ103 and PJ81. Refer to
the information that follows:
P/J103, Single Board Controller PWB.
WARNING P/J81, User Interface PWB.
Ensure that the electricity to the machine is switched off while performing tasks that do The wiring is good.
death or injury. Moving parts can cause injury. Repair the wiring, REP 1.2 or install a new single board controller PWB module/UI har-
Go to the Customer Tools application and adjust the backlight output level. ness, PL 2.10 Item 3.
Refer to REP 2.1 to access the user interface assembly.
Check and re-seat all connectors on the UI control PWB, PL 2.10 Item 11 and UI touch The energy saver button on the UI is flashing, Figure 1.
screen PWB, PL 2.10 Item 6. Y N
Enter dC305 UI test. Perform the relevant tests to check the operation of the UI.
If the problem occurs while entering or exiting sleep mode, go to 01K Sleep Mode RAP.
Procedure
Go to Flag 1. +3.3V is available at P/J130 between pin 1 and 2.
Y N UI touch screen, PL 2.10 Item 5.
Check the harness and wiring, GP 7. Check between P/J130 on the UI control PWB and
P/J133 on the power distribution PWB. The wiring is good. Switch off the machine GP 14. Check the memory module, PL 3.24 Item 12. The memory
Y N module is correctly installed.
Repair the wiring, REP 1.2 or install a new single board controller PWB module/UI Y N
harness, PL 2.10 Item 3. Correctly install the memory module, refer to REP 3.4.
Refer to: Check the software module, PL 3.24 Item 8. The software module is correctly installed.
Y N
Correctly install the software module, refer to, REP 3.3.
Go to Flag 2. +12V is available at P/J130 between pin 3 and 4.
Y N
Check the harness and wiring, GP 7. Check between P/J130 on the UI control PWB and Software module, PL 3.24 Item 8.
P/J133 on the power distribution PWB. The wiring is good. UI control PWB, PL 2.10 Item 11.
Y N UI touch screen PWB, PL 2.10 Item 6.
Repair the wiring, REP 1.2 or install a new single board controller PWB module/UI UI touch screen, PL 2.10 Item 5.
harness, PL 2.10 Item 3.
If the fault remains, install a new single board controller PWB, PL 3.24 Item 3.
Refer to:
01F+12V Distribution RAP.
Go to Flag 3. Check the harness and wiring, GP 7. Check between PJ104 and PJ130. Refer to
the information that follows:
P/J104, Single Board Controller PWB.
P/J130, User Interface PWB.

Energy saver
button.
Figure 1 Energy saver button

OF3 Dead Machine RAP P16 from the test harness to J16 on the side of the LVPS.
P17 from the test harness to J17 on the side of the LVPS.
Use this RAP to diagnose problems with the LVPS that give the following symptoms:
The supplied connector with a loop wire into J5 on the IOT PWB.
The machine does not respond after the power button on the UI has been pressed 3. Connect the power cord and switch on. Allow a few seconds for the LVPS to stabilise.
The machine responds for an instant to the power button on the UI having been pressed, Observe the LEDs on the test box. The Amber LED is lit.
Y N
with a beep, a click or a momentary LED flash, but no power or lights on the UI, no fans
Check that all the connections have been made correctly. Check that there is a good AC
running, no motors on and no solenoids on. There may be a slight clicking noise from the
relays in the LVPS along with slight flashing of some LEDs on the IOT PWB every five to neutral, AC live and ground supply at the customers AC supply point and at the machine
end of the main power cord. If the AC power supply and connections are good, install a
six seconds
new LVPS and base module, PL 1.10 Item 3.
Directly after a FAX kit has been installed, the only LED on the IOT PWB that is lit is CR36
(+3.3V standby), or the UI touch screen is blank, or an alternating red/green/black check- The green LED is lit.
erboard is displayed on the UI touch screen.
Y N
Initial Actions The red LED is lit or flashing. This indicates the following failures:
If the machine has a TAG 155 IOT PWB, ensure the mandatory TAG 156 has been Flashing at 1Hz indicates a +24V failure
installed. Flashing at 0.33Hz an AC fuser output failure
If the UI touch screen is black or blank, but the LVPS fan is running, or there is an LED lit Permanently lit indicates a failure of 3.3VSB, +5V(1), +5V(2), +12V(1), +12V(2) or
on the UI, go to the OF2 Touch Screen Failure RAP +12V sleep
The LVPS can shut down in response to a power surge, requiring a reset. Disconnect the Install a new LVPS and base module, PL 1.10 Item 3.
machine from the AC power supply and leave it disconnected for two minutes, then re-
connect The LVPS has passed the test, but there may be a problem with the IOT PWB.
If the problem occurs while entering or exiting sleep mode, go to 01K Sleep Mode RAP Perform the following IOT PWB check:
Ensure that the correct LVPS and base module has been installed, refer to PL 1.10 Item 3 1. Switch off the power to the LVPS and disconnect the power cord.
If a FAX kit has just been installed and the machine will not respond to the on/off button, 2. Disconnect P26 and P27 from the test box.
the only LED on the IOT PWB that is lit is CR36 (+3.3V standby), the UI touch screen is 3. Connect P26 to J26 on the IOT PWB.
blank, or an alternating red/green/black checkerboard is displayed on the UI touch 4. Connect P27 to J27 on the IOT PWB.
screen, go to the Fax Installation Checkout.
5. Leave all other connections unchanged.
6. Allow a minimum of 2 minutes before the next switch on to allow the LVPS to recover from
Checkout Options any shut downs.
If an LVPS test box, PL 26.11 Item 7 is available, go to LVPS Test Box is Available. If an LVPS
7. Reconnect the power cord and switch on the power to the LVPS.
Test Box is not available go to LVPS Test Box is Not Available.
CR12, CR13, CR15 and CR36 on the IOT PWB are all lit.
Y N
LVPS Test Box is Available Install a new IOT PWB, PL 1.10 Item 2.
Procedure
CR16 on the IOT PWB is lit.
Y N
WARNING Switch off the power to the LVPS and disconnect the power cord. Disconnect P/J14. Wait
Ensure that the electricity to the machine is switched off while performing tasks that do 2 minutes for the LVPS to recover from the +24V shutdown. Reconnect the power cord
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause and switch on the power to the LVPS. CR16 on the IOT PWB is lit.
There is a short circuit on the +24V output from the IOT PWB or an open circuit on
1. Remove the power and control assembly, REP 1.1.
the +12V interlock circuit.
2. Refer to Figure 2 and Figure 3. Make the following connections: Refer to the circuit diagrams in the 01G +24V Distribution RAP. Also refer to the
P27 from the top of the IOT PWB to J27on the test box. 01H Short Circuit and Overload RAP to locate and repair the short circuit.
P26 from the top of the IOT PWB to J26 on the test box. Install a new IOT PWB, PL 1.10 Item 2. Again perform the IOT PWB check to
The supplied test harness into J97 on the test box. ensure that the IOT PWB is now good.
P24 from the test harness into J24 on top of the LVPS. To check for an open circuit on the +12V interlock circuit, refer to the 01-300
Front Door Open RAP circuit diagram.
P25 from the test harness to J25 on the side of the LVPS.
A B
A B C
Install a new HVPS PWB, PL 1.10 Item 5. Again perform the IOT PWB check to ensure Y N
that the HVPS is now good. A resistance reading of 1 M Ohms or greater indicates that the fuse in the LVPS has
blown by a short in the fuser module. Install new parts:
CR12 is lit. Fuser Module (35-55 ppm), PL 10.8 Item 1
Y N
Fuser module (65-90 ppm), PL 10.10 Item 1
There is a short circuit on the +12V output from the IOT PWB. Refer to the circuit dia-
LVPS and base module, PL 1.10 Item 3
grams in the 01F +12V Distribution RAP to locate and repair the short circuit. Again per-
form the IOT PWB check to ensure that the IOT PWB is now good.
Disconnect P/J27 on the IOT PWB, Figure 2. On the IOT PWB less than 100 Ohms is
measured between J27 pin 6 and the machine frame.
CR36 is the only led that is lit.
Y N Y N
Install a new IOT PWB, PL 1.10 Item 2. Again perform the IOT PWB check to ensure that
the IOT PWB is good.
There is a short circuit on the +3.3V or the +5V output from the IOT PWB.
Disconnect P/J5 on the IOT PWB. Using a small metal screwdriver or metal paperclip, short
Refer to the circuit diagrams in the 01D +3.3V Distribution RAP. Also refer to the 01H
Short Circuit and Overload RAP to locate and repair the short circuit. Again perform the between pins 19 and 20 (pin 19 is the top right most pin, pin 20 is the bottom right most pin).
The power supply remains off (dead).
IOT PWB check to ensure that the IOT PWB is now good.
Y N
Refer to the circuit diagrams in the 01E +5V Distribution RAP. Also refer to the 01H Short
The LVPS is on (IOT PWB LEDs CR12, CR13, CR14 and CR15 are lit, also the LVPS
Circuit and Overload RAP to locate and repair the short circuit. Again perform the IOT fan is running) and all stay on. The on/off switch or wiring is defective. Go to the 01J
PWB check to ensure that the IOT PWB is now good.
Power On and LVPS Control Signals RAP to identify and fix the problem.
LVPS Test Box is Not Available Disconnect the power cord. Disconnect all P/Js on the IOT PWB, except for P/J26 and P/J27.
Procedure Remove the waste toner bottle, PL 9.10 Item 1 and waste toner door, PL 9.10 Item 3. Discon-
nect P/J16, P/J17, P/J18, P/J19 and P/J25 on the right end of the LVPS. Connect the power
cord. Using a small metal screwdriver or metal paperclip, short between pins 19 and 20 (pin 19
is the top right most pin, pin 20 is the bottom right most pin).
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do NOTE: CR16 (+24V), will not illuminate now because the +12V interlock circuit is open circuit
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause with P/J16 and P/J17 disconnected.
The LVPS is on (IOT PWB LEDs CR12, CR13, CR14 and CR15 are lit, also the LVPS fan
is running) and all stay on.
Y N
WARNING Disconnect the power cord. Disconnect P/J26 and P/J27 on the IOT PWB. Measure the
Only use the correct plug to connect a power lead to a power outlet. resistance between the machine frame ground point, Figure 1 and P/J27 pins 1 to 8 (top
row), also P/J26 pins 1 to 10. Greater than 100 Ohms is measured on all pins.
Y N
CAUTION
Incorrect voltage may damage the machine. The machine must only be connected to the
power outlet of the correct voltage. Install a new LVPS and base module, PL 1.10 Item 3. If the problem continues, install a
Check that there is a good AC neutral, AC live and ground supply at the customers AC supply new IOT PWB, PL 1.10 Item 2.
point and at the machine end of the main power cord. Also check that the main power cord is
securely connected at both ends. Refer to GP 22 Electrical Power Requirements. If necessary This indicates that the LVPS itself is good, but that there is a short circuit on one of the +3.3V or
install a new main power cord, PL 1.10 Item 10. Remove the rear cover and connect the +5V circuits that were connected to the LVPS. Disconnect the power cord, reconnect P/J5,
power cord. As soon as the power cord is connected the +3.3V standby LED CR36 should and the power cord, then press the on/off switch. The LVPS is on (IOT PWB LEDs CR12,
light, Figure 2. CR36 on the IOT PWB is lit. CR13, CR14 and CR15 are lit, also the LVPS fan is running) and all stay on.
Y N Y N
Check for a blown fuse in the LVPS. Disconnect the power cord from the machine, mea- This indicates that there is a short circuit on one of the +3.3V or +5V circuits connected to
sure the resistance between the AC live pin and the AC neutral pin on the receptacle P/J5. Go to the 01D +3.3V Distribution RAP and the 01E +5V Distribution RAP to trouble-
where the power cord connects to the LVPS and base module, Figure 1. Between 0.250 shoot and repair the cause of the +3.3V or +5V short circuit.
and 0.750 M Ohms is measured.
C D
D
Disconnect the power cord. Reconnect P/J16. Reconnect the power cord and then press the Fax Installation Checkout
on/off switch. The LVPS is on (IOT PWB LEDs CR12, CR13, CR14 and CR15 are lit, also
If a FAX kit has just been installed and the one or more of the following symptoms are evident:
the LVPS fan is running) and all stay on.
Y N The machine will not respond to the on/off button
This indicates that there is a short circuit on one of the +3.3V or +5V circuits connected to
The only LED on the IOT PWB that is lit is CR36 (+3.3V standby)
PJ16. Go to the 01D +3.3V Distribution RAP and the 01E +5V Distribution RAP to trouble-
shoot and repair the cause of the +3.3V or +5V short circuit. The UI touch screen is blank
Disconnect the power cord. Refer to Figure 4, disconnect an correctly reconnect PJ138. Wait 2
Disconnect the power cord. Reconnect P/J17. Reconnect the power cord and then press the minutes for the LVPS to self recover, then reconnect the power cord and switch on the
on/off switch. The LVPS is on (IOT PWB LEDs CR12, CR13, CR14 and CR15 are lit, also machine, GP 14. The machine should now power on correctly.
Y N If a FAX kit has just been installed and an alternating red/green/black checkerboard is dis-
This indicates that there is a short circuit on one of the +3.3V or +5V circuits connected to played on the UI touch screen, Disconnect the power cord. Refer to Figure 4, disconnect an
P/J17. Go to the 01D +3.3V Distribution RAP and the 01E +5V Distribution RAP to trou- correctly reconnect PJ138. Wait 2 minutes for the LVPS to self recover, then reconnect the
bleshoot and repair the cause of the +3.3V or +5V short circuit. power cord and switch on the machine, GP 14. The machine should now power on correctly. If
the machine does not power on correctly, perform an Altboot Software Loading Procedure, GP
Disconnect the power cord. Reconnect P/J18. Reconnect the power cord and then press the 4. If the machine still does not power on correctly, install a new Fax kit, PL 31.35 Item 1 (Line
on/off switch. The LVPS is on (IOT PWB LEDs CR12, CR13, CR14 and CR15 are lit, also 1), or PL 31.40 Item 1 (line 2).
Y N
This indicates that there is a short circuit on one of the +3.3V or +5V circuits connected to
P/J18. Go to the 01D +3.3V Distribution RAP and the 01E +5V Distribution RAP to trou-
bleshoot and repair the cause of the +3.3V or +5V short circuit.
Disconnect the power cord. Reconnect P/J19. Reconnect the power cord and then press the
Y N
This indicates that there is a short circuit on one of the +3.3V or +5V circuits connected to Machine ground frame point
Disconnect the power cord. Reconnect P/J25. Reconnect the power cord and then press the
Y N
This indicates that there is a short circuit on one of the +3.3V or +5V circuits connected to Power cord receptacle
The LVPS, +3.3V circuits and +5V circuits are working correctly, the problem is intermittent,
perform the following actions:
Load software 061.131.221.10401 or greater using the Forced AltBoot Software Loading
procedure, GP 4.
Go to the 01H Short Circuit and Overload RAP to diagnose a short circuit.
Figure 1 Power connections

Figure 2 IOT PWB LED and PJ locations
Figure 4 Correctly installed PJ138
Figure 3 LVPS PJ locations

OF4 Status Codes and Messages RAP OF4a Status Codes in Numerical Order
Use this RAP for faults and messages without fault codes. Status Message Tables
Table 1 01-5XX Status codes
The status code numbers are in the series XX-5XX. However a shortage of 500 series num-
bers means that occasionally other numbers must be used, for example; XX-6XX and XX-9XX. Table 2 02-5XX Status codes
The first two digits identify the relevant functional chain link number. Refer to GP 2 Fault Codes Table 3 03-5XX Status codes
and History Files. Table 4 05-5XX Status codes
Status codes are used to call up UI status messages and are displayed in the Active Messages
Log. Most recent fault and status codes can be displayed on the UI without entering diagnos-
tics, by pressing the Machine Status button on the keypad, touching the Fault tab on the UI, Table 7 08-5XX Status codes
then select as appropriate: Table 8 09-5XX Status codes
All Faults. Table 9 10-5XX Status codes
Active Messages - status codes and a status message. Table 10 11-5XX to 9XX Status codes
Error Log - fault codes. Table 11 12-5XX Status codes
The tables in this procedure bring together the status codes, the relevant RAP or procedure Table 12 14-5XX Status codes
references, and some of the UI messages. Table 13 16-5XX to 7XX Status codes
Table 14 17-5X Status codes
NOTE: Not all status codes are shown in the active message window. Some status codes have
no messages.
Procedure Table 17 22-5XX Status codes
Enter the Fault Codes and History Files, GP 2 and identify and clear any active faults. Go to Table 1 01-5XX Status codes
the following RAPs to identify a status code or message:
Status
OF4a Status Codes in Numerical Order
Code UI Message Reason for Message Reference / Action
OF4b Status Messages in Alphabetical Order
01-510 Close front door Front door open Perform 01-300 RAP
01-512 Close left hand door Left hand door open Perform 01-305 RAP
01-514 Close top tray cover Finisher bin 0 cover open Perform 11-300-110, 11-
302-110, 11-303-110 for
the 2K LCSS, perform
the 11-300-120, 11-302-
120, 11-303-120 for the
1K LCSS, perform the
11-300-171, 11-302-171,
11-303-171 for the HVF.
01-550 No message System in power save mode Used internally by the
network controller

Status
02-521 Custom Services not UI gets no response from EIP Switch off machine and
available. Power Off then service within 20 seconds switch on machine, GP
On and Notify System 14.
Administrator

Xerox WorkCentre 5790 Family 2-613 OF4, OF4a
Table 2 02-5XX Status codes Table 2 02-5XX Status codes
Status Status
Code UI Message Reason for Message Reference / Action Code UI Message Reason for Message Reference / Action
02-530 The User Interface is not Fault detected at UI. Local UI Perform 02-320, 02-380 02-560 Remove Reorder Toner Set by the user interface when Cleared by the user
available. Please call for needs service RAP Cartridge the user enters *33 code to interface once Status
assistance remove the Reorder Notifica- 09-599 is cleared.
02-531 Local interface problem Faults declared. UI running in Perform 02-309, 02-390, tion message when the Toner
detected. Please switch degraded mode 02-391, 02-704, 02-706 Cartridge is replaced.
the machine off and on RAP and the 03D Soft- 02-561 Unable to access the dis- Part of save job for reprint. Select O.K, then attempt
again ware Module Failure play list. Please select O.K selection again.
RAP and then attempt your
02-532 Local interface problem Fault declared. UI software Perform 02-320, 02-380 selection again.
detected. Please switch error. Fault 02-320 called dur- RAP and the 03D Soft-
the machine off and on ing power on sequence ware Module Failure
again RAP Table 3 03-5XX Status codes
02-533 Not all configurable ser- Machine not achieved stable Perform 02-390, 02-391,
Status
vices have achieved a sta- state five minutes from power 02-704, 02-706 RAP
ble state on
02-534 There is a problem with at Machine not achieved stable Perform 02-390, 02-391, 03-500 Printing and scanning are Voltage not present on +24V Perform 03-480 RAP
least one machine service. state five minutes from power 02-704, 02-706 RAP unavailable. Please call rail monitored by IOT
Please switch the machine on for assistance
off then on again. If this 03-501 Please wait. The system prtgeneralReset MIB object on No action, system auto-
does not solve the prob- software and the network the network controller is set to matically reboots which
lem, switch the machine controller are about to be a value of powerCycleReset(4) eliminates the request
off and call for assistance reset from a remote client. for reboot state
02-535 There is a problem with at All services that the UI is wait- Perform 02-390, 02-391, The reset may take sev-
least one machine service. ing for in the registry do not 02-704, 02-706 RAP eral minutes. Any jobs
Please switch the machine appear even though the currently being marked
off then on again. If this Image processing / UI sync will be cancelled
does not solve the prob- occurred 03-503 Fax card not supported The Fax card capabilities Perform 03-336 RAP
lem, switch the machine reported to the SIP are not suf-
off and call for assistance ficient to function adequately in
02-536 There is a problem with at All services that the UI is wait- Perform 02-390, 02-391, the system, (e.g. sleep mode
least one machine service. ing for do not appear in the 02-704, 02-706 RAP not supported).
Please switch the machine registry 03-504 No message The network controller will sim- Clears when the system
off then on again. If this ulate this status when the sys- is put back on line
does not solve the prob- tem is taken offline
lem, switch the machine 03-505 Unsupported scanner Scanner software no longer Switch off machine and
off and call for assistance detected supported switch on machine, GP
02-540 Installation procedure is System Manager install phase Complete install proce- 14. Check software sta-
not complete. Please com- not set to IpinstallComplete or dure tus and upgrade where
plete installation, then DC Platform Manager install necessary
switch the machine off phase not set to IpinstallCom- 03-506 Please wait while your This status is raised while Clears when the report
then on again plete receipt is printing. This auditron copy activity report is has printed
02-550 Auto Configuration is dis- System manager auto-config- Perform 02-390, 02-391, may take up to 7 seconds. printed
abled. Please re-enable uration NVM set to disable 02-704, 02-706 RAP 03-510 Please check the output Paper is delivered to the out- Perform 03-423, 424,
this feature before pro- bin for blank and partially put and a video complete has 433, 434, 821, 822,
ceeding imaged sheets and dis- not been received by the sin- 831, 832 RAP
card them gle board controller PWB

OF4a 2-614 Xerox WorkCentre 5790 Family
Status Status
03-511 Output Bin full. Touch The 90% full sensor is cleared Printing will continue 03-538 An error has occurred - System attempting to recover Cleared if communica-
pause to hold printing before the bin switch timer automatically 15 sec- The system is attempting from an single board controller tion is established. Per-
while emptying the bin expires. onds after raised if the to recover PWB to IOT communication form 03-300, 306, 461,
Pause button is not failure. Fault 03-300 or 03-320 482, 805, 870 RAP, 03-
pressed. is raised. 320 to 03-324 RAP
Or when the Resume 03-539 An error has occurred. Comms failure between the Clears when comms re-
button pressed. The system is attempting IOT and single board controller established, or is con-
Or Automatically 15 to recover. verted to status code
minutes after Pause 03-540 after third recov-
button pressed if ery attempt
Resume button is not
03-540 Communications failure. DC-IOT: three times retry fail at Perform the 03-300,
pressed.
Please call for assistance 100 ms cycle communication - 306, 461, 482, 805, 870
03-520 Power down failure. System fails to power off after Perform 03-374 RAP no response. The DC is unable RAP
Power off cannot be com- request from the UI to communicate with the IOT
pleted. Press the power within one minute of power on
button on the left side of or after three retries
the machine. If there is no
03-541 No message Single board controller-UI: Perform 03-310 RAP
response within 1 minute,
three times retry fail at 100 ms
then remove the power
cycle communication - no
cord. Wait 3 minutes then
response
reinsert the power cord
and switch the machine 03-542 DADH fault. Please call Single board controller-DADH: Clear DADH of originals
on. for assistance three times retry fail at 100 ms - use document glass
cycle communication - no for copy or Fax. Perform
03-525 - Software upgrade NVM re-ini- Cleared when the single
response 03-320 to 03-324 RAP
tialization board controller mod-
ule has completed ini- 03-543 Scanner fault. Please call Single board controller-CCD: Perform 14-310 RAP
tialization, the status will for assistance three times retry fail at 100 ms and the 03D Software
clear cycle communication - no Module Failure RAP
response
03-526 Restoring configuration Software upgrade configura- Cleared when the single
setting. Please wait. Sys- tion reset board controller mod- 03-544 Network controller Single board controller-net- Switch off the machine
tem will reboot when com- ule has completed unavailable. Please call work controller: three times then switch on the
pleted. restoring the configura- for assistance retry fail at 100 ms cycle com- machine, GP 14. Per-
tion settings the status munication - no response form the 03D Software
will clear Module Failure RAP
03-527 Automatic software Sip NC sync failure prior to Switch off the machine, 03-545 Output device communi- IOT-Finisher: three times retry Perform 03-360, 03-408
upgrade failure power on upgrade then switch on the cations fault. Please call fail at 100 ms cycle communi- to 03-410, 03-418 RAP
machine, GP 14 for assistance. cation - no response. 03-360
03-535 Please enter your pass- Machine in service copy mode Status clears on leav- 03-547 Pull out fuser module, IOT-Fuser comms fault. Fault Perform 03-371, 03-372
word and press Enter for password entry ing service copy mode then firmly push it back in 03-371 is raised. RAP
03-536 No message Set on entry to diagnostics. Clears on leaving diag- 03-548 Pull out xerographic mod- IOT-X-Crum comms fault. Perform 03-371, 03-372
(intrusive diagnostic activity in nostics ule, then firmly push it Fault 03-372 is raised. RAP
progress) back in
03-537 Software upgrade com- Indicates machine in IOT soft- Clears on leaving IOT 03-549 Paper Trays are unavail- IOT to trays 1 and 2 comms Perform 03-350, 03-
pleting - please wait ware upgrade status software upgrade able. Call for assistance fault. Fault 03-350 is raised. 351, 03-354 RAP
03-551 Fax service is unavailable Single board controller-FAX: Perform 03-338 RAP
comms error. Fault 03-338 is
raised.

Xerox WorkCentre 5790 Family 2-615 OF4a
Status Status
03-552 Tray 3 and 4 are unavail- IOT microprocessor to HCF Perform 03-359, 03-407 03-568 Job contains too many The single board controller Maximum number of
able. Please call for assis- comms error. Fault 03-359 RAP sheets to be folded and PWB reports that the BM job output sheets that can
tance. raised stabled. See Help for contains too many sheets for be folded and stapled is
03-553 The BM is unavailable. BM communications failure. Perform 11B-171 RAP more details. the BM to fold and staple. 15
Please call for assistance. Fault 03-363 is raised. 03-569 Job contains too many The single board controller Maximum number of
03-554 Network controller is initi- Network controller powered up No action sheets to be folded. See PWB reports that the BM job output sheets that can
ating. Power Off will be but is still initializing. Fault 03- Help for more details. contains too many sheets for be folded is 15
available when initializa- 340 is raised, and will clear the BM to fold
tion has completed. when initial is at ion is com- 03-570 Current job exceeds tray Job is too large for selected None
Please wait. plete capacity, you will be output bin
03-556 Please wait. The system Tray 1 and 2 comms error. Perform 03-350, 03- prompted to empty the
is attempting to recover Fault codes 03-351 and 03- 351, 03-354 RAP tray
from a fault 354 are raised 03-571 The installed staple car- 50 sheet cartridge installed in Press confirm.
03-557 Please wait - the system is Tray 5 comms error. Fault 03- Perform 03-366 RAP tridge can staple a maxi- the HVF
attempting to recover from 366 is raised mum of 50 sheets. Please
a fault confirm to close this win-
dow
03-558 Copying is being pre- The foreign Interface is config- Perform 03-412 RAP
vented by the Access ured and a connected 3rd 03-573 After clearing paper, Image processing reports that Cleared when the IOT
Control device party accessory is reporting as replace any discarded a jam occurred has performed stray
not enabled. tabs with identical tab sheet detection suc-
stock in the correct tray cessfully the status
03-559 Copying is being pre- This status occurs when there The status clears when
clears
vented by the Access is a status 03-558 and the sys- the jobs are deleted. If
Control device tem contains non-held jobs necessary, perform 03- 03-575 Main motor control fault. Main motor not being con- Perform 03-397 RAP
controlled by the Foreign Inter- 412 RAP Printing is unavailable. If trolled. Fault 03-397 raised
face fault persists, call for
assistance. Touch Ignore
03-560 Software cycling control Laser on without printing. Fault Perform 03-395, 396,
Error to use other services
fault. Printing is unavail- 03-396 raised 852, 853 RAP
able. If fault persists, call 03-576 IOT cycled in without IOT cycled in without printing. Perform 03-395, 396,
for assistance. Touch printing Fault 03-395 raised 852, 853 RAP
Ignore Error to use other 03-579 Machine speed configura- Speed in image processing Perform 03-320 to 03-
services / Printing is tion error NVM does not match speed in 324 RAP. Perform 03-
unavailable DADH 330, 03-462 RAP. Refer
03-561 An internal communica- Single board controller wall Perform 03-315, 325, to GP 15 How to Set the
tions error has occurred. clock is not incrementing. Fault 347, 348, 349, 355, 400 Machine Configuration
Switch off the machine 03-325 is raised. RAP 03-580 Machine speed configura- Speed in Image processing Perform 03-330, 03-462
and call for assistance tion error NVM does not match speed in RAP. Refer to GP 15
03-562 No message Image processing POST fail- Perform 03-315, 325, IOT NVM. Fault 03-461 is How to Set the Machine
ure. NVM Integrity ASICEPC- 347, 348, 349, 355, 400 raised. Configuration
Failure. Fault 03-347, 03-348, RAP 03-581 Machine speed configura- Speed in Image processing Perform 03-330, 03-462
03-355 is raised. tion error NVM does not match scanner RAP. Refer to GP 15
03-563 An internal communica- Image processing rotation Perform 03-315, 325, speed. Fault 03-462 is raised. How to Set the Machine
tions error has occurred. memory POST has failed 347, 348, 349, 355, 400 Configuration
Switch off the machine RAP 03-585 Scan to file unavailable Fault 03-331 raised. The sta- Switch off the machine
and call for assistance tus is cleared when status 03- then switch on the
544 is raised. machine, GP 14.
03-586 FAX service unavailable The fault 03-401 or 03-403 is Perform 03-401, 03-
raised. 403. Perform 20A RAP

Status Status
03-587 Machine unavailable The fault 03-417 is raised. Perform 03-417 RAP 03-598 Tray 5 is unavailable. Tray 5 software is installed but Check that all tray 5
03-588 Fax service is unavailable Basic Fax not detected or con- Perform 03-401, 03- Check cabling connec- hardware is not detected control PWB connec-
firmed. 403. Perform 20A RAP tions tions are good. Perform
03-366.
03-589 Fax Service Error A Fax Extended Fax not detected or Perform 20A RAP
Service error has confirmed. 03-600 A daylight saving time Daylight saving time has been No action
occurred. Fax line 2 is change has occurred. The automatically changed
unavailable. Fax line 1 is device clock has been
still available. Contact adjusted.
your System Administra- 03-601 Unable to detect card Smart Card authentication has Perform 03-412 RAP.
tor. reader been enabled but no card
03-590 A Fax Service error has Fax POST failure status Perform 20A RAP reader is installed
occurred. Press the power
button on the left side of
the machine and choose Table 4 05-5XX Status codes
Quick Restart. If fault per-
sists, please call for assis- Status
tance. Code UI Message Reason for Message Reference / Action
03-591 Try turning the machine The single board controller Switch the machine off 05-502 Lower the document Document present in DADH Close the DADH cover.
off and on. Please call for PWB reports that its stored and on, GP 14. If nec- feeder to use it to scan tray and the DADH cover is Perform 05-300 RAP
assistance if the problem machine model ID differs from essary, reload the soft- your documents. open
persists that stored in the IOT ware, GP 4 then re-run 05-503 Reload originals and press Not enough originals during Reload originals
the install wizard, refer Start recovery
to GP 15.
05-504 A nonstandard document A document length is detected Cleared when job can-
03-592 Try turning the machine The single board controller Switch the machine off has been detected. It will during the document feed celled or completed.
off and on. Please call for PWB reports that its stored and on, GP 14. If nec- be scanned to match the cycle that is not consistent with Perform 05C RAP
assistance if the problem machine type differs from that essary, reload the soft- closest standard size the document size assumed by
persists stored in the IOT ware, GP 4 then re-run the DADH sensors and the
the install wizard, refer market region settings
to GP 15.
05-507 Job was deleted because Fault 05-331 is raised. Perform 05-330, 05-
03-593 Try turning the machine The single board controller Switch the machine off a document was larger 331 RAP
off and on. Please call for PWB reports that its stored and on, GP 14. If nec- than expected. Discard
assistance if the problem machine speed ID differs from essary, reload the soft- output. Try flattening the
persists that stored in the IOT ware, GP 4 then re-run document and either re-
the install wizard, refer scan it through the docu-
to GP 15. ment feeder or scan it
03-594 Try turning the machine The single board controller Switch the machine off from the document glass
off and on. Please call for PWB reports that its stored and on, GP 14. If nec- 05-520 Open document feeder Sheet left over DADH feed Remove the sheet. Per-
assistance if the problem machine variant ID differs from essary, reload the soft- top cover sensor after a jam form 05-330, 05-331
persists that stored in the IOT ware, GP 4 then re-run RAP
the install wizard, refer
05-521 Open document feeder Sheet left over DADH take Perform 05-335 Take-
to GP 15.
top cover away sensor after jam away Sensor Failure
03-597 The software that controls Incompatible software Switch the machine off RAP
tray 5 requires updates. detected in the tray 5 controller and on, GP 14. Per-
05-522 Open the document Sheet left over DADH CVT Remove sheet. Perform
Tray 5 is unavailable form 03-419, 03-420
feeder sensor after jam 05-350, 05-352 RAP
05-523 Open the document Sheet left over DADH registra- Remove sheet. Perform
feeder tion sensor after jam 05-340 RAP

Status Status
05-524 Open the document Sheet left over DADH exit sen- Remove sheet. Perform 05-540 Resort and reload all origi- DADH document jam is Replace document on
feeder sor after jam 05-345, 05-346 RAP nals. cleared for a single job DADH input tray to
05-525 Remove all documents Sheet left over DADH docu- Remove sheet. Perform enable recovery. Check
from the document feeder ment present sensor after jam 05B RAP for blanks in output tray.
tray 05-542 Document feeder is Document transport needs ser- Perform 05A RAP
05-526 Open document feeder DADH - sheet near CVT sen- Reset when DADH top unavailable vice.
top cover sor in duplex path. 05-352 fault cover closed after jam 05-544 Resort and reload ALL Document jam is cleared (cov- Resume job command
is raised cleared. Perform 05- originals in the document ers cycled and switch cleared) is given with documents
350, 05-352 RAP feeder and normal job or build job replaced in input tray, if
05-530 No message Document in DADH tray Remove document required, or cancel job
from tray. Perform 05B command is given
RAP 05-546 Reload originals or select On pre-feed the DADH fails to Reload originals or
05-531 No message Document in DADH area 2 Remove document. original size and press recognize the size of the docu- select size. Perform
with no document in area 3 Perform 05-330, 05- Start ment 05C RAP
331, 05-335, 05-340 05-547 Re-order but do not DADH feed roll assembly near Re-order feed roll
RAPs. replace Document Feeder end of life assembly, (35 ppm) PL
05-532 No message Document in DADH area 2 Remove document. Feed Roll 5.15 Item 1 or (40-90
with document in area 3 Perform RAP. Perform ppm) PL 5.17 Item 1.
05-330, 05-331, 05- 05-548 Please follow the instruc- DADH feed roll assembly at Install a new feed roll
335, 05-340 RAPs. tions below to replace the end of life assembly, (35 ppm) PL
05-533 No message Document in DADH area 3 Remove document. document handler feed 5.15 Item 1 or (40-90
Perform RAP. Perform roll: ppm) PL 5.17 Item 1.
05-330, 05-331, 05- 05-560 Document is too short to Document too short for DADH, Remove document
335, 05-340 RAPs. be scanned by the docu- use document glass. Fault 05- from DADH during jam
05-534 Check for a stray original Unscheduled document Clear the document ment feeder, use the docu- 310 raised clearance, Perform 05-
in the document tray detected by any sensor path in the DADH. Per- ment glass 310 RAP
form 05-330, 05-331, 05-586 Try turning the machine off Network controller software No action
05-335, 05-340, 05- and on. Please call for version supplied at power-on is
345, 05-346 RAPs. assistance if the problem not compatible with single
05-535 Close Document Feeder Open DADH cover Close document han- persists board controller PWB. Fault
Top Cover dler. Perform 05-310 03-416 is raised
RAP 05-588 Try turning the machine off Finisher software version sup- Perform 03-360, 03-
05-536 Document feeder is open Open document feeder Close document feeder. and on. Please call for plied is not compatible. Fault 408 to 03-410, 03-418
Perform 05-300 RAP assistance if the problem 03-418 raised RAP If necessary,
persists reload the software, GP
05-537 No message DADH tray empty Put document in tray.
4
Perform 05B RAP
05-589 Try turning the machine off IOT, DADH or UI software ver- Perform 03-300, 306,
05-538 Document feeder is DADH not available. 03-322, Perform 03-320 to 03-
and on. Please call for sion supplied at power-on is 461, 482, 805, 870
unavailable 03-323, 03-324 or 14-320 324 RAP and 14-320
assistance if the problem not compatible with the single RAP, 03-320 to 03-324
raised RAP
persists board controller PWB. RAP, 03-310 RAP. If
05-539 Document feeder feed roll DADH feed head CRU None necessary, reload the
has been replaced replaced. Message automati- software, GP 4
cally cleared half a second
after setting

Status
Status
07-516 Tray 5 empty, please Tray empty sensor detects no Reload paper. If neces-
reload paper sary, perform 07J
06-520 The ROS motor has fail- ROS motor failed. Perform 06-020 RAP 07-517 Inserter empty, please Paper sensor detects no paper Reload paper.
ure. Switch the machine reload
off, wait 3 minutes, then
switch on the machine 07-521 Remove misfed sheet. IOT microprocessor detects Close tray. Perform 07-
again. If the fault persists Close tray 1 Tray 1 open 301 RAP
call for assistance or
press Close to use other 07-522 Remove misfed sheet. IOT microprocessor detects Close tray. Perform 07-
services. Close tray 2 Tray 2 open 302 RAP
06-530 ROS system failure. Print- ROS system failed. Perform 06-340 RAP 07-523 Remove misfed sheet. IOT microprocessor detects Close Tray. Perform 07-
ing is unavailable. If fault Close tray 3 Tray 3 open 303 RAP
persists, call for assis- 07-524 Remove misfed sheet. IOT microprocessor detects Close Tray. Perform 07-
tance. Touch Ignore Error Close tray 4 Tray 4 open 304 RAP
to use other services 07-526 Close tray 5 door Tray 5 door has been detected Close the door, or per-
06-540 ROS laser not being con- ROS laser not being con- Perform 06-350 RAP open form 07-306
trolled trolled. 07-531 Tray 1 is low on paper Tray 1 paper low Perform 07A RAP
07-532 Tray 2 is low on paper Tray 2 paper low Perform 07A RAP
07-533 Tray 3 is low on paper Tray 3 paper low IOT microprocessor
Table 6 07-5XX Status codes detects Tray 3 paper
level at 25%. Perform
Status 07B RAP
07-534 Tray 4 is low on paper Tray 4 paper low IOT microprocessor
07-501 Check the settings for Tray 1 closed or size change Confirm the attributes detects Tray 4 paper
Tray 1 from power-on or open the tray level at 25%. Perform
07-502 Check the settings for Tray 2 closed or size change Confirm the attributes 07B RAP
Tray 2 from power-on or open the tray 07-536 Tray 5 is low on paper Tray 5 paper below 5% full Add paper. If neces-
07-505 Check settings for the Bypass tray size confirmation Confirm the attributes sary, perform 07-373
bypass tray required and 07-374 RAPs
07-506 Adjust position of Tray 1 Tray 1 guides moved out of Open tray 1 and reset 07-539 Tray 5 is overloaded, Paper equals or is more than Remove some paper. If
before proceeding fixed position the paper guides please remove excess 100% full in tray 5 necessary, perform 07-
paper 373 and 07-374
07-507 Adjust position of Tray 2 Tray 2 guides moved out of Open tray 2 and reset
before proceeding fixed position the paper guides 07-541 Tray 1 is out of service, Tray 1 out of service. Perform 07H RAP
please use a different tray
07-511 Tray 1 empty, please Tray 1 paper present sensor Reload paper. If neces-
reload detects no paper in tray sary perform 07A RAP 07-542 Tray 2 is out of service, Tray 2 out of service. Perform 07H RAP
reload detects no paper in tray sary perform 07A RAP 07-543 Tray 3 is out of service, Tray 3 elevate top sensor does Perform 07-355 RAP
please use a different tray not turn on within 7 seconds
after elevator motor on.
reload detects no paper in tray sary perform 07F RAP
07-544 Tray 4 is out of service, Tray 4 elevate top sensor does Perform 07-360 RAP
reload detects no paper in tray sary perform 07F RAP
after elevator motor on
07-515 Bypass Tray empty, Paper present sensor detects Reload paper. If neces-
please reload no paper in bypass tray, while sary perform 07D RAP
attempting to feed from the
bypass

Status Status
07-546 Tray 5 is out of service, Tray 5 cannot feed paper Switch the machine off 07-580 Re-order but do not Near the end of life - ensure Order new feed roll kit,
please use a different tray and on, GP 14. Check replace the Tray 5 Feed new stock is available PL 8.45 Item 2
that the tray is in the Rolls
correct position. Per- 07-581 Slide Tray 5 up to Tray 5 is un-docked Perform 07-372
form 07-306, 07-372, or machine
07-373 RAP
07-590 Replace tray 5 feed rolls The feed head counter has Install new tray 5 feed
07-550 Tray 3 is lifting Tray 3 is lifting. Perform 07-355 RAP reached the end of life figure rolls, PL 8.45 Item 2
07-551 Tray 1 is lifting Tray 1 is lifting. Perform 07-353 RAP 07-592 Check the settings for tray Tray 2 closed or size change Confirm the attributes
07-552 Tray 2 is lifting Tray 2 is lifting. Perform 07-354 RAP from power-on or open the tray
07-560 Tray 4 is lifting Tray 4 is lifting Perform 07-360 RAP
07-561 Tray 5 is lifting, please Tray 5 is currently lifting Perform 07-373
wait Table 7 08-5XX Status codes
07-562 - Tray 5 is currently lowering Perform 07-374
Status
07-563 Tray 5 is unavailable. Tray 5 lifting has stopped Perform 07-373 Code UI Message Reason for Message Reference / Action
Check for obstructions in
Tray 5 08-548 Clear jam from right hand Sheet did not clear the wait Perform 08-115, 08-
side of Tray 5 sensor within the expected 117 RAP
07-564 Tray 5 is unavailable. Tray 5 lowering has stopped Perform 07-374
time
Check for obstructions in
Tray 5 08-550 Open left hand door Sheet over wait sensor Jam clearance. Per-
form 08-100 RAP
07-571 Paper size mismatch. First sheet fed after a tray 1 Check the paper in tray
Check paper in Tray 1. status change does not match 1. Perform 07E RAP 08-551 Open left hand door Tray 1 feed sensor detects Jam clearance. Per-
Some image loss may the confirmed stock paper in feed area on power- form 08-101 RAP
occur on or in standby, 08-101
07-572 Paper size mismatch. First sheet fed after a tray 2 Check the paper in tray 08-552 Open left hand door Tray 2 feed sensor detects Jam clearance. Per-
Check paper in Tray 2. status change does not match 2. Perform 07E RAP paper in feed area on power- form 08-102 RAP
Some image loss may the confirmed stock on or in standby. 08-102
occur 08-553 Open tray 3 Tray 3 feed sensor detects Jam clearance. Per-
07-573 Paper size mismatch. First sheet fed after a tray 3 Check the paper in tray paper in feed area on power- form 08-103, 08-113
Check paper in Tray 3. status change does not match 3. Check that the tray is on or in standby. 08-103 RAP. If the fault
Some image loss may the confirmed stock set to correct paper remains, check the
occur size, (W/O TAG 151) tray 3 exit sensor, refer
ADJ 7.1 or (W/TAG to the 08-131 RAP.
151) ADJ 7.5 08-554 Open left hand door Tray 4 feed sensor detects Jam clearance. Per-
07-574 Paper size mismatch. First sheet fed after a tray 4 Check the paper in tray paper in feed area on power- form 08-104, 08-114
Check paper in Tray 4. status change does not match 4. Check that the tray is on or in standby. 08-104 RAP
Some image loss may the confirmed stock set to correct paper 08-555 Open front door Registration sensor detects Jam clearance. Per-
occur size, (W/O TAG 151) paper in registration area on form 08-150, 08-151
ADJ 7.1 or (W/TAG power-on or in standby. 08-150 RAP
151) ADJ 7.5 08-556 Open front door Paper in duplex path at power- Jam clearance. Per-
07-575 Paper size mismatch. First sheet fed after a bypass Check the paper in on or in standby form 08-160, 08-161
Check paper in Bypass tray status change does not bypass tray and the RAP
tray. Some image loss match the confirmed stock side guide is set cor- 08-557 Open left hand door Paper over the registration Jam clearance. Per-
may occur rectly sensor when feeding from the form 08-155, 08-156
07-576 Paper size mismatch. The first sheet after a tray 5 Confirm the paper size bypass tray RAP
Check paper in tray 5 status change does not match in the UI
the confirmed stock

Status
Status
08-558 Clear jam in Tray 5 Sheet over the feed sensor Jam clearance. Per-
form 08-115, 08-117
RAP 09-540 Xerographic Module The Scorotron cleaning is in Refer to 09-341, 09-
08-561 Open tray 1 Sheet near Tray 1 feed sensor. Jam clearance. Per- cleaning in progress. progress 342 Scorotron Clean-
08-106 form 08-106 RAP Please wait ing Failure RAP
08-562 Open tray 2 Sheet near Tray 2 feed sensor Jam clearance. Per- 09-541 Xerographic Module Scorotron cleaning failure Refer to 09-341, 09-
form 08-106 RAP Cleaning Failure. Copy 342 Scorotron Clean-
and Printing unavailable. ing Failure RAP
08-563 Open tray 3 Sheet near Tray 3 feed sensor Jam clearance. W/O Touch Power Off to switch
TAG 151 Perform 08- machine off or touch
107 RAP. W/TAG 151 Ignore Error to use other
Perform 08-131 RAP, services
check the tray 3 exit
sensor 09-543 Xerographic Module Main- Charge scorotron manual Refer to IQ1 Image
tenance Please follow the cleaning required Quality Entry RAP
08-564 Open tray 4 Sheet near Tray 4 feed sensor Jam clearance. Per- instructions below
form 08-108A RAP
09-545 Toner cartridge status is This status is raised when the No action required.
08-565 Open left hand door Sheet near registration sensor Jam clearance Per- disabled toner gas gauge is disabled The toner gas gauge
form 08-150, 08-151 can be enabled, if
RAP required
08-566 Open front door Sheet near duplex sensor Jam clearance. Per- 09-546 Toner adjustments in Replenisher sump refilling Perform 09-360, 09-
form 08-160, 08-161 progress. Please wait. 361, 09-362, 09-363
RAP RAP
08-567 Open left hand door Paper over the registration Jam clearance. Per- 09-550 Printing is unavailable Photoreceptor erase lamp has Perform 09-350 RAP
sensor when feeding from the form 08-155, 08-156 failed. 09-350 fault
bypass tray RAP
09-560 Printing and Copying are HVPS failure. 09-060 fault Perform 09-060 RAP.
08-568 Clear jam in Tray 5 Paper did not reach the tray 5 Clear jam or perform unavailable
feed sensor in time 08-115, 08-117 RAP
09-570 The Xerographic module is Xerographic module CRUM Perform 09-399 RAP.
08-570 Post jam clearance initial The IOT and finisher device Status clears on com- not compatible with this authorization failure. 09-399.
is at ion in progress are performing the post jam pletion of initialization machine. Please refer to The status clears when the
clearance initialization pro- process the User Guide associated has been cleared
cess to check for stray sheets
09-584 Re-order, but do not Xerographic module near end Re-order a new xero-
08-580 Paper jam not fully cleared A stray sheet has been Jam clearance. Per- replace xerographic mod- of life graphic module, (35
detected in either the IOT or form 08-190 RAP ule ppm) PL 9.22 Item 2,
finisher device during the post (40-90 ppm) PL 9.20
jam clearance initialization rou- Item 2.
tine. 08-190
09-585 Replace Xerographic Mod- Xerographic module end of life Refer to the 03D Soft-
08-590 An unexpected time-out Unexpected event or time-out Perform 08-171 RAP, ule ware Module Failure
was detected for a sheet in for sheet. 08-171, 08-181, 08- 08-181 RAP, 08-182 RAP before a new
the paper path. This may 182 RAP xerographic module is
be due to a different paper installed (35 ppm) PL
in the trays than the 9.22 Item 2, (40-90
machine expects. Please ppm) PL 9.20 Item 2.
check and confirm the con- Refer to GP 27, End of
tents of the paper trays Life Extension

Status Status
09-586 Replace xerographic mod- IOT detects an xerographic Switch the machine off 09-599 Toner cartridge nearly When less than X days pre- Order a new toner car-
ule module failure and on, GP 14. Install empty. Ensure you have a dicted until toner cartridge end tridge, PL 9.15 Item 4,
a new xerographic replacement cartridge of life PL 9.17 Item 4.
module Or cleared when 02-
09-587 The Xerographic Module is The system setting does not Install correct xero- 560 status code is
not compatible with this match the xerographic module graphic module or raised.
machine. type modify setting
09-588 The Xerographic Module is The system setting does not Install correct xero-
not compatible with this match the xerographic module graphic module or Table 9 10-5XX Status codes
machine. market region ID setting modify setting
Status
09-589 The Xerographic Module is The system setting does not Install correct xero- Code UI Message Reason for Message Reference / Action
not compatible with this match the xerographic module graphic module or
machine. speed setting modify speed setting 10-505 The fuser is warming up. Fuser not at temperature Perform 10-322, 10-
Printing may be delayed 324, 10-325, 10-330,
09-590 Ozone filter near end of Ozone life counter near end of Order a new ozone fil-
10-370 RAP
life, ensure you have a life ter, PL 9.25 Item 3.
replacement filter 10-507 Open front door Sheet is near the IOT exit sen- Jam clearance or per-
sor in the non-invert path form 10-120, 10-121,
09-591 Replace Ozone Filter Ozone life counter reaches end Install new ozone fil-
10-126
of life ter, PL 9.25 Item 3
10-508 Open front door Sheet is near the IOT exit sen- Jam clearance or per-
09-592 Toner cartridge empty Toner level sensor registers Install new toner car-
sor in the left hand side of the form 10-120, 10-121,
developer sump not full tridge, PL 9.15 Item 4,
invert path 10-126
PL 9.17 Item 4.
10-509 Open front door Sheet is near the IOT exit sen- Jam clearance or per-
09-593 Replace toner cartridge Accumulated toner dispense Install new toner car-
sor in the right hand side of the form 10-120, 10-121,
time value greater than 27 s tridge. Perform 09-
invert path 10-126
attained, or cycle out event 310, 09-390 RAP
occurs (Toner cartridge empty). 10-510 Clear jam in IOT zone 4 Post fuser sensor detects Perform 10-107, 10-
09-390 paper in post fuser area on 108, 10-109, 10-110
power-on or in standby RAP
09-594 Replace waste toner bottle Waste toner shutdown counter Install new waste toner
value attained OR if waste bottle, PL 9.10 Item 1. 10-511 Open front door Sheet near post fuser sensor Jam clearance or per-
toner shutdown counter value form 10-107, 10-108,
greater than 50% and cycle out 10-109, 10-110 RAP
event occurs 10-512 Open front door IOT exit sensor paper in IOT Jam clearance. Per-
09-595 Waste toner bottle nearly Waste toner full sensor regis- Perform 09B RAP exit area at power -on or start form 10-120, 10-121,
full, ensure you have a ters full for greater than 100 print 10-126 RAP
replacement bottle pages. 10-513 Open front door Sheet near IOT exit sensor Jam clearance. Per-
09-596 Ensure waste toner bottle IOT detects waste bottle door Ensure waste bottle fit- form 10-120, 10-121,
is fitted and waste toner open. ted and door closed. 10-126 RAP
door is closed Perform 09-380 RAP 10-516 Output tray nearly full Printer bin 0 90% full sensor Unload the tray
09-597 Toner control failure Toner concentration process Perform 09-360, 09- made
control failure. 361, 09-362, 09-363 10-520 Replace fuser module Fuser counter reaches 300 k Install new fuser mod-
RAP prints ule, PL 10.10 Item 1,
09-598 Toner control sensor fail- Toner control sensor failure. Perform 09-360, 09- PL 10.8 Item 1. Refer
ure 361, 09-362, 09-363 to GP 27, End of Life
RAP Extension

Status Status
10-521 Re-order but do not Fuser counter reaches 290 k Refer to the 03D Soft- 10-570 Replace fuser module FRU CRUM authorization fail- Perform 10-399 RAP
replace fuser module prints ware Module Failure ure. Status active when fault
RAP before ordering a 10-399 raised
new fuser module, PL 10-571 Clear the jam in Areas 3,4. Paper detected in inverter area Perform 10-132, 10-
10.10 Item 1, PL 10.8 Close the front door when on power up or in standby 133, 10-134 and 10-
Item 1. the paper has been 107, 10-108, 10-109,
10-523 Replace fuser module IOT detects fuser failure Install new fuser mod- removed 10-110
ule, PL 10.10 Item 1, 10-572 Clear the jam in Areas 3,4. Paper detected near the Perform 10-132, 10-
PL 10.8 Item 1. Close the front door when inverter sensor on power up or 133, 10-134 and 10-
10-530 The fuser module is not The system setting does not Install new fuser mod- the paper has been in standby 107, 10-108, 10-109,
compatible with this match the fuser type setting ule or modify settings removed 10-110
machine. Please refer to (service offering)
the user guide
10-531 Incompatible fuser module The system setting does not Install a new fuser or Table 10 11-5XX to 9XX Status codes
match the fuser type setting modify settings
(fuser voltage) Status
10-532 Incompatible fuser module The system setting does not Install a new fuser or
match the fuser OpCo ID set- modify OpCo ID set- 11-500 Ensure output module is Output module un-docked in Dock the output mod-
ting (Market region) ting docked standby. ule. Perform 11-300-
10-533 Incompatible fuser module The system setting does not Install a new fuser or 110, 11-302-110, 11-
match the fuser product speed modify the product 303-110 RAP for 2K
setting speed setting LCSS, 11-300-120,
11-302-120, 11-303-
10-540 Please wait adjusting Fuser temperature control fail- Perform 10-322, 10-
120 for 1K LCSS, 11-
fuser temperature ure. 324, 10-325, 10-330,
300-171, 11-302-171,
10-370 RAP, 10-315,
11-303-171 RAP for
10-320, 10-321, 10-
HVF
323, 10-340, 10-350,
10-360, 10-365, 10- 11-501 Close the output module Output module entry gate Close the exit cover
380 RAP top tray opened in standby
10-545 Fuser module under tem- Fuser warm-up failure. Perform 10-322, 10- 11-502 Close output module top Output module top cover Perform 11-300-110,
perature fault. Printing is 324, 10-325, 10-330, cover opened in standby 11-302-110, 11-303-
unavailable. If fault per- 10-370 RAP 110 RAP for 2K
sists, call for assistance. LCSS, 11-300-120,
Touch Ignore Error to use 11-302-120, 11-303-
other services 120 for 1K LCSS, 11-
300-171, 11-302-171,
10-550 Fuser module temperature Hardware detected fuser fail- Perform 10-315, 10-
11-303-171 RAP for
fault. Printing is unavail- ure. 320, 10-321, 10-323,
HVF
able. If fault persists, call 10-340, 10-350, 10-
for assistance. Touch 360, 10-365, 10-380 11-503 Close output module front Output module front door open Perform 11-300-110,
Ignore Error to use other RAP door in standby 11-302-110, 11-303-
services 110 RAP for 2K
LCSS, 11-300-120,
10-555 Fuser module control fail- Fuser control software failure. Perform 10-322, 10-
11-302-120, 11-303-
ure. Printing is unavail- 324, 10-325, 10-330,
120 for 1K LCSS, 11-
able. If fault persists, call 10-370 RAP
300-171, 11-302-171,
for assistance. Touch
11-303-171 RAP for
Ignore Error to use other
HVF
services

Table 10 11-5XX to 9XX Status codes Table 10 11-5XX to 9XX Status codes
Status Status
11-506 Close the Top Left door of HVF Inserter top cover is open Close cover. Perform 11-518 Open output device door Sheet detected over top exit Perform 11-130-110,
the Finisher. 11-306-171, 11-309- sensor 11-132-110 RAP for
171 RAP 2K LCSS, 11-130-
11-507 Close the Tri-Folding Unit HVF Tri-Folder top cover is Close cover. Perform 120, 11-132-120 RAP
Top Cover. open 11-307-171, 11-308- for 1K LCSS, 11-130-
171 RAP 171, 11-132-171 RAP
for HVF
11-508 Close the Tri-Folding Unit HVF Tri-Folder front door is Close door. Perform
Front Door. open 11-307-171, 11-308- 11-519 Open output device door Sheet near top exit sensor at Perform 11-130-110,
171 RAP shutdown 11-132-110 RAP for
2K LCSS, 11-130-
11-509 Close the Top Left door of HVF Inserter left hand door is Close cover. Perform
120, 11-132-120 RAP
the Finisher. open 11-306-171, 11-309-
for 1K LCSS, 11-130-
171 RAP
171, 11-132-171 RAP
11-510 Open output device door Sheet detected over entry sen- Perform 11-100-110 for HVF
sor RAP for 2K LCSS, 11-
11-520 Clear jam in area 5 Paper or debris covering the Perform 11-140-110,
100-120 for 2K LCSS,
sensors 11-142-110 RAP for
11-100-171, 11-101-
2K LCSS, 11-140-
171 RAP for HVF
120, 11-142-120 RAP
11-511 Open output device door Sheet near entry sensor at Perform 11-100-110 for 1K LCSS, 11-140-
shutdown RAP for 2K LCSS, 11- 171, 11-142-171 RAP
100-120 for 2K LCSS, for HVF
11-100-171, 11-101-
11-521 Open output device door Sheet near 2nd to top exit sen- Perform 11-140-110,
171 RAP for HVF
sor 11-142-110 RAP for
11-512 Open output device door Sheet detected over punch Perform 11-110-110 2K LCSS, 11-140-
sensor RAP for 2K LCSS, 11- 120, 11-142-120 RAP
044-171 to 11-047- for 1K LCSS, 11-140-
171 for HVF 171, 11-142-171 RAP
11-513 Open output device door Sheet near punch sensor at Perform 11-110-110 for HVF
shut down RAP for 2K LCSS, 11- 11-522 Open output device door Sheet over the BM exit sensor Perform 11-180-171,
044-171 to 11-047- 11-182-171 RAP
171 for HVF
11-523 Open output device door Sheet near the BM exit sensor Perform 11-180-171,
11-514 Open output device door Sheet detected over compiler Perform 11-158-171, 11-182-171 RAP
sensor 11-160-171, 162-171,
11-524 Page-over PPI Pickup Sen- Sheet over the inserter pickup Clear the area or per-
163-171 RAP
sor sensor form 11-479-171 RAP
11-515 Open output device door Sheet near 2nd to top exit sen- Perform 11-140-110,
11-525 Page-over PPI Tab Sheet over the inserter tab Clear the area or per-
sor 11-142-110 RAP for
Standby Sensor standby sensor form 11-191-171, 11-
2K LCSS, 11-140-
193-171, 11-194-171,
120, 11-142-120 RAP
11-196-171 RAP
171, 11-142-171 RAP 11-526 Page over Buffer Position Sheet over the buffer position Clear the area or per-
for HVF Sensor sensor form 11-198-171, 11-
199-171 RAP
11-516 Open output device door Sheet detected over edge reg- Perform 11A-110 RAP
istration sensor for 2K LCSS 11-527 Page over exit HVF into Sheet over the HVF exit into Clear the area or per-
Booklet Maker Sensor BM sensor form 11-198-171, 11-
199-171 RAP
11-528 Page over Stacker Bin Exit Sheet over the stacker bin exit Clear the area or per-
Sensor sensor form 11-140-171, 11-
142-171

Status Status
11-529 Page over Tri-fold Entry Sheet over the tri-folder entry Clear the area or per- 11-550 Hole punching is unavail- There are too many pages for Instruct customer to
Sensor sensor form 11-183-171, 11- able the punch to operate use fewer pages in
184-171 RAP the set (max 50
11-530 Page-over BB compiler Sheet over the booklet maker Clear the area or per- sheets)
Sensor entry sensor form 11-183-171, 11- 11-551 Hole punching is unavail- The punch operation has been Perform 11-043-110,
184-171 RAP able taken out of service 11-350-110 RAP for
11-538 Job in progress. Manual Offline stapling requested while Cleared when current 2K LCSS, 11-044-171
stapling will be available a print job is in progress for out- job completed to 11-047-171 RAP
when the current output job put to any bin other than bin 0 for HVF
set completes (top bin) 11-552 Hole punching is unavail- There are too many pages for Instruct customer to
11-539 Job in progress. Please Offline stapling is Ready and a Cleared when offline able the punch to operate use fewer pages in
wait until Manual Stapling user requests a print job for out- stapling mode is can- the set (max 50
job is complete put to the stacker, mailboxes or celled sheets)
BM 11-553 Stapling not available. Stapling disabled, out of service Perform 11-050-110,
11-540 Replace punch head unit Punch head present sensor not Perform 11-043-110, Please call for assistance 11-360-110 RAP for
made 11-350-110 RAP for 2K LCSS, 11-050-
2K LCSS, 11-044-171 120, 11-360-120 RAP
to 11-047-171 RAP for 1K LCSS, 11-050-
for HVF 120, 11-360-120 RAP
for HVF
11-541 Punch Chad Bin Set State The chad bin has been Reinstall the chad bin.
removed from the finisher Perform 11N-171 11-554 Stapling disabled, out of Stapling disabled, out of staples Perform 11-050-110,
RAP staples 11-360-110 RAP for
2K LCSS, 11-050-
11-542 Staple count low. Please BM staples low Perform 11-063-171,
120, 11-360-120 RAP
ensure you have replace- 11-411-171 RAP
ment Xerox staple car-
120, 11-360-120 RAP
tridge.
for HVF
11-543 BM out of staples. Please BM staples empty Perform 11-063-171,
11-555 Stapling feature requires Stapling disabled, zero / one Instruct customer
replace the staple car- 11-411-171 RAP
two or more pages page
tridges
11-560 Staple capacity exceeded. BM disabled - too many pages Each booklet must not
11-545 Staple count low. Please Staple cartridge low Perform 11-364-110
Job completed without sta- exceed 15 sheets
ensure you have replace- RAP for 2K LCSS, 11-
pling
ment Staple Cartridge 364-120 RAP for 1K
LCSS, 11-371-171 to 11-561 BM out of staples. Please BM disabled - out of staples Perform 11-063-171,
11-377-171 RAP for replace the staple car- 11-411-171 RAP
HVF tridges
11-546 Replace staple cartridge Staple cartridge empty Perform 11-364-110 11-562 BM requires two or more BM disabled - zero/one page Requires two or more
RAP for 2K LCSS, 11- pages sheets to enable sta-
364-120 RAP for 1K pling
LCSS, 11-371-171 to 11-563 BM is unavailable. Please BM disabled - out of service Switch off the
11-377-171 RAP for call for assistance machine then switch
HVF on the machine, GP
11-549 Empty chad bin Hole punch chad bin is full and Perform 11-364-110 14. Perform 11B-171
needs emptying RAP for 2K LCSS, RAP
11N-171 for HVF

Status Status
11-564 No message Bin status message received Perform 11-130-110, 11-573 Output tray nearly full Bin 1 90% full sensor made Perform 11-030-110,
from the finisher indicating bin 0 11-132-110 RAP for 11-334-110, 11-335-
out of service 2K LCSS, 11-130- 110, 11-336-110 RAP
120, 11-132-120 RAP for 2K LCSS, 11-030-
for 1K LCSS, 11-130- 120, 11-334-120, 11-
171, 11-132-171 RAP 335-120, 11-336-120
for HVF RAP for 1K LCSS, 11-
11-565 No message Bin status message received Perform 11-140-110, 460-171 to 11-462-
from the finisher indicating bin 1 11-142-110 RAP for 171 RAP for HVF
out of service 2K LCSS, 11-140- 11-574 Output Tray full. Please Finisher bin 2 full Perform 11C-171
120, 11-142-120 RAP empty the Output Tray. RAP
for 1K LCSS, 11-140- 11-575 Output tray nearly full Bin 2 90% full sensor made Perform 11C-171
171, 11-142-171 RAP RAP
for HVF
11-598 Output Trays out of ser- Output trays have reached Cleared when con-
11-566 No message Bin status message received Perform 11-140-110, vice. Remove all paper there capacity. firm button pressed
from the finisher indicating bin 2 11-142-110 RAP for from Output Trays.
out of service 2K LCSS, 11-140-
11-901 Unable to staple. check for Tamper move or paddle roll Clear the paper jam.
120, 11-142-120 RAP
obstructions in the output fault Switch off the
trays machine then switch
171, 11-142-171 RAP
on the machine, GP
for HVF
14. Perform 11-005-
11-570 Finisher bin 0 full Fifty additional prints have been Perform 11-130-110, 110, 11-006-110, 11-
sent to bin 0 since 90% full sen- 11-132-110 RAP for 310-110, 11-311-110
sor made 2K LCSS, 11-130- RAP for 2K LCSS, 11-
120, 11-132-120 RAP 007-110, 11-008-110,
for 1K LCSS, 11-130- 11-312-110, 11-313-
171, 11-132-171 RAP 110, 11-319-110 RAP
for HVF for 2K LCSS, 11-024-
11-571 Output tray nearly full Bin 0 90% full sensor made Perform 11-130-110, 110, 11-025-110 RAP
11-132-110 RAP for for 2K LCSS, 11-005-
2K LCSS, 11-130- 120, 11-006-120, 11-
120, 11-132-120 RAP 310-120, 11-311-120
for 1K LCSS, 11-130- RAP for 1K LCSS, 11-
171, 11-132-171 RAP 007-120, 11-008-120,
for HVF 11-312-120, 11-313-
11-572 Output Tray full. Please Fifty additional prints have been Perform 11-030-110, 120, 11-319-120 RAP
empty the Output Tray. sent to bin 1 since 90% full sen- 11-334-110, 11-335- for 1K LCSS, 11-024-
sor made 110, 11-336-110 RAP 120, 11-025-120 RAP
for 2K LCSS, 11-030- for 1K LCSS, 11-024-
120, 11-334-120, 11- 171, 11-026-171, 11-
335-120, 11-336-120 392-171 to 11-395-
RAP for 1K LCSS, 11- 171, 11-396-171 to
460-171 to 11-462- 11-399-171 RAP for
171 RAP for HVF HVF

Status Status
11-902 Output tray 1 out of ser- Tamper move or Bin 1 or com- Clear the paper jam. 11-904 Output trays 1 and 2 out of Tamper home or paddle roll or Clear the paper jam.
vice. Check for obstruc- piler eject or staple fault Switch off the service. Check for obstruc- compiler or stapling fault Switch off the
tions in output tray 1 machine then switch tions in the output trays machine then switch
on the machine, GP on the machine, GP
14. Perform 11-005- 14. Perform 11-005-
110, 11-006-110, 11- 110, 11-006-110, 11-
310-110, 11-311-110 310-110, 11-311-110
RAP for 2K LCSS, 11- RAP for 2K LCSS, 11-
007-110, 11-008-110, 007-110, 11-008-110,
11-312-110, 11-313- 11-312-110, 11-313-
110, 11-319-110 RAP 110, 11-319-110 RAP
110, 11-025-110 RAP 110, 11-025-110 RAP
120, 11-006-120, 11- 120, 11-006-120, 11-
310-120, 11-311-120 310-120, 11-311-120
007-120, 11-008-120, 007-120, 11-008-120,
11-312-120, 11-313- 11-312-120, 11-313-
120, 11-319-120 RAP 120, 11-319-120 RAP
120, 11-025-120 RAP 120, 11-025-120 RAP
171, 11-026-171, 11- 171, 11-026-171, 11-
392-171 to 11-395- 392-171 to 11-395-
171, 11-396-171 to 171, 11-396-171 to
11-399-171 RAP for 11-399-171 RAP for
HVF HVF
11-903 Some finishing features are Compiler carriage or stapling Clear the paper jam.
unavailable. Check for fault Switch off the
obstructions in the finisher machine then switch
on the machine, GP
14. Perform 11-364-
110 RAP for 2K
LCSS, 11-364-120
RAP for 1K LCSS, 11-
172-171, 11-180-171,
11-182-171, 11-185-
171 to 11-187-171,
11-371-171 to 11-377-
171 RAP for HVF

Status Status
11-905 Offsetting is unavailable Bin 1 offset motor fails to move Clear the paper jam. 11-910 Stapler is unavailable. Stapler head motor 1 fails to Clear obstruction from
from output tray 1. Check or home. Switch off the Check for obstructions in move or not primed stapler. Perform 11-
for obstructions in output machine then switch the stapler. 050-110, 11-360-110
tray 1 on the machine, GP RAP for 2K LCSS, 11-
14. Perform 11-005- 050-120, 11-360-120
110, 11-006-110, 11- RAP for 1K LCSS, 11-
310-110, 11-311-110 371-171 to 11-377-
RAP for 2K LCSS, 11- 171 RAP for HVF
007-110, 11-008-110, 11-911 Stapling is unavailable. Staple head 2 motor fails to Clear obstruction from
11-312-110, 11-313- Check for obstructions in move stapler. Perform 11-
110, 11-319-110 RAP the BM stapler. 063-171, 11-411-171
for 2K LCSS, 11-024- RAP for HVF
110, 11-025-110 RAP
11-912 Some finishing features are Stapler unit 1 fails to move Clear obstruction from
unavailable. Check for stapler. Perform 11-
120, 11-006-120, 11-
obstructions in the stapler. 053-110, 11-370-110
310-120, 11-311-120
371-171 to 11-377-
007-120, 11-008-120,
171 RAP for HVF
11-312-120, 11-313-
120, 11-319-120 RAP 11-913 Booklet making is unavail- Back stop motor fails to move Clear the paper jam.
for 1K LCSS, 11-024- able. Check for obstruc- or not home Switch off the
120, 11-025-120 RAP tions in the BM machine then switch
for 1K LCSS, 11-024- on the machine, GP
171, 11-026-171, 11- 14. Perform 11-065-
392-171 to 11-395- 171, 11-383-171, 11-
171, 11-396-171 to 403-171, 11-413-171,
11-399-171 RAP for 11-414-171 RAP for
HVF HVF
11-908 Hole punching is unavail- Punch head motor fails Clear the paper jam. 11-914 - Rear tamper away home sen- Clear the paper jam.
able. Check for obstruc- Perform 11-043-110, sor failure Switch off the
tions in the hole puncher 11-350-110 RAP for machine then switch
2K LCSS, 11-044-171 on the machine, GP
to 11-047-171 RAP 14. Perform 11-007-
for HVF 110, 11-008-110, 11-
312-110, 11-313-110,
11-909 All output trays are unavail- Punch head home sensor not Clear the paper jam.
11-319-110 RAP for
able. Check for obstruc- made Switch off the
2K LCSS, 11-007-
tions in the finisher machine then switch
120, 11-008-120, 11-
on the machine, GP
312-120, 11-313-120,
14. Perform 11-030-
11-319-120 RAP for
110, 11-334-110, 11-
1K LCSS
335-110, 11-336-110
RAP for 2K LCSS, 11- 11-915 - HVF staple cartridge empty Replace the staple
030-120, 11-334-120, cartridge. Perform 11-
11-335-120, 11-336- 371-171 to 11-377-
120 RAP for 1K 171 RAP
LCSS, 11-044-171 to 11-916 - HVF staples low Replace the staple
11-047-171 RAP for cartridge. Perform 11-
HVF 371-171 to 11-377-
171 RAP

Status Status
11-917 Clear the paper jam in the Sheet over HVF BM compiler Clear the HFV BM 11-931 - Paper is not detected in the Check the paper. If
Finisher. paper present sensor paper present sensor inserter tray necessary, perform
area. Perform 11-172- 11J-171 RAP
171 RAP 11-932 Clear the paper jam in the Sheet detected near the Clear the sheet. If
11-918 - Sheet over tri- folder assist sen- Perform 11-185-171 Finisher. inserter pickup sensor necessary, perform
sor to 11-187-171 RAP 11-191-171, 11-193-
11-919 - Sheet over tri- folder exit sensor Perform 11-185-171 171, 11-194-171, 11-
to 11-187-171 RAP 196-171 RAP
11-920 The Booklet Maker and Tri- Failure of any BM or TF func- Check for obstruc- 11-933 Clear the paper jam in the Sheet detected near the Check the paper. If
folder are currently unavail- tion tions in the HVF BM Finisher. inserter tab standby sensor necessary, perform
able and the tri-folder. 11-191-171, 11-193-
Check that the HVF 171, 11-194-171, 11-
BM and tri-folder 196-171 RAP
interlocks are made. 11-934 - Sheet detected near the entry Clear the sheet.
Switch the machine sensor Check the HVF is
OFF and ON, GP 14. docked and correctly
Check the current aligned. If necessary,
fault codes list for perform 11-100-171,
HVF BM or tri-folder 11-101-171 RAP
faults and perform the 11-935 Clear the paper jam in the Sheet detected near the buffer Clear the sheet. If
appropriate RAP. Finisher. sensor necessary, perform
11-921 Please close the Booklet The stapler position sensor indi- Close the BM stapler 11-157-171, 11-161-
Maker Stapler module cates the stapler module is not module. If necessary, 171 RAP and 11-164-
closed in initialisation perform 11-063-171, 171, 11-165-171 RAP
11-411-171 RAP for 11-936 Clear the paper jam in the Sheet detected near Exit HVF Clear the sheet. If
staple unit 1, and 11- Finisher. to BM entry sensor necessary, perform
403-171, 11-413-171, 11-158-171, 11-160-
11-414-171 RAP for 171, 162-171, 163-
staple unit 2 171 RAP
11-926 Booklet Maker Stapling is Failure of the booklet maker Perform 11-063-171, 11-938 Clear the paper jam in the Sheet detected near the top bin Perform 11-130-171,
currently unavailable stapling functions. 11-411-171 RAP for Finisher. exit sensor 11-132-171 RAP
staple unit 1, and 11-
11-940 - Tray ready for unloading Follow the instruc-
403-171, 11-413-171,
tions to unload the
11-414-171 RAP for
tray. If necessary, per-
staple unit 2
form 11-460-171 to
11-928 - Booklet maker output tray is full Empty the tray. If nec- 11-462-171 RAP for
essary, perform 11C- the stacker tray, 11-
171 RAP 130-171, 11-132-171
11-929 - The stacker tray is 90% full Empty the stacker RAP for the top tray,
tray when conve- and 11C-171 for the
nient. If necessary, HVF BM tray
perform 11-460-171 to 11-941 Pause To Unload Time-out Machine is paused for unload- Follow the instruc-
11-462-171 RAP Warning ing. Need to press button on tions. If necessary,
11-930 - The stacker tray is full Empty the stacker pop up screen perform 11H-171
tray. If necessary, per- 11-942 Pause To Unload Time-out Timer expiry. Wait for machine Follow the instruc-
form 11-460-171 to Warning to pause, then press button on tions. If necessary,
11-462-171 RAP pop up screen perform 11H-171

Status Status
11-943 Booklet Making and Tri- Booklet making or tri-folding Check for obstruc- 11-949 Finisher Insert Stock Out of An insert sheet has not arrived See the message
folding are unavailable. capability degraded tions in the HVF BM Order at its intended output destina- text. If necessary, per-
Check for obstructions and the tri-folder. tion form 11-191-171, 11-
Check that the HVF 193-171, 11-194-171,
BM and tri-folder 11-196-171 RAP and
interlocks are made. 11-100-171, 11-101-
Switch the machine 171 RAP
OFF and ON, GP 14. 11-950 Unexpected Stock Size in A shorter than expected sheet Follow the message
Check the current the Finisher has been fed from the inserter text. Check the size of
fault codes list for the paper in the
HVF BM or tri-folder inserter.
faults and perform the
11-951 Clear the paper jam in the Page detected near the stacker Clear the sheet. If
appropriate RAP.
finisher bin exit sensor necessary, perform
11-944 Inserter is unavailable. Inserter capability degraded Check for obstruc- 11-140-171, 11-142-
Check for obstructions in tions in the inserter. If 171 RAP
the inserter necessary, perform
11-952 Open the Finisher Front Page over Buffer Path Sensor Clear Buffer Path
11-191-171, 11-193-
Door Sensor, perform 11-
171, 11-194-171, 11-
157-171, 11-161-171
196-171 RAP and
RAP and 11-164-171,
11J-171 RAP
11-165-171 RAP for
11-945 Booklet Making available. All trays have degraded capa- Check for obstruc- HVF
All other output trays bility, except booklet maker tions in the buffer,
11-953 Open the Finisher Front Page detected near buffer path Clear sheet near
unavailable stacker and top tray
Door sensor buffer path sensor,
areas. Switch the
perform 11-157-171,
machine OFF and
11-161-171, 11-164-
ON, GP 14. Check
171, 11-165-171RAP
the current fault codes
for HVF
list for faults in the
buffer, stacker and top 11-954 No message 100 sheet staple cartridge N/A
tray areas and per- installed in finisher
form the appropriate 11-955 Open Finisher Top Cover. Page over Inserter Lead Edge Clear Inserter Lead
RAP. Remove Paper. Sensor Edge Sensor, per-
11-946 Clear the paper jam in the Sheet detected near the tri-fold Clear the sheet. If Close Finisher Top Cover. form 11-479-171 RAP
Tri-Folding Unit entry sensor necessary, perform for HVF
11-183-171, 11-184- Table 11 12-5XX Status codes
171 RAP
11-947 Clear the paper jam in the Sheet detected near the tri-fold Clear the sheet. If Status
Tri-Folding Unit exit sensor necessary, perform Code UI Message Reason for Message Reference / Action
11-185-171 to 11-187- 12-530 Offsetting is unavailable. Offsetting catch tray is not in Perform 12-301 RAP
171 Check for obstructions in index position.
11-948 Clear the paper jam in the Sheet detected near the tri-fold Clear the sheet. If the output tray
Tri-Folding Unit assist sensor necessary, perform
11-185-171 to 11-187-
171 RAP

Status
Status
14-564 No message Job is incomplete, scan ser- Resume the scanning
vice is ready and needs a job, or press the can-
14-508 System error, scanner is Status active when start is Switch off the resume command cel key. If the status
unavailable selected but scan service is machine then switch code is still present,
unable to acquire resources on the machine, GP switch off the
14. Wait for a few min- machine, then switch
utes, if scanning is still on the machine, GP
not available, go to 14
03-330, 03-462 RAP 14-565 No message Document is larger than Close status popup or
14-560 Scanner is calibrating, Scanner is calibrating If calibration does not expected press start, Perform
please wait complete, switch off 14A RAP
the machine, then 14-566 Reload originals and press CCD (width) and length sen- Reposition originals
switch on the start sors cannot determine size of and press start, Per-
machine, GP 14. Wait the original form 14A RAP
for a few minutes, if
the scanner contin-
ues to calibrate with-
out completing Table 13 16-5XX to 7XX Status codes
perform 14-703 to 14- Status
706, 712, 714, 716,
718 RAP
14-561 No message Downloaded NVM values are Switch off the 16-500 No message Print from file cabinet is The status is disabled
out of range and too low. SVCM machine, then switch enabled via the Web UI when the print from
received NVM data within cor- on the machine, GP file cabinet is disabled
rect range 14. Wait for a few min- via the Web UI
utes, if scanning is still 16-501 Some network services Not enough memory on the Machine restart initi-
not available perform unavailable. Please notify image processing for JBA ated
03-330, 03-462 RAP the machine administrator
14-562 Adjustments in progress Scanner ready checks are not If the ready check 16-502 The network controller is Status active when ever the Cleared when the net-
complete does not complete, about to be reset network controller detects that a work controller reset
switch off the platform reset is about to occur is initiated
machine, then switch 16-504 Some network services Dynamic domain name regis- Machine restart initi-
on the machine, GP unavailable. Please notify tration process failed ated
14. Wait for a few min- the machine administrator
utes, if the scanner 16-505 Some network services Insufficient memory for E-mail More physical mem-
continues to check unavailable. Please notify ory needs to be
without completing the machine administrator added to the platform
perform 03-330, 03-
462 RAP 16-506 Machine cloning is in pro- Status raised while Network Cleared automati-
cess. This shall take a few controller connectivity settings cally when cloning is
14-563 Scanner has failed to initai- Scanner needs service Switch off the minutes to complete are being cloned completed
ilize. Switch off the machine then switch
machine, wait 3 minutes, on the machine, GP 16-507 Some network services Service location protocol pro- Machine restart initi-
then switch on the 14. Perform 14-110 unavailable. Please notify cess failed ated
machine. If fault persists RAP, 14-310 RAP, 14- the machine administrator
call for assistance, or press 710 RAP 16-508 Some network services Autonet address resolution did Machine restart initi-
close to use other services unavailable. Please notify not work ated
the machine administrator

Status Status
16-509 Some network services Insufficient memory for internet Machine restart initi- 16-524 Some Network Controller The network controllers Ker- Machine restart initi-
unavailable. Please notify fax ated services are not available. beros service process has ated
the machine administrator Please notify the machine stopped
16-510 Some network services E-mail process failed Machine restart initi- administrator
unavailable. Please notify ated 16-525 Some Network Controller The network controllers Scan Machine restart initi-
the machine administrator services are not available. to Distribution service process ated
16-511 Some network services Internet fax process failed Machine restart initi- Please notify the machine has stopped
unavailable. Please notify ated administrator
the machine administrator 16-526 Some Network Controller The network controllers SMB Machine restart initi-
16-512 Some network services USB printer port process failed Machine restart initi- services are not available. service process has stopped. ated
unavailable. Please notify ated Please notify the machine
the machine administrator administrator
16-513 Some network services Simple service discovery proto- Machine restart initi- 16-527 Some Network Controller The network controllers TCP/IP Machine restart initi-
unavailable. Please notify col failed ated services are not available. service process has stopped. ated
the machine administrator Please notify the machine
administrator
16-514 Some network services Post office protocol (for inbound Machine restart initi-
unavailable. Please notify IFAX messages) process failed ated 16-528 Some Network Controller The network controllers WS Machine restart initi-
the machine administrator services are not available. Scan Temp service process has ated
Please notify the machine stopped.
16-517 Some network services SMTP process failed Machine restart initi-
administrator
unavailable. Please notify ated
the machine administrator 16-529 Some Network Controller The network controllers Scan Machine restart initi-
services are not available. Compressor service process ated
16-518 Some Network Controller ESS web services edge client Machine restart initi-
Please notify the machine has stopped.
services are not available. interface does not work ated
administrator
Please notify the machine
administrator 16-535 Immediate Job Overwrite ESS Immediate Image Over- The status is cleared
failed. Please perform and write Error when the ESS com-
16-519 Some Network Controller ESS web services client con- Machine restart initi-
On Demand Overwrite pletes the On
services are not available. troller does not work ated
immediately Demand Image Over-
write
administrator
16-536 Network controller error. The ESS XSA service is The ESS XSA ser-
16-520 Some Network Controller ESS web services server con- Machine restart initi-
Please contact system unavailable. The fault is due to vice becomes avail-
services are not available. troller interface does not work. ated
administrator. a failure of internal communica- able.
tion in the network controller.
administrator
16-537 Incomplete Network Inter- Any scan to distribution service Switch off the
16-521 Some Network Controller The network controllers CPI Machine restart initi-
face window not available machine then switch
services are not available. service process has stopped ated
on the machine, GP
14.
administrator
16-538 Internal address book Could not communicate with Verify LDAP server
16-522 Some Network Controller The network controllers job log Machine restart initi-
unavailable. Please notify the LDAP server setup at web UI, verify
machine administrator server is online, check
network connectivity
administrator
16-523 Some Network Controller The network controllers job Machine restart initi-
services are not available. tracker service process has ated
Please notify the machine stopped
administrator

Status Status
16-539 Cannot connect to prime or Could not communicate with Verify authentication 16-549 Network scanning is not Network controller - failure of If problem persists,
backup authentication primary or alternate authentica- server setup at web available. Please notify any scan to file services Machine restart initi-
server. tion server UI, verify server is machine administrator ated. Resubmit job.
online, check network 16-550 System reset required, Network controller - system Switch off the
connectivity. Can con- please switch off the enters customer sw upgrade machine then switch
figure authentication machine, then switch on mode on the machine, GP
to use guest mode the machine 14.
16-540 Incomplete Network Inter- Death of any authentication Switch off the 16-551 Accounting out of memory. Network controller - accounting Accounting Adminis-
face window services machine then switch Please notify machine log is full or a hard disk full state trator needs to
on the machine, GP administrator exists retrieve accounting
14. data log from the sys-
16-541 Cannot receive internet Could not communicate will Verify POP3 server tem
jobs. Please call for assis- POP3 server settings at UI. Verify 16-552 Software option codes do Network controller - the flag in Switch off the
tance server is online and not match system manager is not in sync. machine then switch
check network con- with the network controller PM on the machine, GP
nectivity 14.
16-542 Image too large to process. Insufficient resources to pro- Reduce scan size, 16-553 Additional memory Network controller - not enough Add memory
Please alter job and scan cess the image reduce scan resolu- required. Please call for physical memory is configured
again tion assistance on the platform to support scan
16-543 Accounting problem. Network controller - authoriza- Authorization should to file
Please notify machine tion file on the system is cor- be disabled until the 16-554 Hardware must be added Network controller - the IPA Re-insert or replace
administrator rupted. No jobs can be accounting SA can or replaced. Please notify card is either broken or missing IPA card
authorized. purge and reload the machine administrator
authorization data-
16-555 Additional memory required Network controller - not enough Add memory
base
to support fax. Please physical memory is configured
16-544 Ensure network cables are Network controller detected that Check the network notify machine administra- on the platform to support lan
properly connected the network cable is discon- cable connections tor fax
nected
16-556 802.1x Network Error The request to authenticate the Ensure the 802.1x
16-545 Network scanning commu- Network controller - unrecover- Machine restart initi- device credentials with the EAP type, username
nication error. Please notify able scan to file communication ated. Resubmit job authentication server has failed and password for the
machine administrator error machine, authentica-
16-546 Network scanning filing Network controller - network Verify destination tion switch and
error. Please notify repository filing error address; check repos- authentication server
machine administrator itory setup; verify match.
repository is online. 16-557 System error, copier is no Network controller - DC plat- Switch off the
Check network con- longer available form fails to recover in less than machine then switch
nectivity. Resubmit 5 minutes after a crash on the machine, GP
the job 14.
16-547 Network scanning tem- Network controller - scan to file Verify remote tem- 16-558 System error, copier is no Network controller - DC com- DC platform call failed
plates could not be template retrieval failure plate pool settings; longer available munications unavailable
retrieved. Please notify verify that the tem-
16-559 BOOTP initialization failure. Network controller - BOOTP Connectivity fix and
machine administrator plate repository is
Please notify machine (failure) configuration of IP, will switch off the machine
online. Check network
administrator use stored IPdata then switch on the
connectivity
machine, GP 14.
16-548 Network scanning error. Network controller - scan to file Resubmit job. If prob-
Please notify machine job processing error lem persists, Machine
administrator restart initiated

Status Status
16-560 Some network services Some processes on the net- Switch off the 16-573 Network printing disabled. Network controller - MF print Switch off the
unavailable. Please notify work controller have failed machine then switch Please notify machine service has failed machine then switch
machine administrator on the machine, GP administrator on the machine, GP
14. 14.
16-561 Network Scanning Unavail- Some scan to file processes Switch off the 16-574 Job status information not The network controller protocol Switch off the
able have died machine then switch available. Please notify module process has stopped machine then switch
on the machine, GP machine administrator on the machine, GP
14. 14.
16-562 Incomplete Network Inter- Network controller - the line Switch off the 16-575 Network controller connec- The network controller registra- Automatic network
face window printer Deamon process has machine then switch tion is about to be reset tion service process has controller reset
failed on the machine, GP stopped
14. 16-576 Network controller connec- The network controller event Automatic network
16-563 Incomplete Network Inter- Network controller - the Novell Switch off the tion is about to be reset notification service process has controller reset
face window Netware connectivity process machine then switch stopped
has failed on the machine, GP 16-577 Network controller connec- The network controller platform Automatic network
14. tion is about to be reset manager service process has controller reset
16-564 Incomplete Network Inter- Network controller - the Net- Switch off the stopped
face window BIOS connectivity process has machine then switch 16-578 Incomplete system infor- The network controller fault ser- Switch off the
failed on the machine, GP mation. Please notify vice process has stopped (fault machine then switch
14. machine administrator logging will be disabled) on the machine, GP
16-565 Incomplete Network Inter- Network controller - the Apple- Switch off the 14.
face window talk connectivity process has machine then switch 16-579 Job status information not The network controller com- Switch off the
failed on the machine, GP available. Please notify pleted job log service and print machine then switch
14. machine administrator SPI processes have stopped on the machine, GP
16-567 Incomplete Network Inter- Network controller - a Postscript Switch off the 14.
face window interpreter error has occur, machine then switch 16-580 Incomplete system infor- The network controller remote Switch off the
causing the process to fail on the machine, GP mation. Please notify configuration process has machine then switch
14. machine administrator stopped on the machine, GP
16-568 Incomplete Network Inter- Network controller - a PCL Switch off the 14.
face window interpreter error has occurred, machine then switch 16-581 Some network services The network controller diagnos- Switch off the
causing the process to fail on the machine, GP unavailable. Please notify tic service process has stopped machine then switch
14. machine administrator on the machine, GP
16-570 Incomplete Network Inter- Network controller - the http Switch off the 14.
face window server (web-UI) has failed machine then switch 16-582 Some network services The network controller authenti- Switch off the
on the machine, GP unavailable. Please notify cation SPI process has stopped machine then switch
16-571 Network printing disabled. Network controller - print ser- Switch off the 14.
Please notify machine vice has failed machine then switch 16-583 Incomplete system infor- The network controller counters Switch off the
administrator on the machine, GP mation. Please notify utility process has stopped machine then switch
16-572 Network printing disabled. Network controller - print SPI Switch off the 14.
Please notify machine service has failed machine then switch 16-584 Network controller connec- The network controller counters Switch off the
administrator on the machine, GP tion is about to be reset document manager process machine then switch
14. has stopped on the machine, GP
14.

Status Status
16-585 Incomplete system infor- The network controller counters Switch off the 16-597 Incomplete Network Inter- The network controller TIFF Switch off the
mation. Please contact the remote configuration synchroni- machine then switch face window interpreter failed machine then switch
Machine Administrator zation process has stopped on the machine, GP on the machine, GP
14. 14.
16-586 Incomplete system infor- The network controller counters Switch off the 16-598 IP interface error. Please Network controller - TCP / IP Contact SA. Another
mation. Please notify SNMP agent process has machine then switch notify machine administra- address is already in use on the IP address needs to
machine administrator stopped on the machine, GP tor network be used
14. 16-599 Some network services Raw TCP/IP printing (port Machine restart initi-
16-588 Some network services The network controller sub- Switch off the unavailable. Please notify 9100) process failed. ated
unavailable. Please notify agent process has failed machine then switch the machine administrator.
machine administrator on the machine, GP
14.
16-589 Incomplete Network Inter- Network controller - serial port Switch off the Table 14 17-5XX Status codes
face window connectivity failed machine then switch
on the machine, GP Status
14. Code UI Message Reason for Message Reference / Action
16-590 Some network services The network controller connec- Switch off the 17-500 Job stored as <job name> CPSR input job has com- No action required. Infor-
unavailable. Please notify tivity configuration process has machine then switch in <folder name> pleted storage mational text
machine administrator failed on the machine, GP 17-501 Save job for Reprint ser- Network controller unavail- Wait for the network con-
14. vice is unavailable. Please able and customer already troller to become avail-
16-591 Ethernet functions are not Network controller - Ethernet Connectivity fix and try again later within pathway, or CPSR fea- able. If necessary,
available. Please notify TCP / IP port connectivity pro- switch off the machine ture suspended Switch off the machine
machine administrator cess failed then switch on the then switch on the
machine, GP 14. machine, GP 14.
16-592 Token Ring functions are Network controller - Token Ring Connectivity fix and 17-502 <Entered name> already Duplicate file names in Enter a different file
not available. Please notify TCP / IP port connectivity failed switch off the machine exists. Please enter a dif- CPSR input are not allowed. name
machine administrator then switch on the ferent name
machine, GP 14. 17-503 Job deleted due to the CPSR input job in progress Make more space for file
16-593 DHCP functions are not Network controller - DHCP Connectivity fix and device storage disk has been deleted due to storage or re-define
available. Please notify address resolution failed switch off the machine becoming full. Stored jobs memory full pathway
machine administrator then switch on the will need to be deleted to
machine, GP 14. make space available
16-594 RARP functions are not Network controller - RARP Connectivity fix and 17-504 Additional memory is Insufficient memory for Delete saved jobs from
available. Please notify address resolution fails switch off the machine required. Please call for CPSR filing cabinet memory
machine administrator then switch on the assistance.
machine, GP 14. 17-510 IP interface error. Please The IPv6 IP address is Use a different address
16-595 Incomplete Network Inter- The network controller Lan-Fax Switch off the notify system administra- already in use
face window service failed machine then switch tor
on the machine, GP 17-511 Build job scanning error Error during scan to email Inform the customer to
14. build job rescan the last segment
16-596 Incomplete Network Inter- The network controller account- Switch off the or delete the job.
face window ing (JBA) service failed machine then switch 17-513 IP interface error. Please The IPv4 IP address is Use a different address
on the machine, GP notify system administra- already in use
14. tor
17-514 IP interface error. Please External Accounting Device Contact SA.
notify system administra- Communication Failure
tor

Status Status
17-518 Some network controller WSD discovery failure Switch off the machine 19-507 System memory is full etc. Memory resources low High EPC usage. Per-
services are not available. then switch on the form 19-401, 19-402,
Please notify the machine machine, GP 14. 19-403 RAP
administrator. 19-508 System memory is full etc. Internal memory handling sta- Usage is above inter-
17-519 Some network controller WSD print service failure Switch off the machine tus mediate EPC usage
services are not available. then switch on the threshold. Perform 19-
Please notify the machine machine, GP 14. 401, 19-402, 19-403
administrator. RAP
17-520 Some network controller WSD scan service failure Switch off the machine 19-509 System memory is full etc. Internal memory job truncated Usage exceeds inter-
services are not available. then switch on the mediate EPC usage
Please notify the machine machine, GP 14. threshold. Perform 19-
administrator. 401, 19-402, 19-403
17-565 Custom Services are not Raised by the network con- Switch off the machine RAP
responding. Try Powering troller when EIP service is then switch on the 19-510 Please wait, the system is At power up, the image disk is Switch off the
Off then On not responding machine, GP 14. attempting to recover not present or faulty. machine, then switch
17-570 Some network controller Communication with NNTP Switch off the machine on the machine, GP
services are not available. server failed then switch on the 14. Perform 03C RAP
Contact system adminis- machine, GP 14. 19-511 Image disk offline. Jobs may Faulty image disk Switch off the
trator. take longer than normal machine, then switch
17-580 Data encryption / decryp- Raised by the network con- No action. Cleared by on the machine, GP
tion is in progress. troller when disk encryption the network controller. 14. Perform 03C RAP
or decryption has been 19-512 Image disk offline. Please Image disk read or write fail- Switch off the
requested call for assistance ure. machine, then switch
on the machine, GP
14. Perform 03C RAP
Table 15 19-5XX Status codes 19-513 Please wait. The image disk The system has detected that Wait for space to
is full. insufficient space is available become available
Status on the image disk
19-514 An image data error has Video job integrity fault. Should clear automat-
19-502 Please wait, freeing memory Out of memory resources. Perform 19-401, 19- occurred etc. ically. If necessary,
Fault 19-401, 19-402 402, 19-403 RAP perform 19-409 RAP
19-503 System memory is full etc. EPC memory resources low Memory becomes 19-515 System memory is full etc. This status code becomes Cleared when the cur-
available, job is can- active when fault 19-403 is rent job completes or
celled or documents raised when the job is
are removed from deleted. Perform 19-
DADH. Perform 19- 401, 19-402, 19-403
401, 19-402, 19-403 RAP
RAP 19-516 System memory is full etc. EPC memory is full. The status code is
19-504 No message EPC memory resources inter- Clears automatically cleared when either
mediate after being raised. the job is cancelled or
Perform 19-404 RAP the user selects the
19-505 An image data error has Compressor DVMA time-out. Perform 19-404 RAP resume option
occurred etc. Fault 19-404 is raised.
19-506 Please wait, your job will Job delayed status High EPC usage. Per-
continue shortly. Do not form 19-401, 19-402,
press the Start button again 19-403 RAP

Status
Codes UI Message Reason for Message Reference / Action
Status
20-570 A Fax Service error has Status active when the fault Perform 20-342 RAP
Codes UI Message Reason for Message Reference / Action
occurred. Press the power 20-342 is raised
20-544 The Fax service is initialis- Basic Fax card restarts User clears or time- button on the left side of the
ing. Please wait. out. (W/O TAG X-001) machine and choose Quick
Install a new compact Restart. If fault persists,
flash, PL 20.10 Item 3 please call for assistance.
20-545 Fax job could not be sent at Error with image processing - User clears or times 20-571 A Fax Service error has Status active when the fault Perform 20-331, 20-
this time, please try again. fax command out (7 seconds) occurred. Press the power 20-339 is raised 339, 20-341 RAP
20-546 Not enough memory to use This status code becomes Cleared when fault button on the left side of the
fax services. Contact your active when fault 20-324 is 20-324 is cleared. machine and choose Quick
system administrator. raised Perform 20-323, 20- Restart. If fault persists,
324 RAP please call for assistance.
20-547 Fax memory is low. Contact This status code becomes Perform 20-323, 20- 20-572 A Fax Service error has Status active when the fault Perform 20-332, 20-
your system administrator. active when fault 20-323 is 324 RAP occurred. Press the power 20-340 is raised 340 RAP
raised button on the left side of the
20-550 A fax service error has Extended card failure detected Install a new extender machine and choose Quick
occurred. Fax line 2 is card and reboot Restart. If fault persists,
unavailable. Fax line 1is still please call for assistance.
available. Contact your sys- 20-580 No message Set if the NVM values supplied The user interface
tem administrator. by the Fax are invalid requests the single
20-556 A fax service error has Basic card failure detected Switch off the board controller PWB
occurred. Press the power machine, then switch for the Fax NVM val-
button on the left side of the on the machine, GP ues
machine and choose quick 14. 20-590 Immediate Job Overwrite Fax immediate image over- Perform 20-710, 20-
restart. If fault persists, call failed. Please perform an write error. Fault 20-710 is 711 RAP.
for assistance. On Demand Overwrite raised.
20-558 A fax memory error has Status active when fault 20- Cleared when fault immediately.
occurred. Contact your sys- 322 is raised 20-322 is cleared.
tem administrator. Perform 20-322 RAP
20-559 A fax service error has Status active when fault 20- Cleared when fault Table 17 22-5XX Status codes
occurred. Press the power 320 is raised 20-320 is cleared. Status
button on the left side of the Perform 20-320 RAP Codes UI Message Reason for Message Reference / Action
machine and choose quick
restart. If fault persists, call 22-501 Please wait... The system is Attempting print recovery. 22- Perform 22-306 to 22-
for assistance. attempting to recover 306, 22-307, 22-309 315, 22-801, 22-814
RAP
20-562 No communication on fax Status active when fault 20- Cleared when fault
line 1. Please check exter- 331 is raised 20-331 is cleared. 22-502 No UI message appears Status active when fault 22- Automatically clears
nal connection Perform 20-331, 20- 310 is raised after being raised
339, 20-341 RAP 22-504 Please delete the job. No No tray configured for media Configure one tray for
20-563 No communication on fax Status active when fault 20- Cleared when fault tray is configured with the this stock size.
line 2. Please check exter- 332 is raised 20-332 is cleared. required paper size. Press
nal connection Perform 20-332, 20- the Job Status button. Then
340 RAP select the Delete Button.
20-565 Max. number of fax jobs in All jobs IDs allocated cannot Cleared when fax job 22-511 Media required for held job This status code becomes Provide media to
the system has been create any more IDs become available is not available active when correct media is complete the held job
reached. Contact your sys- not available for held job or cancel job
tem administrator.

Status Status
Codes UI Message Reason for Message Reference / Action Codes UI Message Reason for Message Reference / Action
22-512 All the paper trays have All trays direct select only Enable one tray for 22-560 Scheduling fault etc. SML error. Switch off the
been disabled for Auto auto select machine then switch
Selection. Auto Paper can- on the machine, GP
not be used with these set- 14.
tings. It is recommended
that at least one tray be
enabled for Auto Selection
22-513 Media required for held job Queued Job being held due to Add paper to the tray
is not available lack of for resources being used to clear
queued job
22-515 One or more queued jobs Queued Job being held due to Add paper to the tray
needs resources. lack of for resources. being used to clear
queued job
22-547 Network controller error. XSA service unavailable. This Perform 22-370 RAP
Please contact system status code becomes active
administrator. when the fault 22-370 is raised
22-552 Optional service mismatch Service option mismatch Install or remove ser-
detected detected vice option. If neces-
sary, perform 22-410
to 22-416, 22-423, 22-
425, 22-428, 22-777
or 22-400 to 22-403,
22-423, 22-426, 22-
427, 22-775
22-553 Optional service installed Service option installed Informational only
22-554 Option service removed Unable to remove optional ser- Refer to 22-410 to 22-
vice 416, 22-423, 22-425,
22-428, 22-777 RAP,
22-417 RAP
22-555 Unable to install option ser- Service option install failed Refer to 22-400 to 22-
vice when any of the faults 22-400, 403, 22-423, 22-426,
22-401, 22-402, 22-403, 22- 22-427, 22-775 RAP,
404, 22-405, 22-406, 22-407 22-404 to 22-406
are raised RAP, 22-407 RAP
22-556 Unable to remove option Service option removal failed Refer to 22-404 to 22-
service when any of the faults 22-410, 406 RAP, 22-400 to
22-411, 22-412, 22-413, 22- 22-403, 22-423, 22-
414, 22-415, 22-416, 22-417 426, 22-427, 22-775
are raised RAP, 22-407 RAP
22-557 Annotation error Annotation Bates number Cleared by the single
overflow. Set by the system on board controller PWB,
the next page after the Bates 7 seconds after raised
number reaches the maximum
of 999999999
22-558 One or more HFSI item An HFSI item has reached or Reset Actual count to
needs attention. exceeded its threshold zero or reset the
threshold

OF4b Status Messages in Alphabetical Order Table 1 Status messages A to F
Status Message Tables Status

UI Message Code Reason for Message Reference / Action
The status message tables contain all the messages to which a status code can be attributed.
A Fax Service error has 03-590 Fax POST failure status Perform 20A RAP
Table 1 Status Messages 1 to 9 and A to F.
occurred. Press the power
Table 2 Status Messages G to N. button on the left side of the
Table 3 Status Messages O to R. machine and choose Quick
Table 4 Status Messages S to X. Restart. If fault persists,
please call for assistance.
Table 1 Status messages A to F
A Fax Service error has 20-570 When the fault 20-342 is raised Perform 20-342 RAP
Status occurred. Press the power
UI Message Code Reason for Message Reference / Action button on the left side of the
802.1x Network Error 16-556 The request to authenticate the Ensure the 802.1x machine and choose Quick
device credentials with the EAP type, username Restart. If fault persists,
authentication server has failed and password for the please call for assistance.
machine, authentica- A Fax Service error has 20-571 When the fault 20-339 is raised Perform 20-331, 20-
tion switch and occurred. Press the power 339, 20-341 RAP
authentication server button on the left side of the
match. machine and choose Quick
A daylight saving time 03-600 Daylight saving time has been No action Restart. If fault persists,
change has occurred. The automatically changed please call for assistance.
device clock has been A Fax Service error has 20-572 When the fault 20-340 is raised Perform 20-332, 20-
adjusted. occurred. Press the power 340 RAP
A fax memory error has 20-558 When fault 20-322 is raised When fault 20-322 is button on the left side of the
occurred. Contact your sys- cleared. Perform 20- machine and choose Quick
tem administrator. 322 RAP Restart. If fault persists,
please call for assistance.
A fax service error has 20-550 Extended card failure detected Install a new extender
occurred. Fax line 2 is card and reboot A nonstandard document 05-504 A document length is detected Cleared when job
unavailable. Fax line 1is has been detected. It will during the document feed cycle cancelled or com-
still available. Contact your be scanned to match the that is not consistent with the pleted. Perform 05C
system administrator. closest standard size document size assumed by the RAP
DADH sensors and the market
A fax service error has 20-556 Basic card failure detected Switch off the
region settings
occurred. Press the power machine, then switch
button on the left side of the on the machine, GP Accounting out of memory. 16-551 Network controller - accounting Accounting Adminis-
machine and choose quick 14. Please notify machine log is full or a hard disk full trator needs to
restart. If fault persists, call administrator state exists retrieve accounting
for assistance. data log from the sys-
tem
A fax service error has 20-559 When fault 20-320 is raised When fault 20-320 is
occurred. Press the power cleared. Perform 20- Accounting problem. 16-543 Network controller - authoriza- Authorization should
button on the left side of the 320 RAP Please notify machine tion file on the system is cor- be disabled until the
machine and choose quick administrator rupted. No jobs can be accounting SA can
restart. If fault persists, call authorized. purge and reload the
for assistance. authorization data-
base
A Fax Service error has 03-589 Extended Fax not detected or Perform 20A RAP
occurred. Fax line 2 is confirmed. Additional memory required 16-555 Network controller - not enough Add memory
unavailable. Fax line 1 is to support fax. Please physical memory is configured
still available. Contact your notify machine administra- on the platform to support lan
System Administrator. tor fax

Xerox WorkCentre 5790 Family 2-639 OF4b
Table 1 Status messages A to F Table 1 Status messages A to F
Status Status
UI Message Code Reason for Message Reference / Action UI Message Code Reason for Message Reference / Action
Additional memory 16-553 Network controller - not enough Add memory All the paper trays have 22-512 All trays direct select only Enable one tray for
required. Please call for physical memory is configured been disabled for Auto auto select
assistance on the platform to support scan Selection. Auto Paper can-
to file not be used with these set-
Additional memory is 17-504 Insufficient memory for CPSR Delete saved jobs tings. It is recommended
required. Please call for filing cabinet from memory that at least one tray be
assistance enabled for Auto Selection
Adjust position of Tray 1 07-506 Tray 1 guides moved out of Tray 1 is opened or An error has occurred - The 03-538 System attempting to recover Cleared if communi-
before proceeding fixed position guides set to the system is attempting to from an single board controller cation is established.
fixed position recover PWB to IOT communication Perform 03-300, 306,
failure. Fault 03-300 or 03-320 461, 482, 805, 870
Adjust position of Tray 2 07-507 Tray 2 guides moved out of Tray 2 is opened or
is raised. RAP, 03-320 to 03-
before proceeding fixed position guides set to the
324 RAP
fixed position
An error has occurred. The 03-539 Comms failure between the Clears when comms
Adjustments in progress 14-562 Scanner ready checks are not If the ready check
system is attempting to IOT and Image processing re-established, or is
complete does not complete,
recover. converted to status
switch off the
code 03-540 after
machine, then switch
third recovery attempt
on the machine, GP
14. Wait for a few min- An image data error has 19-514 19-409 Cleared when status
utes, if the scanner occurred etc. 19-514 is raised. Per-
continues to check form 19-409 RAP
without completing. An image data error has 19-505 Compressor DVMA time-out. Perform 19-404 RAP
Perform 03-330, 03- occurred etc. Fault 19-404 is raised.
462 RAP An internal communica- 03-561 Single board controller wall Perform 03-315, 325,
After clearing paper, 03-573 When the image processing When the IOT has tions error has occurred. clock is not incrementing. Fault 347, 348, 349, 355,
replace any discarded tabs determines that a jam occurred performed stray sheet Switch off the machine and 03-325 is raised. 400 RAP
with identical tab stock in detection successfully call for assistance
the correct tray An internal communica- 03-563 Image processing rotation Perform 03-315, 325,
All output trays are unavail- 11-909 Punch head home sensor not Clear the paper jam. tions error has occurred. memory POST has failed 347, 348, 349, 355,
able. Check for obstruc- made Switch off the Switch off the machine and 400 RAP
tions in the finisher machine then switch call for assistance
on the machine, GP An unexpected time-out 08-590 Unexpected event or time-out Perform 08-171 RAP,
14. Perform 11-030- was detected for a sheet in for sheet. 08-171, 08-181, 08- 08-181 RAP, 08-182
110, 11-334-110, 11- the paper path. This may 182 RAP
335-110, 11-336-110 be due to a different paper
RAP for 2K LCSS, 11- in the trays than the
030-120, 11-334-120, machine expects. Please
11-335-120, 11-336- check and confirm the con-
120 RAP for 1K tents of the paper trays
LCSS, 11-044-171 to
Annotation error 22-557 Annotation Bates number over- Cleared by the single
11-047-171 RAP for
flow. Set by the system on the board controller PWB,
HVF
next page after the Bates num- 7 seconds after raised
ber reaches the maximum of
999999999

OF4b 2-640 Xerox WorkCentre 5790 Family
Status Status
Auto Configuration is dis- 02-550 System manager autoConfigu- Perform 02-390, 02- Booklet Making available. 11-945 All trays have degraded capa- Check for obstructions
abled. Please re-enable ration NVM set to disable 391, 02-704, 02-706 All other output trays bility, except booklet maker in the buffer, stacker
this feature before pro- RAP unavailable and top tray areas.
ceeding Switch the machine
Automatic software 03-527 Sip NC sync failure prior to Switch off the OFF and ON, GP 14.
upgrade failure power on upgrade machine, then switch Check the current
on the machine, GP fault codes list for
14 faults in the buffer,
stacker and top tray
BM is unavailable. Please 11-563 BM disabled - out of service Switch off the
areas and perform the
call for assistance machine then switch
appropriate RAP.
on the machine, GP
14. Perform 11B-171 Booklet making is unavail- 11-913 Back stop motor fails to move Clear the paper jam.
RAP able. Check for obstruc- or not home Switch off the
tions in the BM machine then switch
BM out of staples. Please 11-543 BM staples empty Perform 11-063-171,
on the machine, GP
replace the staple car- 11-411-171 RAP
14. Perform 11-065-
tridges
171, 11-383-171, 11-
BM out of staples. Please 11-561 BM disabled - out of staples Perform 11-063-171, 403-171, 11-413-171,
replace the staple car- 11-411-171 RAP 11-414-171 RAP for
tridges HVF
BM requires two or more 11-562 BM disabled - zero/one page Requires two or more BOOTP initialization failure. 16-559 Network controller - BOOTP Connectivity fix and
pages sheets to enable sta- Please notify machine [failure] configuration of IP, will switch off the machine
pling administrator use stored IPdata then switch on the
Booklet Maker Stapling is 11-926 Failure of the booklet maker Perform 11-063-171, machine, GP 14.
currently unavailable stapling functions. 11-411-171 RAP for Build job scanning error 17-511 Error during scan to email build Inform the customer
staple unit 1, and 11- job to rescan the last seg-
403-171, 11-413-171, ment or delete the job.
11-414-171 RAP for
Bypass Tray empty, please 07-515 MSI document present sensor Perform 07D RAP
staple unit 2
reload detects no paper in MSI while
Booklet Making and Tri- 11-943 Booklet making or tri-folding Check for obstructions attempting to feed from the MSI
folding are unavailable. capability degraded in the HVF BM and
Cannot connect to prime or 16-539 Could not communicate with Verify authentication
Check for obstructions the tri-folder. Check
backup authentication primary or alternate authentica- server setup at web
that the HVF BM and
server. tion server UI, verify server is
tri-folder interlocks are
online, check network
made. Switch the
connectivity. Can con-
machine OFF and
figure authentication
ON, GP 14. Check the
to use guest mode
current fault codes list
for HVF BM or tri- Cannot receive internet 16-541 Could not communicate will Verify POP3 server
folder faults and per- jobs. Please call for assis- POP3 server settings at UI. Verify
form the appropriate tance server is online and
RAP. check network con-
nectivity
Check for a stray original in 05-534 Unscheduled document Clear the document
the document tray detected by any sensor path in the DADH
Check settings for the 07-505 Bypass tray size confirmation Attributes confirmed
bypass tray required or tray opened

Status Status
Check the settings for Tray 07-501 Tray 1 closed or size change Attributes confirmed Clear the paper jam in the 11-935 Sheet detected near the buffer Clear the sheet. If
from power-on or tray opened Finisher sensor necessary, perform
Check the settings for Tray 07-502 Tray 2 closed or size change Attributes confirmed 11-157-171, 11-161-
from power-on or tray opened 171 RAP and 11-164-
171, 11-165-171 RAP
Check the settings for Tray 07-592 Tray 2 closed or size change Attributes confirmed
from power-on or tray opened Clear the paper jam in the 11-936 Sheet detected near Exit HVF Clear the sheet. If
Finisher. to BM entry sensor necessary, perform
Clear jam from right hand 08-548 Sheet did not clear the wait Perform 08-115, 08-
11-158-171, 11-160-
side of Tray 5 sensor within the expected time 117 RAP
171, 162-171, 163-
Clear jam in area 5 11-520 Paper or debris covering the Perform 11-140-110, 171 RAP
sensors 11-142-110 RAP for
Clear the paper jam in the 11-938 Sheet detected near the top bin Perform 11-130-171,
2K LCSS, 11-140-
Finisher. exit sensor 11-132-171 RAP
120, 11-142-120 RAP
for 1K LCSS, 11-140- Clear the paper jam in the 11-951 Sheet detected near the Clear the sheet. If
171, 11-142-171 RAP finisher stacker bin exit sensor necessary, perform
for HVF 11-140-171, 11-142-
171 RAP
Clear jam in IOT zone 4 10-510 Post fuser sensor detects Perform 10-107, 10-
paper in post fuser area on 108, 10-109, 10-110 Clear the paper jam in the 11-946 Sheet detected near the tri-fold Clear the sheet. If
power-on or in standby RAP Tri-Folding Unit entry sensor necessary, perform
11-183-171, 11-184-
Clear jam in Tray 5 08-558 Sheet over the feed sensor Jam clearance. Per-
171 RAP
form 08-115, 08-117
RAP Clear the paper jam in the 11-947 Sheet detected near the tri-fold Clear the sheet. If
Tri-Folding Unit exit sensor necessary, perform
Clear jam in Tray 5 08-568 Paper did not reach the tray 5 Clear jam or perform
11-185-171 to 11-187-
feed sensor in time 08-115, 08-117 RAP
171
Clear the jam in Areas 3,4. 10-571 Paper detected in inverter area Perform 10-132, 10-
Clear the paper jam in the 11-948 Sheet detected near the tri-fold Clear the sheet. If
Close the front door when on power up or in standby 133, 10-134 and 10-
Tri-Folding Unit assist sensor necessary, perform
the paper has been 107, 10-108, 10-109,
11-185-171 to 11-187-
removed 10-110
171 RAP
Clear the jam in Areas 3,4. 10-572 Paper detected near the Perform 10-132, 10-
Close Document Feeder 05-535 Open DADH cover Close document han-
Close the front door when inverter sensor on power up or 133, 10-134 and 10-
Top Cover dler cover. Perform
the paper has been in standby 107, 10-108, 10-109,
05-310 RAP
removed 10-110
Close output module front 11-503 Output module front door open Perform 11-300-110,
Clear the paper jam in the 11-917 Sheet over HVF BM compiler Clear the HFV BM
door in standby 11-302-110, 11-303-
Finisher. paper present sensor paper present sensor
110 RAP for 2K
area. Perform 11-172-
LCSS, 11-300-120,
171 RAP
11-302-120, 11-303-
Clear the paper jam in the 11-932 Sheet detected near the Clear the sheet. If 120 for 1K LCSS, 11-
Finisher. inserter pickup sensor necessary, perform 300-171, 11-302-171,
11-191-171, 11-193- 11-303-171 RAP for
171, 11-194-171, 11- HVF
196-171 RAP
Clear the paper jam in the 11-933 Sheet detected near the Check the paper. If
Finisher. inserter tab standby sensor necessary, perform
11-191-171, 11-193-
171, 11-194-171, 11-
196-171 RAP

Status Status
Close output module top 11-502 Output module top cover Perform 11-300-110, Copying is being prevented 03-559 Status 03-558 occurs and the Perform 03-412 RAP
cover opened in standby 11-302-110, 11-303- by the Access Control system contains non-held jobs
110 RAP for 2K device controlled by the Foreign Inter-
LCSS, 11-300-120, face
11-302-120, 11-303- Current job exceeds tray 03-570 Job is too large for selected None
120 for 1K LCSS, 11- capacity, you will be output bin
300-171, 11-302-171, prompted to empty the tray
11-303-171 RAP for
Custom Services not avail- 02-521 UI gets no response from EIP Switch off machine
HVF
able. Power Off then On service within 20 seconds and switch on
Close front door 01-510 Front door open Perform 01-300 RAP and Notify System Admin- machine, GP 14.
Close left hand door 01-512 Left hand door open Perform 01-305 RAP istrator
Close the output module 11-501 Output module entry gate Close the exit cover Custom Services are not 17-565 Raised by the network control- Switch off the
top tray opened in standby responding. Try Powering ler when EIP service is not machine then switch
Close the Top Left door of 11-506 HVF Inserter left hand door is Close cover. Perform Off then On responding on the machine, GP
the Finisher. open 11-306-171, 11-309- 14.
171 RAP DADH fault. Please call for 03-542 Single board controller-DADH: Clear DADH of origi-
Close the Top Left door of 11-509 HVF Inserter left hand door is Close cover. Perform assistance three times retry fail at 100 ms nals - use document
the Finisher. open 11-306-171, 11-309- cycle communication - no glass for copy or FAX.
171 RAP response Perform 05A RAP
Close the Tri-Folding Unit 11-508 HVF Tri-Folder front door is Close door. Perform Data encryption / decryp- 17-580 Raised by the network control- No action. Cleared by
Front Door. open 11-307-171, 11-308- tion is in progress. ler when disk encryption or the network controller
171 RAP decryption has been requested
Close the Tri-Folding Unit 11-507 HVF Tri-Folder top cover is Close cover. Perform DHCP functions are not 16-593 Network controller - DHCP Connectivity fix and
Top Cover. open 11-307-171, 11-308- available. Please notify address resolution failed switch off the machine
171 RAP machine administrator then switch on the
machine, GP 14.
Close top tray cover 01-514 Finisher bin 0 cover open Perform 11-300-110,
11-302-110, 11-303- Document feeder is open 05-536 Open document handler Close document han-
110 for the 2K LCSS, dler. Perform 05-300
perform the 11-300- RAP
120, 11-302-120, 11- Document feeder feed roll 05-539 DADH feed head CRU None
303-120 for the 1K has been replaced replaced. Message automatic
LCSS, perform the 11- 0.5 s after setting
300-171, 11-302-171, Document feeder is 05-538 DADH not available. 03-322, Perform 05-305 RAP,
11-303-171 for the unavailable 03-323, 03-324 or 14-320 03-320 to 03-324 RAP
HVF. raised and 14-320 RAP
Close tray 5 door 07-526 Tray 5 door has been detected Close the door, or per- Document feeder is 05-542 DADH document transport Perform 05A RAP
open form 07-306 unavailable needs service
Communications failure. 03-540 DC-IOT: three times retry fail at Perform the 03-300, Document is too short to be 05-560 Document too short for DADH, Remove document
Please call for assistance 100 ms cycle communication - 306, 461, 482, 805, scanned by the document use document glass. Fault 05- from DADH during
no response. The DC is unable 870 RAP feeder, use the document 310 raised jam clearance, Per-
to communicate with the IOT glass form 05-310 RAP
within one minute of power on
Ethernet functions are not 16-591 Network controller - Ethernet Connectivity fix and
or after three retries
available. Please notify TCP / IP port connectivity pro- switch off the machine
Copying is being prevented 03-558 When the Foreign Interface is Perform 03-412 RAP machine administrator cess failed then switch on the
by the Access Control configured and a connected 3rd machine, GP 14.
device Party accessory is reporting
that it is not enabled.

Status Status
Empty chad bin 11-549 Hole punch chad bin is full and Perform 11-364-110 Finisher Insert Stock Out of 11-949 An insert sheet has not arrived See the message text.
needs emptying RAP for 2K LCSS, Order at its intended output destina- If necessary, perform
11N-171 for HVF tion 11-191-171, 11-193-
Ensure output module is 11-500 Output module un-docked in Dock the output mod- 171, 11-194-171, 11-
docked standby. ule. Perform 11-300- 196-171 RAP and 11-
110, 11-302-110, 11- 100-171, 11-101-171
303-110 RAP for 2K RAP
LCSS, 11-300-120, Fuser module control fail- 10-555 Fuser control software failure. Perform 10-322, 10-
11-302-120, 11-303- ure. Printing is unavailable. 324, 10-325, 10-330,
120 for 1K LCSS, 11- If fault persists, call for 10-370 RAP
300-171, 11-302-171, assistance. Touch Ignore
11-303-171 RAP for Error to use other services
HVF Fuser module temperature - Fuser lamps not under control. Perform the 10-315,
Ensure network cables are 16-544 Network controller detected Check the network fault 10-320, 10-321, 10-
properly connected that the network cable is dis- harness connections 323, 10-340, 10-350,
connected 10-360, 10-365, 10-
Ensure waste toner bottle 09-596 IOT detects waste bottle door Ensure the waste bot- 380 RAP
is fitted and waste toner open. tle is installed and the Fuser module temperature 10-550 Hardware detected fuser fail- Perform 10-315, 10-
door is closed door is closed. Per- fault. Printing is unavail- ure. 320, 10-321, 10-323,
form 09-380 RAP able. If fault persists, call 10-340, 10-350, 10-
Extensible services are not 17-565 Raised by the network control- Switch off the for assistance. Touch 360, 10-365, 10-380
responding. Try powering ler when EIP service is not machine then switch Ignore Error to use other RAP
off then on responding on the machine, GP services
14. Fuser module under tem- 10-545 Fuser warm-up failure. Perform 10-322, 10-
Fax card not supported 03-503 The Fax card capabilities Perform 03-336 RAP perature fault. Printing is 324, 10-325, 10-330,
reported to the SIP are not suf- unavailable. If fault per- 10-370 RAP
ficient to function adequately in sists, call for assistance.
the system, (e.g. sleep mode Touch Ignore Error to use
not supported). other services
Fax job could not be sent at 20-545 Error with image processing - User clears or times
this time, please try again. fax command out (7 seconds)
Fax service is unavailable 03-551 Single board controller-FAX: Perform 03-338 RAP Table 2 Status messages G to N
communication error. Fault 03- Status
338 is raised. UI Message Code Reason for Message Reference / Action
FAX service unavailable 03-586 When the fault 03-401 or 03- Perform 20A RAP
Hardware must be added 16-554 Network controller - the IPA Re-insert or replace
403 is raised.
or replaced. Please notify card is either broken or missing IPA card
Fax service is unavailable 03-588 Basic Fax not detected or con- Perform 20A RAP machine administrator
firmed.
Hole punching is unavail- 11-550 There are too many pages for Instruct customer to
Fax memory is low. Contact 20-547 When fault 20-323 is raised Perform 20-323, 20- able the punch to operate use fewer pages in
your system administrator. 324 RAP the set (max 50
Finisher bin 0 full 11-570 Fifty additional prints have Perform 11-130-110, sheets)
been sent to bin 0 since 90% 11-132-110 RAP for Hole punching is unavail- 11-551 The punch operation has been Perform 11-043-110,
full sensor made 2K LCSS, 11-130- able taken out of service 11-350-110 RAP for
120, 11-132-120 RAP 2K LCSS, 11-044-171
for 1K LCSS, 11-130- to 11-047-171 RAP for
171, 11-132-171 RAP HVF
for HVF

Table 2 Status messages G to N Table 2 Status messages G to N
Status Status
Hole punching is unavail- 11-552 There are too many pages for Instruct customer to Incomplete Network Inter- 16-540 Death of any authentication Switch off the
able the punch to operate use fewer pages in face window services machine then switch
the set (max 50 on the machine, GP
sheets) 14.
Hole punching is unavail- 11-908 Punch head motor fails Clear the paper jam. Incomplete Network Inter- 16-562 Network controller - the line Switch off the
able. Check for obstruc- Perform 11-043-110, face window printer Deamon process has machine then switch
tions in the hole puncher 11-350-110 RAP for failed on the machine, GP
2K LCSS, 11-044-171 14.
to 11-047-171 RAP for Incomplete Network Inter- 16-563 Network controller - the Novell Switch off the
HVF face window Netware connectivity process machine then switch
Image disk offline. Jobs 19-511 Faulty image disk Switch off the has failed on the machine, GP
may take longer than nor- machine, then switch 14.
mal on the machine, GP Incomplete Network Inter- 16-564 Network controller - the Net- Switch off the
14. Perform 03C RAP face window BIOS connectivity process has machine then switch
Image disk offline. Please 19-512 Image disk read or write failure. Switch off the failed on the machine, GP
call for assistance machine, then switch 14.
on the machine, GP Incomplete Network Inter- 16-565 Network controller - the Apple- Switch off the
14. Perform 03C RAP face window talk connectivity process has machine then switch
Image too large to process. 16-542 Insufficient resources to pro- Reduce scan size, failed on the machine, GP
Please alter job and scan cess the image reduce scan resolu- 14.
again tion Incomplete Network Inter- 16-567 Network controller - a Post- Switch off the
Immediate Job Overwrite 16-535 ESS Immediate Image Over- The status is cleared face window script interpreter error has machine then switch
failed. Please perform and write Error when the ESS com- occur, causing the process to on the machine, GP
On Demand Overwrite pletes the On fail 14.
immediately Demand Image Over- Incomplete Network Inter- 16-568 Network controller - a PCL Switch off the
write face window interpreter error has occurred, machine then switch
Immediate Job Overwrite 20-590 Fax immediate image over- Perform 20-710, 20- causing the process to fail on the machine, GP
failed. Please perform an write error. Fault 20-710 is 711 RAP. 14.
On Demand Overwrite raised. Incomplete Network Inter- 16-570 Network controller - the http Switch off the
immediately. face window server (web-UI) has failed machine then switch
Incompatible fuser module 10-531 The system setting does not Install a new fuser or on the machine, GP
match the fuser type setting modify settings 14.
(fuser voltage) Incomplete Network Inter- 16-589 Network controller - serial port Switch off the
Incompatible fuser module 10-532 The system setting does not Install a new fuser or face window connectivity failed machine then switch
match the fuser OpCo ID set- modify OpCo ID set- on the machine, GP
ting (Market region) ting 14.
Incompatible fuser module 10-533 The system setting does not Install a new fuser or Incomplete Network Inter- 16-595 The network controller Lan-Fax Switch off the
match the fuser product speed modify the product face window service failed machine then switch
setting speed setting on the machine, GP
Incompatible network con- 03-528 Low speed controller fitted to Switch off the 14.
troller high speed copier machine, then switch Incomplete Network Inter- 16-596 The network controller account- Switch off the
on the machine, GP face window ing (JBA) service failed machine then switch
14 on the machine, GP
Incomplete Network Inter- 16-537 Any scan to distribution service Switch off the 14.
face window not available machine then switch
on the machine, GP
14.

Status Status
Incomplete Network Inter- 16-597 The network controller TIFF Switch off the IOT cycled in without print- 03-576 IOT cycled in without printing. Perform 03-395, 396,
face window interpreter failed machine then switch ing Fault 03-395 raised 852, 853 RAP
on the machine, GP IP interface error. Please 16-598 Network controller - TCP / IP Contact SA. Another
14. notify machine administra- address is already in use on the IP address needs to
Incomplete system infor- 16-585 The network controller counters Switch off the tor network be used
mation. Please contact the remote configuration synchroni- machine then switch IP interface error. Please 17-510 The IPv6 IP address is already Use a different
Machine Administrator zation process has stopped on the machine, GP notify system administrator in use address
14.
IP interface error. Please 17-513 The IPv4 IP address is already Use a different
Incomplete system infor- 16-578 The network controller fault ser- Switch off the notify system administrator in use address
mation. Please notify vice process has stopped (fault machine then switch
IP interface error. Please 17-514 External Accounting Device Contact SA.
machine administrator logging will be disabled) on the machine, GP
notify system administrator Communication Failure
14.
Job contains too many 03-568 When the BM job contains too Maximum number of
Incomplete system infor- 16-580 The network controller remote Switch off the
sheets to be folded and sta- many sheets for the BM to fold output sheets that can
mation. Please notify configuration process has machine then switch
bled. See Help for more and staple. be folded and stapled
machine administrator stopped on the machine, GP
details. is 15
14.
Job contains too many 03-569 When the BM job contains too Maximum number of
Incomplete system infor- 16-583 The network controller counters Switch off the
sheets to be folded. See many sheets for the BM to fold output sheets that can
mation. Please notify utility process has stopped machine then switch
Help for more details. be folded is 15
14. Job deleted due to the 17-503 CPSR input job in progress has Make more space for
device storage disk becom- been deleted due to memory file storage or re-
Incomplete system infor- 16-586 The network controller counters Switch off the
ing full. Stored jobs will full define pathway
mation. Please notify SNMP agent process has machine then switch
need to be deleted to make
space available
14.
Job in progress. Manual 11-538 Offline stapling requested while Cleared when current
Inserter empty, please 07-517 Paper sensor detects no paper Reload paper.
stapling will be available a print job is in progress for out- job completed
reload
when the current output job put to any bin other than bin 0
Inserter is unavailable. 11-944 Inserter capability degraded Check for obstructions set completes (top bin)
Check for obstructions in in the inserter. If nec-
Job in progress. Please 11-539 Offline stapling is Ready and a Cleared when offline
the inserter essary, perform 11-
wait until Manual Stapling user requests a print job for stapling mode is can-
191-171, 11-193-171,
job is complete output to the stacker, mailboxes celled
11-194-171, 11-196-
or BM
171 RAP and 11J-171
RAP Job status information not 16-574 The network controller protocol Switch off the
available. Please notify module process has stopped machine then switch
Installation procedure is not 02-540 System Manager install phase Complete install pro-
complete. Please com- not set to IpinstallComplete or cedure
14.
plete installation, then DC Platform Manager install
switch the machine off then phase not set to IpinstallCom- Job status information not 16-579 The network controller com- Switch off the
on again plete available. Please notify pleted job log service and print machine then switch
machine administrator SPI processes have stopped on the machine, GP
Internal address book 16-538 Could not communicate with Verify LDAP server
14.
unavailable. Please notify the LDAP server setup at web UI, verify
machine administrator server is online, check Job was deleted because a 05-507 Fault 05-331 is raised. Perform 05-330, 05-
network connectivity document was larger than 331 RAP
expected. Discard output.
Internal power supply fail- 09-560 HVPS failure. 09-060 fault Perform 09-060 RAP.
Try flattening the docu-
ure. Printing is unavailable.
ment and either re-scan it
If fault persists, call for
through the document
assistance. Touch Ignore
feeder or scan it from the
Error to use other services
document glass

Status Status
Local interface problem 02-531 Faults declared. UI running in Perform 02-309, 02- Network controller connec- 16-575 The network controller registra- Automatic network
detected. Please switch the degraded mode 390, 02-391, 02-704, tion is about to be reset tion service process has controller reset
machine off and on again 02-706 RAP and the stopped
03D Software Module Network controller connec- 16-576 The network controller event Automatic network
Failure RAP tion is about to be reset notification service process has controller reset
Local interface problem 02-532 Fault declared. UI software Perform 02-320, 02- stopped
detected. Please switch the error. Fault 02-320 called dur- 380 RAP and the 03D Network controller connec- 16-577 The network controller platform Automatic network
machine off and on again ing power on sequence Software Module Fail- tion is about to be reset manager service process has controller reset
ure RAP stopped
Lower the document feeder 05-502 Document present in DADH Perform 05-300 RAP Network controller connec- 16-584 The network controller counters Switch off the
to use it to scan your docu- tray and the DADH cover is tion is about to be reset document manager process machine then switch
ments open has stopped on the machine, GP
Machine cloning is in pro- 16-506 Status raised while Network Cleared automatically 14.
cess. This shall take a few controller connectivity settings when cloning is com- Network controller error. 22-547 XSA service unavailable. This Perform 22-370 RAP
minutes to complete are being cloned pleted Please contact system status code becomes active
Machine speed configura- 03-579 Speed in image processing Perform 03-320 to 03- administrator. when the fault 22-370 is raised
tion error NVM does not match speed in 324 RAP. Perform 03- Network controller error. 16-536 The ESS XSA service is The ESS XSA service
DADH 330, 03-462 RAP. Please contact system unavailable. The fault is due to becomes available.
Refer to GP 15 How administrator. a failure of internal communica-
to Set the Machine tion in the network controller.
Configuration
Network controller is initiat- 03-554 network controller machine No action
Machine speed configura- 03-580 Speed in Image processing Perform 03-330, 03- ing. Power Off will be avail- powered up but network con-
tion error NVM does not match speed in 462 RAP. Refer to GP able when initialization has troller still initializing. Fault 03-
IOT NVM. Fault 03-461 is 15 How to Set the completed. Please wait. 340 is raised.
raised. Machine Configura-
Network controller unavail- 03-544 Single board controller-net- Switch off the
tion
able. Please call for assis- work controller: three times machine then switch
Machine speed configura- 03-581 Speed in Image processing Perform 03-330, 03- tance retry fail at 100 ms cycle com- on the machine, GP
tion error NVM does not match scanner 462 RAP. Refer to GP munication - no response 14. Perform the 03D
speed. Fault 03-462 is raised. 15 How to Set the Software Module Fail-
Machine Configura- ure RAP
tion
Network printing disabled. 16-571 Network controller - print ser- Switch off the
Machine unavailable 03-587 The fault 03-417 is raised. Perform 03-417 RAP Please notify machine vice has failed machine then switch
Main motor control fault. 03-575 Main motor not being con- Perform 03-397 RAP administrator on the machine, GP
Printing is unavailable. If trolled. Fault 03-397 raised 14.
fault persists, call for assis- Network printing disabled. 16-572 Network controller - print SPI Switch off the
tance. Touch Ignore Error Please notify machine service has failed machine then switch
to use other services administrator on the machine, GP
Max. number of fax jobs in 20-565 All jobs IDs allocated cannot When fax job IDs 14.
the system has been create any more become available Network printing disabled. 16-573 Network controller - MF print Switch off the
reached. Contact your sys- Please notify machine service has failed machine then switch
tem administrator. administrator on the machine, GP
Media required for held job 22-513 Queued Job being held due to Add paper to the tray 14.
is not available lack of for resources being used to clear Network scanning commu- 16-545 Network controller - unrecover- Machine restart initi-
queued job nication error. Please notify able scan to file communication ated Resubmit job
Media required for held job 22-511 When correct media is not Provide media to machine administrator error
is not available available for held job complete the held job
or cancel job

Table 2 Status messages G to N
Status
Table 3 Status messages O to R
Status
Network scanning error. 16-548 Network controller - scan to file Resubmit job. If prob-
Please notify machine job processing error lem persists, Machine
administrator restart initiated Offsetting is unavailable 11-905 Bin 1 offset motor fails to move Clear the paper jam.
Network scanning filing 16-546 Network controller - network Verify destination from output tray 1. Check or home. Switch off the
error. Please notify repository filing error address; check repos- for obstructions in output machine then switch
machine administrator itory setup; verify tray 1 on the machine, GP
repository is online. 14. Perform 11-005-
Check network con- 110, 11-006-110, 11-
nectivity. Resubmit 310-110, 11-311-110
the job RAP for 2K LCSS, 11-
007-110, 11-008-110,
Network scanning is not 16-549 Network controller - failure of If problem persists, 11-312-110, 11-313-
available. Please notify any scan to file services Machine restart initi- 110, 11-319-110 RAP
machine administrator ated. Resubmit job. for 2K LCSS, 11-024-
Network scanning is 03-567 S2X job started but Switch the machine 110, 11-025-110 RAP
unavailable. Check cabling S2X_Ready line not detected off and on, GP 14. for 2K LCSS, 11-005-
connections Check the connec- 120, 11-006-120, 11-
tions. 310-120, 11-311-120
Network scanning tem- 16-547 Network controller - scan to file Verify remote tem- RAP for 1K LCSS, 11-
plates could not be template retrieval failure plate pool settings; 007-120, 11-008-120,
retrieved. Please notify verify that the tem- 11-312-120, 11-313-
machine administrator plate repository is 120, 11-319-120 RAP
online. Check net- for 1K LCSS, 11-024-
work connectivity 120, 11-025-120 RAP
Network Scanning Unavail- 16-561 Some scan to file processes Switch off the for 1K LCSS, 11-024-
able have died machine then switch 171, 11-026-171, 11-
on the machine, GP 392-171 to 11-395-
14. 171, 11-396-171 to
11-399-171 RAP for
No communication on fax 20-562 When fault 20-331 is raised When fault 20-331 is HVF
line 1. Please check exter- cleared. Perform 20-
nal connection 331, 20-339, 20-341 Offsetting is unavailable. 12-530 Offsetting catch tray is not in Perform 12-301 RAP
RAP Check for obstructions in index position.
the output tray
No communication on fax 20-563 When fault 20-332 is raised When fault 20-332 is
line 2. Please check exter- cleared. Perform 20- One or more HFSI item 22-558 An HFSI item has reached or Reset Actual count to
nal connection 332, 20-340 RAP needs attention. exceeded its threshold zero or reset the
threshold
No UI message appears 22-502 When fault 22-310 is raised Automatically clears
after being raised One or more queued jobs 22-515 Queued Job being held due to Add paper to the tray
needs resources. lack of for resources. being used to clear
Not all configurable ser- 02-533 Machine not achieved stable Perform 02-390, 02- queued job
vices have achieved a sta- state five minutes from power 391, 02-704, 02-706
ble state on RAP Open document feeder top 05-520 Sheet left over DADH post feed Remove sheet
cover sensor after a jam
Not enough memory to use 20-546 When fault 20-324 is raised When fault 20-324 is
fax services. Contact your cleared. Perform 20- Open document feeder top 05-521 Sheet left over DADH TAR sen- Remove sheet
system administrator. 323, 20-324 RAP cover sor after jam
Open document feeder top 05-526 DADH - sheet near CVT sensor Reset when DADH
cover in duplex path. 05-352 fault is top cover closed after
raised jam cleared. Perform
05-350, 05-352 RAP

Table 3 Status messages O to R Table 3 Status messages O to R
Status Status
Open output device door 11-510 Sheet detected over entry sen- Perform 11-100-110 Open output device door 11-521 Sheet near 2nd to top exit sen- Perform 11-140-110,
sor RAP for 2K LCSS, 11- sor 11-142-110 RAP for
100-120 for 2K LCSS, 2K LCSS, 11-140-
11-100-171, 11-101- 120, 11-142-120 RAP
171 RAP for HVF for 1K LCSS, 11-140-
Open output device door 11-511 Sheet near entry sensor at Perform 11-100-110 171, 11-142-171 RAP
shutdown RAP for 2K LCSS, 11- for HVF
100-120 for 2K LCSS, Open front door 08-555 Registration sensor detects Jam clearance. Per-
11-100-171, 11-101- paper in registration area on form 08-150, 08-151
171 RAP for HVF power-on or in standby. 08-150 RAP
Open output device door 11-512 Sheet detected over punch Perform 11-110-110 Open front door 08-556 Paper in duplex path at power- Jam clearance. Per-
sensor RAP for 2K LCSS, 11- on or in standby form 08-160, 08-161
044-171 to 11-047- RAP
171 for HVF Open left hand door 08-557 Paper over the registration sen- Jam clearance. Per-
Open output device door 11-513 Sheet near punch sensor at Perform 11-110-110 sor when feeding from the form 08-155, 08-156
shut down RAP for 2K LCSS, 11- bypass tray RAP
044-171 to 11-047- Open finisher front door 11-952 Page over Buffer Path Sensor Clear Buffer Path
171 for HVF Sensor, perform 11-
Open output device door 11-514 Sheet detected over compiler Perform 11-158-171, 157-171, 11-161-171
sensor 11-160-171, 162-171, RAP and 11-164-171,
163-171 RAP 11-165-171 RAP
Open output device door 11-515 Sheet near 2nd to top exit sen- Perform 11-140-110, Open finisher front door 11-953 Page detected near buffer path Clear sheet near
sor 11-142-110 RAP for sensor buffer path sensor,
2K LCSS, 11-140- perform 11-157-171,
120, 11-142-120 RAP 11-161-171 RAP and
for 1K LCSS, 11-140- 11-164-171, 11-165-
171, 11-142-171 RAP 171 RAP
for HVF Open Finisher Top Cover. 11-955 Page over Inserter Lead Edge Clear Inserter Lead
Open output device door 11-516 Sheet detected over edge reg- Perform 11A-110 RAP Remove Paper. Sensor Edge Sensor, per-
istration sensor for 2K LCSS Close Finisher Top Cover. form 11-479-171 RAP
Open output device door 11-518 Sheet detected over top exit Perform 11-130-110, Open front door 08-566 Sheet near duplex sensor Jam clearance
sensor 11-132-110 RAP for Open left hand door 08-567 Paper over the registration sen- Jam clearance
2K LCSS, 11-130- sor when feeding from the
120, 11-132-120 RAP bypass tray
Open front door 10-507 Sheet is near the IOT exit sen- Jam clearance
171, 11-132-171 RAP
sor in the non-invert path
for HVF
Open front door 10-508 Sheet is near the IOT exit sen- Jam clearance
Open output device door 11-519 Sheet near top exit sensor at Perform 11-130-110,
sor in the left hand side of the
shutdown 11-132-110 RAP for
invert path
2K LCSS, 11-130-
120, 11-132-120 RAP Open front door 10-509 Sheet is near the IOT exit sen- Jam clearance
for 1K LCSS, 11-130- sor in the right hand side of the
171, 11-132-171 RAP invert path
for HVF Open front door 10-511 Sheet near post fuser sensor Jam clearance
Open front door 10-512 IOT exit sensor paper in IOT Jam clearance. Per-
exit area at power -on or start form 10-107, 10-108,
print 10-109, 10-110 RAP

Status Status
Open front door 10-513 Sheet near IOT exit sensor Jam clearance. Per- Optional service mismatch 22-552 Service option mismatch Install or remove ser-
form 10-107, 10-108, detected detected vice option. If neces-
10-109, 10-110 RAP sary, perform 22-410
Open left hand door 08-550 Sheet over wait sensor Jam clearance. Per- to 22-416, 22-423, 22-
form 08-100 RAP 425, 22-428, 22-777
or 22-400 to 22-403,
Open left hand door 08-551 Tray 1 feed sensor detects Jam clearance. Per-
22-423, 22-426, 22-
paper in feed area on power-on form 08-101 RAP
427, 22-775
or in standby, 08-101
Output Bin full 03-511 When the 90% full sensor is Printing will continue
Open left hand door 08-552 Tray 2 feed sensor detects Jam clearance. Per-
cleared before the bin switch automatically 15 sec-
paper in feed area on power-on form 08-102 RAP
timer expires. onds after raised if the
or in standby. 08-102
Pause button is not
Open left hand door 08-554 Tray 4 feed sensor detects Jam clearance. Per- pressed.
paper in feed area on power-on form 08-104, 08-114 Or when the Resume
or in standby. 08-104 RAP button pressed.
Open left hand door 08-565 Sheet near registration sensor Jam clearance Or Automatically 15
Open output device door 11-522 Sheet over the BM exit sensor Perform 11-180-171, minutes after Pause
11-182-171 RAP button pressed if
Resume button is not
Open output device door 11-523 Sheet near the BM exit sensor Perform 11-180-171,
pressed.
11-182-171 RAP
Output device communica- 03-545 IOT-Finisher: three times retry Perform 03-360, 03-
Open the document feeder 05-523 Sheet left over DADH registra- Remove sheet
tions fault. Please call for fail at 100 ms cycle communi- 408 to 03-410, 03-418
tion sensor after jam
assistance. cation - no response. 03-360 RAP
Open the document feeder 05-524 Sheet left over DADH exit sen- Remove sheet. Per-
sor after jam form 05-345, 05-346
RAP
Open tray 1 08-561 Sheet near tray 1 feed sensor. Jam clearance. Per-
08-106 form 08-106 RAP
Open tray 2 08-562 Sheet near tray 2 feed sensor Jam clearance
Open tray 3 08-553 Tray 3 feed sensor detects Jam clearance. Per-
paper in feed area on power-on form 08-103, 08-113
or in standby. 08-103 RAP. If the fault
remains, check the
tray 3 exit sensor,
refer to the 08-131
RAP.
Open tray 3 08-563 Sheet near tray 3 feed sensor Jam clearance. W/O
TAG 151 Perform 08-
107 RAP. W/TAG 151
Perform 08-131 RAP,
check the tray 3 exit
sensor
Open tray 4 08-564 Sheet near tray 4 feed sensor Jam clearance
Option service removed 22-554 Unable to remove optional ser- Refer to 22-410 to 22-
vice 416, 22-423, 22-425,
22-428, 22-777 RAP,
22-417 RAP
Optional service installed 22-553 Service option installed

Status Status
Output tray 1 out of service. 11-902 Tamper move or Bin 1 or com- Clear the paper jam. Output trays 1 and 2 out of 11-904 Tamper home or paddle roll or Clear the paper jam.
Check for obstructions in piler eject or staple fault Switch off the service. Check for obstruc- compiler or stapling fault Switch off the
output tray 1 machine then switch tions in the output trays machine then switch
on the machine, GP on the machine, GP
14. Perform 11-005- 14. Perform 11-005-
110, 11-006-110, 11- 110, 11-006-110, 11-
310-110, 11-311-110 310-110, 11-311-110
007-110, 11-008-110, 007-110, 11-008-110,
11-312-110, 11-313- 11-312-110, 11-313-
110, 11-319-110 RAP 110, 11-319-110 RAP
110, 11-025-110 RAP 110, 11-025-110 RAP
120, 11-006-120, 11- 120, 11-006-120, 11-
310-120, 11-311-120 310-120, 11-311-120
007-120, 11-008-120, 007-120, 11-008-120,
11-312-120, 11-313- 11-312-120, 11-313-
120, 11-319-120 RAP 120, 11-319-120 RAP
120, 11-025-120 RAP 120, 11-025-120 RAP
171, 11-026-171, 11- 171, 11-026-171, 11-
392-171 to 11-395- 392-171 to 11-395-
171, 11-396-171 to 171, 11-396-171 to
11-399-171 RAP for 11-399-171 RAP for
HVF HVF
Output Tray full. Please 11-572 Fifty additional prints have Perform 11-030-110,
empty the Output Tray. been sent to bin 1 since 90% 11-334-110, 11-335-
full sensor made 110, 11-336-110 RAP
120, 11-334-120, 11-
335-120, 11-336-120
460-171 to 11-462-
171 RAP for HVF
Output Tray full. Please 11-574 Finisher bin 2 full Perform 11C-171 RAP
empty the Output Tray.
Output tray nearly full 10-516 Printer bin 0 90% full sensor Unload the tray
made
Output tray nearly full 11-571 Bin 0 90% full sensor made Perform 11-130-110,
11-132-110 RAP for
2K LCSS, 11-130-
120, 11-132-120 RAP
171, 11-132-171 RAP
for HVF

Status Status
Output tray nearly full 11-573 Bin 1 90% full sensor made Perform 11-030-110, Paper size mismatch. 07-572 First sheet fed after a tray 2 sta- Check the paper in
11-334-110, 11-335- Check paper in Tray 2. tus change does not match the tray 2. Perform 07E
110, 11-336-110 RAP Some image loss may confirmed stock RAP
for 2K LCSS, 11-030- occur
120, 11-334-120, 11- Paper size mismatch. 07-573 First sheet fed after a tray 3 sta- Check the paper in
335-120, 11-336-120 Check paper in Tray 3. tus change does not match the tray 3. Check that the
RAP for 1K LCSS, 11- Some image loss may confirmed stock tray is set to correct
460-171 to 11-462- occur paper size, (W/O TAG
171 RAP for HVF 151) ADJ 7.1 or (W/
Output tray nearly full 11-575 Bin 2 90% full sensor made Perform 11C-171 RAP TAG 151) ADJ 7.5
Output Trays out of service. 11-598 Output trays have reached their Cleared when con- Paper size mismatch. 07-574 First sheet fed after a tray 4 sta- Check the paper in
Remove all paper from capacity. firm button pressed Check paper in Tray 4. tus change does not match the tray 4. Check that the
Output Trays. Some image loss may confirmed stock tray is set to correct
Ozone filter near end of life, 09-590 Ozone life counter near end of Order a new ozone fil- occur paper size, (W/O TAG
ensure you have a replace- life ter, PL 9.25 Item 3. 151) ADJ 7.1 or (W/
ment filter TAG 151) ADJ 7.5
Page-over BB compiler 11-530 Sheet over the booklet maker Clear the area or per- Paper size mismatch. 07-576 The first sheet after a tray 5 sta- Confirm the paper
Sensor entry sensor form 11-183-171, 11- Check paper in tray 5 tus change does not match the size in the UI
184-171 RAP confirmed stock
Page over Buffer Position 11-526 Sheet over the buffer position Clear the area or per- Paper size mismatch. 07-575 First sheet fed after a bypass Check the paper in
Sensor sensor form 11-198-171, 11- Check paper in Bypass tray status change does not bypass tray and the
199-171 RAP tray. Some image loss may match the confirmed stock side guide is set cor-
occur rectly
Page over exit HVF into 11-527 Sheet over the HVF exit into Clear the area or per-
Booklet Maker Sensor BM sensor form 11-198-171, 11- Paper Trays are unavail- 03-549 IOT microprocessor: comm Perform 03-350, 03-
199-171 RAP able. Call for assistance error. Fault 03-350 is raised. 351, 03-354 RAP
Page-over PPI Pickup Sen- 11-524 Sheet over the inserter pickup Clear the area or per- Pause To Unload Time-out 11-941 Machine is paused for unload- Follow the instruc-
sor sensor form 11-479-171 RAP Warning ing. Need to press button on tions. If necessary,
pop up screen perform 11H-171
Page-over PPI Tab 11-525 Sheet over the inserter tab Clear the area or per-
Standby Sensor standby sensor form 11-191-171, 11- Pause To Unload Time-out 11-942 Timer expiry. Wait for machine Follow the instruc-
193-171, 11-194-171, Warning to pause, then press button on tions. If necessary,
11-196-171 RAP pop up screen perform 11H-171
Page over Stacker Bin Exit 11-528 Sheet over the stacker bin exit Clear the area or per- Please check the output bin 03-510 When paper is delivered to the Perform 03-423, 424,
Sensor sensor form 11-140-171, 11- for blank and partially output and a video complete 433, 434, 821, 822,
142-171 imaged sheets and discard has not been received by the 831, 832 RAP
them single board controller PWB
Page over Tri-fold Entry 11-529 Sheet over the tri-folder entry Clear the area or per-
Sensor sensor form 11-183-171, 11- Please close the Booklet 11-921 The stapler position sensor Close the BM stapler
184-171 RAP Maker Stapler module indicates the stapler module is module. If necessary,
not closed in initialisation perform 11-063-171,
Paper jam not fully cleared 08-580 A stray sheet has been Jam clearance. Per-
11-411-171 RAP for
detected in either the IOT or fin- form 08-190 RAP
staple unit 1, and 11-
isher device during the post
403-171, 11-413-171,
jam clearance initialization rou-
11-414-171 RAP for
tine. 08-190
staple unit 2
Paper size mismatch. 07-571 First sheet fed after a tray 1 sta- Check the paper in
Check paper in Tray 1. tus change does not match the tray 1. Perform 07E
Some image loss may confirmed stock RAP
occur

Status Status
Please delete the job. No 22-504 No tray configured for media Configure one tray for Please wait... The system 22-501 Attempting print recovery. 22- Perform 22-306 to 22-
tray is configured with the this stock size. is attempting to recover 306, 22-307, 22-309 315, 22-801, 22-814
required paper size. Press RAP
the Job Status button. Then Please wait while your 03-506 This status is raised while Clears when the
select the Delete Button. receipt is printing. This may auditron copy activity report is report has printed
Please enter your pass- 03-535 Machine in service copy mode Status clears on leav- take up to 7 seconds. printed
word and press Enter for password entry ing service copy mode Post jam clearance initial is 08-570 The IOT and finisher device are Status clears on com-
Please follow the instruc- 05-548 DADH feed roll assembly at Install a new feed roll at ion in progress performing the post jam clear- pletion of initialization
tions below to replace the end of life assembly, (35 ppm) ance initialization process to process
document handler feed roll PL 5.15 Item 1 or (40- check for stray sheets
90 ppm) PL 5.17 Item Power down failure. Power 03-520 System fails to power off after Perform 03-374 RAP
1. off cannot be completed. request from the UI
Please wait, adjusting fuser 10-540 Fuser temperature control fail- Perform 10-322, 10- Press the power button on
temperature ure. 324, 10-325, 10-330, the left side of the machine.
10-370 RAP, 10-315, If there is no response
10-320, 10-321, 10- within 1 minute, then
323, 10-340, 10-350, remove the power cord.
10-360, 10-365, 10- Wait 3 minutes then rein-
380 RAP sert the power cord and
Please wait, freeing mem- 19-502 Out of memory resources. Fault Perform 19-401, 19- switch the machine on.
ory 19-401, 19-402 402, 19-403 RAP Printing and scanning are 03-500 Voltage not present on 24 V rail Perform 03-480 RAP
Please wait, freeing mem- 17-580 Out of memory resources. Fault Perform 19-401, 19- unavailable. Please call for monitored by IOT
ory. 19-401, 19-402 402, 19-403 RAP assistance
Please wait. The image 19-513 The system has detected that Wait for space to Printing is unavailable 09-550 Photoreceptor erase lamp has Perform 09-350 RAP
disk is full. insufficient space is available become available failed. 09-350 fault
on the image disk Pull out fuser module, then 03-547 IOT-FRU: unable to read from Perform 03-371, 03-
Please wait, the system is 19-510 At power up, the image disk is Switch off the firmly push it back in FRU. Fault 03-371 is raised. 372 RAP
attempting to recover not present or faulty. machine, then switch Pull out xerographic mod- 03-548 IOT-XRU: unable to read from Perform 03-371, 03-
on the machine, GP ule, then firmly push it back XRU. Fault 03-372 is raised. 372 RAP
14. Perform 03C RAP in
Please wait. The system is 03-556 When fault codes 03-351 and Perform 03-350, 03- Punch Chad Bin Set State 11-541 The chad bin has been Reinstall the chad bin
attempting to recover from 03-354 are raised 351, 03-354 RAP removed from the finisher Perform 11N-171
a fault Raise document handler 05-522 Sheet left over DADH CVT sen- Remove sheet
Please wait - the system is 03-557 Tray 5 comms error. Fault 03- Perform 03-366 RAP sor after jam
attempting to recover from 366 is raised RARP functions are not 16-594 Network controller - RARP Connectivity fix and
a fault available. Please notify address resolution fails switch off the machine
Please wait. The system 03-501 prtgeneralReset MIB object on None machine administrator then switch on the
software and the network the network controller is set to a machine, GP 14.
controller are about to be value of powerCycleReset(4) Reload originals and press 14-566 CCD (width) and length sen- Reposition originals
reset from a remote client. start sors cannot determine size of and press start, Per-
The reset may take sev- the original form 14A RAP
eral minutes. Any jobs cur-
Reload originals and press 05-503 Not enough originals during Reload originals
rently being marked will be
Start recovery
cancelled
Reload originals or select 05-546 On pre-feed the DADH fails to Reload originals or
Please wait, your job will 19-506 Job delayed status High EPC usage. Per-
original size and press Start recognize the size of the docu- select size. Perform
continue shortly. Do not form 19-401, 19-402,
ment 05C RAP
press the Start button again 19-403 RAP

Status Status
Remove documents from 05-502 Document present in DADH Lower the document Replace punch head unit 11-540 Punch head present sensor not Perform 11-043-110,
the paper tray and close tray with DADH cover open handler to scan your made 11-350-110 RAP for
the cover documents. Perform 2K LCSS, 11-044-171
05-300 RAP to 11-047-171 RAP for
Remove all documents 05-525 Sheet left over DADH docu- Remove sheet. Per- HVF
from the document feeder ment present sensor after jam form 05B RAP Replace staple cartridge 11-546 Staple cartridge empty Perform 11-364-110
tray RAP for 2K LCSS, 11-
Remove misfed sheet. 07-521 IOT microprocessor detects Close tray. Perform 364-120 RAP for 1K
Close tray 1 Tray 1 open 07-301RAP LCSS, 11-371-171 to
11-377-171 RAP for
HVF
Remove misfed sheet. 07-522 IOT microprocessor detects Close tray. Perform
Close tray 2 Tray 2 open 07-302 RAP Replace toner cartridge 09-593 Accumulated toner dispense Install new toner car-
time value greater than 27 s tridge. Perform 09-
Remove misfed sheet. 07-523 IOT microprocessor detects Close Tray. Perform
attained, or cycle out event 310, 09-390 RAP
Close tray 3 Tray 3 open 07-303 RAP
occurs (Toner cartridge empty).
Remove misfed sheet. 07-524 IOT microprocessor detects Close Tray. Perform 09-390
Close tray 4 Tray 4 open 07-304 RAP
Replace tray 5 feed rolls 07-590 The feed head counter has Install new tray 5 feed
Remove Reorder Toner 02-560 Set by the user interface when Cleared by the user reached the end of life figure rolls, PL 8.45 Item 2
Cartridge the user enters *33 code to interface once Status
Replace waste toner bottle 09-594 Waste toner shutdown counter Install new waste
remove the Reorder Notifica- 09-599 is cleared.
value attained OR if waste toner bottle, PL 9.10
tion message when the Toner
toner shutdown counter value Item 1.
Cartridge is replaced.
greater than 50% and cycle out
Re-order but do not replace 05-547 DADH feed head near end of Replace feed head or event occurs
Document Feeder Feed life end of life status
Replace Xerographic Mod- 09-585 Xerographic module end of life Refer to the 03D Soft-
Roll
ule ware Module Failure
Re-order but do not replace 10-521 Fuser counter reaches 290 k Refer to the 03D Soft- RAP before a new
fuser module prints ware Module Failure xerographic module is
RAP before ordering a installed, (35 ppm) PL
new fuser module, PL 9.22 Item 2, (40-90
10.10 Item 1, PL 10.8 ppm) PL 9.20 Item 2.
Item 1. Refer to GP 27, End
Re-order but do not replace 07-580 Near the end of life - ensure Order new feed roll of Life Extension
the Tray 5 Feed Rolls new stock is available kit, PL 8.45 Item 2 Replace xerographics mod- 09-586 IOT detects an xerographic Switch the machine
Re-order, but do not 09-584 Xerographic module near end Re-order a new xero- ule module failure off and on, GP 14.
replace xerographic mod- of life graphic module Install a new xero-
ule graphic module
Replace fuser module 10-520 Fuser counter reaches 300 k Install new fuser mod- Resort and reload all origi- 05-540 DADH document jam is cleared Replace document on
prints ule, PL 10.10 Item 1, nals. for a single job DADH input tray to
PL 10.8 Item 1. enable recovery.
Replace fuser module 10-523 IOT detects fuser failure Install new fuser mod- Check for blanks in
ule, PL 10.10 Item 1, output tray. Resume
PL 10.8 Item 1. or cancel job
Replace fuser module 10-570 FRU CRUM authorization fail- Perform 10-399 RAP Resort and reload ALL the 05-544 Document jam is cleared (cov- Resume job com-
ure. When fault 10-399 raised originals in the document ers cycled and switch cleared) mand is given with
feeder and normal job or build job documents replaced
Replace Ozone Filter 09-591 Ozone life counter reaches end Install new ozone fil-
in input tray, if
of life ter, PL 9.25 Item 3
required, or cancel job
command is given

Table 3 Status messages O to R Table 4 Status messages S to X
Status Status
Restoring configuration set- 03-526 Software upgrade configura- When the Image pro- Scanner is calibrating, 14-560 Scanner is calibrating If calibration does not
ting. Please wait. System tion reset cessing module has please wait complete, switch off
will reboot when com- completed restoring the machine, then
pleted. the configuration set- switch on the
tings machine, GP 14. Wait
ROS laser not being con- 06-540 ROS laser not being controlled. Perform 06-350 RAP for a few minutes, if
trolled the scanner contin-
ues to calibrate with-
ROS system failure. Print- 06-530 ROS system failed. Perform 06-340 RAP
out completing
ing is unavailable. If fault
perform 14-703 to 14-
persists, call for assistance.
706, 712, 714, 716,
Touch Ignore Error to use
718 RAP
other services
Scheduling fault etc. 22-560 SML error. Switch off the
machine then switch
on the machine, GP
Table 4 Status messages S to X 14.
Status Slide Tray 5 up to machine 07-581 Tray 5 is un-docked Perform 07-372
UI Message Code Reason for Message Reference / Action Sip FireWire card not sup- 03-502 SIP FireWire card vendor and No action
Save job for Reprint ser- 17-501 Network controller unavailable Wait for the network ported device ID not in list of sup-
vice is unavailable. Please and customer already within controller to become ported FireWire cards
try again later pathway, or CPSR feature sus- available. Switch off Software cycling control 03-560 Laser on without printing. Fault Perform 03-395, 396,
pended the machine then fault. Printing is unavail- 03-396 raised 852, 853 RAP
switch on the able. If fault persists, call
machine, GP 14. for assistance. Touch
Scan to file unavailable 03-585 Fault 03-331 raised Switch off the Ignore Error to use other
machine then switch services / Printing is
on the machine, GP unavailable
14. Software option codes do 16-552 Network controller - the flag in Switch off the
Scanner fault. Please call 03-543 Single board controller-CCD: Perform 14-310 RAP not match system manager is not in sync. machine then switch
for assistance three times retry fail at 100 ms and the 03D Software with the network controller PM on the machine, GP
cycle communication - no Module Failure RAP 14.
response Software upgrade complet- 03-537 IOT software upgrade status None
Scanner has failed to initai- 14-563 Scanner needs service Switch off the ing - please wait
ilize. Switch off the machine then switch Some finishing features are 11-903 Compiler carriage or stapling Clear the paper jam.
machine, wait 3 minutes, on the machine, GP unavailable. Check for fault Switch off the
then switch on the 14. Perform 14-110 obstructions in the finisher machine then switch
machine. If fault persists RAP, 14-310 RAP, 14- on the machine, GP
call for assistance, or press 710 RAP 14. Perform 11-364-
close to use other services 110 RAP for 2K
LCSS, 11-364-120
172-171, 11-180-171,
11-182-171, 11-185-
171 to 11-187-171,
11-371-171 to 11-377-
171 RAP for HVF

Table 4 Status messages S to X Table 4 Status messages S to X
Status Status
Some finishing features are 11-912 Stapler unit 1 fails to move Clear obstruction from Some network services 16-509 Insufficient memory for internet Machine restart initi-
unavailable. Check for stapler. Perform 11- unavailable. Please notify fax ated
obstructions in the stapler. 053-110, 11-370-110 the machine administrator
RAP for 2K LCSS, 11- Some network services 16-510 E-mail process failed Machine restart initi-
371-171 to 11-377- unavailable. Please notify ated
171 RAP for HVF the machine administrator
Some network controller 17-570 Communication with NNTP Switch off the Some network services 16-511 Internet fax process failed Machine restart initi-
services are not available. server failed machine then switch unavailable. Please notify ated
Contact system administra- on the machine, GP the machine administrator
tor. 14.
Some network services 16-512 USB printer port process failed Machine restart initi-
Some network services 16-560 Some processes on the net- Switch off the unavailable. Please notify ated
unavailable. Please notify work controller have failed machine then switch the machine administrator
Some network services 16-513 Simple service discovery proto- Machine restart initi-
14.
unavailable. Please notify col failed ated
Some network services 16-581 The network controller diagnos- Switch off the the machine administrator
unavailable. Please notify tic service process has stopped machine then switch
Some network services 16-514 Post office protocol (for Machine restart initi-
unavailable. Please notify inbound IFAX messages) pro- ated
14.
the machine administrator cess failed
Some network services 16-582 The network controller authen- Switch off the
Some network services 16-517 SMTP process failed Machine restart initi-
unavailable. Please notify tication SPI process has machine then switch
unavailable. Please notify ated
14.
Some network services 16-599 Raw TCP/IP printing (port Machine restart initi-
Some network services 16-588 The network controller sub- Switch off the
unavailable. Please notify 9100) process failed. ated
unavailable. Please notify agent process has failed machine then switch
the machine administrator.
14. Some Network Controller 16-521 The network controllers CPI Machine restart initi-
Some network services 16-590 The network controller connec- Switch off the
unavailable. Please notify tivity configuration process has machine then switch
administrator
machine administrator failed on the machine, GP
14. Some Network Controller 16-522 The network controllers job log Machine restart initi-
Some network services 16-501 Not enough memory on the Machine restart initi-
unavailable. Please notify image processing for JBA ated
administrator
Some Network Controller 16-523 The network controllers job Machine restart initi-
Some network services 16-504 Dynamic domain name regis- Machine restart initi-
services are not available. tracker service process has ated
unavailable. Please notify tration process failed ated
administrator
Some network services 16-505 Insufficient memory for E-mail More physical mem-
Some Network Controller 16-524 The network controllers Ker- Machine restart initi-
unavailable. Please notify ory needs to be added
services are not available. beros service process has ated
the machine administrator to the platform
Some network services 16-507 Service location protocol pro- Machine restart initi- administrator
unavailable. Please notify cess failed ated
Some Network Controller 16-525 The network controllers Scan Machine restart initi-
services are not available. to Distribution service process ated
Some network services 16-508 Autonet address resolution did Machine restart initi- Please notify the machine has stopped
unavailable. Please notify not work ated administrator

Status Status
Some Network Controller 16-527 The network controllers SMB Machine restart initi- Stapler is unavailable. 11-910 Stapler head motor 1 fails to Clear obstruction from
services are not available. service process has stopped. ated Check for obstructions in move or not primed stapler. Perform 11-
Please notify the machine the stapler. 050-110, 11-360-110
administrator RAP for 2K LCSS, 11-
Some Network Controller 16-528 The network controllers WS Machine restart initi- 050-120, 11-360-120
services are not available. Scan Temp service process ated RAP for 1K LCSS, 11-
Please notify the machine has stopped. 371-171 to 11-377-
administrator 171 RAP for HVF
Some Network Controller 16-529 The network controllers Scan Machine restart initi- Stapling is unavailable. 11-911 Staple head 2 motor fails to Clear obstruction from
services are not available. Compressor service process ated Check for obstructions in move stapler. Perform 11-
Please notify the machine has stopped. the BM stapler. 063-171, 11-411-171
administrator RAP for HVF
Some network controller 17-518 WSD discovery failure Switch off the Stapling not available. 11-553 Stapling disabled, out of service Perform 11-050-110,
services are not available. machine then switch Please call for assistance 11-360-110 RAP for
Please notify the machine on the machine, GP 2K LCSS, 11-050-
administrator. 14. 120, 11-360-120 RAP
Some network controller 17-519 WSD print service failure Switch off the
120, 11-360-120 RAP
services are not available. machine then switch
for HVF
Please notify the machine on the machine, GP
administrator. 14. System error, copier is no 16-557 Network controller - DC plat- Switch off the
longer available form fails to recover in less than machine then switch
Some network controller 17-520 WSD scan service failure Switch off the
5 minutes after a crash on the machine, GP
services are not available. machine then switch
14.
Please notify the machine on the machine, GP
administrator. 14. System error, copier is no 16-558 Network controller - DC com- DC platform call failed
longer available munications unavailable
Staple capacity exceeded. 11-560 BM disabled - too many pages Each booklet must not
Job completed without sta- exceed 15 sheets System error, scanner is 14-508 When start is selected but scan Switch off the
pling unavailable service is unable to acquire machine then switch
resources on the machine, GP
Staple count low. Please 11-542 BM staples low Perform 11-063-171,
14. Wait for a few min-
ensure you have replace- 11-411-171 RAP
utes, if scanning is still
ment Staple Cartridge.
not available, go to
Staple count low. Please 11-545 Staple cartridge low Perform 11-364-110 03-330, 03-462 RAP
ensure you have replace- RAP for 2K LCSS, 11-
System memory is full etc. 19-503 EPC memory resources low Memory becomes
ment Staple Cartridge 364-120 RAP for 1K
available, job is can-
LCSS, 11-371-171 to
celled or documents
11-377-171 RAP for
are removed from
HVF
DADH. Perform 19-
Stapling disabled, out of 11-554 Stapling disabled, out of staples Perform 11-050-110, 401, 19-402, 19-403
staples 11-360-110 RAP for RAP
2K LCSS, 11-050-
System memory is full etc. 19-507 Memory resources low High EPC usage. Per-
120, 11-360-120 RAP
form 19-401, 19-402,
19-403 RAP
120, 11-360-120 RAP
for HVF System memory is full etc. 19-508 Internal memory handling sta- Usage is above inter-
tus mediate EPC usage
Stapling feature requires 11-555 Stapling disabled, zero / one Instruct customer
threshold. Perform 19-
two or more pages page
401, 19-402, 19-403
RAP

Status Status
System memory is full etc. 19-515 This status code becomes Cleared when the cur- The network controller is 16-502 When ever the network control- When the network
active when fault 19-403 is rent job completes or about to be reset ler detects that a platform reset controller reset is initi-
raised when the job is is about to occur ated
deleted. Perform 19- The scanner could not Document size sensor failure. Perform 14A RAP
401, 19-402, 19-403 match the original with a Input module angle sensor fail-
RAP known size. ure.
System memory is full etc. 19-516 EPC memory is full. The status code is The ROS motor has failure. 06-520 ROS motor failed. Perform 06-020 RAP
cleared when either Switch the machine off,
the job is cancelled or wait 3 minutes, then switch
the user selects the on the machine again. If
resume option the fault persists call for
System reset required, 16-550 Network controller - system Switch off the assistance or press Close
please switch off the enters customer sw upgrade machine then switch to use other services.
machine, then switch on mode on the machine, GP The software that controls 03-597 Incompatible software detected Switch the machine
the machine 14. tray 5 requires updates. in the tray 5 controller off and on, GP 14.
The BM is unavailable. 03-553 BM communications failure. Perform 11B-171 RAP Tray 5 is unavailable Perform 03-419, 03-
Please call for assistance. Fault 03-363 is raised. 420
The Booklet Maker and Tri- 11-920 Failure of any BM or TF func- Check for obstructions The User Interface is not 02-530 Fault detected at UI. Local UI Perform 02-320, 02-
folder are currently unavail- tion in the HVF BM and available. Please call for needs service 380 RAP
able the tri-folder. Check assistance
that the HVF BM and The Xerographic module is 09-570 Xerographic module CRUM Perform 09-399 RAP.
tri-folder interlocks are not compatible with this authorization failure. 09-399.
made. Switch the machine. Please refer to The status clears when the
machine OFF and the User Guide associated has been cleared
ON, GP 14. Check
The Xerographic Module is 09-587 The system setting does not Install correct xero-
the current fault codes
not compatible with this match the xerographic module graphic module or
list for HVF BM or tri-
machine. type modify setting
folder faults and per-
form the appropriate The Xerographic Module is 09-588 The system setting does not Install correct xero-
RAP. not compatible with this match the xerographic module graphic module or
machine. market region ID setting modify setting
The Fax service is initialis- 20-544 Basic Fax card restarts User clears or time-
ing. Please wait. out. (W/O TAG X-001) The Xerographic Module is 09-589 The system setting does not Install correct xero-
Install a new compact not compatible with this match the xerographic module graphic module or
flash, PL 20.10 Item 3 machine. speed setting modify speed setting
The fuser is warming up. 10-505 Fuser not at temperature Perform 10-322, 10- There is a problem with at 02-534 Machine not achieved stable Perform 02-390, 02-
Printing may be delayed 324, 10-325, 10-330, least one machine service. state five minutes from power 391, 02-704, 02-
10-370 RAP Please switch the machine on 706RAP
off then on again. If this
The fuser module is not 10-530 The system setting does not Install new fuser mod-
does not solve the problem,
compatible with this match the fuser type setting ule or modify settings
switch the machine off and
machine. Please refer to (service offering)
call for assistance
the user guide
There is a problem with at 02-535 All services that the UI is wait- Perform 02-390, 02-
The installed staple car- 03-571 50 sheet cartridge installed in Press confirm.
least one machine service. ing for in the registry do not 391, 02-704, 02-706
tridge can staple a maxi- the HVF
Please switch the machine appear even though the Image RAP
mum of 50 sheets. Please
off then on again. If this processing / UI sync occurred
confirm to close this win-
does not solve the problem,
dow
call for assistance

Status Status
There is a problem with at 02-536 All services that the UI is wait- Perform 02-390, 02- Tray 3 is lifting 07-550 Tray 3 is lifting. Perform 07-355 RAP
least one machine service. ing for do not appear in the reg- 391, 02-704, 02- Tray 3 is low on paper 07-533 Tray 3 paper low IOT microprocessor
Please switch the machine istry 706RAP detects Tray 3 paper
off then on again. If this level at 25%. Perform
does not solve the problem, 07B RAP
Tray 3 is out of service, 07-543 Tray 3 elevate top sensor does Perform 07-355 RAP
call for assistance
Token Ring functions are 16-592 Network controller - Token Ring Connectivity fix and after elevator motor on.
not available. Please notify TCP / IP port connectivity failed switch off the machine
Tray 3 and 4 are unavail- 03-552 IOT microprocessor to HCF Perform 03-359, 03-
machine administrator then switch on the
able. Please call for assis- communication error. Fault 03- 407 RAP
machine, GP 14.
tance. 359 raised
Toner adjustments in 09-546 Replenisher sump refilling Perform 09-360, 09-
Tray 4 empty, please reload 07-514 Tray 4 paper present sensor Perform 07F RAP
progress. Please wait. 361, 09-362, 09-363
detects no paper in tray
RAP
Tray 4 is lifting 07-560 Tray 4 is lifting Perform 07-360 RAP
Toner cartridge empty 09-592 Toner level sensor registers Install new toner car-
developer sump not full tridge, PL 9.15 Item 4. Tray 4 is low on paper 07-534 Tray 4 paper low IOT microprocessor
detects Tray 4 paper
Toner cartridge nearly 09-599 When less than X days pre- Order a new toner
level at 25%. Perform
empty. Ensure you have a dicted until toner cartridge end cartridge, PL 9.15
07B RAP
replacement cartridge of life Item 4.
Or cleared when 02- Tray 4 is out of service, 07-544 Tray 4 elevate top sensor does Perform 07-360 RAP
560 status code is please use a different tray not turn on within 7 seconds
raised. after elevator motor on
Toner cartridge status is 09-545 This status is raised when the No action required. Tray 5 empty, please reload 07-516 Tray empty sensor detects no Reload paper. If nec-
disabled toner gas gauge is disabled The toner gas gauge paper essary, perform 07J
can be enabled, if Tray 5 is lifting, please wait 07-561 Tray 5 is currently lifting Perform 07-373
required Tray 5 is out of service, 07-546 Tray 5 cannot feed paper Switch the machine
Toner control failure 09-597 Toner concentration process Perform 09-360, 09- please use a different tray off and on, GP 14.
control failure. 361, 09-362, 09-363 Check that the tray is
RAP in the correct posi-
Toner control sensor failure 09-598 Toner control sensor failure. Perform 09-360, 09- tion. Perform 07-306,
361, 09-362, 09-363 07-372, or 07-373
RAP RAP
Tray 1 empty, please reload 07-511 Tray 1 paper present sensor Perform 07A RAP Tray 5 is overloaded, 07-539 Paper equals or is more than Remove some paper.
detects no paper in tray please remove excess 100% full in tray 5 If necessary, perform
paper 07-373 and 07-374
Tray 1 is low on paper 07-531 Tray 1 paper low Perform 07A RAP
Tray 5 is low on paper 07-536 Tray 5 paper below 5% full Add paper. If neces-
Tray 1 is out of service, 07-541 Tray 1 out of service. Perform 07H RAP
sary, perform 07-373
and 07-374 RAPs
Tray 2 empty, please reload 07-512 Tray 2 paper present sensor Perform 07A RAP
Tray 5 is unavailable. 03-598 Tray 5 software is installed but Check that all tray 5
detects no paper in tray
Check cabling connections hardware is not detected control PWB connec-
Tray 2 is low on paper 07-532 Tray 2 paper low Perform 07A RAP tions are good. Per-
Tray 2 is out of service, 07-542 Tray 2 out of service. Perform 07H RAP form 03-366.
please use a different tray Tray 5 is unavailable. 07-563 Tray 5 lifting has stopped Perform 07-373
Tray 3 empty, please reload 07-513 Tray 3 paper present sensor Perform 07F RAP Check for obstructions in
detects no paper in tray Tray 5
Tray 1 is lifting 07-551 Tray 1 is lifting. Perform 07-353 RAP
Tray 2 is lifting 07-552 Tray 2 is lifting. Perform 07-354 RAP

Status Status
Tray 5 is unavailable. 07-564 Tray 5 lowering has stopped Perform 07-374 Unable to install option ser- 22-555 Service option install failed Refer to 22-400 to 22-
Check for obstructions in vice when any of the faults 22-400, 403, 22-423, 22-426,
Tray 5 22-401, 22-402, 22-403, 22- 22-427, 22-775 RAP,
Try turning the machine off 03-591 The single board controller Switch the machine 404, 22-405, 22-406, 22-407 22-404 to 22-406
and on. Please call for PWB reports that its stored off and on, GP 14. If are raised RAP, 22-407 RAP
assistance if the problem machine model ID differs from necessary, reload the Unable to remove option 22-556 Service option removal failed Refer to 22-400 to 22-
persists that stored in the IOT software, GP 4 then service when any of the faults 22-410, 403, 22-423, 22-426,
re-run the install wiz- 22-411, 22-412, 22-413, 22- 22-427, 22-775 RAP,
ard, refer to GP 15. 414, 22-415, 22-416, 22-417 22-404 to 22-406
Try turning the machine off 03-592 The single board controller Switch the machine are raised RAP, 22-407 RAP
and on. Please call for PWB reports that its stored off and on, GP 14. If Unable to staple. check for 11-901 Tamper move or paddle roll Clear the paper jam.
assistance if the problem machine type differs from that necessary, reload the obstructions in the output fault Switch off the
persists stored in the IOT software, GP 4 then trays machine then switch
re-run the install wiz- on the machine, GP
ard, refer to GP 15. 14. Perform 11-005-
Try turning the machine off 03-593 The single board controller Switch the machine 110, 11-006-110, 11-
and on. Please call for PWB reports that its stored off and on, GP 14. If 310-110, 11-311-110
assistance if the problem machine speed ID differs from necessary, reload the RAP for 2K LCSS, 11-
persists that stored in the IOT software, GP 4 then 007-110, 11-008-110,
re-run the install wiz- 11-312-110, 11-313-
ard, refer to GP 15. 110, 11-319-110 RAP
Try turning the machine off 03-594 The single board controller Switch the machine
110, 11-025-110 RAP
and on. Please call for PWB reports that its stored off and on, GP 14. If
assistance if the problem machine variant ID differs from necessary, reload the
120, 11-006-120, 11-
persists that stored in the IOT software, GP 4 then
310-120, 11-311-120
re-run the install wiz-
ard, refer to GP 15.
007-120, 11-008-120,
Try turning the machine off 05-588 Finisher software version sup- Perform 03-360, 03- 11-312-120, 11-313-
and on. Please call for plied is not compatible. Fault 408 to 03-410, 03-418 120, 11-319-120 RAP
assistance if the problem 03-418 raised RAP If necessary, for 1K LCSS, 11-024-
persists reload the software, 120, 11-025-120 RAP
GP 4 for 1K LCSS, 11-024-
Try turning the machine off 05-589 IOT, DADH or UI software ver- Perform 03-300, 306, 171, 11-026-171, 11-
and on. Please call for sion supplied at power-on is not 461, 482, 805, 870 392-171 to 11-395-
assistance if the problem compatible with the single RAP, 03-320 to 03- 171, 11-396-171 to
persists board controller PWB. 324 RAP, 03-310 11-399-171 RAP for
RAP. If necessary, HVF
reload the software, Unexpected Stock Size in 11-950 A shorter than expected sheet Follow the message
GP 4 the Finisher has been fed from the inserter text. Check the size of
Unable to access the dis- 02-561 Part of save job for reprint. Select O.K, then the paper in the
play list. Please select O.K attempt selection inserter.
and then attempt your again. Unsupported scanner 03-505 Scanner software no longer Switch off machine
selection again. detected supported and switch on
Unable to detect card 03-601 Smart Card authentication has Perform 03-412 RAP. machine, GP 14.
reader been enabled but no card Check software sta-
reader is installed tus and upgrade
where necessary

Table 4 Status messages S to X OF5 Boot Up Failure RAP
Status
Use this procedure if the following behavior is seen;
Waste toner bottle nearly 09-595 Waste toner full sensor regis- Perform 09B RAP The machine does not come to a Ready to scan your job state
full, ensure you have a ters full for greater than 100
The UI displays the message System Unavailable
replacement bottle pages.
The UI displays a Please Wait or Machine Self Test In Progress message
Xerographic Module Clean- 09-541 Scorotron cleaning failure Refer to 09-341, 09-
ing Failure. Copy and Print- 342 Scorotron Clean- The UI has a black/white, dark/blank or green UI touch screen and the power saver LED
ing unavailable. Touch ing Failure RAP on the UI is flashing
Power Off to switch The UI displays the green splash screen, the energy saver led is off but all other LEDs are
machine off or touch Ignore lit as with normal operation
Error to use other services The machine has failed to load software
Xerographic Module clean- 09-540 When the Scorotron cleaning is Refer to 09-341, 09-
Initial Actions
ing in progress. Please wait in progress 342 Scorotron Clean-
ing Failure RAP Check that the power cord is connected to the machine.
Xerographic Module Main- 09-543 Charge scorotron manual Refer to IQ1 Image Refer to Service Bulletin T7694-04-11 for software information.
tenance. Please follow the cleaning required Quality Entry RAP Switch off the machine GP 14. Remove the power cord from the customer power socket.
instructions below Wait two minutes, then reconnect the plug into the socket. Switch on the machine, GP 14.
If the fault still occurs then follow the procedure.
If a boot up failure has occurred after the installation of new components, ensure those
new components are compatible with the machine.
Check the LEDs on the IOT PWB, OF7 IOT PWB Diagnostics RAP.
For 35 to 55 ppm machines. Check CR18 on the single board controller PWB, PL 3.24
Item 3 is flashing. If CR18 is not flashing go to:
01D +3.3V Distribution RAP
Remove then re-install the software module, PL 3.24 Item 8.
Remove then re-install the memory module(s), PL 3.24 Item 12.
Disconnect then reconnect all the PJs on the single board controller PWB, PL 3.24.
Check all the PJs are correctly connected on the UI control PWB, PL 2.10 Item 11.
Check the UI harness connection to the Single board controller PWB, Wiring Diagram 12,
PL 3.24.
Check the hard disk drive, 03C Hard Disk Failure RAP.
If the problem occurs while entering or exiting sleep mode, go to 01K Sleep Mode RAP.

Xerox WorkCentre 5790 Family 2-661 OF4b, OF5
A B C D
Procedure CR12 on the SBC PWB is flashing at a very dim intensity.
Y N
Reseat the HDD data cable PJ115 on the single board controller PWB and
WARNING the HDD power cable on the power distribution PWB. CR12 on the SBC
PWB is flashing at a very dim intensity.
Y N
Load software 061.131.221.10401 or greater using the Forced Alt-
Boot Software Loading procedure, GP 4. If the fault still exists, install
new components as necessary:
WARNING
HDD data cable, PL 3.22 Item 11.
Only use the correct plug to connect a power lead to a power outlet.
HDD power cable, PL 3.22 Item 10.
CAUTION
Incorrect voltage may damage the machine. The machine must only be connected to the If the user UI touch screen is still black/white, dark/blank or green and the
power outlet of the correct voltage. power saver LED is flashing, load software 061.131.221.10401 or greater
1. Switch off the machine, GP 14. using the Forced AltBoot Software Loading procedure, GP 4.
2. Disconnect the DADH communication/power cable, PL 5.10 Item 6 from the single board
If the user UI touch screen is still black/white, dark/blank or green and the
controller PWB.
power saver LED is flashing, perform the AltBoot Software Loading procedure,
3. If an LCSS, HVF or HVF BM is installed, disconnect the communication cable from GP 4.
PJ151, and the finisher power cord from PJ22 on the power and control module.
4. Install a finisher bypass harness, PL 26.10 Item 7. The UI displays the green splash screen, the energy saver led is off but all
5. If a fax is installed, remove the embedded fax PWB, PL 20.10 Item 4. other LEDs are lit as with normal operation
6. Switch on the machine, GP 14. Y N
The machine boots up.
Y N
Switch off the machine, GP 14. Remove the software module, PL 3.24 Item 8. Check
Perform the following;
that the contacts of the software module are clean. If necessary, clean the contacts
Check the UI, if necessary perform the OF2 Touch Screen Failure RAP.
using a lint free wiper, PL 26.10 Item 13. Install the software module fully into the
Go to: socket. Switch on the machine, GP 14.
01F +12V Distribution RAP, check the +12V supplies to the SBC PWB If the fault still exists, load software 061.131.221.10401 or greater using the Forced
01E +5V Distribution RAP, check the +5V supplies to the SBC PWB AltBoot Software Loading procedure, GP 4.
01D +3.3V Distribution RAP, check the +3.3V supplies to the SBC PWB If the fault still exists, install a new software module, PL 3.24 Item 8
01B 0V Distribution RAP, check the 0V supplies to the SBC PWB
The voltage supplies are good 1. Switch off the machine, GP 14. Remove the memory module(s), PL 3.24 Item 12.
Y N Check that the contacts of the memory module(s) are clean. If necessary, clean the
Repair the wiring or connectors or install new part as necessary. contacts using a lint free wiper, PL 26.10 Item 13. Install the memory module(s) fully
into the socket(s). Switch on the machine, GP 14.
CR22 and CR12 on the SBC PWB are lit incessantly, all other LEDs are off.
2. Switch off the machine, GP 14. Remove the software module, PL 3.24 Item 8. Check
Y N
that the contacts of the software module are clean. If necessary, clean the contacts
CR23 and CR24 on the SBC PWB are lit incessantly.
using a lint free wiper, PL 26.10 Item 13. Install the software module fully into the
Y N
socket. Switch on the machine, GP 14.
CR18 on the SBC PWB is flashing
Y N 3. If the fault is still present, install new components as necessary:
Ensure that the memory module is installed in PJ203 on the single board Memory module(s), PL 3.24 Item 12
controller PWB. Software module, PL 3.24 Item 8
Software model, PL 3.24 Item 8.
A B C D A
A
NOTE: Re-install the original embedded fax PWB. Connect the DADH communication/power OF6 Ozone and Air Systems RAP
cable. Connect the output device communication cable and power cord.
Use this RAP to diagnose faulty machine fans. Faulty fans can cause smells or overheating.
Connect the DADH communication/power cable. Switch on the machine, GP 14. The
machine boots up. Procedure
Y N
Install a new DADH PWB, PL 5.10 Item 5.
NOTE: Re-install the original embedded fax PWB. Connect the output device communi- WARNING
cation cable and power cord. Ensure that the electricity to the machine is switched off while performing tasks that do
Connect the output device communication cable and power cord. Switch on the machine, GP death or injury. Moving parts can cause injury.
14. The machine boots up.
Identify the suspect fan. Check that the fan is working correctly:
Y N
The output device is a HVF with a booklet maker. Photoreceptor Fan
Y N Ozone Fan
Install new components as necessary: Power and Control Assembly Fan
1K LCSS PWB, PL 11.124 Item 1. Single Board Controller Cooling Fan
2K LCSS PWB, PL 11.26 Item 1. Vacuum Transport Fan
HVF PWB, PL 11.157 Item 2 Duplex Paper Path Cooling Fans
Photoreceptor Fan
Disconnect the booklet maker PWB. The machine boots up.
Y N This fan draws air in at the rear of the machine and uses a duct to direct the air flow over the
Install a HVF PWB, PL 11.157 Item 2. ROS, through the photoreceptor module and over the post fuser area. If the fan is suspect, go
to the 09C Photoreceptor Fan RAP.
Install a new BM PWB, PL 11.166 Item 10.
Ozone Fan
Re-install the original embedded fax PWB. Switch on the machine, GP 14. The machine This fan draws air from the photoreceptor module and out through the ozone filter. Refer to PL
boots up. 9.25 Item 1 and to Wiring Diagram 6.
Y N
Install new components as necessary: If the components of this system are not in a good condition, ozone will not be removed from
Embedded fax PWB, PL 20.10 Item 4. the xerographic area and deletions with shortened xerographic module life can be expected.
(W/O TAG X-001) Compact flash memory, PL 20.10 Item 3. Check the following:
(W/O TAG X-001) Extended fax PWB, PL 20.10 Item 2.
Check that the ozone seal on the rear face of the short paper path is in a good condition,
Riser PWB, PL 3.22 Item 3. if necessary install a new seal, PL 31.10 Item 6 seal replacement kit.
Install a new single board controller PWB, PL 3.24 Item 3. Check that the ozone seal on the front face of the main drive module is in a good condi-
tion, if necessary install a new seal, PL 31.10 Item 6 seal replacement kit.
If necessary, reload the software. Refer to GP 4 Machine Software.
Enter dC330 code 09-030 to run the ozone fan. If the fan does not run, refer to Wiring Dia-
gram 6, if necessary install a new ozone fan, PL 9.25 Item 1.
Check that the ozone filter is not blocked, if necessary install a new ozone filter PL 9.25
Item 3.
Power and Control Assembly Fan
This fan draws in air from the rear of the machine and blows it into the power supply. The fan is
hard wired into the power supply. Refer to PL 1.10 Item 1.

Xerox WorkCentre 5790 Family 2-663 OF5, OF6
Single Board Controller Cooling Fan OF7 IOT PWB Diagnostics RAP
This fan is located within the single board controller PWB module. This fan draws air into the
single board controller PWB module and blows the air onto the single board controller PWB. Purpose
To assist in identifying any suspected problems with the IOT PWB. If directed here from
Refer to the information that follows: another procedure always return to that procedure.
Perform the IOT PWB corruption check before a new IOT PWB is installed. If the fault still
Wiring Diagram 3.
occurs after completing this check then install a new IOT PWB.
Vacuum Transport Fan
This fan draws air down through the short paper path to assist the transport of A6 paper. Refer Procedure
to PL 10.25 Item 1 short paper path (W/O TAG 114) and Wiring Diagram 7.
Duplex Paper Path Cooling Fans WARNING

This consists of a cooling fan, exhaust fan and a cooling duct assembly, all of which are inte- Ensure that the electricity to the machine is switched off while performing tasks that do
grated into the front door. The cooling fan 2 is located in the middle of the front door, PL 8.11 not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Item 6. This fan draws in air via the cooling duct into the front door and directs the air across death or injury. Moving parts can cause injury.
the duplex transport area and into the image exit area. The cooling fan 1 is located in the front Perform the following checks:
door, PL 8.11 Item 3. This fan draws air from the inverter base pan area and exhausts the air
IOT NVM Corruption Check.
via the cooling duct in the front door.
IOT PWB Voltage Check.
W/O TAG 120 machines. The fans are turned on and off simultaneously and only operate dur- IOT PWB Communications Check.
ing the duplex mode. A thermistor is located in the inverter assembly which will switch the fans Ensure the machine is in normal mode (not standby mode).
on when the temperature reaches 48 degrees C (119 degrees F) during a duplex job. If the
thermistor fails, then the fans will switch on at the start of a duplex job. IOT NVM Corruption Check
Corruption of the IOT NVM can cause paper jams, fuser temperature or xerographic control
The fans are enabled or disabled in dC131 location 09-116. The fans are run in dC330 code
faults. Perform these steps before a new IOT PWB is installed.
09-036 Duplex cooling fans.
W/TAG 120 machines. There is no thermistor on the inverter assembly. Consequently, there is
no thermistor control for cooling fan 1 or cooling fan 2. The fans are turned on only when the 1. Enter dC131 location 09-271 Developer Age. Note the developer age value. Also check
green start button is pressed or a print is sent to the machine. when the developer was last changed, to ensure that the age value is correct.
2. Go to dC132 NVM initialization - Copier
NOTE: On 65-90 ppm machines W/TAG 120 there is no inverter thermistor. 3. Select Machine Variable NVM.
Refer to cooling fan 1, cooling fan 2 and the thermistor in Wiring Diagram 11. 4. Select Initialize.
5. Switch off the machine, then switch on the machine, GP 14. Check if the fault still occurs.
If the fault does not occur, then go to step 6.
If the fault still occurs, install a new IOT PWB, PL 1.10 Item 2.
6. Perform dC604 Registration Setup Procedure.
7. Enter dC131 location 09-069 TCSensorCtrlVoltage. Record the value on the NVM sheet
stored in the wallet on the rear cover.
8. Enter dC131 location 09-271 Developer Age. Check that the value for the developer age
is correct, reset the value if required.
9. Perform SCP 6 Final Actions

OF6, OF7 2-664 Xerox WorkCentre 5790 Family
IOT PWB Voltage Check
1. On the IOT PWB check that the voltage-present LEDs that follow are on, Figure 1:
CR12 - Indicates the presence of 3.3V.
CR13 - Indicates the presence of 5V.
CR36 - Indicates the presence of 3.3V standby supply voltage.
2. If CR16 is not on, but 24V is present at P/J27 pin 1, perform the 01G +24V Distribution
RAP. If +24V is not present at P/J27, pin 1, check the voltage at P/J26 pin 9. This is the
Low Power Mode Enable signal. If this signal is high, install a new LVPS and base mod-
ule, PL 1.10 Item 3.
3. If no LEDs are on, or only the CR36 3.3Vsb is on, go to 01H Short Circuits and Overloads
RAP.
IOT PWB Communications Check
1. Switch off the machine GP 14. Switch on the machine, GP 14. Observe the following con-
ditions, Figure 1:
CR14 is off.
CR27 is flashing at about 2 Hz.
CR28 and CR29 are flashing alternately at about 1 Hz.
2. If any of the above conditions do not apply, perform the steps that follow: Figure 1 IOT PWB LED and switch locations
Switch off the machine, GP 14.
Use the jumpers to short J17 pins 1 and 2, J18 pins 1 and 2, J19 pins 1 and 2, Figure
1.
After the machine has power up, switch off the machine, GP 14.
Lift the jumpers from J17, J18 and J19. Park the jumpers on one pin only.
3. If any of the above conditions still fail, then install a new IOT PWB, PL 1.10 Item 2.

OF8 Multi-feed RAP Install new components as necessary, PL 7.15.
To solve several sheet multi-feeds or extra blank sheet output problems.
Initial Actions
WARNING
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.
Refer to IQ1 Image Quality Entry RAP.
Check the paper specification, GP 20.
Multi-feed from the bypass tray, go to 07D 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:
Fan the paper.

Turn the paper round or turn the paper over.
Remove four or five sheets from the top of the stack.
When loading multi-reams of paper into tray 3 or tray 4. Remove the top and bottom sheet
from each ream. This will prevent ream interface multi-feeds.
For tray 1 and tray 2 check the following:
Check that the paper tray side guides are set to the correct paper size.
Separation
The paper tray drops when the tray is pulled out and the tray elevates when pushed in. strip
Check the paper feed assembly, REP 8.1.
Check the paper feed rolls, REP 8.35.
The paper trays for worn, broken or missing components.
Install new components as necessary, PL 7.10 Item 1.
For tray 3 and tray 4 (W/O TAG 151) check the following:
The tray drops when the tray is pulled out, and elevates when the tray is closed.
Check tray 3 paper feed assembly, REP 8.2.
Install new components as necessary, PL 8.30 Item 1.
The separation strips are located correctly on the tray, Figure 1.
Feed head
Remove the spacers in the tray 3 feed assembly, Figure 2.
NOTE: The tray 3 spacers are fitted to reliably feed the sheets with large amounts of
up-curl, which normally occurs in very dry environments. Removing these spacers
will decrease the multi-feed rate, but may increase the mis-feed rate if the paper is
curled. These spacers are not fitted to any other tray.

OF9 False Fuser End of Life RAP
Use this RAP if the fuser module has reached its end of life, 400,000 prints, prematurely.
Initial Actions
WARNING
Enter dC131 location 09-064 FRU Total Count, then check the fuser module image count. If the
image count is unexpectedly high, 422,000 or greater, then the CRUM data is corrupted.
Procedure
1. Refer to Wiring Diagram 6. Check the wiring harness at PJ141. Repair the wiring as nec-
essary, REP 1.2.
2. Check that the wires from the vacuum transport fan have not been trapped in the fuser
CRUM socket, Figure 1. Repair the wiring or install a new short paper path assembly, PL
10.25 Item 1. Use a cable tie to route the wires away from the fuser module.
3. Check for damage to the fuser CRUM socket on the drives module, (35-55 ppm) PL 4.15
Item 1, (65-90 ppm) PL 4.10 Item 1.
4. Check for damage to the CRUM plug on the fuser module, (35-55 ppm) PL 10.8 Item 1,
Remove the spacers (65-90 ppm) PL 10.10 Item 1.
5. If the fault remains, go to OF10 Intermittent Failure RAP and refer to the Electrostatic Dis-
charge Checkout.
Figure 2 Tray 3 Spacers
For tray 3 and tray 4 (W/TAG 151) check the following:

The tray moves down when the tray is pulled out, and moves up when the tray is closed.
Install new components as necessary, PL 8.32, PL 8.33.
Perform ADJ 8.3 Tray 3 and Tray 4 Retard Roll Pressure (W/Tag 151)
For tray 5 check the following:
The tray moves down when the door is opened, and moves up when the door is closed.
Check the tray 5 paper feed assembly.
Check the tray 5 paper feed rolls, PL 8.45 Item 2.
For the Bypass tray, perform the following:
Ensure that the customer is not filling the tray above the max fill line.
Clean the feed roll and retard pad with a damp cloth with water.
Install a new feed roll, REP 8.21 and retard pad, REP 8.22, PL 7.30 Item 21.

OF10 Intermittent Failure RAP
Use this RAP to locate failures when no specific cause can be found, i.e. if the machine resets
to Ready to scan your job or Please wait during a print / copy run, or a fault code occurs
which cannot easily be repeated.
Initial Actions
WARNING
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury.
Perform the following to gather additional information about the fault:
Ask the customer if there are any specific functions that cause the fault to occur; e.g.
using the input or output module, or making reduced images.
Enter faults mode and check the active messages and the event log. If a fault code is
Fuser connector raised when the failure occurs, then go to the appropriate RAP.
Make copies and observe where the paper stops and which components are switched on
or off when the failure occurs.
Check if there is a repetitive pattern to the failure.
CRUM connector
Procedure
Go to the relevant checkout:
Customer Power Supply Checkout
External Electrical Equipment Checkout
Cable tie Common Causes Checkout
Connectors and Wiring Checkout
Power Supply Checkout
Wire to vacuum transport EPROMs Checkout
fan Electric Motors Checkout
Solenoids and Clutches Checkout
Switches and Sensors Checkout
High Voltage Arcing Checkout
Figure 1 Fuser and CRUM connector
Registration Guide Checkout
Developer Assembly Checkout
Xerographic Module and Corotron Checkout
Electrostatic Discharge Checkout
Paper Trays 1 to 5 Checkout
Duplex Transport Assembly Checkout
Output Device Checkout

Customer Power Supply Checkout Check for pinched wires near moving parts.
The DADH module harness for broken wiring and ensure that the ground terminals are
secure.
WARNING For the continuity of harnesses by checking for wire breaks inside insulation. Gently pull
Take care when measuring AC mains (line) voltage. Electricity causes death or injury. the relevant connector and wire while measuring continuity.
Check that all the PWB and in-line connections are good; refer to PJ Locations.
Check the continuity of the ground connections to the copy cartridge, fuser module and
CAUTION
input and output modules. Refer to the 01A Ground Distribution RAP.
If you suspect that the customer power supply is incorrect, do not try to correct the customer
Check that all the input and output module static eliminators are connected correctly and
power supply. Do not reconnect the printer. Inform the customer and your manager.
in good condition; refer to the relevant input or output module RAP.
Measure the customer power supply voltage at the power outlet and check that the cus-
tomer power supply is within specification; Refer to GP 22 Electrical Power Require- Power Supply Checkout
ments. Check the power cord for continuity. Refer to the 01C AC Power RAP.
Check that the customer power supply does not drop below the specification when the
copier is making copies; use a digital meter and select Peak Hold. Refer to GP 22 Elec- EPROMs Checkout
trical Power Requirements. Check that all EPROMs are installed correctly. Refer to REP 3.4 Single Board Controller and
External Electrical Equipment Checkout Power Distribution PWBs.
Electric Motors Checkout

WARNING Refer to GP 10 How to Check a Motor and perform the following:
Take care when measuring AC mains (line) voltage. Electricity causes death or injury. 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.
If the fault still exists, locate the PWB that drives the motor and install a new PWB.
CAUTION
If you suspect that the customer power supply is incorrect, do not try to correct the customer Solenoids and Clutches Checkout
power supply. Do not reconnect the machine. Inform the customer and your manager. Refer to GP 12 How to Check a Solenoid or Clutch and perform the following:
Perform the following: Check that the components are installed correctly.
Ask the customer if there is any electrical equipment, which uses a large amount of cur- Check that there is no mechanical binding, slipping or interference.
rent, that is connected to the same supply circuit as the machine. Enter the relevant output codes and check that the energizing of the components is reli-
With the customer's assistance, check if the failure occurs when electrical equipment near able. Check if the fault is caused when the components de-energize.
to the machine is switched ON or OFF. If it is suspected that a clutch or solenoid is faulty, install a new component as necessary.
If possible, connect the machine to a different supply circuit from the equipment that is If the fault still exists, locate the PWB that drives the component and install a new PWB.
causing the problem.
Switches and Sensors Checkout
Common Causes Checkout Refer to GP 11 How to Check a Sensor and GP 13 How to Check a Switch and perform the fol-
Make the following checks of common causes of intermittent failures: lowing:
Check for intermittent connections in the fuser connector assembly, (35-55 ppm) PL 4.15 Check that the components are clean and installed correctly. Ensure that the wiring to the
Item 9, (65-90 ppm) PL 4.10 Item 9. components is connected correctly.
Check for intermittent connections in the wiring to the exposure lamp, (W/TAG 150) PL Enter the relevant input codes and check that the sensing of the components is reliable.
14.15 Item 9 or (W/O TAG 150) PL 14.25 Item 9. Check if the fault is caused when the components are actuated.
Check that the interlock switch S01-300; PL 1.10 Item 7, is fully actuated by the front If it is suspected that a switch or sensor is faulty, install a new component as necessary.
interlock. If the fault is eliminated when an interlock cheater is installed, check that the If the fault still exists, locate the PWB that controls the component and install a new PWB.
interlock actuator bracket is not damaged. Install new parts as necessary.
High Voltage Arcing Checkout
Connectors and Wiring Checkout
Use this Checkout when there are intermittent 03-XXX failures and the suspect cause is high
Refer to REP 1.2 for details of wiring harness repair. voltage arcing.
Check the following: Refer to the 09-060 HVPS Fault RAP and complete all of the actions to check the HVPS.
Visible signs of damage to the wiring and the ribbon cables.

Registration Guide Checkout Electrostatic Discharge Checkout
Check that the upper registration and lower registration guides are not shorted to ground. Perform the following:
If a short to ground is found, inspect the guides and harnesses between the registration If the fault only occurs when feeding from a specific paper tray, go to Paper Trays 1 to 5
guide and bias lead at CB terminal on the HVPS. Checkout.
Check that there is continuity between the upper and lower registration guide. Check that If the fault only occurs when only making duplex copies, go to Duplex Transport Assembly
the registration bias terminal screw is tight. Checkout.
Check that the bias contact on the registration guide is not damaged, PL 8.15 Item 23. Check that all EPROMs and the NVM are seated correctly and that the connectors are not
Check that the transfer / detack corotron shield is not damaged. Install a new transfer / damaged. Refer to REP 3.4 Single Board Controller and Power Distribution PWBs.
detack corotron, (35 ppm) PL 9.22 Item 8, (40-90 ppm) PL 9.20 Item 2. If the registration Paper Trays 1 to 5 Checkout
guide is damaged, install a new guide, (35-55 ppm), PL 8.15 Item 4, (65-90 ppm), PL 8.17
Check that the paper tray size detection sensors match the size of paper in the trays.
Item 4.
Check that the control panel indicators display the correct size of paper.
Developer Assembly Checkout (W/O TAG 151, 35-55 ppm) Check that the ground plate, PL 8.30 Item 17, has good con-
Check the harness between DB terminal on the HVPS and PJ94 on the black developer tact with the drive shaft and continuity with the ground. If continuity to ground is an open
assembly for shorts to ground or damage. circuit or high resistance install a new ground plate. Refer to the 01A Ground Distribution
Check the ground line from PJ93 pin 10 on the developer assembly is in place and that RAP.
the connector is installed correctly and undamaged. Confirm that there is continuity Perform the Electrostatic Discharge Checkout.
between the connector and ground.
Refer to the appropriate RAPs to check the operations of sensors, feed components and
Inspect the developer assembly for damage and or incorrect assembly that may cause associated harnessing.
arcing.
If no fault is found, install a new developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90
08-103, 08-113 Tray 3 Misfeed Entry RAP
Xerographic Module and Corotron Checkout 08-104, 08-114 Tray 4 Misfeed Entry RAP
Check the transfer / detack corotron guide and the surface of the photoreceptor for dam-
08-115, 08-117 Tray 5 Misfeed RAP
age and contamination that indicates that these components are colliding with each other.
Ensure that both components are installed correctly. Duplex Transport Assembly Checkout
Inspect the transfer / detack corotron for correct installation. If any damage or wear is Check the operation of the duplex tray latch.
identified, install new transfer / detack corotron, (35 ppm) PL 9.22 Item 8, (40-90 ppm) PL Check the ground connections on the duplex transport assembly. Refer to 01A Ground
9.20 Item 2. Distribution RAP.
Check that the charge scorotron leaf spring on the drives module for damage. Check the Check for continuity between the upper guide and the transport drive shafts.
spring and the terminal on the xerographic module for signs of arcing. Check that the duplex transport is located correctly, REP 8.7 Duplex Transport.
Disconnect the corotron harnesses one at a time from the HVPS. Make copies to deter-
mine if the fault is caused by one of these components. Install new components if the fault
is determined and isolated.
Inspect the HVPS and its surrounding area for signs of arcing. If necessary install a new
Check the corotron harnesses on the HVPS for damage and short circuits to ground.
Check that the corotron wires are correctly tensioned and terminal blocks are clean and
free of arcing marks.
Check the transfer / detack corotron is located correctly in the short paper path assembly.
Ensure that the short paper path moves freely and latches in the correct position. Refer to
the replacement procedure in REP 10.1.
Check the bias contact on the registration guide for damage, (35-55 ppm), PL 8.15 Item
23, (65-90 ppm), PL 8.17 Item 23.
Check that there is continuity between the upper and lower registration guide and that the
bias terminal screw is tight.

Output Device Checkout OF11 Waste Toner Contamination RAP
To run the machine without the output device connected, use a finisher bypass harness, PL Use this RAP if there is excessive waste toner contamination in the machine or on the cus-
26.10 Item 7. If the problem is cleared, then go to the appropriate output device. tomers floor.
1K LCSS. Check the following: Procedure

Ground connection on the power cord, PL 11.124 Item 8.
Static eliminator on bin 0 entry, PL 11.118 Item 7.
Static eliminator on the tamper assembly, PL 11.112 Item 5. WARNING
Static eliminator on the bin 1 entry, PL 11.120 Item 7. Ensure that the electricity to the machine is switched off while performing tasks that do
Check that all of the connectors on the 1K LCSS PWB are pushed fully home. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Ensure that all of the ground wires are connected to the frame. death or injury. Moving parts can cause injury.
Check all the harnesses for damage and short circuit to ground. Waste toner is being deposited in the waste toner bottle.
Y N
2K LCSS. Check the following:
Remove the waste toner bottle and waste toner door, REP 9.1. Place a sheet of paper in
Ground connection on the power cord, PL 11.26. the bottom of the aperture from where the waste toner bottle was removed, to collect
Static eliminator on bin 0 entry, PL 11.22 Item 7. fallen toner. Enter dC330, code 09-010 photoreceptor motor. Push back the waste toner
Static eliminator on the tamper assembly, PL 11.16 Item 5. shutter, Figure 1, to expose the auger. The auger rotates.
Static eliminator on the bin 1 entry, PL 11.23 Item 7. Y N
Install a new main drive module, (35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10
Check that all of the connectors on the LCSS PWB are pushed fully home. Ensure
Item 1.
that all of the ground wires are connect to the frame.
Check all the harnesses for damage and short circuit to ground. Perform the following
NOTE: The HVF may optionally have a tri folder and inserter unit. Where fitted, these Remove and examine the shutter, Figure 1. Ensure that the shutter operates cor-
should also be checked. rectly and allows waste toner to reach the bottle. If necessary install a new shutter,
(35-55 ppm) PL 4.15 Item 11, (65-90 ppm) PL 4.10 Item 13.
HVF. Check the following:
Remove the auger damper, (35-55 ppm) PL 4.15 Item 13, (65-90 ppm) PL 4.10 Item
Ground connection to the power supply unit, PL 11.157 Item 1. 11. Remove the xerographic module. Use a toner vacuum cleaner to remove waste
Static eliminator on BM entry. PL 11.161 Item 26. toner from the duct between the xerographic module and the waste toner bottle. Re-
Exit brush on HVF top exit, PL 11.155. install all removed components. Monitor the waste toner bottle during subsequent
Static eliminator on BM exit, PL 11.168 Item 16. customer use of the machine.
Exit brush on the Tri folder right hand frame, PL 11.190. Waste toner is being deposited in the waste toner bottle
Y N
Ground wire on the BM compiler motor, PL 11.166 Item 4.
Install new components:
Ground wire on the BM back stop motor, PL 11.163 Item 1.
1. Xerographic module, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2.
Ground wires to HVF entry and exit feed motors, PL 11.150.
2. Main drive module, (35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.
Ground wires to HVF buffer reed and bypass feed motors, PL 11.150.
Ground wire to front of HVF paddle module, PL 11.145 Item 2. Perform SCP 6 Final Actions.
Ground wire to the HVF offset motor, PL 11.140 Item 19.
Ground wire to HVF paper pusher motor, PL 11.145 Item 13. Check that the waste toner bottle is undamaged and that the waste toner bottle seal, Figure 1,
is undamaged.
Ground wire to HVF staple assembly, PL 11.140 Item 14.
If necessary, install new parts:
Check that all of the connectors on the HVF PWB, and BM PWB are pushed fully
Waste toner bottle, PL 9.10 Item 1.
home. Ensure that all of the ground wires are connected to the frame.
Shutter assembly, (35-55 ppm) PL 4.15 Item 11, (65-90 ppm) PL 4.10 Item 13.
Where the Tri Folder and the Inserter options are installed check that the PWB con-
nectors are pushed fully home. Ensure that all of the ground wires are connected to
the frame
Ground wire on the inserter PWB, PL 11.179 Item 9.
Inserter docking PJ and connector.
Check all the harnesses for damage and short circuit to ground.

OF12 False Xerographic Module End of Life RAP
Use this RAP if the xerographic module has reached its end of life, 400,000 prints, prematurely.
Initial Actions
Waste toner door
WARNING
Waste toner bottle death or injury. Moving parts can cause injury.
Enter dC131 location 09-063 XRU Total Count, then check the xerographic module image
count. If the image count is unexpectedly high, 422,000 or greater, then the CRUM data is cor-
rupted.
Procedure
1. Refer to Wiring Diagram 6. Check the wiring harness at PJ144. Repair the wiring as nec-
essary, REP 1.2.
2. Check for damage to the xerographic module CRUM connector, (35-55 ppm) PL 4.10
Item 4 or (65-90 ppm) PL 4.12 Item 4. If necessary, install a new drives module, (35-55
ppm) PL 4.15 Item 1 or (65-90 ppm) PL 4.10 Item 1.
3. Check for damage to the CRUM plug on the xerographic module, (35 ppm) PL 9.22 Item
2 or (40-90 ppm) PL 9.20 Item 2. If necessary, install a new xerographic module.
4. Refer to Wiring Diagram 11. Make sure all connectors on the HVPS and PJ55 are secure.
5. Install a new HVPS, PL 1.10 Item 5.
6. If the fault remains, go to OF10 Intermittent Failure RAP and refer to the Electrostatic Dis-
charge Checkout.
Shutter
Waste toner bottle seal

OF13 Convenience Stapler RAP
To identify problems with the convenience stapler.
Procedure
WARNING
WARNING
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. Convenience stapler
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.
Check that the power lead is correctly connected to the convenience stapler, Figure 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.

OF14 Extensible Interface Platform RAP OF15 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. As necessary, perform the following: 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-
Reload the Machine software, GP 4, using the Altboot process. Ask the customer to
ton within the Xerox Secure Access tools window. Once communication is re-established the
resubmit the EIP enablement file and restore EIP settings
stored Xerox Secure Access setting are restored.
Install a new UI control PWB, PL 2.10 Item 11.
2. Request the customer to check their network and software.
Card reader or
biometric device Server
Client PC
workcentre
Ethernet - secure link
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 LEDs 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 LEDs 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 LEDs 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
Secure Access is installed correctly, and ask customer to check the configuration at the
server.
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
remains locked after a card is swiped, re-orient the card and re-swipe.
Try a known good card in the reader. If the other card is working on the problem Card
Reader. Ask customer to make sure the card corresponds to a valid Secure Access
Account.
Try the card in a known good reader. If the card is working on a known good Card Reader,
it may be a problem with the Secure Access Authentication Device. Check to see is the
LEDs on the Secure Access Authentication Device are on.
The Red LED on Card Reader Flashes Slowly
This indicates the reader is connected to the controller but the controller is not connected
to the server. Check the Ethernet green LED on the Authentication Device.
If the Ethernet green LED on the Authentication Device is off, make sure the connectors
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-
trator.
If the Ethernet green LED on the Authentication Device is either on or flashing, contact
the Secure Access Administrator.
The Red LED on Card Reader Flashes Rapidly
This indicates a valid card but does not correspond to a valid Secure Access Account at
the server, test with a known valid users card.
If all cards react the same way, this indicates the Server Configuration may not be correct.
Ask customer to check the Server Configuration.
If all the card react this way, this indicates the cards are not valid. Ask customer to check
the Server Configuration
The Card Reader LEDs 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.

3 Image Quality
Image Quality RAPs
IQ1 Image Quality Entry RAP.......................................................................................... 3-3
IQ2 Defects RAP ............................................................................................................. 3-10
IQ3 Xerographic RAP...................................................................................................... 3-14
IQ4 Fuser Module RAP ................................................................................................... 3-17
IQ5 Print Damage RAP ................................................................................................... 3-17
IQ6 Narrow Bands RAP .................................................................................................. 3-19
IQ7 DADH, Document Glass and Scanner RAP ............................................................. 3-19
IQ8 Skew RAP ................................................................................................................ 3-20
IQ9 Unacceptable Received Facsimile Image Quality RAP............................................ 3-22
IQ10 Image Quality Improvement RAP ........................................................................... 3-23
IQ11 Light Copies RAP ................................................................................................... 3-24
IQ12 Barber Pole Deletions / Developer Leakage RAP .................................................. 3-29
IQ13 Cockle Deletion RAP .............................................................................................. 3-32
Image Quality Specifications

IQS 1 Solid Area Density................................................................................................. 3-33
IQS 2 Background ........................................................................................................... 3-34
IQS 3 Fusing ................................................................................................................... 3-35
IQS 4 Resolution ............................................................................................................. 3-35
IQS 5 Skew ..................................................................................................................... 3-36
IQS 6 Copy / Print Defects .............................................................................................. 3-37
IQS 7 Registration ........................................................................................................... 3-38
IQS 8 Magnification ......................................................................................................... 3-39
November 2014 Image Quality

Image Quality November 2014
A
IQ1 Image Quality Entry RAP Exit diagnostics. Use the prints of the internal test pattern and make copies of these from the
DADH. The copies of the internal test pattern are good.
Use this RAP to determine the source of an image quality problem.
Y N
On a correctly registered document with border erase either on or off, an image quality defect Go to the IQ7 DADH, Document Glass and Scanner RAP.
within 5 mm of the edge of the sheet is acceptable.
Use the print of the internal test pattern and make three copies from the document glass. The
Initial Actions copies of the internal test pattern are good.
Check the condition of the paper. Do not use incorrectly cut paper, damp paper, paper Y N
with rough edges, badly drilled paper, paper with wrapper wax or glue. Paper and media Check the image quality defects. The defects on the copies are identical.
should be stored flat, enclosed in wrappers, in a cool dry environment. Y N
Check that the paper is within specifications. GP 20. Go to the IQ2 Defects RAP.
Check that paper tray guides are set to the correct paper size.
Check the document guides on the DADH. Go to the IQ7 DADH, Document Glass and Scanner RAP.
Check the original documents for defects. If the documents are damaged passing through
Compare the image dimensions of the internal test pattern with the prints through the DADH
the DADH, go to the 05F Damaged Documents RAP.
and from the document glass. Refer to IQS 8 Magnification. The dimensions are within
Ensure that the image adjustment mode selections are those used by the customer.
specifications.
Clean the charge and transfer/detack corotron.
Y N
Procedure Go to ADJ 3.2 Magnification Adjustment.
If necessary, refer to IQ1 Internal Test Patterns for:
A description of image quality defects. If possible, use the customer document to make a copy from the document glass or through
The optimum test pattern to be used to diagnose the defect. the DADH, at 100% magnification. Make another copy at a different magnification setting.
Compare the images, Figure 1. The defect is on the same part of the image.
An example of all internal test patterns.
Y N
If possible, use the customer job to recreate the image quality problem.
Return to the start of this procedure and select a different internal test pattern to check the
Enter Diagnostics, GP 1. Select Other Routines. Select dC606 Print Test Patterns. Select a image quality.
suitable test pattern. Select 1 Sided. Press Start Test. The printed images of the internal
test pattern are good.
There is a defect on the scanning optics. Refer to ADJ 14.1 Optics Cleaning Procedure (W/O
Y N TAG 150) or ADJ 14.2 Optics Cleaning Procedure (W/TAG 150).
Go to IQ2 Defects RAP.
Check the back of the prints for toner contamination. The back of the prints are clean.
Y N
Select a suitable test pattern. Select 2 Sided. Press Start Test. The printed images of the
internal test pattern are good.
Y N
Check the prints for damage. The prints are not damaged.
Y N
Go to the IQ5 Print Damage RAP.
If a facsimile card is installed, send a test facsimile to the machine. The facsimile image
quality is good.
Y N
Compare the facsimile print with an internal test pattern print. The facsimile print and
the internal print display the same defect.
Y N
Go to IQ9 Unacceptable Received Facsimile Image Quality RAP.
Figure 1 The defect location check
A

Xerox WorkCentre 5790 Family 3-3 IQ1
IQ1 Internal Test Patterns Table 1 Image quality defects
Table 1 defines the image defect, gives a description of the defect and identifies the optimum Optimum
test pattern to be used. Image quality internal test
defect Description of defect pattern
Table 2 describes the test patterns and the purpose for which they should be used to identify
Non uniformity Variation in image quality and density across the print. See 5
image quality defects. also uneven density.
Offsetting A previous image that was not removed from the fuser roll 14
Use the test patterns 1, 2, 5, 8, 14, 16 and 19 for image quality analysis. The other test patterns
during the cleaning cycle. The image is repeated at regular
are designed for the use of initial machine calibration by the manufacturer.
intervals.
Table 1 Image quality defects Part images Incomplete or missing images. 5, 16, 19
and missing
Optimum
images
Image quality internal test
Print damage Creases, curl, cuts, folds, wrinkles, or embossed marks are 5
defect Description of defect pattern
visible on the print.
Background Uniform darkening across all the non print areas 1
Repeat images Refer to offsetting defects and residual image defects. 14, 19
Bands Grey to dark in the light or non-image areas of the print in the 2, 5
Residual A previous image that was not removed from the photorecep- 14, 19
process direction or across the process direction. See also image tor during the cleaning cycle.
narrow bands.
Rotated image The image on the printed document has turned 90 Degrees 19
Barber pole A series of finger print deletions that form a pattern like a bar- 5
to the image printed on the original document.
deletions ber pole or auger marks. The deletions are repeated at proxi-
Skew A difference in angular alignment between image on the print 16
mately 7 cm and are approximately 30 degrees to the lead
edge throughout a grey or dark dusting. and the original document.
Beads on print Developer beads in the light or non-image areas of the print. 2, 1 Skips. Loss or stretching of the image, and compression of the 16
image, in bands across the process direction.
Black image A print that is black or grey all over, but has no visible image 1
Smears Loss or stretching of the image, and compression of the 16
of the original document.
image, in bands across the process direction.
Blank image No visible image. 5
Smudges Darker images across the process direction. 5
Blurred image Part or whole of the image has the appearance of being out 19, 16
Spots Dark spots in the non-image areas of the print. 1, 2
of focus. Refer to IQS 4 Resolution.
Streaks Lines on the print, in the process direction of the non-image 2, 5
Dark prints Very dark background with a visible image. 1, 19
area.
Deletions Areas of the image missing from the print. Deletions may be 2, 5, 8, 16
in the form of white spots, marks, lines, or whole areas of Stretched and The image on the paper is stretched or distorted. 16
distorted
toner missing from the print.
images
Displaced and Distorted images, part images and missing images (scram- 5, 16, 19
Toner contami- Random black spots or marks 2
fragmented bled images). Displaced images.
image nation on the
back of prints
Light images The image is visible on the print, but with insufficient solid 11, 15
Uneven den- Variation in image density across the print. See also non uni- 5
area density.
sity formity.
Lines Black or white lines across the process direction or in the pro- 2, 5, 8
Unfused prints The toner image on the finished print is not fused to the print 14
cess direction. See also the description, displaced and frag-
mented image. medium.
Magnification At 100% magnification the printed image differs from the size 11, 19
of the image on the original document. Refer to IQS 8 Magni-
fication.
Marks Dark marks in the non-image areas of the print. 1, 2
Misregistration The image on the paper is Misregistration. Refer to IQS 7 16
Registration.
Narrow Bands Bands across the process direction visible in halftone areas. 8

IQ1 3-4 Xerox WorkCentre 5790 Family
Table 2 Internal test patterns
Number Description Purpose
1 Blank sheet, Figure 2. 0% area coverage. Background defects
spots, scratches.
2 75 dpi, 0 degrees 25% area cover- Light density uniformity, deletions, lines,
age halftone. Figure 3. bands, streaks and photoreceptor defects.
3 106 dpi, 45 degrees, 25% area cov- Light density uniformity, deletions, lines,
erage halftone. Figure 3. bands and streaks.
4 212 dpi, 45 degrees, 25% area cov- Reserved for engineering investigations.
erage halftone. Figure 3. Stress test pattern. Will not be defect free.
5 106 dpi, 45 degrees, 50% area cov- Uniformity, fuser defects, lines, bands,
erage halftone. Figure 4. streaks and smears. Barber Pole deletions.
6 212 dpi, 45 degrees, 50% halftone. Reserved for engineering investigations.
Figure 4. Stress test pattern. Will not be defect free.
7 424 dpi, 45 degrees, 50% halftone. Reserved for engineering investigations.
Figure 4. Stress test pattern. Will not be defect free.
8 Perpendicular lines 2 on 2 off. Figure Motion quality. ROS, developer, registration
5. transport, fuser and intermediate gear trains. Figure 2 Test pattern 1.
9 Perpendicular lines 8 on 56 off. Fig- Reserved for engineering investigations.
ure 7. Stress test pattern. Will not be defect free.
10 Parallel lines 8 on 56 off. Figure 6. Lines that run LE to TE.
11 Combined grey scales. Figure 8. This test pattern is for engineering develop-
ment and used in the light copies RAP.
12 Perpendicular bands. 25 mm (1 inch) Solid area reproducibility. For checking fus-
on and 25 mm (1 inch) off black. Fig- ing, stripper finger marks, solid area, offset-
ure 9. ting and cleaning.
.
13 Perpendicular lines 2 on 30 off. Fig- Motion quality, wobble (ROS).
ure 10.
14 12cm. (4.75 inches) Lead edge black Fuser offsetting and cleaning failure. Stress
band. Figure 11. test for stripping from the fuser.
15 Tone reproduction curve. Step- 21 mm wide strips that run inboard to out-
wedge 106 dpi, 45 degrees. Figure board of varying area coverage. The 50%
12. wedge is used for checking IOT darkness.
16 Quadrille 4 on 60 off. Figure 13. Used to check for deletions, skew and skips.
17 Ladder chart. Figure 14. Registration and skew.
18 Manufacturing, tone reproduction 10 mm wide strips that run inboard to out-
curve. 10 mm strips (235 lines), board of alternating area coverage. Used in
alternating area coverage, 50%, manufacturing for automated measurements.
25%, 75%, 0%, 100% repeating Figure 3 Test patterns 2, 3 and 4
(right to left) with a 3 mm white bor-
der. Figure 15.
19 Field test pattern. Uniformity areas, Registration, resolution, uniformity, streaks
registration marks and resolutions and bands
targets. Figure 16.

Figure 4 Test patterns 5, 6 and 7 Figure 6 Test pattern 9
Figure 5 Test pattern 8 Figure 7 Test pattern 10

Figure 9 Test pattern 12



IQ2 Defects RAP
Use this RAP to resolve image quality defects.
On a properly registered document, with border erase is either on or off, an image defect (dele-
tion/disturbance within 5 mm of the edge of the sheet is acceptable.
Ensure IQ1 Image Quality Entry RAP is performed before starting this RAP.
Initial Actions
WARNING
Check the error log for the following codes: 09-310, 09-390, 09-360, 09-361, 09-362, 09-363. If
any of the codes are displayed, go to the 09-310, 09-390 Low Toner Sensor Failure RAP or the
09-360, 09-361, 09-362, 09-363 Toner Concentration Sensor Failure RAP.
Procedure
Refer to the appropriate image quality failure and perform the appropriate action.
Background. Refer to the IQS 6 Copy / Print Defects and IQS 2 Background. Go to the
IQ3 Xerographic RAP.
Bands. Go to the IQ3 Xerographic RAP.
White bands on a grey or dark dusting. Check for developer leakage, refer to Developer
Assembly Checkout.
Barber pole deletions. A series of finger print deletions that form a pattern like a barber
pole or auger marks. The deletions are repeated at proximately 7 cm and are approxi-
mately 30 degrees to the lead edge throughout a grey or dark dusting. Go to IQ12 Barber
Pole Deletions/Developer Leakage RAP.
Beads on print. Clean the following:
Developer beads hanging from the developer roll and the lower lip, Figure 1.
The developer roll area, above and in the recesses below the roll, Figure 1.
The halo guide and the registration guide, Figure 1.
The drive roll assembly, PL 8.15 Item 9 and under the registration roll cover, PL 8.15
Item 5. Refer to Figure 1.
The duplex paper path (35-55 ppm) PL 8.22 or (65-90 ppm) PL 8.20.
The base pan of the machine.
Go to IQ3 Xerographic RAP and complete the Xerographic Module and Short Paper Path
Checkout and the Developer Assembly Checkout.
Improperly seated transfer/detack end block covers, or a misadjusted halo guide can
score the surface of the drum, leading to developer loss and premature xerographic mod-
ule replacement. Perform ADJ 9.4 Xerographic cleaning.
Black band. Copies have a black band 1 inch wide from top of the copy. At start print the
scan carriage assembly moves to the right, starts to scan and then pulsates for an inch.
Check the connections on the scanner PWB. Install a new scanner PWB, (W/O TAG 150)
PL 14.20 Item 1 or (W/TAG 150) PL 14.10 Item 1.

IQ1, IQ2 3-10 Xerox WorkCentre 5790 Family
Black image. Check the following conditions: a. Install a new xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL
If both the print and the copy are completely black, go to the 06-350 ROS Laser Not 9.20 Item 2.
Under Control RAP. b. Perform dC132 NVM Initialisation and select the All Copier MVN routine. Do
If only the print is good, but the copy is black, go to the 14-703 to 14-706, 712, 714, not save/restore NVM to/from the machine resident diskette because this may
716, 718 Failure To Calibrate Entry RAP and perform the Exposure Lamp Check. restore corrupted NVM. However if the NVM on the machine resident diskette
was saved from a time when the machine did not have the fault, then and NVM
For other black images, go to the IQ3 Xerographic RAP.
restore should be performed.
Blank image. Perform the following:
c. If the problem continues, Install a new fuser module assembly, PL 10.8 Item 1
Insert a door cheat and make a copy. At the same time use a flashlight and illumi-
(35 to 55 ppm) PL 10.10 Item 1 (65 to 90 ppm).
nate the photoreceptor between the developer and the xerographic module. Check
the following: d. If the problem continues, perform the OF7 IOT PWB Diagnostics rap, before
installing a new IOT PWB, PL 1.10 Item 2.
If the copy is completely blank, go to the IQ3 Xerographic RAP.
e. If the problem continues, Install a new fuser connector assembly, PL 4.10 Item
If the copy has a dark band go to the 06-340 ROS Laser Failure RAP.
9 (65 to 90 ppm) PL 4.15 Item 9 (35 to 55 ppm).
If the blank images are additional output. Go to the OF8 Multifeed RAP
f. If the problem continues, Install a new LVPS and base module PL 1.10 Item 3.
Check the developer drives:
Dark prints. Go to the IQ3 Xerographic RAP.
1. Remove the xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL
Deletions. Check the following:
9.20 Item 2.
If the deletions are on the duplex side of a print or copy, go the IQ5 Print Damage
2. Make a visible bald patch on the developer roll by moving the developer brush.
RAP. Also refer to the white lines defect.
3. Re-install the xerographic module.
Intermittent (1 in 50 to 1 in 400 copies) irregularly-shaped deletions positioned near
4. Enter dC330 code 04-010 main motor, MOT04-010. Run MOT04-010 for the centre of the leading edge, and on either side of the print. This type of deletion is
approximately 5 seconds. known as Cockle deletion, refer to IQ13 Cockle Deletion RAP.
5. Remove the xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL If the deletions are small spots, this can be caused by beads on the image. Refer to
9.20 Item 2. the beads on print defect.
6. Check for the visible bald patch on the developer roll. If the patch is still visible, If the deletions are faded or deleted areas on the outboard area of prints and copies
check the drives to the developer, GP 7. and installing a new xerographic module removes the defect, but it returns within
If 09-060 faults are in the fault history log, go to the 09-060 HVPS Faults RAP. 2500 prints/copies and the defect gets worse over time, check the ozone system, go
Blurred image. Check that the documents are flat on the document glass. Use a new to OF6 Ozone and Air Systems RAP.
ream of paper. Check the transfer and detack corotrons wires are secure and taut. If nec- Go to the IQ3 Xerographic RAP.
essary perform the following: Displaced and fragmented image. Check the following:
1. Install a new transfer / detack corotron, (35 ppm) PL 9.22 Item 8 or (40-90 ppm) PL If the machine is lower than 750 metres (2461 feet) above sea level, go to the IQ3
9.20 Item 2. Xerographic RAP.
2. The xerographic drum may be heat damaged by fuser temperature control prob- If the machine is higher than 750 metres (2461 feet) above sea level, check the
lems. Look for the indicators that follow: transfer / detack assembly for arcing. If necessary go to dC131 NVM Read / Write
Characters on copies/prints are bold, thick and smeared looking (burred, out of location 09-098 Altitude. Check the value is correct.
focus). Refer to IQ7 DADH, Document Glass and Scanner RAP. Perform the IQ7 Scanner
An inspection of the photoreceptor reveals a yellow/green haze on the drum Checkout.
surface. Refer to OF10 Intermittent Failure RAP and perform the Electrostatic Discharge
The top photoreceptor seal, which is normally white, may be yellow/brown, Checkout.
curled and shrunken. Grey images. Dark grey images too dark or light images too light. Go to ADJ 9.2 Image
Make a print of internal test pattern 5, refer to dC606. The defect can some- Quality Adjustment Routine as an initial action. If ADJ 9.2 fails to solve the problem, go to
times be a fairly well defined darker band approximately 25mm (1 inch) wide ADJ 9.5 Optimize Dark and Light Grey Image.
running from inboard to outboard on the photoreceptor. Other times it may not Light images. Go to the IQ11 Light Copies RAP.
be a well defined and there may be more than one defect area on the drum. Lines. Perform the following:
There may be 10-315 or 10-320 faults in the fault history file. If there are dark lines in the process direction that are continuous from edge to edge
The cause of this fault is the fuser lamp coming on and staying on in standby, the of the image, install a new xerographic module, (35 ppm) PL 9.22 Item 2, (40-90
excessive heat damages the drum, due to an intermittent fault. Perform the actions ppm) PL 9.20 Item 2.
that follow:

White lines or deletions in the process direction that are continuous from edge to Offsetting. A toner image that adheres to the fuser roll or output rolls and transfers to
edge of the image. Check the following: another area of the print. The repeat intervals for a fuser roll defects are at 110mm for all
Contamination of the scorotron. Refer to IQ3 Xerographic RAP speeds.
Damage to the fuser roll. Refer to IQ4 Fuser Module RAP The repeat intervals for the pressure roll are 110 mm for 35-55 ppm and 126 mm for 65-
Spots or marks on the CVT glass. Refer to IQ7 DADH, Document Glass and 90 ppm machine due to the different size of the pressure roll.
Scanner RAP Perform the following:
White lines in the process direction that are continuous from edge to edge of the Check that the fuser roll is cleaned and lubricated by the fuser web. Go to IQ4 Fuser
image can be caused by ROS contamination. Perform the following: Module RAP
1. Print test pattern 5. Check the fuser web motor, refer to the 10A Fuser Web Motor RAP
2. Remove the xerographic module, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL Part images and missing images. Go to 05C Document Size Sensor Failure RAP.
9.20 Item 2. Print damage. Go to the IQ5 Print Damage RAP.
3. Remove the ROS securing screw, refer to REP 6.1. Repeat image defects. Perform the following:
4. Push the ROS to the rear of the machine. If the distance between repeated defects in the process direction on A3
(11X17inches) printed images is 264 mm, install a new xerographic module, (35
NOTE: The ROS will move back approximately 12 mm (0.5 inch).
ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20 Item 2.
5. Install the xerographic module. If the repeated distance between defects in the process direction is 110mm (35-
6. Print test pattern 5. 55ppm) or 126mm (65-90ppm), go to the IQ4 Fuser Module RAP.
7. Check the printed test patterns. If the line has moved, perform ADJ 6.1 ROS If the repeated distance between defects in the cross process direction is 90mm and
Window Cleaning Procedure and if necessary, ADJ 6.2 ROS Cleaning Proce- 80mm (3.54 and 3.15 inches) that line up with the xerographic module stripper fin-
dure. gers, go to the IQ3 Xerographic RAP and perform the Xerographic Module and Short
Paper Path Checkout.
8. Return the ROS to the correct location. Install the ROS securing screw.
If there other defects that are repeated in sequential images, install a new xero-
If the problem persists, go to the IQ3 Xerographic RAP.
graphic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20 Item 2.
Magnification. Refer to IQS 8 Magnification. Go to ADJ 3.2 Magnification Adjustment.
Residual image. Perform the following:
Marks and Spots. Perform the following:
If the repeated residual image on A3 (11X17 inches) paper is 264 mm, install a new
Check the original documents for spot and marks.
xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20 Item 2.
Refer to the IQS 6 Copy / Print Defects. Go to the IQ3 Xerographic RAP.
If the problem persists, go to the IQ3 Xerographic RAP
Misregistration. Perform the following:
Rotated image. Go to the 14A Scanning Document Size Entry RAP.
1. Go to dC131a NVM tables and refer to the chain 8 table and check that the buckle
Scrambled image. Perform the following:
settings are set to default for 08-152, 08-169, 08-170, 08-171 and 08-172. Increase
the values in increments of 10 until the problem is resolved. Check the connections on the ROS data cable, PJ113 on the single board controller
PWB and PJ122 on the ROS, PL 3.24 Item 15. Refer to Wiring Diagram 12.
2. Open the front door, install a cheat in the front door interlock. Run the copies and
Check for a loose or missing bias connection to the halo guide, PL 8.15 Item 23. A
observe the jam clearance knob 4b on the front of the registration roll. The knob
bad connection can cause arcing and show on the print as a scrambled image.
must turn / stop while making copies. If the knob turns continuously and does not
stop, install a new registration clutch, PL 8.15 Item 7 (35-55 ppm), PL 8.17 Item 7 Skew. Refer to the IQS 5 Skew and the IQ8 Skew RAP.
(65-90 ppm). Skips. Skips are associated with a variation in the relative scan speed of the projected
3. If the registration is variable after a developer spillage over the registration transport, image and the rotation speed of the photoreceptor.
install a new registration clutch, PL 8.15 Item 7. Refer to the IQS 6 Copy/Print Defects. Go to the IQ3 Xerographic RAP
4. If the top edge registration is variable after a dC604 Registration Setup. Check that Smears. Smears are associated with a variation in the rotation speed of the photorecep-
the ROS securing screw is tight, refer to REP 6.1 ROS. tor or speed of the paper.
5. For any other registration problem, refer to dC604 Registration Setup. Refer to the IQS 6 Copy/Print Defects. Go to the IQ3 Xerographic RAP
Narrow bands. Go to IQ6 Narrow Bands RAP Smudges. They are caused by the unfused image being disturbed. Go to the IQ3 Xero-
Non uniformity. Perform the following: graphic RAP.
Go to IQ3 Xerographic RAP and complete the ROS Checkout. Streaks. The result of disturbance either before or after image transfer. Go to the IQ3
Print internal test pattern 12. If the print has a non uniform density defect, install a Xerographic RAP.
new ROS, PL 6.10 Item 4. Stretched and distorted images. Perform the following:
Go to and complete the Developer Assembly Checkout

If the defect is present on Fax, Scan to E-mail or Scan to File, send the job at a Install a new transfer/detack corotron, (35 ppm) PL 9.22 Item 8 or (40-90 ppm)
higher resolution. Select fine or super fine resolution. PL 9.20 Item 2.
Check for the paper stalling or catching as it passes under the xerographic drum.
Check for wear or damage on the transport rolls. CAUTION
Check the document feed, refer to IQ7 DADH, Document Glass and Scanner RAP. If the NVM values are increased, paper stripping faults can occur. The faults can
Perform the DADH checkout. include damage to the lead edge of the paper, paper jams, stripper finger contamina-
Toner contamination on the back of prints and excessive toner contamination tion and marks on copies.
inside of the machine. Perform the following: If the uneven density is still present, enter Diagnostics, GP 1. Enter dC131.
If it is possible to access dC131 location 09-351 and set it to 4, the correct level of Refer to chain 9 NVM xerographic setting values 09-015 and 09-018. Increase
software is already loaded, go to step 1, if not load software: both values in increments of 5 to a maximum of 150.
NOTE: SPAR releases are case sensitive, enter the code exactly as it appears. Check that the developer assembly has been correctly installed, REP 9.2.
ADJ 6.1 ROS Window Cleaning Procedure.
W/O TAG 155 IOT PWB, load general release SMP 1,061.131.221.10401 or
ADJ 6.2 ROS Cleaning Procedure.
higher, available at http://www.support.xerox.com/support/enus.html
If problem persists go to IQ3 Xerographic RAP.
W/TAG 155 IOT PWB, load SPAR version 061.132.221.29100 or higher, avail-
able at https://www.xrxgsn.com/admin/user/spar release.ihtml. The SPAR Unfused prints. Refer to the IQS 3 Fusing and IQ4 Fuser Module RAP.
release code is WC57xxSpar.
1. Set NVM values:
a. Set dC131 location 09-351 Disp. Const. B to a value of 4.
b. Set dC131 locations 09-004, 09-005 and 09-006 to a value of 501.
c. Access dC131 location 09-069 and lower the value by 100.
Switch the machine off, then switch the machine on, GP 14. Print 200 of inter-
nal test pattern 15 to decrease the toner concentration, refer to IQ1.
2. Clean the contaminated areas:
Base pan
Transfer/detack corotron, Figure 1
Green handles
Short paper path assembly, (35 ppm) PL 9.22 Item 3 or (40-90 ppm) PL
9.20 Item 3
Front door
Registration nip assembly, PL 8.15 Item 5
Tray 1 and tray 2
Lower bias guide, PL 8.15 Item 22
3. Perform ADJ 9.3 Developer Magnetic Seal Brush Adjustment.
4. Copy test pattern 82E2020 and print internal test patterns 11 and 15. Go to
IQ11 Light Copies RAP and asses the image quality.
5. If required, Perform IQ10 Image Quality Improvement RAP to optimize the
image quality.
If the problem persists go to the IQ3 Xerographic RAP.
Uneven Density. Perform the following:
If the uneven density occurs at 20 mm (0.75 inches) intervals in a band along the
lead edge of the paper, perform the following:
Enter Diagnostics, GP 1. Enter dC131. Refer to chain 9 NVM xerographic set-
ting values 09-015 and 09-018. Ensure the values are set to default.
Refer to IQS 1 Solid Area Density, to check for the correct density.

IQ3 Xerographic RAP
Use this RAP to determine the cause of the image quality problem.
Developer roll area
Initial Actions
Developer roll and lower lip
WARNING
Magnetic developer seal
brush not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Halo guide WARNING

Follow the service procedure exactly as written. Use of controls or adjustments other
than those specified in this manual, may result in an exposure to invisible laser radia-
Transfer / Detack tion. During servicing, the invisible laser radiation can cause eye damage if looked at
corotron directly.
Perform the following checks and if necessary, install new components:
Check that the photoreceptor fan is working. If the fan is working, air will be drawn into the
air intake. If necessary refer to the 09C Photoreceptor Fan RAP and the OF6 Ozone and
Air Systems RAP.
(65-90 ppm) Check that the duplex cooling fans are working, refer to the OF6 Ozone and
Air Systems RAP.
Check that the relative humidity sensor is working. Go to the 09-365 Relative Humidity
Sensor Failure RAP.
Registration roll
cover Perform ADJ 9.4 Xerographics Cleaning.
Check the registration / developer bias harness connection, (35-55 ppm) PL 9.17 Item 6
or (65-90 ppm) PL 9.15 Item 6. Figure 1.
Check that the corotron lead connections to the HVPS are secure, PL 1.10 Item 5. If nec-
essary, refer to 09-060 HVPS Faults RAP.
Check for loose ground connections. Go to the 01A Ground Distribution RAP.
Make prints. If the image quality defect is still present perform the procedure.
Procedure
The following components can cause image quality defects. Perform the checks:
Xerographic Module and Short Paper Path Checkout
Developer Assembly Checkout
Fuser Module Checkout
ROS Checkout
Scanner Checkout
Xerographic Module and Short Paper Path Checkout
Check the xerographic module stripper fingers for wear, damage and contamination. If
necessary install a n XRU skids kit, PL 9.20 Item 19 (40-90ppm), PL 9.22 Item 21
(35ppm).

If there are xerographic module stripper finger marks (three marks/dots/spots that line up 2. If the problem continues, Increase the DC component of the Detack LE voltage by
with the xerographic module stripper fingers) on the edge or the body of the prints/copies, decreasing by 20 bits the NVM values in dC131 code 09-015, detack LE side 1 and
together with some or all of the following symptoms: dC131 code 09-018 detack LE side 2.
Toner contamination of the xerographic module stripper fingers and /or star wheels 3. If the problem continues, reduce the fuser standby temperature, dC131 code 10-028
on the stripper finger arms and fuser run temperature dC131 code 10-029 by 10 bits each. Change the fuser
Broken or missing stripper fingers caused by frequent jam clearances card stock offset value, dC330 code 10-059 from 15 to 30.
Paper wrinkles 4. If the problem continues, decrease the fuser nip pressure (from and rear) by 2 turns.
Inverter jams Hold the xerographic module and view the rear end. Check the toner reclaim drive cou-
pling is free to rotate in a clockwise direction. If the black drive coupling does not rotate
Dog eared copies/print
freely, install a new xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20
The detack transformer in the HVPS has failed or is failing, so there is no voltage or a low Item 2.
voltage supplied to the detack corotron. Perform the following:
Check that the surface of the photoreceptor is not chipped, scored or scratched. The
1. Detack voltage check:
damage can be caused by the covers on the end blocks of the transfer / detack. Check
Remove the outboard shield from the transfer/detack corotron that the covers are locked in position. Check that the halo guide is not in contact with the
Set the service meter to read AC volts, set the range to 0000 drum.
Connect the positive meter lead to the small spring that tensions the detack If the photoreceptor is damaged, install a new xerographic module, (35 ppm) PL 9.22 Item
corotron wire 2 or (40-90 ppm) PL 9.20 Item 2.
Connect the negative meter lead to the machine frame Check that there is continuity between the halo guide and the registration guide, Figure 1.
Cheat the front door interlock switch Raise and lower the short paper path assembly, PL 10.25 Item 1, several times to ensure
that the continuity is consistent. If the continuity is inconsistent, examine the registration
Enter dC330 code09-064, detack corotron, press start. The meter should read
and halo guide bias contact for deformation, PL 8.15 Item 23. Figure 1.
OL (over limit), if it does not, the detack voltage is below specification
If the transfer / detack corotron, Figure 1, is contaminated with toner. Perform the Devel-
2. Ensure the detack lead is connected to the HVPS.
oper Assembly Checkout.
3. Check that there is continuity in the detack circuit by checking for 47K Ohms
between the small spring that tensions the detack corotron wire and the HV detack Raise and lower the short paper path assembly, PL 10.25 Item 1, to ensure that the trans-
fer / detack corotron is parallel to the photoreceptor. Check that the movement of raising
lead at the HVPS. If necessary install a new transfer/detack harness, PL 9.20 Item 9.
the short paper path assembly is smooth, REP 10.1.
4. Ensure the chute bias (CB) lead is connected to the HVPS and the other end is con-
Check the waste toner system, refer to OF11 Waste Toner Contamination RAP.
nected to the spade connector on the registration transport. Check the continuity of
this lead is less than 1 ohm. Developer Assembly Checkout
5. If checks 2, 3 and 4 are good and check 1 shows that the detack voltage is below Operate the xerographic module latch, (35 ppm) PL 9.22 Item 7 or (40-90 ppm) PL 9.20
specification, install a new HVPS, PL 1.10 Item 5. Item 7. Check the operation of the latch mechanism. Check the operation of the devel-
If there are xerographic module stripper finger marks (three marks/dots/spots that line up oper paddle, (35 ppm) PL 9.22 Item 14 or (40-90 ppm) PL 9.20 Item 14.
with the xerographic module stripper fingers) on the edge or the body of the prints/copies Check that the developer assembly moves freely and rests against the xerographic mod-
that only occur on the second side of a duplexed copy/print job, together with some or all ule, refer to REP 9.2 Developer Assembly.
of the following symptoms: Check the magnetic developer brush seal for a uniform profile. Refer to ADJ 9.3 Devel-
Toner contamination of the xerographic module stripper fingers and /or star wheels oper Magnetic Seal Brush Adjustment.
on the stripper finger arms If the transfer / detack corotron, Figure 1, is contaminated with toner, perform ADJ 9.3
Broken or missing stripper fingers caused by frequent jam clearances Magnetic Developer Seal Brush Adjustment.
Paper wrinkles Install a new developer module, (35-55 ppm) PL 9.17 Item 2 or (65-90 ppm) PL 9.15 Item
Inverter jams 2.
Dog eared copies/print After a new developer module has been installed, check the image quality. Print internal
test pattern 2 and 5, run 25 of each. If there is an image quality problem, install a new
Damp, defective or low quality paper. During the first pass through the fuser and inverter
the paper develops excessive curl. If the set of the curl matches the curvature of the pho- xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20 Item 2.
toreceptor drum during the duplex pass, there is a greater tendency toward stripper finger Fuser Module Checkout
marks, jams and dog ears. Perform the following: Check the fuser rolls and stripper fingers for toner and developer contamination. If con-
1. Use fresh quality paper from an un-opened ream. tamination is present, go to the IQ4 Fuser Module RAP.

ROS Checkout
Perform ADJ 6.1 ROS Window Cleaning Procedure.
Perform ADJ 6.2 ROS Cleaning Procedure.
Check there are no obstructions between the ROS and the photoreceptor window. Developer roll and lower lip
Check the connection PJ122, Wiring Diagram 12 and the ROS power distribution / com-
munication harness, PL 6.10 Item 5, from the ROS to the single board controller PWB.
Check that all the connections to the single board controller PWB are good, GP 7.
Check that the ROS securing screw is tight, refer to REP 6.1 ROS.
Scanner Checkout Magnetic developer seal
brush
Check the exposure lamp (W/O TAG 150) PL 14.25 Item 9 or (W/TAG 150) PL 14.15 Item 9.
Halo guide
Registration roll
area
Transfer corotron
Registration guide
Detack corotron
Registration / developer bias

harness connection. Registration and halo guide bias contact.

IQ4 Fuser Module RAP IQ5 Print Damage RAP
Use this RAP for fuser module related problems. Use this RAP when the prints have nicks, tears, creases, folds, curled edges or wrinkles.
Procedure
Procedure
WARNING
death or injury. Moving parts can cause injury. Enter Diagnostics, GP 1. Enter dC606. Select the internal test pattern 14. Make prints to iden-
Perform the following: tify where the prints are damaged.
Enter Diagnostics, GP 1. Enter dC131. Refer to chain 10 NVM fuser setting values; 10- Check the paper supply for the following:
028; 10-029; 10-059. Check the NVM values. If the NVM values are increased, fusing
Curled paper in the paper trays, go to Curl Measurement.
performance is improved, but contamination can occur. If the NVM values are decreased,
fusing performance is reduced. If the paper in trays 1 and 2 has excessive curl install TAG 001 and TAG 002 Tray 1
and tray 2 Lip kit.
Poor fusing can be caused by alternative quality paper and heavily embossed envelopes,
In high humidity environments, If there is excessive curl on paper in trays 3 and 4
GP 20. If the customer is using alternative quality paper, select the card stock setting on
install TAG 111 HCF Heater kit.
the GUI. Adjusting 10-059 only changes the fuser temperature when card stock is
selected. Some 200 gsm papers do not fuse correctly. Check the paper path, Figure 2 for the following:
Check that the customer is using tray 1 and tray 2 for alternative quality paper or Obstructions.
heavy weight paper. Damaged guides and rolls, GP 7. Pay particular attention to the areas that align with the
Refer to IQS 3 Fusing. damage on the prints. For example, fuser stripper fingers.
Check the following for wear and contamination: The edges of the paper path for protruding objects.
Stripper fingers. If possible remove the contamination. If the stripper fingers are Ensure that the paper feed does not skew the paper, go to the appropriate procedure:
damaged or worn, install a new fuser stripper fingers, (35-55 ppm) PL 10.8 Item 4 or 08-101 Tray 1 Misfeed RAP
(65-90 ppm) PL 10.10 Item 4. 08-102 Tray 2 Misfeed RAP
Fuser rolls. If the fuser rolls are damaged or worn, install a new fuser module, (35-55 08-103, 08-113 Tray 3 Misfeed Entry RAP
ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1. 08-104, 08-114 Tray 4 Misfeed Entry RAP
08-115, 08-117 Tray 5 Misfeed Entry RAP
NOTE: Do not change the fuser module, because of the appearance of wrinkles on
the pressure roll. This is normal for the pressure roll, caused by the conductive Check that the paper strips from the xerographic module and enters the fuser nip cor-
sleeve that stretches as the silicon rubber base of the roll expands. The pressure rectly. If necessary, perform the following:
rolls are more wrinkled due to the higher run temperatures on the 65-90 ppm If the paper does not correctly strip from the xerographic module, ensure that all the
machines. HT leads on the HVPS PWB are correctly connected, refer to REP 1.1.
If the paper is contacting the upper fuser roll before entering the fuser roll nip, check
Fuser web. If this is heavily contaminated or shows no sign of advancement, go to that the short paper path is correctly latched and the transfer/detack corotron, (35
the 10A Fuser Web Motor RAP. ppm) PL 9.22 Item 8 or (40-90 ppm) PL 9.20 Item 2, is correctly positioned, ADJ 9.1
Corotron Cleaning.
Check that the fuser roll stripper fingers are clean.
If the prints are creased or wrinkled after the fuser module, then install a new fuser mod-
ule, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1.
Ensure that paper path sensor actuators move freely, GP 7.
If the paper is corrugated after passing through the fuser module, install a new tri-roll shaft
If the paper is curled after passing through the fuser module, go to Curl Measurement.
Check the inverter for damage or wear, GP 7.

Xerox WorkCentre 5790 Family 3-17 IQ4, IQ5
If the paper has a dog ear on the inboard corner, install a rear gravity gate finger kit, PL
10.12 Item 25.
Check the duplex and registration transport assemblies for damage or wear and ensure
the jam clearance latch is located correctly.
If the paper displays wrinkles due to excessive buckle in the duplex or registration
transport, perform ADJ 8.2 Buckle Timing.
If the output device suffers from poor stacking, perform the following as necessary:
Check that the output device is not positioned near an air conditioning or ventilation
output duct. Air flow across the output bins can cause poor stacking.
11K-110 2K LCSS Poor Stacking RAP.
11J-120 1K LCSS Poor Stacking RAP.
11G-171 HVF BM Poor Stacking RAP.
Remove the output device, then connect a finisher bypass harness, PL 26.10 Item 7. Tray 1
Check the paper path through the inverter assembly, PL 10.11 Item 23.
If the paper has excessive curl after passing through the inverter, install TAG 046 (35-
Tray 2
55ppm), TAG 047 (65-90 ppm) Inverter Decurler Kit or TAG 148 for OCT configured
machines. For machines W/TAG 046, W/TAG 047 or W/TAG 148 perform ADJ 10.1
Inverter Decurler Adjustment.
If the paper path and the duplex path are good, check that the paper and other media used, is
of the correct weight and size, GP 20.
Tray 5 Tray 3
Tray 4
Curl Measurement
Make five singled sided prints. Refer to Figure 1. If the curl on the print exceeds 13mm (0.5
inch), perform the following checks:
Check the paper storage and wrapping
Turnover the paper stack in the paper tray
Use paper from a new ream
Install an inverter decurler kit. PL 10.20 Item 1
If the problem continues, go to the IQ4 Fuser Module RAP. Figure 2 Paper path
Place the print on a flat surface. Measure the curl within 5 seconds.
Maximum allowable curl for any paper size in any direction: 13mm (0.5inch)
Figure 1 Curl height measurement

IQ6 Narrow Bands RAP IQ7 DADH, Document Glass and Scanner RAP
Use this RAP to determine the cause of narrow bands. Use this RAP to identify failures caused by the DADH, document glass and the scanner.
Ensure IQ1 Image Quality Entry RAP is performed before starting this RAP. Ensure IQ1 Image Quality Entry RAP is performed before starting this RAP.
Procedure Procedure
WARNING WARNING
Check the pitch of the bands. The bands have a regular pitch. Perform the following:
Y N DADH Checkout
Bands that are irregular are caused by worn gears in the following areas. Examine the Document Glass Checkout
gears, the shafts and the bearings, GP 7.
Scanner Checkout (W/O TAG 150)
Registration transport gears; PL 8.15 Item 17, PL 8.15 Item 18 and PL 8.15 Item 19.
Scanner Checkout (W/TAG 150)
Registration transport drive pulley, (35-55 ppm) PL 4.17 Item 14 or (65-90 ppm) PL
4.12 Item 15. DADH Checkout
Main drive belts; (35-55 ppm) PL 4.17 Item 9 or (65-90 ppm) PL 4.12 Item 9 and PL Perform the following:
4.12 Item 18. Clean the underside of the DADH area around the CVT roll, PL 5.25.
Developer drive gear, (35-55 ppm) PL 4.17 Item 15 or (65-90 ppm) PL 4.12 Item 17. Clean the top surface of the CVT glass and the document glass. Refer to ADJ 14.1 Optics
Fuser drive gear, (35-55 ppm) PL 4.17 Item 10 or (65-90 ppm) PL 4.12 Item 10. Cleaning Procedure (W/O TAG 150) or ADJ 14.2 Optics Cleaning Procedure (W/TAG
150).
Developer assembly, (35-55 ppm) PL 9.17 or (65-90 ppm) PL 9.15.
If the documents are skewed. Check that the document input guides are correctly
Short paper path (W/O TAG 114) gears, PL 10.25 Item 3 and PL 10.25 Item 5.
adjusted.
Check that the DADH is seated correctly, perform the ADJ 5.2 DADH Height Adjustment.
The ROS makes the narrow bands that are only visible on half tones prints. Make copies from the DADH and the document glass. If the copies from the DADH are
lighter or darker than those from the document glass, perform the following:
Machine speed of 35-55 ppm, the pitch is 9.8 bands to 1cm (25 bands to 1 inch).
Go to dC131 NVM Read / Write location 15-007 CVT scanning image gain. The
Machine speed of 65-90 ppm, the pitch is 10 bands to 1 cm (25 bands to 1 inch).
default value is 3. If the value is increased copies made from the DADH will be
To resolve banding caused by motion wobble of the ROS, install a new ROS, PL 6.10 Item 4.
darker. If the value is decreased, copies made from the DADH will be lighter.
Make copies from the DADH. If the copies have a background problem, perform the fol-
lowing:
Check the DADH height, Refer to ADJ 5.2 DADH Height Adjustment.
Check the registration. Refer to dC604 Registration Setup.
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.
Make copies from the DADH. If the copies are stretched or smudged, perform the follow-
ing:
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
fault persists, re-adjust the height of the DADH as necessary.
If the fault persists after the height of the DADH has been adjusted, install a new
DADH baffle assembly, PL 5.30 Item 5. Re-adjust the height of the DADH to the
default setting, refer to ADJ 5.2 DADH Height Adjustment.

Document Glass Checkout IQ8 Skew RAP
Perform the following: Use this RAP to determine the source of skew.
Clean the top surface of the CVT glass and the document glass. Refer to ADJ 14.1 Optics
Cleaning Procedure (W/O TAG 150) or ADJ 14.2 Optics Cleaning Procedure (W/TAG Ensure IQ1 Image Quality Entry RAP is performed before starting this RAP.
150).
Check the position of the document pad, ADJ 5.6 DADH Document Pad. Initial Actions
Check that the white AGC strips on the document glass and the CVT glass are at the front
and underside of the glass.
Scanner Checkout (W/O TAG 150) WARNING
If the copy of the internal test is fragmented and displaced, check the following: death or injury. Moving parts can cause injury.
The ribbon cable from the CCD PWB to the to the scanner PWB. Refer to Wiring Perform the misregistration procedure in the IQ2 Defects RAP.
Diagram 15.
The harness connections from the CCD PWB to the single board controller PWB.
Procedure
Refer to Wiring Diagram 15.
Enter dC606. Use the internal test pattern 16 and select 1 Sided. Make 5 prints. Check the
If fragmented and displaced images appear in a regular pattern across process
prints for skew, IQS 5 Skew. The prints are skewed.
direction, remove and re-seat all memory modules, PL 3.24 Item 12.
Y N
If necessary, go to 03-330A, 03-462A Single Board Controller PWB to Scanner Use the internal test pattern 16 and select 2 Sided. Make 5 prints. Check the prints for
Faults RAP (W/O TAG 150). skew, IQS 5 Skew. The prints are skewed.
Raise the DADH. Make a copy from the document glass. If the exposure lamp does not Y N
illuminate, go to the 14D Exposure Lamp Failure RAP. Use a print of the internal test pattern 16 as a master and make 5 copies from the
Check the mirrors and exposure lamp for contamination, refer to ADJ 14.1 Optics Clean- document glass. Check the copies for skew. The copies are skewed.
ing Procedure (W/O TAG 150). Y N
Scanner Checkout (W/TAG 150)
Use a print of the internal test pattern 16 as a master and make 5 copies fed
Perform the following: through the DADH, Figure 1. Check the copies for skew. The copies are
If the copy of the internal test is fragmented and displaced, check the following: skewed.
The ribbon cables from the CCD PWB to the scanner PWB. Refer to Wiring Diagram Y N
18. No skew is present. Re-define the image quality defect. Refer to IQ1
The harness connections from the scanner PWB to the scanner daughter PWB. Image Quality Entry RAP.
Refer to Wiring Diagram 16 and Wiring Diagram 19.
The skew is originating in the DADH. Go to ADJ 5.3 DADH Skew Adjustment.
Reseat the scanner daughter PWB, PL 3.24 Item 20.
If fragmented and displaced images appear in a regular pattern across process There is a skew problem originating in the scanner. Complete a visual check of the
direction, remove and re-seat all memory modules, PL 3.24 Item 12. following:
If necessary, go to 03-330B, 03-462B Single Board Controller PWB to Scanner The mirrors are not loose and are held securely in place.
Faults RAP (W/TAG 150).
The scan carriage is not damaged and moves freely.
Raise the DADH. Make a copy from the document glass. If the exposure lamp does not
The scan cables are wrapped around their drive pulleys, refer to REP 14.10
illuminate, go to the 14-703B to 14-706B, 712B, 714B, 718B Failure To Calibrate RAP (W/
Scan Idler Pulleys.
TAG 150) and perform the Exposure Lamp Check.
If necessary, install a new scanner, (W/O TAG 150) PL 14.20 Item 1 or (W/TAG
Check the mirrors and exposure lamp for contamination. Refer to ADJ 14.2 Optics Clean-
150) PL 14.10 Item 1.
ing Procedure (W/TAG 150).
The skew occurs in the duplex paper path.
Check the nip and drive rolls in the inverter assembly, PL 10.12 and PL 10.14.
Check the drive and idler rolls in the duplex transport, (35-55 ppm) PL 8.22 Item 7 or
(65-90 ppm) PL 8.20 Item 7.
A
A
Using the prints made from dC606, check the prints for distortion by measuring between the
lines produced. The lines are parallel to each other.
Y N
Install a new ROS, PL 6.10 Item 4. Document path
Make five prints from each tray and the bypass tray to identify the source of skew.
Check the feed rolls and guides for contamination.
Check the feed rolls and transport rolls for wear. Install new parts as necessary. If MOD/
TAG 151 is installed and there is skew from tray 3 or tray 4, install a new idler roll assem-
bly (metal shaft), PL 8.36 Item 8 in the tray 3 transport base. Also install a new idler roll
assembly (metal shaft), PL 8.33 Item 2 in the HCF exit area.
If the skew is from the HCF W/TAG 151, install TAG 153. If TAG 153 is already installed,
check for wear on the tray 3 and 4 skew brackets. If necessary install new skew brackets,
PL 7.18 Item 15 and PL 7.18 Item 16.
Check that there is no variation in the size or weight of the sheets of paper in each tray.
Check that the paper weight and type is within the specification. Refer to GP 20 Paper
and Media Size Specifications.
Check that the paper size guides are set correctly.
Check the separator strips on the paper tray for wear. Refer to OF8 Multifeed RAP.
Check that the bypass tray width guides are set correctly.
Check the bypass tray pre-reg nip rolls. If necessary, install a skew bypass tray spares kit,
Document width guides
PL 7.30 Item 29.
Open the left hand door and check for wear on the ribs, Figure 2. If necessary install a
new bypass tray and left hand door assembly, PL 7.30 Item 1. CVT glass
Check that the interlock cover is not loose, PL 7.30 Item 23. If necessary bias the cover to
the right and tighten the two screws.
Check the paper paths for obstructions. Refer to IQ5 Print Damage RAP.
Check the registration clutch. Refer to 08-150, 08-151 Registration Jam Entry RAP. Figure 1 Document path through the DADH
Check that the locking foot of the registration transport is correctly located in the base
frame, REP 8.4.

IQ9 Unacceptable Received Facsimile Image Quality RAP
Use this RAP to identify the causes of poor reception.
Initial Actions
WARNING
Verify the following:

This problem occurs only when receiving transmissions.
This problem occurs on all receiving transmissions.
Check the Facsimile Options Settings. Check the NVM location 20-254 Fax Country set-
ting is correct.
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
(W/O TAG X-001) Go 20H Embedded Fax PWB Voltage Checkout.
(W/TAG X-001) Check the machine ground connections, refer to the 01A Ground
Check for wear on the ribs Distribution RAP. If the machine ground connections are good, request that the cus-
tomer has the power outlet socket checked.
Receive the document at a slower receive speed. Set the NVM location 20-289 Line 1 = 11 and
location 20-290 Line 2 = 11. The image quality is acceptable.
Y N
Figure 2 Left hand door 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 20.10 Item 4.
A B
A B
Perform the following: IQ10 Image Quality Improvement RAP
(W/O TAG X-001) Go 20H Embedded Fax PWB Voltage Checkout. Use this RAP if the customer is not satisfied with the image quality.
(W/TAG X-001) Check the machine ground connections, refer to the 01A Ground
Distribution RAP. If the machine ground connections are good, request that the cus- The image quality can be altered by changing the image quality defaults. This will optimize the
tomer has the power outlet socket checked. image quality to the unique requirements of the customer.
Inform the remote user of the required changes to the settings. A combination of changes may give the best result. It is recommended to change the image
quality options and then perform ADJ 9.5 Optimize the Dark and Light Grey Image. The alter-
native would be to change the image quality options.
Initial Actions
WARNING
Perform IQ3 Xerographics RAP before starting this procedure
Make a copy of the customer document that shows the defect and keep as a reference.
Ensure that the customer image quality requirements are understood.
Perform ADJ 9.2 Image Quality Adjustment Routine. If the image quality routine does not
correct the image quality defect. Enter dC131 and reset location 09-321 and 09-322 to the
default value and continue with the procedure.
Procedure
Make a copy of the customers document with different image quality setups until the image
quality has been improved. Use different combinations of the image quality options that are
available. Set the image quality setting, as the default.
Refer to the image adjustments options that follow.

Normal. Standard setting for most originals.
Text. Use for originals containing text or line art.
Halftone Photo. Use for high quality lithographic images or continues tone photo with
text and / or graphics.
Photo. Use for continuous tone photographs.
Lighter / Darken. One to seven levels can be selected by using the slider.
Background Suppression. Select Off or On (default).
Sharpness. One to seven levels can be selected by using the slider
Contrast. One to seven levels can be selected by using the slider
Screen. This option is preset On with Normal, Text and Halftone Photo Original Type
options. Set to Special or Auto (default)
Special Enhances continuous tone photographs or high quality frequency halftone
images. Use to create smoother, less grainy output, but risk of blotchy copy quality
defects.
Auto. Eliminates the risk of blotches or small areas that have different texture or pat-
tern appearance than surrounding area. This may produce a grainier picture than if
Special is used.

IQ11 Light Copies RAP
Use this RAP when the machine is making light copies.
1. Login to Customer Administrator Tools, GP 24. In the Tools Pathway, select:
Feature Defaults.
Perform IQ1 Image Quality Entry RAP before starting this RAP.
Set Copy Defaults.
Image Quality. Initial Actions
2. Change the settings as required.
NOTE: If the Text or the Halftone Photo option are selected then the Sharpness and Con-
WARNING
trast slider are greyed out. The Text option is the same as High Contrast 2. The Halftone
Photo is the same as Low Contrast 1. Ensure that the electricity to the machine is switched off while performing tasks that do
Save the image quality options to be used as the default setting. death or injury. Moving parts can cause injury.
Select End Defaults and Exit Tools. Examine the fault log and troubleshoot any current 06-XXX, 09-XXX, 10-XXX or 14-XXX
3. Run different jobs to confirm that the changes made have not caused other image quality faults.
problems. Clean the platen and CVT glass. Refer to ADJ 14.1 Optics Cleaning Procedure (W/O TAG
4. If the image quality still does not meet the requirements of the customer, go to ADJ 9.5 150) or ADJ 14.2 Optics Cleaning Procedure (W/TAG 150).
Optimize the Dark and Light Grey Image. Ensure the white patch on the CVT glass is to the front of the machine and is facing down-
5. Record the new values in the machine log book. wards.
6. Perform NVM Save and Restore, GP 5. Remove and inspect the xerographic module. If the drum is discolored or hazy, install a
new module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20 Item 2. Check the opera-
tion of the photoreceptor and ozone fans, refer to OF6 Ozone and Air Systems RAP.
Clean the charge corotron, ADJ 9.4.
Clean the transfer/detack corotron, ADJ 9.1.
Clean the erase lamp, ADJ 9.4.
Clean the ROS window, ADJ 6.1.
With the xerographic module in the machine, remove the fuser module. Reach under the
bottom back end of the short paper path, PL 10.25, push it upwards to ensure it is posi-
tioned against the bottom frame of the xerographic module. If the short paper path will not
latch properly, inspect it for damage and if necessary, install a new short paper path mod-
ule, PL 10.25 Item 1, REP 10.1.
Check that there is toner in the toner cartridge.
Check that the machine is level. If the machine is not level, the developer can leak from
the developer module, causing light images.
Print internal test print 5, dC606 and check for barber pole deletions. Refer to IQ12 Barber
Pole Deletions / Developer Leakage RAP.
Remove the developer unit and check that the magnetic roll can be turned using normal
force. If it is too difficult or too easy to turn, or if developer spills out, install a new devel-
oper module, and toner dispenser module, PL 9.15, PL 9.17, items 1 and 2.
If a new developer module and toner dispenser were installed as directed in the previous
bullet point, check that the waste toner auger is operating. Refer to the OF11 Waste Toner
Contamination RAP.

Procedure NOTE: The effect of altering the charge grid voltage is best monitored by observing the
4.1 line pair, the 3.4 text area and the bulls-eye targets on this test pattern. Decreasing
This procedure is written in two parts. Go to the relevant part.
the charge grid voltage darkens the grey scale. Increasing the charge grid voltage light-
Part 1 is to be performed on newly installed machines that have not had any new parts or NVM
values changed. ens the grey scale. To save new NVM values, exit diagnostics correctly and ensure the
machine reboots.
Part 2 is to be performed on machines that have had parts or NVM values changed or when
performing part 1 does not satisfy the customers requirements.
Part 1 Table 1 Charge grid NVM location 09-003 values
1. Make one platen copy of test pattern 82E2010 (A4), or 82E2020 (8.5 x 11 inches). Speed Min/Max Values Default Value
2. Refer to Figure 1. Evaluate the copy at each numbered area as shown in the figure. 35 ppm 370/470 420
45/55 ppm 380/480 430
KEY: 65/75/90 ppm 370/470 420
1 Text areas 3.0 and 3.3 should 4. Save the new NVM value then exit diagnostics via call closeout. Use the copier reboot
be clearly visible option. Evaluate another platen copy of test pattern 82E2010/82E2020. If necessary,
lower the value in NVM location 09-003 by decrements of 10 until the copy meets the
specification.
3 The 2.0, 2.2 and 2.4 squares 5. If the copy still fails to meet the specification after decreasing the charge grid value by a
should be darker than in the origi- total of 50, go to Part 2 of this procedure.
nal document 6. If the copy meets the specification, record the 09-003 NVM value in the machine log book.
Save a copy of the test pattern 82E2010/2020 in the log book. Save the NVM, GP 5.
Part 2
Perform this part of the procedure on machines that have had new parts or have had NVM val-
2 The 4.1 line pairs should be ues changed. Also, perform this part of the procedure when copies have failed to meet the
clearly visible specification in Part 1.
Make the following copies and prints. With normal copy quality settings, make one DADH and
one platen copy of test pattern 82E2010 (A4), or 82E2020 (8.5x11 inches). Then run one each
of Internal Test Patterns 11, and 15, dC606. Mark these START and save them for reference.
4 The bulls eye targets should be Figure 1, Figure 4 and Figure 5 show examples of these.
clearly reproduced Enter diagnostics dC131. Refer to Table 2. Enter the appropriate NVM values dependant on
machine speed. In the table NC = No Change.
1 Text area 3.4 should be clearly Table 2 Image Quality Adjustment Routine Values
visible
Speed DC131 NVM locations for IQA routine
3-400 3-401 3-402 3-403 3-404 3-405 3-406
Figure 1 Copy of test pattern 82E2010 / 82E2020 35 ppm 136 13 NC NC NC NC NC
45/55 ppm 136 13 2500 1500 0 0 135000
65/75/90 136 13 NC NC NC NC NC
CAUTION ppm
Do not set the charge grid voltage outside the minimum or maximum values
3. If the copy does not meet the above specification, alter the charge grid voltages. Enter Save the new NVM value and exit diagnostics using the call closeout and the machine reboot
diagnostics dC131, location 09-003 and decrease the value by 25. Refer to Table 1. option.
Perform the Image Quality Adjustment Routine, ADJ 9.2.
Make one DADH and one platen copy of test pattern 82E2010/82E2020. Then run one each of
Internal Test Patterns 11, and 15, dC606. Compare these copies and prints to Figure 1, Figure
4 and Figure 5. The copies fail to meet the specification.
Y N
The copies are good. Perform Final Actions.

A B
Remove the xerographic module. Remove the developer module REP 9.2. Clear the developer Run 200 copies of internal test pattern 12, then produce a solid black print using the Solid
from the developer roll by rotating the drive gear. Re-install the developer and xerographic Black Print Routine. Check the solid black area of the print using the density reference
modules. Enter dC330, code 04-010 main motor MOT04-010. Run MOT04-010 for approxi- chart, Figure 3, as checked previously. The print is solid black and meets the specifi-
mately 5 seconds. Remove the xerographic module and inspect the developer roll. The devel- cation.
oper roll has developer on its surface. Y N
Y N Install a new developer module, (35-55 ppm) PL 9.17 Item 2 or (65-90 ppm) PL 9.15
Check the drives to the developer, GP 7. If no problem is found, install a new developer Item 2.
paddle, PL 9.20 Item 14. If necessary, install a new developer module, (35-55 ppm) PL
9.17 Item 2 or (65-90 ppm) PL 9.15 Item 2. The solid black reproduction is good.
If applicable, save the customer auditron, using the PWS Auditron Save and Restore tool. Perform the ROS Check, then return and continue with this procedure.
Perform dC132, All Copier NVM initialisation. This sets the machine NVM to default. Make one Produce one DADH and one platen copy of 82E2020/2010. Evaluate the copies as shown in
DADH and one platen copy of test pattern 82E2010/82E2020. Then run one each of Internal Figure 1. The copies fail to meet the specification.
Test Patterns 11, and 15, dC606. Compare these copies and prints to Figure 1, Figure 4 and Y N
Figure 5. The copies fail to meet the specification. The copies are good. Perform Final Actions.
Y N
The copies are good. Perform Final Actions within this procedure. Enter diagnostics dC131, refer to Table 2 and enter the appropriate NVM values dependant on
machine speed.
Check dC131 NVM location 09-069. If the value is between 805 and 1200, do not perform the Perform the Image Quality Adjustment Routine, ADJ 9.2.
following action, but continue with this procedure. If the value is not between 805 and 1200, Perform Final Actions.
perform the following action:
Change the value to 1000. Save the new NVM value and exit diagnostics using the call Solid Black Print Routine
closeout and the machine reboot option. Run 200 copies of internal test print 12 to stabi-
Unscrew the head of an AA Mini-Mag Lite, tool number 600T01824. Ensure fresh batteries are
lise the machine. Copy and evaluate test pattern 82E2010/82E2020 and print and evalu-
installed. With the light lit, place the Mini-Mag Lite in the slot on the top side of the xerographics
ate internal test patterns 11 and 15. Refer to Figure 1, Figure 4 and Figure 5. If the copies module, with the back of the Mini-Mag Lite to the rear of the module, Figure 2. Run one copy.
and prints now meet the specification, perform Final Actions. If the copies and prints still
Remove the Mini-Mag Lite to prevent light shock on the drum.
fail to meet the specification, continue with this procedure.
Produce a solid black print. Refer to the Solid Black Print Routine. Evaluate the print as follows: On the copy, the area of the drum that was blocked by the Mini-Mag Lite should be white. The
Use the density reference chart 82P520 or 82E8230. Compare the solid black area of the print, area of the drum illuminated by the Mini-Mag Lite should be solid black.
with the 1.3 -1.5 reference patches of the chart, Figure 3. If using 82P520, the solid black print ROS Check
should be darker than the 1.4 reference, but lighter than the 1.5 reference. If using 82E8230,
Print one internal test print 15, dC606. Evaluate the print, refer to Figure 4:
the solid black print should be as dark or darker than the 1.3, but lighter than the 1.5. The
solid black is good and not grey or mottled.
Y N CAUTION
Check that the toner dispenser is working. Open the bypass tray and remove the upper Do not set the laser tight levels outside the minimum or maximum values
left hand cover, PL 8.10 Item 3. Refer to Wiring Diagram 10. Monitor the voltage on the
1. The two darkest bands, 7 and 8, should be solid black and almost or completely indistin-
red wire on pin 8 of PJ93 while printing 20 copies of test pattern 82E2010/82E2020. This
guishable from each other. If bands 7 and 8 are not solid black, refer to Table 3. Enter
is the output of the toner concentration sensor. The voltage should be between +1.5V and
diagnostics dC131, location 06-001. Raise or lower the value by 250. Raising the value
+2.8V. The voltage is correct.
darkens the print density and merges the darker bands. Lowering the value lightens the
Y N
print density and separates the darker bands. If this part of the specification cannot be
If the voltage is consistently above +2.8V, the toner dispenser is not operating cor-
met, clean the ROS, ADJ 6.2. If necessary, install a new ROS, PL 6.10 Item 4.
rectly. Install a new toner dispenser module, (35-55 ppm) PL 9.17 Item 1 or (65-90
ppm) PL 9.15 Item 1. 2. Bands 1 to 6 inclusive should all be distinct from each other.
If the voltage is below +1.5V, install a new developer module, (35-55 ppm) PL 9.17 3. Band 1 may be white or light grey. If any of these bands merge, the single board controller
Item 2 or (65-90 ppm) PL 9.15 Item 2. PWB is defective. Install a new single board controller PWB, PL 3.24 Item 3.
Table 3 Laser light level NVM location 06-001 values
Enter diagnostics dC131, location 09-069. Increase the value by 200, or to the maximum
value of 1200 if an increase of 200 is not available. Speed Min/Max Values Default Value
Save the new NVM value and exit diagnostics using the call closeout and the machine 35 ppm 3000/4471 3471
reboot option. 45/55 ppm 1500/3050 2250
65/75/90 ppm 1500/3200 2400
B
4. When the specifications in the above three steps are met, the ROS is functioning
correctly.
Final Actions
Record all changes in the log book for future reference. Perform an NVM Save, GP 5 then
SCP 6 Final Actions. Make one DADH and one platen copy of 82E2020/2010. Run one
copy each of internal test patterns 11, and 15, dC606. Mark these FINISH and write the
new NVM values on these prints and copies. Save these documents in the machine for
future reference.
Run sample customer documents. If necessary, use the image quality options (sharp-
ness/contrast/lighter/darker) on the UI to customize the look of the customer's copies as
detailed in IQ10.
Run dC604 Registration Setup Routine.
Restore the customers auditron data, using the PWS Auditron Save and Restore Tool.
Record any image quality options selected onto the customer copy, and save in the
machine for future reference.
REAR
Figure 3 Density reference chart 82P520/82E8230

AA Mini Mag Lite
FRONT
Xerographics module
Figure 2 Xerographics module with AA Mini Mag-lite

1
Bands 7 and 8 should merge
or nearly merge, and should
be evenly black
2
Bands 1 to 6 should all be
distinct
3
Bands 1 can be white or
light grey
These three areas

should be grey. They
should not be white.
8 7 6 5 4 3 2 1
Figure 4 Internal test print 15
Figure 5 Internal test print 11

A
IQ12 Barber Pole Deletions / Developer Leakage RAP Perform the following:
Use this RAP to cure barber pole deletions and developer leakage problems. Remove the upper left hand cover, PL 8.10 Item 3. Run the machine and check for
approximately -350V on the single red wire at the high voltage connection to the devel-
oper module. Wiring Diagram 11. If necessary, go to 09-060 HVPS Fault RAP.
Initial Actions
Ensure there is a good fit between the trickle door at the rear of the developer module and
the trickle tube. Refer to Figure 2 and Figure 3.
WARNING If there has been a developer spillage into the base pan of the machine, check the devel-
oper module latching. The developer module locates onto two locating pins at the front of
the machine and two locating pins in the rear frame of the machine. Refer to Figure 3 and
Figure 4. Ensure the locating pins are clean and perpendicular, (at 90 degrees), to the
machine rear frame.
Check that the machine is level. If the machine is not level, developer can leak from the
Check for, and remove any excess material round the locating holes on the developer
developer module.
module. If necessary, apply some plastislip grease, PL 26.10 Item 8 around the locating
Clean the charge scorotron, ADJ 9.4. holes to ensure smooth operation. If the developer module still will not latch properly,
Clean the transfer/detack corotron, ADJ 9.1. install a new developer paddle, (35 ppm) PL 9.22 Item 14 or (40-90 ppm) PL 9.20 Item 14.
(35 ppm) Ensure the scorotron cleaning tool is fully pushed to the back of the xerograph- If a large amount of developer material has been lost, discard the remaining developer
ics module. and install a full developer charge, (65-90 ppm) PL 9.15 Item 27 or (35-55) PL 9.17 Item
Check and clean the erase lamp, ADJ 9.4. 25. Reset the HFSI developer counter, GP 17.
Check that the high voltage connections and the PJs on the HVPS are correctly and If there is still developer leakage, install a new xerographics module, (35 ppm) PL 9.22
securely seated. Refer to 09-060 HVPS Fault RAP. Item 2 or (40-90 ppm) PL 9.20 Item 2. At the same time, install a new developer module,
(35-55) PL 9.17 Item 2 or (65-90 ppm) PL 9.15 Item 2.
Procedure If the customer copies books, instruct them in the use of the Bound Original feature on the
Image Adjustment screen. Also, instruct the customer to use the scorotron cleaning tool,
Print the internal test pattern 5, dC606. If the barber pole deletions are present, they appear as
three times every day.
shown in Figure 1.
These deletions appear when 0.5kg (1.1 lbs) or more of the developer is lost from the devel-
oper module. This represents half of the developer charge. The causes of loss of developer
are:
A damaged, (scored or scratched), drum. The drum can be scratched by a mis-adjusted
or bent detack / transfer corotron.
A contaminated charge corotron can create an electrostatic hot spot on the drum. Con-
tamination can be caused by excessive book copying without having selected the Bound
Original feature on the image adjustment screen.
The machine is not level. A 2 degree tilt, front to rear, causes developer to leak out from
the overflow tube in the rear of the developer module, into the waste bottle.
The spacing between the developer module and the Xerographics module is incorrect. In
this case, developer spills out at the magnetic brush into the base pan of the machine.
A defective developer module. If the magnet separates from the magnetic roll, developer
may spill out of the developer module, along the length of the magnetic roll. Worn devel-
oper bearings can allow developer to leak out the housing at the inboard and outboard
ends.
Remove the xerographics module and examine the drum surface for chips, scores and
scratches. It is important to note that the drum is usually scored at the inboard or outboard end,
in the non-image area. Scores in these areas are as serious as in the image area. The drum
surface is good.
Y N
Install a new xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90) PL 9.20 Item 2. Dis-
card the remaining developer and install a full developer charge, (65-90 ppm) PL 9.15
Item 27 or (35-55) PL 9.17 Item 25.

Trickle tube
Figure 2 Developer trickle tube
Figure 1 Example of barber pole deletions

Front locating Rear locating
pins pins
Locating hole Trickle door Locating hole
REAR VIEW
Figure 3 Developer trickle door and rear locating holes Figure 4 Developer module locating pins

IQ13 Cockle Deletion RAP These deletions appear when the paper is buckled in the duplex transport and registration
transport assemblies. The effect of the buckling forms a permanent ripple in each sheet of
Use this RAP to cure intermittent cockle deletion on buckled/rippled copies.
paper which leads poor image transfer. The known causes of paper buckle are:
Worn/damaged components within the duplex transport assembly.
Initial Actions worn/damaged components within the registration transport assembly
Remove the duplex transport assembly, REP 8.7, then inspect the assembly for damage, GP
7. The duplex transport assembly is in good condition.
WARNING
Y N
Ensure that the electricity to the machine is switched off while performing tasks that do Install a new duplex transport assembly, (35-55 ppm) PL 8.22 Item 1 or (65-90 ppm) PL
Perform the IQ1 Image entry RAP before starting this RAP. Remove the registration transport assembly, REP 8.4, then inspect the assembly for damage,
GP 7. The registration transport assembly is in good condition.
Procedure Y N
Replace the registration transport assembly, (35-55 ppm) PL 8.15 Item 1 or (65-90 ppm)
Print internal test pattern number 16, dC606. Run 20 off 1 and 2 sided copies of test pattern
PL 8.17 Item 1.
number 16, and then check the copies for cockle deletions. If cockle deletions are present they
appear as shown in Figure 1.
Refer to GP 18, lubricate the registration transport nip assembly.
Print internal test pattern number 16, dC606. Run 20 off 1 and 2 sided copies of test pattern
number 16, and then check the copies for cockle deletions. The copies are good.
Y N
Lead edge of test pattern 16 Perform ADJ 8.2 Simplex and Duplex Buckle Timing.
Record all changes in the log book for future reference. Perform SCP 6 Final Actions.
Typical areas of image deletion
Figure 1 Cockle deletions

IQS 1 Solid Area Density
Documents
Test patterns: 82E2000 (A3 and 11X17) 82E2010 (A4) 82E2020 (8.5X11) and the solid area
density scale, 82E8230 (SIR 542.00) for reference.
Specification
Compare the copies of one of the above 82E series test patterns, Figure 1, made from the doc-
ument glass, with the solid area density scale, 82E8230 (SIR 542.00). The density of the 2.1;
2.3; and 2.5 areas must be as dark or darker than the 1.3 reference, but less than 1.5. The 3.0,
3.3 and 3.4 text areas should all be visible. The 4.1 line pair should be visible. The 2.0, 2.2 and
2.4 squares should be darker than the original document. The bullseye targets should be
clearly reproduced.
Compare a print of the internal test pattern 12, Figure 2, with the solid area density scale,
82E8230 (SIR 542.00). The density of the solid areas must be as dark or darker than the 1.3
reference, but less than 1.5.
Corrective action
If the solid area density specification is not met, then go to the IQ1 Image Quality Entry RAP.
Figure 2 Internal test pattern 12
SIR 542.00
82E2000
Figure 1 Test patterns

Xerox WorkCentre 5790 Family 3-33 IQS 1
IQS 2 Background
Documents
Test patterns: 82E2000 (A3 and 11X17) 82E2010 (A4) 82E2020 (8.5X11) and visual scale,
82P448 for reference.
Specification
Compare the copies of one of the above 82E series test patterns, Figure 1, made from the doc-
ument glass, with the visual scale, 82P448. The background of the copies must not be darker
than the reference area B.
Compare a print of the internal test pattern 1, Figure 2, with the visual scale, 82P448. The
background of the print must not be darker than the reference area B.
Corrective Action
If the background specification is not met, then go to the IQ1 Image Quality Entry RAP.
Figure 2 Internal test pattern 1
SIR 494.00
82P448
82E2000
Figure 1 Test pattern

IQS 2 3-34 Xerox WorkCentre 5790 Family
IQS 3 Fusing IQS 4 Resolution
Documents Documents
Test Patterns: 82E2000 (A3 and 11X17) 82E2010 (A4) 82E2020 (8.5X11). Test patterns: 82E2000 (A3 and 11X17) 82E2010 (A4) 82E2020 (8.5X11).
Procedure Specification
Make 5 copies of the test pattern, Figure 1. Check the fusing by folding one of the copies Make copies of a test pattern. from the document glass. Examine the targets of the second
through the center of a solid area. Use a finger to apply medium pressure along the fold to copy to determine the overall resolution of the copy. The lines identified by the letter H, Figure
crease the paper. Unfold the copy. Use a finger to lightly rub the area of the fold and adjacent 1, should be clearly reproduced at 100%
areas.
Corrective action
Specification If the resolution specification is not met, refer to IQ1 Image Quality entry RAP.
Any break should measure less than 1mm (1/32 inch) across the line of a fold. Any area
rubbed with a cloth should not smudge or the image lift off the surface of the paper. When
checking the fusing on heavy weight paper (200gsm), rub the image with a finger. Images
fused on the smooth side have a greater resistance to rubbing than images fused on the rough
side. Do not attempt to fold heavy weight paper, as this breaks the fibres.
Rub these area with a finger.
Fold the print across these solid areas


Xerox WorkCentre 5790 Family 3-35 IQS 3, IQS 4
IQS 5 Skew
Documents Measure from this datum line to the edge
Test patterns: 82E2000 (A3 and 11X17) 82E2010 (A4) 82E2020 (8.5X11). of the print.
Specification
Refer to Table 1, Skew measurement. Area A
Table 1 Skew measurement

Source of paper DADH Document glass Printer
All trays lead edge registration 3mm (1/8 inch) 1.3mm (1/16 inch) 1mm (1/32 inch)
Bypass tray 3mm (1/8 inch) 1.3mm (1/16 inch) 1mm (1/32 inch)
Duplex 3mm 1.3mm (1/16 inch) 1mm (1/32 inch)
Skew measurement
The amount of skew is determined by the difference, A from B Figure 1, measured from the
datum line to the lead edge of the print or copy. The distance between area A and area B is
250mm (10 inches). Use internal test prints 16 or 17 to check printer skew.
Corrective Action
Refer to IQ1 Image Quality Entry RAP.
Area B
Measure from this datum line to the

edge of the print.
Figure 1 Skew measurement

IQS 6 Copy / Print Defects Skips and smears
The printer should produce prints free of defects. Any defects not explicitly covered by this Skips and smears are image disturbances that are assessed using the ladder scale, A. Use
specification should be considered as a fault. one of the test patterns, 82E2000 (A3 and 11X17) 82E2010 (A4) 82E2020 (8.5X11). Refer to
Table 3 to assess image disturbances.
Show through
Table 3 Skips and smears
No show through of the underside of the document handler should be visible when using Xerox
80gsm (20lb) or heavier paper as an input document. The check is made with the document Maximum number
handler closed and in normal copy / print mode. Some show through might occur using 60gsm Magnification ratio% disturbances Test area of document
(15lbs) paper as documents. All magnification None Ladder scale A. 3 line pairs
Oil on copies or prints

Paper wrinkle
No oil should be evident on any print when viewed normally. Oil should not be visible on any
Paper wrinkles which result in the loss of information are unacceptable at any level. In any
transparency when viewed using an overhead projector. It should be possible to mark fused
mode, copy / prints containing wrinkles or creases which do not result in the loss of information
transparencies with a spirit based marker pen.
may occur less frequently than 1 in 500 consecutive copies / prints in that mode. This is appli-
cable to all base line papers; to simplex and duplex prints, provided the paper is stored inside
Dark spots the printer and that the printer is operated within the environmental specification.
Dark spots are toner deposits in the background area of a copy / print. The specification for the
number spots and the size of the allowable spot size shown in Table 1. The specification is for Hole Punch Performance
the total image area; document glass and CVT glass; and the whole of the imaged area on the
photoreceptor. To assess for dark spots use the internal test pattern number 1. The hole punch unit makes a set of holes near the trail edge of single copies or prints. The
dimension between the holes are set by the hole punch. The position of the holes from the trail
edge is controlled by the software that uses timing information from the punch sensor. The
Table 1 Dark spots
specification for the hole positions in the top to bottom direction is +/-2 mm, with A4 / 80 gsm
Maximum number of spots per photoreceptor (8.5x11, 75 gsm) simplex, from a single tray in a nominal environment. For all paper sizes,
circumference, 264 mm (10.4 ins) X width across process weights, trays and environments, the specification is +/-3 mm.
Spot diameter direction
0.4 mm. and larger (1/64 0
inch)
No more than 2 sheets with more than 3 spots per 25x25mm
square (per square inch)
White spots
White spots are areas visible on a half tone or solid area where the toner has failed to be
deposited. The specification for the number and size of allowable spots is shown in Table 2.
The specification is for the whole of the imaged area on the photoreceptor. To assess for white
spots use the internal test pattern 5.
Table 2 White spots

Maximum number of spots per photoreceptor
circumference, 264 mm (10.4 ins) X width across
Spot diameter process direction
0.4mm. and larger (1/64 inch) 0
No more than 2 spots in any 25x25mm area (1 square inch)

IQS 7 Registration
Area C
Documents Top edge
Test patterns: 82E2010 (A4), 82E2020 (8.5 X 11)
Specifications
Refer to Table 1.
Area A
Table 1 Registration measurement
Printer
Source of paper DADH Document glass reference only
All trays, bypass tray and 2.3 mm (3/32 inch) 1.6 mm (1/16 inch) 1.6 mm (1/16 inch)
duplex lead edge registration
All trays, bypass tray and 3 mm (1/8 inch) 2.1 mm (3/32 inch) 1.6 mm (1/16 inch)
duplex top edge registration
Registration measurement
Use the areas A and B on the test pattern, Figure 1, to measure the displacement of the lead
edge on the image. Use the area C, Figure 1, to measure the top edge displacement. The dis-
placement measured at A and B should be equal.
NOTE: If a difference between measurements at A and B of a DADH copy are greater than 3
mm, refer to IQS 5 Skew.
NOTE: If a difference between measurements at A and B of a document glass copy are

greater than 1.3 mm, refer to IQS 5 Skew.
Corrective Action
Refer to ADJ 3.1 Registration Setup.
Area B
Figure 1 Registration measurement

IQS 8 Magnification NOTE: There are no across process direction adjustments.
Documents
Use the internal test pattern generated in dC604 Registration Setup.
Specifications
Refer to Table 1.
Table 1 Specifications
Source of image In process direction Across process direction
Printer (In ambient conditions equal to and less than 0.4% equal to and less than 0.4%
using 80gsm/20lb A4/letter
LEF)
Printer (In hot/wet or cool/dry equal to and less than 0.5% equal to and less than 0.5%
conditions using other papers)
Document glass less than + 0.7% to -0.7% less than + 0.7% to -0.7%
DADH less than + 1% to -0.5% less than + 0.7% to -0.7%
Magnification measurement
Make copies of the registration test pattern from the document glass and through the DADH.
Fold the printed images across Zone A to Zone C and from Zone B to Zone D. Lay the folded
printed images over the unfolded test pattern. Compare the dimensions, Figure 1.
Corrective action
Refer to ADJ 3.2 Magnification Adjustment.
Figure 1 Magnification check

4 Repairs and Adjustments
REPs 1 - Standby Power REP 5.14 Feed Roll Assembly ........................................................................................ 4-70
REP 1.1 Power and Control Assembly............................................................................ 4-5 REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt......................................... 4-72
REP 1.2 Wiring Harness Repairs .................................................................................... 4-9 REP 5.16 Document Width Sensor ................................................................................. 4-74
REP 1.3 Molex SL Connectors........................................................................................ 4-9 REP 5.17 Input Tray Static Eliminator............................................................................. 4-75
REP 1.4 Male Hirose DF1B Connectors ......................................................................... 4-12 REP 5.18 Exit Roll Idler................................................................................................... 4-76
REP 1.5 AMP EI Connectors .......................................................................................... 4-14 REP 5.19 DADH Removal............................................................................................... 4-77
REP 1.6 Hirose DF11 Connectors .................................................................................. 4-16 REP 5.20 Mylar Guide Strip ............................................................................................ 4-78
REP 1.7 AMP CT Connectors ......................................................................................... 4-17
REP 1.8 Door Interlock Switch ........................................................................................ 4-18
REPs 6 - ROS
REP 1.9 LVPS and Base Module.................................................................................... 4-19 REP 6.1 ROS .................................................................................................................. 4-79
REP 1.10 HVPS .............................................................................................................. 4-20 REPs 7 - Paper Supply
REP 1.11 Molex Mini-Fit Junior Connectors ................................................................... 4-22 REP 7.1 Tray 1 and Tray 2 Removal .............................................................................. 4-81
REPs 2 - User Interface REP 7.2 Tray 3 and Tray 4 Removal (W/O TAG 151) .................................................... 4-82
REP 7.3 Tray 3 and Tray 4 Elevator Motor (W/O TAG 151) ........................................... 4-83
REP 2.1 User Interface Assembly................................................................................... 4-25
REP 7.4 Tray 3 and Tray 4 Elevator Cables (W/O TAG 151) ......................................... 4-84
REP 2.2 User Interface Touch Screen PWB................................................................... 4-26
REP 7.5 Bypass Tray and Left Hand Door Assembly ..................................................... 4-86
REP 2.3 User Interface Control PWB.............................................................................. 4-27
REP 7.6 Tray 1 and Tray 2 Paper Guides....................................................................... 4-87
REP 2.4 User Interface Touch Screen ............................................................................ 4-28
REP 7.7 Tray 3 and Tray 4 Stack Height Sensor (W/O TAG 151).................................. 4-88
REPs 3 - Machine Run Control REP 7.8 Tray 3 and Tray 4 Stack Limiter (W/O TAG 151).............................................. 4-89
REP 3.1 IOT PWB........................................................................................................... 4-29 REP 7.9 Tray 3 and Tray 4 Home Switch (W/O TAG 151) ............................................. 4-90
REP 3.2 Hard Disk Drive................................................................................................. 4-30 REP 7.10 HCF Control PWB (W/O TAG 151)................................................................. 4-91
REP 3.3 Software Module ............................................................................................... 4-31 REP 7.11 Tray 3 and Tray 4 Elevator Damper and Gears (W/O TAG 151).................... 4-92
REP 3.4 Single Board Controller and Power Distribution PWBs..................................... 4-33 REP 7.12 Tray 1 and Tray 2 Paper Size Cams............................................................... 4-94
REP 7.13 Tray 5 Empty Sensor ...................................................................................... 4-95
REPs 4 - Main Drives REP 7.14 Tray 5 Stack Height Sensor ............................................................................ 4-96
REP 4.1 Main Drive Module (35-55 ppm) ....................................................................... 4-37 REP 7.15 Tray 5 Down Sensor ....................................................................................... 4-97
REP 4.2 Main Drive PWB (35-55 ppm) ........................................................................... 4-42 REP 7.16 Tray 5 Elevator Motor Assembly..................................................................... 4-98
REP 4.3 Main Drive Belt, Drive Gears and Idlers (35-55 ppm) ....................................... 4-43 REP 7.17 Tray 5 Upper Limit Switch............................................................................... 4-100
REP 4.4 Photoreceptor Drive Gear ................................................................................. 4-44 REP 7.18 Tray 5 Down Limit Switch ............................................................................... 4-100
REP 4.5 Main Drive Module (65-90 ppm) ....................................................................... 4-45 REP 7.19 Un-docking and Docking Tray 5...................................................................... 4-101
REP 4.6 Main Drive PWB (65-90 ppm) ........................................................................... 4-49 REP 7.20 Tray 1 and Tray 2 Lift Gear Assembly ............................................................ 4-104
REP 4.7 Main Drive Belts, Drive Gears and Idlers (65-90 ppm) ..................................... 4-52 REP 7.21 Tray 5 Elevator Rack Assembly...................................................................... 4-105
REP 7.22 Tray 3 and Tray 4 Removal (W/TAG 151) ...................................................... 4-107
REPs 5 - DADH REP 7.23 Tray 3 and Tray 4 Elevator Motor (W/TAG 151) ............................................. 4-109
REP 5.1 Top Cover Assembly......................................................................................... 4-55 REP 7.24 Tray 3 and Tray 4 Elevator Cables (W/TAG 151) ........................................... 4-110
REP 5.2 Top Access Cover Assembly ............................................................................ 4-56 REP 7.25 Tray 3 and Tray 4 Stack Height Sensor (W/TAG 151).................................... 4-112
REP 5.3 Feed Assembly ................................................................................................. 4-57 REP 7.26 Tray 3 and Tray 4 Home Sensor (W/TAG 151) .............................................. 4-113
REP 5.4 Input Tray Assembly ......................................................................................... 4-58 REP 7.27 HCF Control PWB (W/TAG 151)..................................................................... 4-114
REP 5.5 Baffle Assembly ................................................................................................ 4-59 REP 7.28 Tray 3 and Tray 4 Elevate Damper Assembly (W/TAG 151) .......................... 4-115
REP 5.6 Takeaway Roll Assembly.................................................................................. 4-61 REP 7.29 Tray 5 Elevator Tray Guides ........................................................................... 4-116
REP 5.7 Duplex Solenoid................................................................................................ 4-62
REP 5.8 Takeaway and CVT Sensor .............................................................................. 4-64
REPs 8 - Paper Transport
REP 5.9 Length Detect Sensors ..................................................................................... 4-65 REP 8.1 Tray 1 and Tray 2 Paper Feed Assembly ......................................................... 4-119
REP 5.10 Registration Sensor ........................................................................................ 4-66 REP 8.2 Tray 3 Paper Feed Assembly (W/O TAG 151) ................................................. 4-119
REP 5.11 Exit Sensor...................................................................................................... 4-67 REP 8.3 Tray 4 Paper Feed Assembly (W/O TAG 151) ................................................. 4-121
REP 5.12 DADH Counterbalance ................................................................................... 4-68 REP 8.4 Registration Transport ...................................................................................... 4-123
REP 5.13 Exit Roll Assembly .......................................................................................... 4-69 REP 8.5 Registration Clutch............................................................................................ 4-126
REP 8.6 Registration Sensor and Wait Sensor (35-55ppm) ........................................... 4-127
November 2014 Repairs/Adjustments

REP 8.7 Duplex Transport .............................................................................................. 4-128 REPs 9 - Xerographics
REP 8.8 Duplex Motor and Drive Belts ........................................................................... 4-129 REP 9.1 Waste Toner Bottle Assembly .......................................................................... 4-197
REP 8.9 Bypass Tray Feed Solenoid.............................................................................. 4-130 REP 9.2 Developer Assembly......................................................................................... 4-198
REP 8.10 Tray 3 and Tray 4 Transport Motor (W/O TAG 151)....................................... 4-130 REP 9.3 Ozone Fan ........................................................................................................ 4-199
REP 8.11 Tray 3 and Tray 4 Transport Drive Gear (W/O TAG 151)............................... 4-131 REP 9.4 Waste Toner Full Sensor .................................................................................. 4-200
REP 8.12 Tray 1 and Tray 2 Transport Drive Belt .......................................................... 4-133 REP 9.5 Toner Dispense Module.................................................................................... 4-201
REP 8.13 Tray 3 Transport Assembly (W/O TAG 151)................................................... 4-134 REP 9.6 Xerographic Module Latch ................................................................................ 4-203
REP 8.14 Tray 3 Feed Sensor Actuator (W/O TAG 151)................................................ 4-135 REP 9.7 Developer Paddle ............................................................................................. 4-205
REP 8.15 Registration Sensor (65-90 ppm).................................................................... 4-135 REP 9.8 Transfer / Detack Harness................................................................................ 4-205
REP 8.16 Tray 1 and Tray 2 Transport Rolls and Bearings ............................................ 4-138 REP 9.9 Erase Lamp ...................................................................................................... 4-206
REP 8.17 Wait Sensor (65-90ppm)................................................................................. 4-139 REP 9.10 Auger Damper ................................................................................................ 4-207
REP 8.18 Tray 1 and Tray 2 Transport Roll Drives Motor .............................................. 4-142
REP 8.19 Bypass Tray Feed Head ................................................................................. 4-143 REPs 10 - Print Transport and Fusing
REP 8.20 Bypass Tray Drive Gear ................................................................................. 4-145 REP 10.1 Short Paper Path Assembly............................................................................ 4-211
REP 8.21 Bypass Tray Feed Roll ................................................................................... 4-146 REP 10.2 Inverter Assembly ........................................................................................... 4-213
REP 8.22 Bypass Tray Retard Pad................................................................................. 4-147 REP 10.3 Inverter Motor ................................................................................................. 4-218
REP 8.23 Bypass Tray Empty Sensor ............................................................................ 4-148 REP 10.4 Inverter Path Solenoid .................................................................................... 4-219
REP 8.24 Tray 1 or Tray 2 Feed Sensor......................................................................... 4-149 REP 10.5 Inverter Nip Solenoid ...................................................................................... 4-220
REP 8.25 Tray 5 Feed Sensor ........................................................................................ 4-151 REP 10.6 Nip Roll Guide................................................................................................. 4-220
REP 8.26 Registration Drive Roll Assembly ................................................................... 4-153 REP 10.7 Upper Baffle Assembly ................................................................................... 4-222
REP 8.27 Registration Transport Drive Belt.................................................................... 4-154 REP 10.8 Nip Split Shaft Assembly ................................................................................ 4-223
REP 8.28 Tray 3 Feed Sensor (W/O TAG 151) .............................................................. 4-155 REP 10.9 Shaft Actuator ................................................................................................. 4-225
REP 8.29 Tray 3 Takeaway Roll Assembly (W/O TAG151) ........................................... 4-155 REP 10.10 Fuser Latch................................................................................................... 4-226
REP 8.30 Tray 3 Transport Roll Assembly (W/O TAG 151) ........................................... 4-158 REP 10.11 Inverter Gate................................................................................................. 4-227
REP 8.31 Tray 3 and Tray 4 Transport Roll (W/O TAG 151) .......................................... 4-160 REP 10.12 Tri-Roll Shaft Assembly ................................................................................ 4-229
REP 8.32 Duplex Sensor ................................................................................................ 4-162 REP 10.13 Fuser Web Motor Assembly ......................................................................... 4-232
REP 8.33 Tray 5 Transport Drive Belt............................................................................. 4-164 REP 10.14 Exit Shaft Assembly...................................................................................... 4-233
REP 8.34 Tray 5 Feed Rolls ........................................................................................... 4-165 REP 10.15 Intermediate Drive Belt (W/O TAG 114) ....................................................... 4-234
REP 8.35 Tray 1 and Tray 2 Feed Rolls ......................................................................... 4-166 REP 10.16 Fuser Exit Switch .......................................................................................... 4-237
REP 8.36 Tray 5 Feed Motor .......................................................................................... 4-167 REP 10.17 IOT Exit Sensor ............................................................................................ 4-239
REP 8.37 Tray 5 Transport motor ................................................................................... 4-167 REP 10.18 Inverter Output Guide Assembly................................................................... 4-241
REP 8.38 Tray 5 Takeaway Roller.................................................................................. 4-168 REP 10.19 Tri-Roll Nip Split Solenoid............................................................................. 4-243
REP 8.39 Tray 1 and Tray 2 Retard Roll Friction Clutch ................................................ 4-170 REP 10.20 Inverter Sensor ............................................................................................. 4-244
REP 8.40 Tray 3 Paper Feed Assembly (W/TAG 151) ................................................... 4-170
REPs 11-110 - 2K LCSS
REP 8.41 Tray 4 Paper Feed Assembly (W/TAG 151) ................................................... 4-172
REP 11.1-110 2K LCSS Covers ..................................................................................... 4-245
REP 8.42 HCF Transport Motor (W/TAG 151)................................................................ 4-174
REP 11.2-110 Input Drive Belt and Paper Entry Transport Motor .................................. 4-246
REP 8.43 Tray 3 Transport Gear Pulley (W/TAG 151) ................................................... 4-175
REP 11.3-110 Intermediate Paper Drive Belt ................................................................. 4-247
REP 8.44 Tray 3 Transport Assembly (W/TAG 151) ...................................................... 4-176
REP 11.4-110 Paper Output Drive Belt and Paper Transport Exit Motor ....................... 4-248
REP 8.45 Tray 3 Exit Sensor (W/TAG 151) .................................................................... 4-177
REP 11.5-110 Bin 1 Drive Belts ...................................................................................... 4-249
REP 8.46 Tray 3 Takeaway Roll Assembly (W/TAG151) ............................................... 4-177
REP 11.6-110 Tamper Assembly.................................................................................... 4-252
REP 8.47 Tray 3 and Tray 4 Transport Roll (W/TAG 151).............................................. 4-179
REP 11.7-110 Hole Punch Unit, Motor and Sensors ...................................................... 4-253
REP 8.48 Tray 3 Stack Height Sensor (W/TAG 151)...................................................... 4-181
REP 11.8-110 Stapler Traverse Assembly ..................................................................... 4-255
REP 8.49 Tray 3 Empty Sensor (W/TAG 151)................................................................ 4-181
REP 11.9-110 Staple Head Unit ..................................................................................... 4-257
REP 8.50 Tray 3 Feed Sensor (W/TAG 151).................................................................. 4-182
REP 11.10-110 Ejector Assembly Sensors..................................................................... 4-258
REP 8.51 Tray 4 Stack Height Sensor (W/TAG 151)...................................................... 4-183
REP 11.11-110 Bin 1 Level Sensors............................................................................... 4-259
REP 8.52 Tray 4 Empty Sensor (W/TAG 151)................................................................ 4-184
REP 11.12-110 Paddle Wheel Shaft Assembly .............................................................. 4-260
REP 8.53 Tray 4 Feed Sensor (W/TAG 151).................................................................. 4-185
REP 11.13-110 2K LCSS Un-Docking ............................................................................ 4-263
REP 8.54 Tray 3 and Tray 4 Feed Assembly Feed Rolls (W/TAG 151) ......................... 4-186
REP 11.14-110 2K LCSS PWB....................................................................................... 4-264
REP 8.55 Tray 3 Paper Guide (W/TAG 151) .................................................................. 4-192
REP 11.15-110 Entry Guide Cover ................................................................................. 4-265
REP 8.56 Tray 4 Paper Guide (W/TAG 151) .................................................................. 4-193
REP 11.16-110 Docking Latch Assembly ....................................................................... 4-266
REP 8.57 Tray 3 Transport Clutch Drive Assembly (W/TAG 151) .................................. 4-195
REP 11.17-110 Ejector Belt ............................................................................................ 4-268
Repairs/Adjustments November 2014

REPs 11-120 - 1K LCSS REP 11.35-171 Diverter Exit Gate .................................................................................. 4-339
REP 11.1-120 1K LCSS Covers...................................................................................... 4-269 REP 11.36-171 Crease Blade Assembly ........................................................................ 4-340
REP 11.2-120 Input Drive Belt and Transport Motor 1.................................................... 4-270 REP 11.37-171 Stacker Driving Shaft Bearings.............................................................. 4-343
REP 11.3-120 1K LCSS Stability Foot ............................................................................ 4-271 REP 11.38-171 HVF Stacker Bin 1 Main Drive Belts ...................................................... 4-344
REP 11.4-120 Paper Output Drive Belt and Transport Motor 2 ...................................... 4-272 REP 11.39-171 HVF BM Diverter Gate........................................................................... 4-345
REP 11.5-120 Bin 1 Drive Belts ...................................................................................... 4-273 REP 11.40-171 HVF Input Roll ....................................................................................... 4-346
REP 11.6-120 Tamper Assembly.................................................................................... 4-275 REP 11.41-171 HVF Inserter Guide Roll......................................................................... 4-347
REP 11.7-120 Stapler Assembly and SH1 Paper Sensor............................................... 4-276 REP 11.42-171 HVF Buffer Pocket Roll.......................................................................... 4-348
REP 11.8-120 Ejector Assembly and Sensors................................................................ 4-278 REP 11.43-171 HVF Booklet Entrance Roll .................................................................... 4-349
REP 11.9-120 Bin 1 Upper Level Sensor........................................................................ 4-279 REP 11.44-171 HVF Buffer Lower Roll ........................................................................... 4-350
REP 11.10-120 Paddle Wheel Shaft Assembly .............................................................. 4-280 REP 11.45-171 HVF Buffer Upper Roll ........................................................................... 4-351
REP 11.11-120 1K LCSS Removal................................................................................. 4-283 REP 11.46-171 HVF Stacker Exit Feed Roll ................................................................... 4-352
REP 11.12-120 1K LCSS PWB....................................................................................... 4-284 REP 11.47-171 HVF Top Exit Feed Roll ......................................................................... 4-353
REP 11.13-120 Entry Guide Cover ................................................................................. 4-285 REP 11.48-171 Paddle Module Driving Motor Assembly................................................ 4-355
REP 11.14-120 Docking Latch Assembly and Docking Interlock Switch ........................ 4-286 REP 11.49-171 Compiler Paddle Module ....................................................................... 4-356
REP 11.50-171 BM Exit Sensor ...................................................................................... 4-357
REP 11.15-120 Ejector Belt ............................................................................................ 4-287
REP 11.51-171 Compiler Paper Pusher Motor Assembly............................................... 4-357
REPs 11-171 - HVF REP 11.52-171 BM Crease Rolls, Gears, Clutch and Bearings...................................... 4-358
REP 11.1-171 HVF Covers ............................................................................................. 4-289 REP 11.53-171 Compiler Paper Pusher ......................................................................... 4-362
REP 11.2-171 HVF Stapler Assembly............................................................................. 4-292 REP 11.54-171 Sensor Assembly................................................................................... 4-363
REP 11.3-171 Top Tray .................................................................................................. 4-294 REP 11.55-171 HVF Power Supply Unit ......................................................................... 4-364
REP 11.4-171 Bin 1 Removal ......................................................................................... 4-295 REP 11.56-171 BM Right Hand Cover............................................................................ 4-365
REP 11.5-171 Right Side-Cover Removal ...................................................................... 4-296 REP 11.57-171 HVF Main PWB...................................................................................... 4-367
REP 11.6-171 HVF Ejector Assembly Removal.............................................................. 4-297 REP 11.58-171 BM Crease Nip Springs ......................................................................... 4-368
REP 11.7-171 Pressing Plate Fingers............................................................................. 4-301 REP 11.59-171 Crease Roll Gate Assembly................................................................... 4-370
REP 11.8-171 Front and Rear Support Fingers .............................................................. 4-301 REP 11.60-171 BM Paper Guide Assembly.................................................................... 4-374
REP 11.9-171 HVF Offset Motor Assembly .................................................................... 4-303 REP 11.61-171 BM Module............................................................................................. 4-376
REP 11.10-171 Stacker Idler Rolls.................................................................................. 4-304 REP 11.62-171 BM Slide Assembly................................................................................ 4-381
REP 11.11-171 Front Tamper Motor Assembly .............................................................. 4-305 REP 11.63-171 Entry Feed Motor 1 ................................................................................ 4-384
REP 11.12-171 Bin 1 Elevator Motor Assembly.............................................................. 4-306 REP 11.64-171 Bypass Feed Motor................................................................................ 4-384
REP 11.13-171 HVF and HVF BM Un-Docking .............................................................. 4-307 REP 11.65-171 Buffer Feed Motor.................................................................................. 4-385
REP 11.14-171 HVF Top Jam Clearance Guide Assembly ............................................ 4-308 REP 11.66-171 Exit Feed Motor 2 .................................................................................. 4-385
REP 11.15-171 HVF Rear Tamper Assembly................................................................. 4-309 REP 11.67-171 Tri-Folder Covers................................................................................... 4-386
REP 11.16-171 BM Flapper ............................................................................................ 4-311 REP 11.68-171 Tri-Folder Drive Assembly ..................................................................... 4-387
REP 11.17-171 BM PWB ................................................................................................ 4-312 REP 11.69-171 Drive Coupling Assembly....................................................................... 4-390
REP 11.18-171 BM Crease Blade Motor ........................................................................ 4-314 REP 11.70-171 Tri-Folder Feed Roller and Drive Belt .................................................... 4-391
REP 11.19-171 BM Crease Roll Motor ........................................................................... 4-316 REP 11.71-171 Tri-Folder Assist Gate Solenoid............................................................. 4-392
REP 11.20-171 BM Backstop Motor Assembly............................................................... 4-317 REP 11.72-171 Crease Roll Springs............................................................................... 4-392
REP 11.21-171 BM Backstop Assembly ......................................................................... 4-318 REP 11.73-171 Tri-Folder Top Door Cover and Idler Assemblies .................................. 4-393
REP 11.22-171 BM Entry Roll......................................................................................... 4-321 REP 11.74-171 Tri-Folder Roller Assembly and Diverter Solenoid................................. 4-394
REP 11.23-171 BM Entry Sensor.................................................................................... 4-322 REP 11.75-171 Bin 1 Limit Switches............................................................................... 4-396
REP 11.24-171 BM Crease Roll Gate Motor................................................................... 4-324 REP 11.76-171 Bin 1 Upper Level Sensor...................................................................... 4-397
REP 11.25-171 BM Compiler Motor and BM Flapper Motor ........................................... 4-324 REP 11.77-171 Tri-Folder Door Interlock Switches and Sensor ..................................... 4-397
REP 11.26-171 Back Stop Drive Assembly .................................................................... 4-325 REP 11.78-171 Tri-Folder Entry and Assist Gate Sensors ............................................. 4-398
REP 11.27-171 BM Staple Heads................................................................................... 4-327 REP 11.79-171 Tri Folder Exit Sensor ............................................................................ 4-398
REP 11.28-171 BM Stapler Bracket Assembly ............................................................... 4-328 REP 11.80-171 Tri-Folder Control PWB ......................................................................... 4-399
REP 11.29-171 BM Conveyor Belts ................................................................................ 4-332 REP 11.81-171 Tri-Folder and Bin 2 Tray Harnesses..................................................... 4-399
REP 11.30-171 BM Tamper Assembly and Tamper 1 Motor.......................................... 4-334 REP 11.82-171 Inserter Undocking................................................................................. 4-400
REP 11.31-171 HVF Buffer Guide Assembly.................................................................. 4-336 REP 11.83-171 Inserter Front and Rear Covers ............................................................. 4-401
REP 11.32-171 HVF Input Jam Clearance Guide........................................................... 4-337 REP 11.84-171 Inserter Motor ........................................................................................ 4-402
REP 11.33-171 Buffer Pocket Jam Clearance Guide Assembly..................................... 4-337 REP 11.85-171 Inserter PWB ......................................................................................... 4-402
REP 11.34-171 Inserter Jam Clearance Guide Assembly .............................................. 4-339 REP 11.86-171 Inserter Clutch ....................................................................................... 4-403
REP 11.87-171 Inserter Top Cover Interlock Switch....................................................... 4-404

REP 11.88-171 Left Hand Door Interlock Switch ............................................................ 4-404 ADJs 6 - ROS
REP 11.89-171 Main Tray and Paper Length Sensors ................................................... 4-405 ADJ 6.1 ROS Window Cleaning Procedure .................................................................... 4-457
REP 11.90-171 Bottom Tray and Paper Sensors ........................................................... 4-406 ADJ 6.2 ROS Cleaning Procedure.................................................................................. 4-458
REP 11.91-171 Inserter Top Cover and IDG Pickup Sensor .......................................... 4-407
ADJs 7 - Paper Trays
REP 11.92-171 Inserter Top Left Door and Acceleration Sensor ................................... 4-407
ADJ 7.1 Tray 3 and Tray 4 Paper Tray Guide Setting (W/O TAG 151) .......................... 4-459
REP 11.93-171 LE and TE Sensors ............................................................................... 4-408
ADJ 7.2 Tray 5 Paper Tray Guide Setting....................................................................... 4-460
REP 11.94-171 Inserter Bottom Plate Sensor ................................................................ 4-409
ADJ 7.3 Tray 5 Module to Machine Alignment................................................................ 4-461
REP 11.95-171 Inserter Pickup Assembly and Reverse Feed Roller ............................. 4-410
ADJ 7.4 Tray 5 Module Tray Alignment .......................................................................... 4-463
REP 11.96-171 HVF Fixed and Adjustable Casters ....................................................... 4-411
ADJ 7.5 Tray 3 and Tray 4 Paper Tray Guide Setting (W/TAG 151) .............................. 4-464
REP 11.97-171 Pause to Unload PWB ........................................................................... 4-413
ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield................................................. 4-466
REP 11.98-171 Inserter Idle Roller Assembly................................................................. 4-413
REP 11.99-171 Tri-Folder Removal ................................................................................ 4-415 ADJs 8 - Paper Feed and Registration
REP 11.100-171 Ejector Paddle Assembly (W/TAG V-007)........................................... 4-416 ADJ 8.1 Registration Setup ............................................................................................. 4-473
REP 11.101-171 Paddle Wheel ...................................................................................... 4-417 ADJ 8.2 Simplex and Duplex Buckle Timing ................................................................... 4-473
ADJ 8.3 Tray 3 and Tray 4 Retard Roll Pressure (W/Tag 151)....................................... 4-474
REPs 12 - OCT ADJ 8.4 Tray 3 and Tray 4 Nudger Roll Pressure (W/Tag 151)...................................... 4-475
REP 12.1 OCT Fingers Install ......................................................................................... 4-419
ADJs 9 - Xerographics
REPs 14 - Scanner ADJ 9.1 Corotron Cleaning ............................................................................................. 4-477
REP 14.1 Scanner .......................................................................................................... 4-421 ADJ 9.2 Image Quality Adjustment Routine.................................................................... 4-477
REP 14.2 Exposure Lamp Inverter and Fuse (W/O TAG 150) ....................................... 4-423 ADJ 9.3 Developer Magnetic Seal Brush Adjustment ..................................................... 4-478
REP 14.3 Document Size Sensors (W/O TAG 150) ....................................................... 4-424 ADJ 9.4 Xerographics Cleaning ...................................................................................... 4-482
REP 14.4 DADH Closed Switch ...................................................................................... 4-424 ADJ 9.5 Optimize Dark and Light Grey Image ................................................................ 4-483
REP 14.5 Scanner PWB (W/O TAG 150) ....................................................................... 4-425 ADJs 10 - Print Transport and Fusing
REP 14.6 CVT Glass, Document Glass and CVT Ramp ................................................ 4-426
ADJ 10.1 Inverter Decurler Adjustment........................................................................... 4-485
REP 14.7 Scan Carriage Home Sensor .......................................................................... 4-427
REP 14.8 Input Module Angle Sensor ............................................................................ 4-428 ADJs 11-110 - 2K LCSS
REP 14.9 Exposure Lamp............................................................................................... 4-428 ADJ 11.1-110 2K LCSS Bin 1 Level................................................................................ 4-487
REP 14.10 Scan Idler Pulleys ......................................................................................... 4-429 ADJ 11.2-110 Machine to 2K LCSS Alignment............................................................... 4-487
REP 14.11 Scan Motor (W/O TAG 150) ......................................................................... 4-430 ADJ 11.3-110 Hole Punch Position................................................................................. 4-488
REP 14.12 Scan Cables ................................................................................................. 4-431 ADJ 11.4-110 Motor Drive Belt Tensioning..................................................................... 4-489
REP 14.13 Scanner Drive Belt (W/O TAG 150) .............................................................. 4-434
REP 14.14 Top Cover ..................................................................................................... 4-435 ADJs 11-120 - 1K LCSS
REP 14.15 Scan Motor (W/TAG 150) ............................................................................. 4-436 ADJ 11.1-120 1K LCSS Bin 1 Level................................................................................ 4-491
REP 14.16 Scan Motor and Scan Carriage Drive Belts (W/TAG 150) ............................ 4-436 ADJ 11.2-120 Motor Drive Belt Tensioning..................................................................... 4-491
REP 14.17 Exposure Lamp Inverter (W/TAG 150) ......................................................... 4-438 ADJs 11-171-HVF / HVF BM
REP 14.18 Scan Carriage Ribbon Harness (W/TAG 150) .............................................. 4-440
ADJ 11.1-171 Machine to HVF/HVF BM, HVF BM to Tri-folder Alignment ..................... 4-493
REP 14.19 Scanner PWB (W/TAG 150) ......................................................................... 4-441 ADJ 11.2-171 Tri-Folder Paper Size Setting ................................................................... 4-494
REP 14.20 Document Size Sensor 1 and Document Size Sensor 2 (W/TAG 150) ........ 4-441 ADJ 11.3-171 Stapler Anvil Alignment ............................................................................ 4-495
ADJs 3 - Registration ADJ 11.4-171 Crease Blade Position.............................................................................. 4-498
ADJ 11.5-171 Booklet Tamping ...................................................................................... 4-501
ADJ 3.1 Registration Setup ............................................................................................. 4-443
ADJ 11.6-171 Booklet Compiling Position ...................................................................... 4-503
ADJ 3.2 Magnification Adjustment .................................................................................. 4-443
ADJ 11.7-171 Booklet Crease Position........................................................................... 4-505
ADJs 4 - Machine Lubrication ADJ 11.8-171 Booklet Staple Position ............................................................................ 4-506
ADJ 4.1 Machine Lubrication .......................................................................................... 4-445 ADJ 11.9-171 Booklet Maker Skew ................................................................................ 4-506
ADJ 11.10-171 Motor Drive Belt Tensioning ................................................................... 4-507
ADJs 5 - DADH ADJ 11.11-171 Idler Drive Belt Tensioning ..................................................................... 4-508
ADJ 5.1 DADH Drive Belt Adjustment............................................................................. 4-451 ADJ 11.12-171 Tri-Folder Fold Adjustment..................................................................... 4-509
ADJ 5.2 DADH Height Adjustment.................................................................................. 4-452 ADJ 11.13-171 HVF Performance Improvement (W/TAG V-006)................................... 4-510
ADJ 5.3 DADH Skew Adjustment ................................................................................... 4-454 ADJ 11.14-171 BM Diverter Solenoid Position ............................................................... 4-516
ADJ 5.4 DADH Cleaning Procedure ............................................................................... 4-455 ADJs 14 - Scanner
ADJ 5.5 DADH Registration Adjustment ......................................................................... 4-456 ADJ 14.1 Optics Cleaning Procedure (W/O TAG 150) ................................................... 4-517
ADJ 5.6 DADH Document Pad ....................................................................................... 4-456 ADJ 14.2 Optics Cleaning Procedure (W/TAG 150) ....................................................... 4-517

REP 1.1 Power and Control Assembly
Parts List on PL 1.10
1
Removal Remove the nut.
WARNING 2
Remove the ground
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
wires from the ground
customer supply while performing tasks that do not need electricity. Electricity can point.
WARNING
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the IOT
PWB.
Figure 1 ESD Symbol
NOTE: 1. If a new power and control assembly complete with IOT PWB is to be installed refer
to REP 3.1 IOT PWB.
NOTE: 2. Before starting this procedure, read and record the dC131 NVM values in location
09-271 Developer age, and 09-069 TC sensor control voltage. After installing the new IOT
PWB, perform an NVM restore, GP 5, and write the values recorded from the old IOT PWB into
NVM locations 09-271 and 09-069. Load software if required, GP 4. In diagnostics, on the Ser-
vice Info screen, select the serial number box and enter the machine serial number as it
appears on the serial number plate on the front frame of the machine.
1. Pull out tray 1 and tray 2 approximately 100mm (4 inches).

2. Disconnect accessories and the output device.
3. Remove the rear cover, PL 8.10 Item 1.
4. Remove the waste toner bottle door assembly, REP 9.1.
5. Figure 2. Disconnect the ground wires from the ground point.
Figure 2 Main frame ground point

Xerox WorkCentre 5790 Family 4-5 REP 1.1
6. Figure 3. Remove the cable ties. 7. Figure 4. Remove the securing screw from the power and control assembly.
1
Remove screw
Remove
cable tie.
2
Move the power
and control
assembly to the
left.
Figure 4 Power and control assembly
Cut cable tie.
Figure 3 Cable tie and ground connection

REP 1.1 4-6 Xerox WorkCentre 5790 Family
8. Figure 5. Disconnect PJ24 and all of the HT leads on the HVPS PWB. 9. Figure 6. Disconnect all the PJs on the IOT PWB except PJ14.
1
Disconnect PJ24.
2 Figure 6 IOT PWB

Disconnect all the HT
leads on the HVPS PWB
10. Figure 7. Disconnect all of the PJs from the LVPS.
Figure 5 HVPS PWB
Figure 7 LVPS
11. Remove the power and control assembly.

Replacement 3. Figure 9. Ensure that the nut on the ground connection is tightened to secure the ground
terminals.
If a new LVPS and base module is installed with the HVPS and IOT PWB transferred from
the failed LVPS and base module then perform steps 1 to 3. 4. Figure 9. Use a digital multimeter set to a resistance range. Verify that there is continuity
between the ground pin on PJ21 and the frame ground connection.
If a new power and control assembly complete with IOT PWB has been installed then per-
form steps 1 to 4.
Main frame ground connection.

CAUTION
Ensure the HT leads are correctly connected. Do not connect the female spade connector
between the male spade connector and the outer casing of the HT leads.
CAUTION
Do not trap the harnesses when the power and control assembly is installed.
1. Figure 8. Ensure that the bypass tray cable is routed as shown under the bracket.
PJ148 on the main drive PWB.
Ground pin
on PJ21.
Figure 9 Ground check
5. Reconnect the power cord and switch on the machine, GP 14.

6. If necessary, reload the software set, GP 4.
NOTE: After the software reload has been completed, the machine resets and gives a
message Restoring Configuration Settings. Do not switch off the machine or intervene
during this NVM transformation process.
Bypass tray cable 7. Check the machine serial number and the machine configuration, GP 15.
Figure 8 Bypass tray cable
2. Refer to Figure 8. Check that PJ148 has not been disconnected on the Main Drive PWB.

REP 1.2 Wiring Harness Repairs REP 1.3 Molex SL Connectors
Purpose 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, GP 14. Disconnect the power cord from the
from the customer supply while performing tasks that do not need electricity. Electricity customer supply while performing tasks that do not need electricity. Electricity can
can cause death or injury. Moving parts can cause injury. cause death or injury. Moving parts can cause injury.
NOTE: Molex connectors have small black housings in single or double rows, formed with min-
iature square section pins and sockets.
WARNING
Do not attempt any repairs to the power cord or safety ground harness/conductor. 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.
NOTE: Safety ground connections use green/yellow cables, or green cables with a yellow Therefore it will be necessary to disassemble the housing as shown in Figure 1.
stripe or band.
The steps that follow identify the relevant procedures for repairing the various connectors con-
tained within the copier.
1. If wiring is damaged, use connector splicing blocks to repair damaged wiring.
2. The following harness assemblies are not repairable; install new parts: 1 2
Attach the Molex connector.
Any ribbon harness. Hold the wires from the
Single board controller module / LVPS/IOT PWB harness, PL 3.24 Item 14. bold row connector.
ROS data cable, PL 3.24 Item 15.
Single board controller module / UI harness, PL 3.24 Item 11.
Riser PWB/Power distribution PWB harness, PL 3.22 Item 1.
Single board controller module/CCD PWB harness, PL 3.24 Item 9.
Single board controller PWB/scanner driver PWB/CCD PWB harness (W/OTAG
150), PL 3.24 Item 7.
Single board controller PWB/DADH comms/scanner power harness (W/TAG 150)
PL 3.24 Item 7.
3. The following connectors can be repaired by removing the faulty terminals and installing
new terminals: 3
Molex SL connectors - REP 1.3. Bend the housing open.
Male Hirose DF1B connectors - REP 1.4.
AMP EI connectors - REP 1.5.
Hirose DF11 connectors - REP 1.6.
5 4
AMP CT connectors - REP 1.7. Pull out A row.
Pull out B row connector.
Molex Mini-Fit Junior connectors - REP 1.11.
Figure 1 Disassembling the connector.

Xerox WorkCentre 5790 Family 4-9 REP 1.2, REP 1.3
2. Figure 2. Remove the terminal from the connector housing using the Molex extractor tool. Replacement
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,
then close the tool just enough to hold the terminal.
1
Insert Molex tool.
2
Press prong flat.
3
Push terminal out of housing
using a male terminal from the
repair kit. 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.
Figure 2 Removing the terminal.
3. Cut off the damaged terminal, then strip 3mm of insulation from the end of the wire.

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 fasten the insulation of the wire in the outer grip of the terminal.
Correct
Incorrect
Loose strands of wire
Figure 4 Crimping the insulation grip. Crimp loose
Insulation in 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
connectors into the housing taking care that the A connector is fitted on the fastener
side.

REP 1.4 Male Hirose DF1B Connectors Replacement
Removal
CAUTION
There are different terminals for large gauge and small gauge wire. Ensure that the correct
WARNING replacement terminal is used.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 1. Select the correct replacement terminal and identify the appropriate crimp positions for
customer supply while performing tasks that do not need electricity. Electricity can the terminal.
NOTE: These connectors can be repaired using either crimp terminals or pre-crimped ter-
1. Figure 1. Remove the damaged terminal from the housing.
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.
1
Raise plastic tab with
suitable tool, to
release terminal.
2
Remove terminal from Figure 2 Crimping the terminal.
housing.
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
Figure 1 Remove the terminal the terminal.

4. Figure 3. Insert the crimped terminal into the appropriate position of the crimp tool, then 5. Figure 4. Check that the crimp is correctly made.
close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi-
nal.
Correct
Incorrect
Wire exposed
Insulation In crimp
crimp loose
Figure 3 Crimping the insulation grip.

Figure 4 Inspecting the finished crimp.

REP 1.5 AMP EI Connectors
Removal
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 2
customer supply while performing tasks that do not need electricity. Electricity can Remove terminal from housing.
NOTE: The male housings contain socket terminals, and the female housings contain pin ter-
minals.
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
and the terminal type.
1
Depress prong to
release terminal.
1
Insert a paper clip to
release prong.
Figure 2 Terminal removal; female housing.
2
Remove terminal from
housing.
Figure 1 Terminal removal; male housing.

Replacement 4. Figure 4. Insert the crimped terminal into the appropriate position of the crimp tool and
close the crimp tool to firmly fasten the insulation of the wire in the cable grip of the termi-
1. Select the correct replacement terminal and identify the appropriate crimp positions for
nal.
the terminal.
tool enough to hold the terminal.
Figure 4 Crimping the insulated grip.
Figure 3 Crimping the terminal.
3. Insert the wire completely into the terminal, so that the stripped portion of the wire is in the
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.

5. Figure 5. Check that the crimp is correctly made. REP 1.6 Hirose DF11 Connectors
Removal
Correct
WARNING
customer supply while performing tasks that do not need electricity. Electricity can
NOTE: The male housing contains female terminals that cannot be crimped in the field; if a ter-
Incorrect minal is damaged, install a new terminal with flying lead.
1. Figure 1. Remove the damaged terminal from the connector housing.

Wire exposed
Insulation in crimp
1
Raise plastic tab with suitable tool, to release terminal.
Crimp loose 2
Remove terminal from
housing.
Figure 5 Inspect the finished crimp
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.

REP 1.5, REP 1.6 4-16 Xerox WorkCentre 5790 Family
REP 1.7 AMP CT Connectors 2. Figure 1. Remove the damaged crimp terminal from the connector housing.
Removal
WARNING
customer supply while performing tasks that do not need electricity. Electricity can Raise plastic tab with suitable tool, to release terminal.
2
CAUTION Remove terminal from
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-
ment terminals with flying leads, connected to the existing wiring with connector splicing blocks
(removal steps 2 and 3). Repairing IDC connectors is performed by installing a complete
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
terminal connectors.
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 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.

REP 1.8 Door Interlock Switch 3. Figure 2. Remove the interlock switch.

Removal
WARNING
WARNING
1. Pull the fuser module out a short way.
2. Figure 1. Release the door interlock switch.
2
Repeat step 1 to release the
other side of the switch. 1
Rotate the body of the
switch to remove.
1
Insert a steel rule or feeler
gauge. Push to release the
catch and simultaneously pull
the switch forward.
Figure 2 Removing switch
Replacement
Reverse the removal procedure to replace the door interlock switch.
Figure 1 Releasing switch

REP 1.9 LVPS and Base Module 4. Figure 2. As necessary, remove the output device harness and tray 5 harness from the
LVPS and base module.
Removal 1
Remove 4 hex
head screws.
WARNING
2
Disconnect PJ515.
WARNING
Figure 1 ESD Symbol 3

Remove the output device
1. Remove the power and control assembly, REP 1.1. harness and tray 5 harness.
2. Remove the HVPS, (2 screws) and the IOT PWB, (8 screws), from the old LVPS and base
module.
3. Remove the insulating sheet from behind the HVPS.
Figure 2 Remove the output device harness and tray 5 harness
Replacement
CAUTION
Do not over tighten the four hex head screws. The screws break very easily.
1. The Replacement procedure is the reverse of the Removal procedure.

REP 1.10 HVPS 2. Figure 2. Remove the HVPS.

Removal 4
Remove the
HVPS.
WARNING
customer supply while performing tasks that do not need electricity. Electricity can Disconnect 6
cause death or injury. Moving parts can cause injury. HT connectors.
WARNING
Figure 1 ESD Symbol
1. Remove the rear cover, PL 8.10 Item 1. 3

Remove 2 screws.
2
Disconnect PJ55.
Figure 2 Remove the HVPS

Replacement 3. Figure 4. Use a digital multimeter set to a resistance range. Verify that there is continuity
between the ground pin on PJ21 and the frame ground connection.
1. Reverse the removal procedure to replace the HVPS.
2. Figure 3. Ensure that the white plastic insulator underneath the HVPS is seated correctly
under the locating tabs and over the two metal studs.
Frame ground
connection.
Metal
studs.
(35-55 ppm only)

Ground pin on PJ21.
HVPS PWB locating tabs.

(65-90 ppm only)
Ground pin on PJ21.
Figure 3 HVPS insulator and push clips
Figure 4 Ground connection check

REP 1.11 Molex Mini-Fit Junior Connectors 1. Figure 2. Remove the terminal from the housing, using the Molex, Mini-Fit extractor tool.
Removal
WARNING
2
Withdraw the terminal from
customer supply while performing tasks that do not need electricity. Electricity can the connector body.
WARNING
1
Insert prongs fully down the
sides of the terminal.
Figure 1 ESD Symbol
Figure 2 Removing the terminal

Replacement 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.
1. Select the correct terminal type.
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 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.
Correct
Incorrect
Insulation in crimp
Wire exposed
Figure 5 Inspecting the finished crimp

REP 2.1 User Interface Assembly 2. Remove the user interface assembly, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
CAUTION 2
Ensure that E.S.D. procedures are observed during the removal and installation of the user Disconnect PJ905,
1 PJ130 and PJ81 then
interface assembly. Remove 2 screws.
carefully remove the
1. Open the front door, PL 8.10 Item 10. UI assembly.
Figure 2 UI assembly removal
Replacement
1. The replacement is the reverse of the removal procedure. Refer to GP 6 before the
screws are installed.
2. If prompted, reload the software set, GP 4. The software will automatically upgrade or
downgrade when the machine is switched on, GP 14.

REP 2.2 User Interface Touch Screen PWB
Parts List on PL 2.10 CAUTION
The cable clamps are very fragile and only need to be moved slightly to release the ribbon
Removal
cables.
3. Remove the user interface touch screen clamp assembly, Figure 2.
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 4 3
customer supply while performing tasks that do not need electricity. Electricity can Remove 3 screws Remove 1 screw.
cause death or injury. Moving parts can cause injury. marked A.
Figure 1 ESD Symbol
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the user
interface touch screen PWB.
1. Remove the user interface assembly, REP 2.1
2. Put the user interface assembly on a flat surface.
2
1 Disconnect the ribbon
5 Disconnect the 4 ribbon cables cable from PJ908.
Remove the clamp from the UI touch screen PWB.
assembly. Take care not
to damage the ribbon
cables.
Figure 2 Remove the clamp assembly
4. Carefully release the UI control panel PWB from the screen clamp.
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 before the screws are
installed.

REP 2.3 User Interface Control PWB
The cable clamps are very fragile and only need to be moved slightly to release the ribbon
Removal
cables.
3. Remove the user interface control PWB, Figure 2.
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the user
interface control PWB.
1. Remove the user interface assembly, REP 2.1 3
Remove 6 screws marked
2. Put the user interface assembly on a flat surface. A, then the UI control PWB.
2
Disconnect PJ909.
1
Remove the ribbon
cables.
Figure 2 UI control PWB removal
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 before the screws are
installed.

REP 2.4 User Interface Touch Screen 4. Remove the user interface touch screen, Figure 2.

Removal
WARNING
Figure 1 ESD Symbol
1
CAUTION Raise the end of the touch screen,
then remove the touch screen in
Ensure that E.S.D. procedures are observed during the removal and installation of the user the direction of the arrow.
interface touch screen.
1. Remove the user interface assembly, REP 2.1
2. Put the user interface assembly on a flat surface.
3. Remove the user interface screen clamp assembly, refer to REP 2.2.
Figure 2 UI control PWB removal
Replacement
1. The replacement is the reverse of the removal procedure. Refer to GP 6 before the
screws are installed.
2. When replacing the ribbon cables, the blue flash should face away from the UI control
PWB.

REP 3.1 IOT PWB 2. Check the machine serial number and the machine configuration, GP 15. If necessary, in
diagnostics, on the Service Info screen, select the serial number box and enter the
Parts List on PL 1.10 machine serial number as it appears on the front frame of the machine.
Removal 3. If necessary, perform a NVM restore, GP 5.
4. Enter dC131. Write the developer age value 09-271. Write the TC sensor control voltage
09-069.
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the IOT
PWB.
2. Enter dC131. Record the developer age value 09-271. Record the TC sensor control volt- Figure 2 IOT PWB
age 09-069.
NOTE: If the developer age is unavailable then record HFSI-developer copies.
3. Figure 2, disconnect the PJs from the IOT PWB.
NOTE: 35ppm IOT PWBs do not have PJ33 and PJ64.
4. Remove the IOT PWB (8 screws).

Replacement
If a new IOT PWB has been installed, perform steps 1 and 2.
Install the new IOT PWB. Ensure the IOT PWB ground contact screw is tight on the IOT
PWB, Figure 3. Ensure the contact faces are clean. Ensure the screw is bright plated and
not black. Perform 1 below.
If necessary, reload the software set, GP 4. The machine will automatically upgrade or
downgrade the software when the machine is switched on.
NOTE: After the software reload has been completed, the machine resets and gives a
message Restoring Configuration Settings. Do not switch off the machine or intervene
during this NVM transformation process. IOT PWB ground contact screw
Figure 3 IOT PWB ground contact screw

REP 3.2 Hard Disk Drive 2. Remove the hard disk drive, Figure 2 and Figure 3.
Parts List on PL 3.22 Item 2

Removal
WARNING
Figure 1 ESD Symbol
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the disk
1 2 3 4
drive.
Disconnect PJ999 Disconnect the Remove two Remove the hard disk drive
1. Pull out the single board controller PWB module, PL 3.24 Item 1. data cable screws and mounting bracket.
Figure 2 Hard disk drive removal

REP 3.3 Software Module
Removal
WARNING
1
Remove
four screws
Figure 1 ESD Symbol
NOTE: During this procedure, the most recent Golden NVB Restore file will be required. The
2 file is available from the Office Black & White and ColorQube GSN library, number 10231. Be
Remove the hard disk drive aware that the file on the faulty software module may be corrupt.
from the mounting bracket.
NOTE: If the machine does not behave as expected during this procedure, switch off the
machine, GP 14, then switch on the machine.

2. Pull out the single board controller PWB module, PL 3.24 Item 1.
Figure 3 Hard disk drive removal 3. If installed, remove the embedded fax PWB, PL 20.10 Item 4.
4. If the machine has a finisher installed, remove the finisher then install a finisher bypass
Replacement harness, PL 26.10 Item 7. Refer to the relevant procedure:
1. Replacement is the reverse of the removal procedure. REP 11.11-120 1K LCSS Removal.
2. Perform an Altboot, GP 4. REP 11.13-110 2K LCSS Un-Docking.
REP 11.13-171 HVF/HVF BM Un-Docking.

5. Remove the software module, Figure 2. NOTE: This will load the SCD on to the new software module and upgrade the software if
necessary.
7. If necessary, switch off the machine, GP 14. Install the finisher then the embedded fax.
8. Check that the machine has the correct levels of software.
9. Press the Machine Status button.
2 a. Go to Tools / Device Settings / General / Date and Time.
Remove the software
b. Set Date: Follow the instructions on the screen to set the correct date.
module.
c. Set Time: Select 12 Hour (AM / PM) or 24 Hour clock. Follow the instructions on the
screen to set the correct time.
d. Press Reboot to exit.
10. Perform SCP 6 Final Actions.
1
Release the 2 catches.
Figure 2 Software module removal
Replacement
1. Install the new software module, refer to Figure 2. Press the ends of the module firmly
downwards and the catches will return to their original positions.
NOTE: Some or all of the following messages will appear on the UI:
Ready to scan your job.
Install phase incomplete.
Check settings for Tray 1.
Machine speed configuration error, power down / ignore.
Local interface problem detected. Please switch the machine off / on.
3. Perform GP 15 How to Set the Machine Configuration.

4. Perform an AltBoot, GP 4.
NOTE: The software module is not upgraded when the machine is switched on.
5. Perform an NVM restore, GP 5.
NOTE: The following warning may be displayed; The NVM you are trying to restore has
been generated from a different version set number.
Select Yes to continue.
6. When the restore is complete, close the NVM save and restore tool. The UI should now
display Ready to scan. Switch off, then switch on the machine, GP 14.

REP 3.4 Single Board Controller and Power Distribution
PWBs
Removal
WARNING
Figure 1 ESD Symbol
2. If installed, remove the foreign interface PWB, PL 3.22 Item 4 from the single board con-
troller PWB.
NOTE: Record the location of the memory module(s) before removal.
NOTE: Remove the memory module(s) and the software module by pressing the side
catches downwards. When reinstalling the memory and software modules, press each
end of the modules down firmly and the catches will return to their original position.
3. Remove the memory module, PL 3.24 Item 12 from the single board controller PWB.
4. Remove the software module from the single board controller PWB, REP 3.3.
5. (W/TAG 150 Only). Disconnect the PJs from the scanner daughter PWB, PL 3.24 Item
20. Remove the scanner daughter PWB.
6. Disconnect the PJs from the relevant PWBs:
7. Remove the embedded fax module, riser PWB or single board controller PWB, Figure 2.
NOTE: Only perform steps 1 to 4 of the removal procedure shown in Figure 2 if an
embedded fax module is installed. Later riser PWBs do not have PJ156.

3
Slide the fax clip away from
the embedded fax module.
2
Release the corner of the
embedded fax module from
the fax clip.
1
Loosen 1 screw.
4
Remove 1 screw, then the embedded
fax module from the riser PWB.
5
Remove 4 screws
from the riser PWB.
PJ156
6 10
Remove the riser PWB.
Remove 6 screws then the
See NOTE.
Power Distribution PWB.
7 Memory modules
(W/TAG 150 Only) Remove 1 spacer. PJ203
NOTE: The other 2 spacers are removed after
the SBC PWB has been removed. 9
Remove 12 screws then the
Single Board Controller PWB.
8
Remove 4 screws
Figure 2 Single board controller PWB module
8. (W/TAG 150 Only) Remove the 2 remaining spacers, PL 3.24 Item 19 and nuts from the
single board controller PWB.

Replacement
CAUTION
Ensure the DADH / Power distribution PWB harness from PJ152 at the rear of the SIP tray is
not routed under the single board controller PWB. It must be routed away from the PWB, to the
right.
1. Ensure the first memory module is installed in PJ203 on the single board controller PWB.
Refer to Figure 2.
2. Install the software module, REP 3.3.
3. Connect the power cord and switch on the machine, GP 14.

REP 4.1 Main Drive Module (35-55 ppm) 5. Disconnect PJ93 and the bias lead on the developer module, Figure 1.

Removal
WARNING
WARNING
CAUTION
The 35 ppm Main Drive Modules are not interchangeable with 45-55 or 65-90 ppm Main Drive
Modules. Before you begin this repair procedure, ensure that the new Main Drive Module is the
correct part number for your machine speed and model.
1. Pull out fuser module approximately 100mm, (4 inches), PL 10.8 Item 1.
2. Drop down the short paper path assembly, PL 10.25 Item 1.
3. Remove the xerographic module, PL 9.20 Item 2, and place in a black bag.
4. Remove the left hand cover, PL 8.10 Item 3.
Disconnect PJ93. Disconnect bias lead.
Figure 1 Developer module
6. Remove the two screws securing the developer module, REP 9.2.
7. Pull the developer module out approximately 100mm (4 inches).
10. Remove the ozone filter and duct, PL 9.25 Item 2.

11. Move the power and control assembly to the rear, Figure 2.
CAUTION
Take care when removing PJ1 on the IOT PWB, the pins can be easily damaged.
2 12. Disconnect PJs on the power and control assembly, (35 ppm) Figure 3, (40-55 ppm) Fig-
Disconnect PJ24.
ure 4.
1
Remove screw.
Disconnect PJ2.
Disconnect
PJ25.
Disconnect
PJ18.
3
Move Power supply to
the rear.
Disconnect HT
lead C and G.
Figure 2 Power supply
Disconnect PJ35. Disconnect PJ1.

15. Unclip the wiring harness from the retaining clip and move the harness away from the
drives module, Figure 5.
16. Disconnect PJ57 on the waste toner door switch, Figure 5.
Disconnect
PJ2.
Disconnect
PJ25.
Disconnect
PJ18.
2
Disconnect PJ57.
Disconnect HT
lead C and G.
Disconnect PJ35
and PJ64. Disconnect PJ1.
13. Remove the main frame ground wire, refer to the 01A Ground Distribution RAP.
14. Remove the waste toner full sensor, REP 9.4.
1
Remove harness
from the retaining
clip.
Figure 5 Harness and door switch

17. Prepare to remove the main drive assembly, Figure 6. Replacement
Replacement is the reverse of the removal procedure.
CAUTION
Do not trap the harnesses when the main drives module is located onto the dowels. Take care
when reconnecting PJ1 on the IOT PWB, the pins can easily be damaged.
1. It is important that the short paper path assembly is held in the up position before install-
ing the main drives module, Figure 7.
3
Slide the assembly off the
location dowels. 2 1
Remove 7 silver screws Disconnect PJ147,
marked A. PJ148 and PJ149.
Figure 6 Main drive module
18. Slide the assembly off of the location dowels.
Support the short paper path.
Figure 7 Short paper path assembly

2. If a new main drives module is installed, check that the drive speed is correct. The 35 ppm
modules have black drive gears, Figure 8. The 40-55 ppm modules have white drive
gears, Figure 9.
3. Lubricate the developer module support pin on the main drive module drives plate with
Plastislip grease, (35 ppm) Figure 8, (40-55 ppm) Figure 9.
Fuser drive gear.

Lubricate the support pin.
40-55 ppm white gears.
Lubricate the support pin.

Fuser drive gear.
35 ppm black gears. Figure 9 Main drive module 40-55 ppm
4. Manually rotate the main drive motor to engage the drive between the drives plate and the
inverter transport before tightening up the seven mounting screws, Figure 6.
5. Take care when connecting PJ1 on the IOT PWB, make sure to align the pins correctly.
Figure 8 Main drives module 35 ppm 6. If a new drives module or developer drive gear is installed, reset the developer count to
zero in the HFSI feature screen. Refer to GP 17 High Frequency service Items.

REP 4.2 Main Drive PWB (35-55 ppm) 3. Remove the main drive PWB, Figure 2.

Removal
WARNING
WARNING
2. Remove the flywheel (3 short screws), Figure 1.
3 1
Remove main drive motor Disconnect 7 PJs
PWB 2 marked B.
Remove 6 black
screws marked A.
Figure 2 Main drive PWB
Replacement
1
2 Remove 3 short screws.
Remove the flywheel.
Figure 1 Remove the flywheel

REP 4.3 Main Drive Belt, Drive Gears and Idlers (35-55
ppm)
Removal
WARNING
WARNING
1. Remove the main drive module, REP 4.1.
2. To remove the main drive belt, (35 ppm), refer to Figure 1.
To remove the main drive belt, (40-55 ppm), refer to Figure 2.
3 2
Remove the drive belt. Slip the drive belt over the 1
pulley on the belt tensioner. Remove the circlip and
intermediate drive gear.
Figure 2 Main drive belt 40-55 ppm
3 2 1
Remove the drive belt. Slip the drive belt over Remove the circlip and
the pulley on the belt intermediate drive gear.
tensioner.
Figure 1 Main drive belt 35 ppm

3. Refer to Figure 3, remove the following: REP 4.4 Photoreceptor Drive Gear
Output paper path drive gear.
Parts List on (35-55 ppm) PL 4.15, (65-90 ppm) PL 4.10.
Fuser drive gear.
Registration transport drive gear.
Removal
Developer drive gear.
Idler rolls WARNING
WARNING
1. Remove rear cover, PL 8.10 Item 1.
Remove the
circlip, paper
path drive gear
Remove the circlip and spring.
and the developer
drive gear.
Remove the circlip and Remove the circlip and

the registration transport Remove the the fuser drive gear.
drive gear. idler rolls.
Figure 3 Remove drive gears and idlers
Replacement
CAUTION
The spring loaded belt tensioner, Figure 1 is a floating type and should not be locked down.
If a new developer drive gear is installed, reset the developer count to zero in the HFSI feature
screen. Refer to GP 17 High Frequency service Items.

REP 4.5 Main Drive Module (65-90 ppm)
CAUTION Parts List on PL 4.10
When the drive gear is removed from the shaft, the dowel pin may drop onto the IOT PWB or
Removal
LVPS.
2. Remove the photoreceptor drive gear, Figure 1.
WARNING
WARNING
CAUTION
The 35 ppm, 45-55 ppm and 65-90 ppm main drive modules are not interchangeable. Before
this procedure is begun, ensure that the new main drive module is the correct part number for
the machine.
1. Pull out fuser module approximately 100mm, (4 inches), PL 10.10 Item 1.
2. Drop down short paper path assembly, PL 10.25 Item 1.
3. Remove the xerographic module, PL 9.20 Item 2, and place in a black bag.
4. Remove left hand cover, PL 8.10 Item 3.
1 2 3
Remove three short Remove the screw Remove the drive gear
screws and the flywheel. and collar. and the dowel pin.
Figure 1 Photoreceptor drive gear
Replacement
Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.
NOTE: Turn the drive shaft, so that the dowel pin is horizontal then locate the drive gear onto
the drive shaft.

5. Disconnect PJ93 and the bias lead on the developer module, Figure 1. 11. Move the power and control assembly to the rear, Figure 2.
2
Disconnect PJ24.
1
Remove the
screw.
3
Move Power supply to
Disconnect PJ93. Disconnect bias lead. the rear.
Figure 1 Developer module Figure 2 Power supply
6. Remove the two screws securing the developer module, REP 9.2.
7. Pull the developer module out approximately 100mm (4 inches).
10. Remove the ozone filter and duct, PL 9.25 Item 2.

15. Unclip the wiring harness from the retaining clip and move the harness away from the
drives module, Figure 4.
CAUTION
16. Disconnect PJ57 on the waste toner door switch, Figure 4.
Take care when removing PJ1 on the IOT PWB, the pins can be easily damaged.
12. Disconnect PJs on the power and control assembly, Figure 3.
Disconnect
PJ2.
Disconnect
PJ25.
2
Disconnect Disconnect PJ57.
PJ18.
Disconnect HT
lead C and G.
Disconnect PJ35
and PJ64.
Disconnect PJ1.
13. Remove the main frame ground wire, refer to the 01A Ground Distribution RAP. 1
14. Remove the waste toner full sensor, REP 9.4. Remove harness
from the retaining
clip.
Figure 4 Harness and door switch

17. Prepare to remove the main drive assembly, Figure 5.
CAUTION
Do not trap the harnesses when the main drives module is located onto the dowels. Take care
when reconnecting PJ1 on the IOT PWB, the pins can easily be damaged.
1. It is important that the short paper path assembly is held in the up position before install-
ing the main drives module, Figure 6.
3
Slide the assembly off the
location dowels. 2 1
Remove 7 silver screws Disconnect PJ147,
marked A. PJ148 and PJ149.
Figure 5 Main drive module
18. Slide the assembly off the location dowels.

Replacement Support the short paper path.
Figure 6 Short paper path assembly

REP 4.6 Main Drive PWB (65-90 ppm)
The belt tensioners are of the floating type, and are spring loaded. They should not be locked
Removal
down.
2. Lubricate the developer module support pin on the main drive module drives plate with
Plastislip grease, Figure 7. WARNING
WARNING
1. Remove the main drive module, REP 4.5.
2. Remove the PJs from the main drive PWB, Figure 1.
2
Disconnect PJ142.
1
Disconnect PJ146,
Lubricate the support pin. PJ154 and PJ151.
Figure 7 Main drives module
3. Manually rotate the main drive motor to engage the drive between the drives plate and the
inverter transport before tightening the seven mounting screws, Figure 5.
4. Rotate the jam clearance knob 4c and ensure that the registration shaft turns freely.
5. Take care when connecting PJ1 on the IOT PWB, make sure to align the pins correctly.
6. If a new drives module or developer drive gear is installed, reset the developer count to
zero in the HFSI feature screen. Refer to GP 17 High Frequency service Items.
Figure 1 Disconnect the PJs

3. Remove the main drive PWB, Figure 2. 4. Remove the drives support bracket on the main drive module, Figure 3. Then remove the
drive belt and the main drive PWB,
Remove 4 screws.
Figure 2 Main drive PWB

3
Remove the main
drive PWB.
1
2 Remove 6 screws.
Remove the support bracket.
Figure 3 Drives support bracket

Replacement 2. Ensure that the support bracket on the main drive module is located correctly with the
drive shafts and the collar, Figure 5. Then secure the support bracket.
CAUTION
down.
1. Ensure that the drives bracket is located in the tabs on the drives plate, Figure 4. Then
secure the main drive PWB to the drives plate.
Position the collar and 3 shafts correctly in the bracket
Figure 5 Main drive module support bracket
3. Before installing the main drive module turn the drive gears by hand to position the drive
belts correctly on the drive gears.
1
Ensure that the tabs are located in the bracket.
Figure 4 Main drive PWB location

REP 4.7 Main Drive Belts, Drive Gears and Idlers (65-90 3. Refer to Figure 2, to remove the following:
Main drive belt 2
ppm)
Fuser drive gear
Parts List on PL 4.12 Output paper path drive gear
Removal Intermediate drive gear
Idler
WARNING
Remove the circlip,
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the output paper path
customer supply while performing tasks that do not need electricity. Electricity can drive gear and the
cause death or injury. Moving parts can cause injury. spring.
WARNING
1. Remove the main drive module, REP 4.5. 1
2. Remove the drives support bracket, Figure 1. Remove circlip
and intermediate
drive gear.
Remove the idler. Remove the circlip and

2 fuser drive gear / pulley.
Remove drive belt 2.
Figure 2 Remove drive belt 2
2 1
Remove the support Remove six screws.
bracket.
Figure 1 Drives support bracket

4. Refer to Figure 3, remove the following: Replacement
Main drive belt 1 Replacement is the reverse of the removal procedure.
Developer drive gear
Registration drive gear
Idlers CAUTION
Remove the circlip and the down.
developer drive gear / pulley.
1. Ensure that the support bracket on the main drive module is located correctly on the drive
shafts and the collar, Figure 4.
Remove the circlip and

registration drive pulley.
Remove the idlers.
1
Remove the drive belt 1.
Figure 3 Remove drive belt 1
Position the collar and 3 shafts correctly in the bracket.
Figure 4 Main drive module support bracket
2. Turn the drive gears by hand to position the drive belts correctly on the drive gears and
tensioner rolls.
3. If a new developer drive gear is installed, reset the developer count to zero in the HFSI
feature screen. Refer to GP 17 High Frequency service Items.

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
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
CAUTION
Be careful when the self tapping screw is installed into a plastic component, refer to GP 6.
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
Removal CAUTION
The replacement is the reverse of the removal procedure. Make sure that the 2 springs on the
WARNING idler roll are in the correct position, Figure 2. Then install the top cover.
Takeaway idler roll
1. Open the DADH top cover. 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.
3 2
Remove the top Remove the screw and
access cover the bracket.
assembly.
CVT idler roll torsion

spring
1
Disconnect PJ191 and
Figure 2 Torsion springs
the ground harness.
Figure 1 Top access cover assembly

REP 5.3 Feed Assembly NOTE: 40-90 ppm machines have an in-line connector between PJ184 and the document
present sensor. Disconnect the in-line connector before removing the feed assembly.
Parts List on (35 ppm) PL 5.15, (40-90 ppm) PL 5.17
Removal
WARNING
1
Disengage the hinges.
WARNING
2
Remove 4 self tapping
1. Open the DADH top cover. screws marked A.
2. Remove the DADH rear cover, PL 5.10 Item 1.
3. Remove the feed roll assembly, REP 5.14.
4. Remove the feed assembly, Figure 1.
6
Remove the feed
assembly.
3 In-line connector. 4 5
Disconnect PJ183, See NOTE. Release the Disconnect the ground
PJ184 and PJ187. harness. harness.
Figure 1 Feed assembly
Replacement
CAUTION
The replacement is the reverse of the removal procedure.

REP 5.4 Input Tray Assembly
Parts List on PL 5.35 8 7
Remove the input 6
Removal Remove 3 self tapping Loosen the screw.
tray assembly. screws marked A.
WARNING
WARNING
1. Remove the DADH, REP 5.19.
2. Remove the feed assembly, REP 5.3.
NOTE: To release the tension of the drive belts, refer to ADJ 5.1.
3. Remove the input tray assembly, Figure 1.
5 1
Disconnect PJ190. Release the tension on the
CVT motor drive belt.
2
Disconnect the ground harness.
4 3
Release the Release the tension and disengage
harness. the drive belt.
Figure 1 Input tray assembly
Replacement
CAUTION
1. The replacement is the reverse of the removal procedure.
2. Perform the feed motor and the CVT motor, belt tension adjustment, ADJ 5.1.

REP 5.5 Baffle Assembly 6. Prepare to remove the baffle assembly, Figure 1.

Removal
WARNING
2
Release the harness.
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. 1
Disconnect the link arm.
1. Remove the DADH, REP 5.19. 3
2. Remove the top access cover assembly, REP 5.2. Disconnect PJ189.
4. Remove the input tray assembly, REP 5.4.
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. 9. Remove the baffle assembly, Figure 3.
8. Slide the baffle assembly lower cover, Figure 2.
DADH frame.
2
Disengage the hinge
pin.
3
Slide the tab through
slot in DADH frame.
4
3 Remove the baffle
Disengage the lugs in the lower assembly.
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

Replacement REP 5.6 Takeaway Roll Assembly
CAUTION Removal
The replacement is the reverse of the removal procedure. Make sure that the torsion springs
and harness are in the correct position, Figure 4. 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
White spacers. customer supply while performing tasks that do not need electricity. Electricity can
Black 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
4 Release the duplex sole-
Disconnect the ground harness. noid from the clips.
2
3 1 Release the harness.
Remove the drive assembly. Release the tension and
disengage the drive belts.
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.
CAUTION
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
Removal CAUTION
Be careful when the self tapping screw is installed into plastic component, refer to GP 6
The replacement is the reverse of the removal procedure. Make sure the spring plate and idler
WARNING roll torsion springs are in the correct position. Also make sure that the CVT sensor actuator is
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the in the correct position below the CVT roll and the idler shaft. Refer to Figure 1 and Figure 2.
customer supply while performing tasks that do not need electricity. Electricity can Then install the top cover assembly,
Takeaway idler roll

WARNING torsion spring
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 sensor.
CVT idler roll torsion

spring
Spring plate.
CVT idler roll Figure 2 Torsion springs

shaft.
Figure 1 Takeaway and CVT sensors

REP 5.9 Length Detect Sensors 3. Remove the length detect sensors, Figure 1.

Removal
1
Remove the ground harness
WARNING and bracket.
Ground harness.
See CAUTION.
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. Remove the relevant cover:
(35 ppm) Input tray assembly lower cover, PL 5.35 Item 21.
(40-90 ppm) Lower cover (right), PL 5.35 Item 9 and Lower cover (left), PL 5.35 Item 20.
Length sensor 2.
2
Length sensor 1. Disconnect the correct PJ. Remove
the correct sensor.
Figure 1 Length detect sensors
Replacement
CAUTION

REP 5.10 Registration Sensor Replacement
Removal CAUTION
The replacement is the reverse of the removal procedure. Make sure that the torsion spring is
WARNING installed correctly, Figure 2.
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.
1
Remove 2 screws. 2 3
Carefully release the Remove the pre-scan
torsion spring. idler roll. Figure 2 Torsion spring
Figure 1 Registration sensor

REP 5.11 Exit Sensor
Be careful to prevent damage to the document pad when the document pad is removed from
Removal
the baffle assembly.
2. Prepare to remove the exit sensor, Figure 1.
WARNING
1. Raise the DADH.
3
Disengage the lugs in the lower
cover.
4 2
Remove the lower cover. Remove 2 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, GP 14. Disconnect the power cord from the
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).
Figure 2 Exit sensor
Replacement
CAUTION
Take care when installing self tapping screw into plastic components, refer to GP 6.

Replacement REP 5.13 Exit Roll Assembly
CAUTION Removal
1. The replacement is the reverse of the removal procedure. Make sure the ground tags are
attached when the counterbalances are installed Figure 1. WARNING
2. Perform the steps that follow: Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
DADH height adjustment, ADJ 5.2. customer supply while performing tasks that do not need electricity. Electricity can
DADH registration adjustment, ADJ 5.5. cause death or injury. Moving parts can cause injury.
3. If a new right counterbalance has been installed, perform the DADH skew adjustment, 1. Remove the feed assembly, REP 5.3.
ADJ 5.3. 2. Remove the input tray assembly, REP 5.4.
CAUTION
(40-90 ppm) Lower cover (right), PL 5.35 Item 9 and Lower cover (left), PL 5.35 Item
20.
The right counterbalance

ground tag.
The left counterbalance

ground tag.
Figure 1 Ground tags

4. Remove the exit roll assembly, Figure 1. REP 5.14 Feed Roll Assembly
Parts List on (35 ppm) PL 5.15, (40-90 ppm) PL 5.17
Removal
Black spacers.
WARNING
E-clip.
Ground harness.
See CAUTION.
1
Remove the exit roll
assembly.
Figure 1 Exit roll assembly
Replacement
CAUTION
Take care when installing self tapping screws into plastic components, refer to GP 6.
The replacement is the reverse of the removal procedure. Make sure the spacers and E-clips
are installed correctly, refer to Figure 1.

2. Remove the DADH feed roll assembly, Figure 1. Replacement
1. The replacement is the reverse of the removal procedure. When the feed rolls are
installed, make sure the lowest roll, (retard roll), is positioned as shown in Figure 2.
2. If a new feed roll assembly is installed, select dC131 chain 5, location 05-001 and reset
the copy count to zero.
3. If a new feed roll assembly is installed, reset the DADH feed count to zero in the HFSI fea-
ture screen. Refer to GP 17 High Frequency Service Items.
1
Completely raise the feed
roll assembly (2 clicks).
2
Raise the feed roll assembly Key Retard roll
cover.
3
Remove the feed roll assem-
bly.
Figure 2 Retard roll position
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

REP 5.15 Duplex Gate, CVT Roll and CVT Motor, Drive Belt
When the top access cover assembly, feed assembly, input tray assembly and CVT roll are
Removal
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-
WARNING screws.
6. Disengage the back CVT roll bearing, Figure 2.
3. Remove the DADF drive assembly, refer to REP 5.7.
4. Remove the duplex gate, Figure 1.
1 1
Compress the two ends of
Lift out the duplex
the bearing together.
gate.
2
Push the bearing to disengage.
Figure 2 Bearing
Figure 1 Duplex gate

7. Release the front CVT roll bearing, PL 5.25 Item 4. Remove the CVT roll and CVT motor, Replacement
drive belt, Figure 3.
1. The replacement is the reverse of the removal procedure. Make sure the white washer is
installed correctly, Figure 4.
2. Perform the DADH CVT motor adjustment, refer to ADJ 5.1.
CVT roll.
White washer.
1
Remove the CVT roll.
2
Remove the CVT motor drive
belt.
Figure 3 CVT roll
Figure 4 Replacement

REP 5.16 Document Width Sensor
1
Removal Release the harness.
WARNING
customer supply while performing tasks that do not need electricity. Electricity can Disconnect PJ193.
CAUTION Arm
3
Remove the document width sensor.
4. Remove the document width sensor, Figure 1.
Ground harness.
Figure 1 Document width sensor
Replacement
CAUTION
1. The replacement is the reverse of the removal procedure. Make sure the document width
sensor arm is attached correctly, refer to Figure 1.

REP 5.17 Input Tray Static Eliminator 3. Remove the input tray static eliminators, Figure 1.

Removal Ground harness.
WARNING
CAUTION
1
Remove the correct
static eliminator.
Figure 1 Static eliminators
Replacement
CAUTION

REP 5.18 Exit Roll Idler 4. Remove the exit roll idlers, Figure 2.

3
Removal Remove the 2 bearings.
WARNING
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.
2
Lift out the exit
roll idlers.
1
Carefully remove the torsion
spring and the document finger.
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
CAUTION Removal
The replacement is the reverse of the removal procedure. Make sure that the torsion spring
and document finger are installed correctly, refer to Figure 3. 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.
WARNING
Torsion spring. 1. Disconnect the communication/power cable, PL 5.10 Item 6 and the DADH ground har-
ness, PL 5.10 Item 11.
2. Raise the DADH.
Document finger.
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 5.
3. Remove the old mylar guide strip, PL 5.30 Item 14.
4. Use cleaning fluid to remove any contamination from the baffle assembly.
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
2 of the baffle assembly.
Remove the DADH.
2
Position the centre of the
mylar guide over the centre
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. Select dC131 chain 5, location 05-001. Reset the copy count to zero.
c. Reset the DADH feed count to zero in the HFSI feature screen. Refer to GP 17 High
Frequency Service Items.
d. DADH height adjustment, ADJ 5.2.
e. DADH registration adjustment, ADJ 5.5.
f. DADH skew adjustment, ADJ 5.3. Figure 1 Mylar guide

REP 6.1 ROS
Parts List on PL 6.10 Front Rear
Removal
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
can cause death or injury. Moving parts can cause injury.
WARNING
Slide the ROS to the rear to align
1 cut out. Lift the rear of the ROS.
Remove screw. See Caution.
WARNING
Avoid exposure to laser beam. Invisible laser radiation.
Figure 1 Laser Beam Symbol
3
Slide the ROS to the rear to
clear the front dowels, then lift
up and out. 4
Disconnect the
harnesses at the
Figure 2 ESD Symbol ROS, then
remove the ROS.
1. Remove the scanner, REP 14.1
CAUTION
Take care not to damage the wiring at the rear of the ROS.
2. Figure 3, remove the ROS.
Figure 3 ROS removal

Replacement
Reverse the removal procedure to replace the ROS.
CAUTION
Ensure that the harnesses are not damaged when the ROS is installed.
1. If installing a new ROS, ensure that the ROS is the correct one for the machine speed.
Check that the part number is correct, PL 6.10 Item 4. The part number and the machine
speed are labelled on the underside of the ROS, as shown in Figure 4.
2. Figure 4. Ensure that the harness is routed correctly.
Label (Underneath).
Harness routing.
Figure 4 ROS harness routing
3. Go to dC604 Registration Setup, check/adjust the registration.

4. Perform ADJ 9.2 Image Quality Adjustment Routine.

REP 7.1 Tray 1 and Tray 2 Removal NOTE: The removal procedure for tray 1 and tray 2 is the same.

Removal
WARNING
WARNING Tray stop Tray stop

CAUTION
Do not stack the trays one on top of the other tray. The top tray can damage the bottom tray,
which can cause misfeeds or paper jams.
1. Remove tray 1 or tray 2, Figure 1.
1 3
Pull out the tray.
Release the right
side of the tray,
then the left.
2
Lift the front of tray.
Figure 1 Tray 1 and tray 2 removal
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.

REP 7.2 Tray 3 and Tray 4 Removal (W/O TAG 151) NOTE: If tray 4 needs to be removed then remove tray 3 first.
Parts List on PL 7.15 NOTE: If only tray 3 is to be removed then do not remove the left hand stop.
Removal 4. Remove the stops, Figure 2.
WARNING
WARNING
1. Remove the paper from the two trays.
2. Remove the right hand cover, PL 7.25 Item 7.
3. Remove the tray 3 and tray 4 front covers, Figure 1.
1
3 2 Remove the right
Remove the left Remove the stop (tray 3).
stop (tray 4). centre stop.
1
Remove 3 screws, then Figure 2 Rail stops removal
the tray 3 front cover.
5. Lift and pull to remove the tray complete with the guide rails.
2
Remove 2 screws, then the tray 4 front cover.
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 when refitting the
Figure 1 Tray 3 and tray 4 front covers removal
screws to secure tray 3 and tray 4 front covers.
NOTE: When installing tray 3 or tray 4 ensure that the tray rails are located correctly in the
base of the HCF, Figure 3.

REP 7.3 Tray 3 and Tray 4 Elevator Motor (W/O TAG 151)
Tray 4 rail location. Removal
WARNING
WARNING
1. Pull out tray 3 and tray 4.
2. Remove the rear cover from the HCF, PL 7.25 Item 1.
3. Disconnect PJ395 or PJ397 elevator motor harness from the HCF control PWB,
4. Disconnect the harness from the low paper sensor on the elevator motor.
Tray 3 rail location.
Figure 3 Location of the tray rails

5. Remove the tray 3 or tray 4 elevator motor, Figure 1. REP 7.4 Tray 3 and Tray 4 Elevator Cables (W/O TAG 151)
HCF control PWB.
Removal
WARNING
Tray 4 elevator
motor. WARNING
NOTE: The elevator drives at the front and at the rear are similar for both trays.
1. Remove tray 3 (W/O TAG 151) or tray 4 (W/O TAG 151), REP 7.2.
2. Release the cables from the appropriate front drive pulley, Figure 1.
2
Tray 3 elevator motor. 2 Remove the short cable
Remove the from the drive pulley.
elevator
motor.
1
Remove the 3
screw. Remove the long cable
from the drive pulley.
Low paper
sensor.
Figure 1 Elevator motor removal 1

Remove the E-clip.
Replacement
Figure 1 Front elevator cables release

3. Remove the appropriate front elevator cables, Figure 2. 4. Remove the appropriate rear elevator cable:
NOTE: The short cable is located over the outer pulley and the long cable is located over Tray 3, Figure 3
the inner pulley. Tray 4, Figure 4
2
1 Tray 4 pulley Tray 3 Remove the metal
Remove the 2 pulley carriers carriers. pulley plate if fitted. 3
from the appropriate tray carriers. Remove the
pulley carrier.
5
Remove the cable
6
Pass cable through
the base of the tray.
Tray 3
drive 4
Tray 4 2 shaft.
drive shaft. Remove the drive 1
Remove the cables through
dog and end cap. Remove the E-clip.
the base of the tray.
Figure 3 Tray 3 rear cable removal

Figure 2 Front elevator cables removal

REP 7.5 Bypass Tray and Left Hand Door Assembly
Metal plate Parts List on PL 7.30
Removal
5
Remove the 3
pulley carriers. WARNING
4
Remove the metal
plate if fitted. WARNING
2. Remove the waste toner bottle and door, REP 9.1.
3
Remove the cable 3. Prepare to remove the bypass tray, Figure 1.
2
6 Remove the drive dog
Pass the cable through 1 and end cap. 1
the base of the tray. Remove the E-clip. Disconnect
PJ636 and
PJ36.
Replacement
Tray 3 front cables.

1. Thread the short cable over the inner groove on the pulley.
2. Thread the long cable over the outer groove on the pulley.
Tray 3 rear cable.
Thread the medium length cable over the inner groove on the pulley. Figure 1 Preparation
1. Thread the long cable over the inner groove on the pulley. 4. Remove upper left hand cover, PL 8.10 Item 3.
2. Tread the short cable over the outer groove on the pulley. 5. Pull out the extender tray on the bypass tray.
Tray 4 rear cable.
Thread the medium length cable over the outer groove on the pulleys.

6. Remove the bypass tray and left hand door assembly, Figure 2. REP 7.6 Tray 1 and Tray 2 Paper Guides
NOTE: Check that the point of the hinge pin has not damaged the wiring harness. Parts List on PL 7.10
Removal
WARNING
1 WARNING
Remove the Take care during this procedure. Sharp edges may be present that can cause injury.
hinge pin.
NOTE: The removal procedure is the same for tray 1 and for tray 2.
1. Remove the paper then remove the tray, REP 7.1.
2. Remove the paper width guide and paper lift plate, Figure 1.
2
Remove the left
door and bypass 4
tray. Remove the
paper lift plate
Wiring harness.
3
Lift and remove
Figure 2 Door and tray removal the paper guide.
Replacement
2
1 Press the green tab and move the side
CAUTION Raise the paper lift plate. guide towards the centre of the tray.
When replacing the hinge pin, do not damage the wire harness.
Figure 1 Paper width guide removal
2. Connect PJ636 and PJ36 before installing the bypass tray and the left door assembly,
refer to Figure 1.
3. Make sure that the bypass tray and left door assembly is correctly aligned before inserting
the hinge pin.
4. Perform the dC604 Registration Setup.

3. Remove the paper length guide, Figure 2. REP 7.7 Tray 3 and Tray 4 Stack Height Sensor (W/O TAG
151)
2
Remove the Parts List on PL 8.30, PL 8.31
length guide. Removal
WARNING
1 Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
Lift the tab using a customer supply while performing tasks that do not need electricity. Electricity can
small screwdriver cause death or injury. Moving parts can cause injury.
WARNING
1. Remove the required paper feed assembly:
Tray 3 paper feed assembly (W/O TAG 151), REP 8.2.
Tray 4 paper feed assembly (W/O TAG 151), REP 8.3.
Figure 2 Paper length guide removal
Replacement
2. Locate the paper length guide correctly in the base of the tray, Figure 3.
1
Locate the ribbon tag
in the paper guide.
3
2 Press down on the two
Position the paper guide tabs and slide the paper
over the cut outs. guide into position.
Figure 3 Paper length guide location

2. Disconnect and remove the stack height sensor, Figure 1. REP 7.8 Tray 3 and Tray 4 Stack Limiter (W/O TAG 151)
Removal
WARNING
WARNING
1. Remove tray 1 and tray 2, REP 7.1.
2. Remove tray 3 (W/O TAG 151), REP 7.2.
3. Perform the following:
Remove the tray 3 stack limiter and bracket, Figure 1.
Remove the tray 4 stack limiter and bracket, Figure 2.
Stack limit switch.

1
Use a small screwdriver to press down
the tab to release the bracket.
1
Unclip and remove the
stack height sensor.
Figure 1 Stack height sensor removal
Replacement 2
The replacement is the reverse of the removal procedure. 3 Slide the bracket to the front
Remove the stack limiter and remove.
from the bracket.
Figure 1 Tray 3 Limiter and bracket

REP 7.9 Tray 3 and Tray 4 Home Switch (W/O TAG 151)
1 Parts List on PL 7.20
Use a small screwdriver to press down Removal
the tab to release the bracket.
WARNING
WARNING
The removal procedure is the same for tray 3 and tray 4.
1. Pull out tray 3 or tray 4.

3. Remove the tray home switch and holder, Figure 1.
3 2
Slide the bracket to the front
Remove the stack limiter
and remove.
from the bracket.
Figure 2 Tray 4 stack limiter and bracket
Replacement
1
Remove the
screw.
2
Lift and remove the holder.
Figure 1 Switch and holder removal

4. Remove the tray home switch, Figure 2. REP 7.10 HCF Control PWB (W/O TAG 151)
3
Disconnect the harness. Removal
WARNING
1
Release the harness.
2
Press the tabs to release the switch.
Figure 1 ESD Symbol
Figure 2 Switch removal
CAUTION
Replacement
Ensure that E.S.D. procedures are observed during the removal and installation of the HCF
Control PWB.
Ensure that the tabs on the switch holder locate correctly in the holes in the base, Figure 3. 1. Remove the rear cover, PL 7.25 Item 1.
The tab on the switch holder

must locate in the hole in the
base of the machine
Figure 3 Switch holder location

2. Remove the HCF control PWB, Figure 2. REP 7.11 Tray 3 and Tray 4 Elevator Damper and Gears (W/
O TAG 151)
Removal
WARNING
WARNING
1. Remove tray 3 (W/O TAG 151) or tray 4 (W/O TAG 151), REP 7.2.
2. Remove the damper from tray 3, Figure 1.
3
Press the clip
to release the
2 PWB.
1 Remove the
Disconnect all PJ screw.
connectors.
Figure 2 HCF control PWB removal
Replacement
1. Replacement is the reverse of the removal procedure.
2. After completing the replacement procedure, perform dC604 Registration Setup.
2 1
Lift and remove the damper. Remove the screw.
Figure 1 Tray 3 damper removal

3. Remove the damper from tray 4, Figure 2. 4. To remove the drive gears, Figure 3.
1
Pinch the two sections of the
shaft together and pull off the
gears.
Figure 3 Gears removal
Replacement
2 1
Lift and remove the damper. 1. The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting
Remove the screw. the screws.
2. Ensure the gears are correctly aligned, Figure 4.

1
Align the two gears as shown
and then push the gears onto
the shaft.
Figure 4 Gears installation

REP 7.12 Tray 1 and Tray 2 Paper Size Cams 4. Remove the cams for tray 1 or tray 2, Figure 2.
Parts List on PL 7.10 NOTE: The cams are the same for tray 1 and for tray 2. The small cam is for the tray
home position and the larger cams are for the paper size position.
Removal
WARNING
Home cam.
1
WARNING Remove the necessary
Take care during this procedure. Sharp edges may be present that can cause injury. cams.
1. Remove the output device.
3. Remove tray 1 or tray 2 leaf spring, Figure 1. 4 paper size cams.
Figure 2 Cams removal
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.
Leaf spring for tray 2. Leaf spring for tray 1.
1
Remove the screw and leaf spring for the relevant tray.
Figure 1 Leaf springs removal

REP 7.13 Tray 5 Empty Sensor 3. Remove tray 5 empty sensor, Figure 2.

Removal
WARNING
WARNING
1. Remove the top cover, PL 7.60 Item 10.
2. Prepare to remove the tray 5 empty sensor, Figure 1.
1 2
Disconnect the harness. Press the tabs to release the sensor.
Figure 2 Tray 5 empty sensor removal
Replacement
1. The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting
the screws.
2. Make sure that the spring on the paper feed assembly is in the correct position, Figure 3.
3
1 2 Lift the upper 1
Disconnect the harness. Remove eight screws marked A. plate. Place the spring under the
post.
Figure 3 Feed assembly spring

3. Make sure that the spring is positioned on top of the nip roll shaft when the upper plate is REP 7.14 Tray 5 Stack Height Sensor
installed, Figure 4.
Removal
WARNING
Spring position. WARNING

Figure 4 Nip roll spring 1. Remove the top cover, PL 7.60 Item 10.
2. Prepare to remove the tray 5 stack height sensor, Figure 1.
4. Check that the correct screw is used to attach the upper plate.
5. Check the position of the chute spring, Figure 5.
1
Disconnect the harness.
1
Position the spring on the top of the chute upper insert.
Figure 5 Upper insert chute spring
6. Check that the harness routing is correct, refer to Figure 1.

3. Remove tray 5 stack height sensor, Figure 2. REP 7.15 Tray 5 Down Sensor
Removal
WARNING
WARNING
2. Remove the tray 5 down sensor, Figure 1.
1
Press the tabs to release the sensor.
Figure 2 Sensor removal
Replacement
the screws.
2. Check that the harness routing is correct, refer to Figure 1.
3. Perform ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield.
2 1
Remove the sensor. Disconnect the
harness.
Replacement
screws.

REP 7.16 Tray 5 Elevator Motor Assembly NOTE: The tray 5 paper tray must be supported before the elevator motor assembly is
removed.
Removal
1
Disconnect:
WARNING PJ518 on the
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the encoder,
In-line ground
connectors
cause death or injury. Moving parts can cause injury. and
PJ530.
WARNING
1. Remove the paper from the tray.
3. Remove the tray 5 elevator motor assembly, Figure 1.
5 4 3 2
Slide the motor off Remove the Release the cable Disconnect the motor
the shaft. KL clip. tie on the motor. connections.
Figure 1 Motor assembly removal
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 Encoder sensor removal

Replacement 7. Exercise the elevator motor with one sheet of paper in the tray. Observe that the harness
tracks properly between the mylar guide and the rear channel. Figure 4.
1. To help with the installing of a new elevator motor, support the paper tray on two reams of
paper.
2. Make sure that the encoder sensor is positioned on the elevator motor assembly, Figure 2. Mylar guide.
the screws.
4. Check that the harness is routed in the channel on the plastic bracket, Figure 3.
Rear channel.
Check that the wires in the

harness 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.
The ramp slides
against the mylar, to
keep the harness in
the correct position.
Figure 4 Location of the harness
8. Check the registration, refer to dC604.

REP 7.17 Tray 5 Upper Limit Switch REP 7.18 Tray 5 Down Limit Switch
Parts List on PL 8.40, PL 7.68 Parts List on PL 7.70
Removal Removal
WARNING WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 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 customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. cause death or injury. Moving parts can cause injury.
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.
1. Remove the rear cover, PL 7.60 Item 9. 1. The tray needs to be positioned in the middle of its travel. If the tray must be repositioned,
2. Remove the tray 5 upper limit switch, Figure 1. refer to REP 7.16. Disengage the elevator motor from the tray and move the tray to the
required position. Re-engage the elevator motor to hold the tray.
2. Remove the tray lift top cover, Figure 1.
2
Remove two
screws and
remove the
switch.
1
Disconnect the 1
harness. Remove
three screws.
Figure 1 Upper limit switch removal 2

Remove the tray lift top cover.
Replacement Figure 1 Paper tray release

3. Remove the tray 5 down limit switch, Figure 2. REP 7.19 Un-docking and Docking Tray 5
Removal
WARNING
WARNING
WARNING
Take care not to topple Tray 5.
1 2 3 Tray 5 is unstable when undocked from the machine.
Disconnect the harness. Remove two screws. Remove the switch
Do not show the customer how to undock Tray 5.
1. Remove the paper from the tray.
Figure 2 Remove tray 5 down limit switch
Replacement
the screws.
2. Check that the wires are not trapped when refitting the tray lift top cover.

2. Engage the transit lock, Figure 1. 4. At the rear of the machine release the docking latch and pull the tray 5 module away from
the machine, Figure 2.
1 3
Open the door Close the door
1
2 Press the lever to release
Lift the lever and move it to the front. the latch.
Figure 1 Transit lock engage

Figure 2 Tray 5 un-docking
3. Pull the tray 5 module away from the machine until the transit lock engages.

Replacement 3. Release the transit lock and push the tray 5 module into the working position against the
machine, Figure 4.
1. The docking is the reverse of the un-docking procedure.
2. Dock and lock the tray 5 module to the machine, Figure 3.
1 3
Open the door Close the door
1 2
Align the tray 5 module with the docking plate on the Lift the latch and move it to the rear to
machine. Push the module to dock and lock the tray 5 release the lock.
module to the machine.
Figure 4 Transit lock release
Figure 3 Tray 5 module docking
4. Perform ADJ 7.3 Machine to Tray 5 Alignment.

REP 7.20 Tray 1 and Tray 2 Lift Gear Assembly NOTE: Make a note of the position of the two screws on the gear assembly, for replace-
ment purposes.
3. Raise the paper lift plate. Raise the paper tray lift arm to its fullest extent and slide it
Removal towards the rear of the tray. This releases the pin from the quadrant as shown in Figure 1.
WARNING
WARNING
1. Remove the tray, REP 7.1.
2. Remove the paper width guide, REP 7.6.
1
Slide the raised arm to
the rear of the tray.
4
2 3 Remove the gear assembly,
Remove Remove the quadrant and the bush
the pin. 2 screws. behind the quadrant.
Quadrant
Figure 1 Lift gear removal
Replacement
The existing gears are snap fitted to the shafts and can be removed to allow the new gears to
be pushed on.
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.b

REP 7.21 Tray 5 Elevator Rack Assembly 4. Remove the top cover PL 7.60 Item 10, front cover PL 7.60 Item 8 and rear cover PL 7.60
Item 9.
Parts List on PL 7.68 5. Remove the tray 5 elevator motor assembly, REP 7.16.
Removal 6. Remove the frame top brace, PL 7.68 Item 3.
7. Remove the crash bar, PL 7.68 Item 2.
8. Disconnect the tray 5 transport motor, PL 8.40 Item 2.
WARNING
9. Disconnect the feed motor, PL 8.40 Item 3.
from the customer supply while performing tasks that do not need electricity. Electricity 10. Remove the upper feeder assembly, PL 8.40 Item 1, refer to REP 8.38.
can cause death or injury. Moving parts can cause injury. 11. Prepare to remove the tray assembly, Figure 2.
WARNING
Take care during this procedure. Sharp edges may be present can cause injury. Access slot
1. Release the cable clamp from the rear cover, Figure 1.
1
Raise the tray assembly until 2
the front tray level drive gear Remove the front tray
clip is in alignment with the level drive gear clip from
access slot of the frame the elevator motor shaft
1 2
Press the locking clip Slide the cable clamp
towards the module upward and remove
Figure 1 Cable clamp release
2. Remove any paper from tray 5, then un-dock tray 5, REP 7.19.
3. Remove the two front door hinge pins, PL 7.60 Item 3, then remove the front door assem-
bly, PL 7.60 Item 1.

12. Remove the tray assembly, Figure 3. Replacement
3 4 2. Refer to Figure 4 when Installing the front elevator rack.
Remove the elevator Remove the tray assembly
motor shaft from the tray 5 module NOTE: Only the front elevator rack has a clearance cut-out to accommodate the front
door interlock switch, Figure 4.
Front elevator rack
1
Ensure the cut-out of the of
the front elevator rack is
positioned around the front
door interlock switch
Front door interlock switch

2 1
Remove the rear tray level Raise the tray assembly until the rear tray level drive
drive gear clip from the gear clip and the elevator motor shaft are in alignment
elevator motor shaft with the access slot of the frame Figure 4 Front elevator rack
Figure 3 Tray assembly rear view
13. Remove the front and rear drive gears, PL 7.68 Item 28.
14. Remove the front elevator rack, PL 7.68 Item 14. Slide the rack upwards within the frame
then lift the rack away from the tray 5 module.
15. Remove the rear elevator rack, PL 7.68 Item 13. Slide the rear elevator rack upwards
within the frame, then lift the rack away from the tray 5 module.

3. After the front and rear drive gears are re-installed ensure that the tray assembly is re- REP 7.22 Tray 3 and Tray 4 Removal (W/TAG 151)
installed in the same horizontal plane as the base of the tray 5 module, Figure 5.
Parts List on PL 7.18.
Removal
WARNING
WARNING
1. Remove the paper from the two trays.
3. Remove the tray 3 and tray 4 front covers, Figure 1.
1 2
Lower the tray Press down firmly onto the base of the tray 5 module
Figure 5 Tray alignment check
4. Keep the tray assembly against the base of the tray 5 module, then reinstall the elevator
motor shaft.
5. 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-
cedure from step 3.
Lower feed assembly
1
Remove 4 screws, then
remove the tray 3 front cover.
2
Remove 2 screws then
remove the tray 4 front cover.
Figure 1 Tray front covers removal
Tray assembly
Figure 6 Tray alignment

NOTE: If only tray 3 is to be removed then do not remove the left hand stop.
NOTE: If tray 4 needs to be removed then remove tray 3 first.

4. Remove the stops, Figure 2.
3 2 1
Remove the screw and Remove the screw Remove the screw and
the left stop (tray 4). and the centre stop. the right stop (tray 3).
Figure 2 Tray 3 and tray 4 rail stops

5. Lift and pull to remove the tray complete with the guide rails.
Replacement
The replacement is the reverse of the removal procedure. Refer to GP 6 when refitting the
screws to secure tray 3 and tray 4 front covers.
NOTE: When installing tray 3 or tray 4 ensure that the tray rails are located correctly in the
base of the HCF, Figure 3.
Figure 3 Location of the tray rails

REP 7.23 Tray 3 and Tray 4 Elevator Motor (W/TAG 151) 5. Remove the tray 3 or tray 4 elevator motor, Figure 1.

Removal
2
Disconnect P/J14
WARNING
customer supply while performing tasks that do not need electricity. Electricity can Disconnect
cause death or injury. Moving parts can cause injury. the sensor
harness
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. P/J14
1. Pull out tray 3 and tray 4.
2. Remove the rear cover from the HCF, PL 7.25 Item 1. P/J13
3. Disconnect PJ395 or PJ397 elevator motor harness from the HCF control PWB,
4. Disconnect the harness from the low paper sensor on the elevator motor.
3 4
Remove Remove the tray 4
the screw elevator motor
4
Remove the tray 3 elevator motor
3
Remove the screw
2
Disconnect P/J13
1
Disconnect the sensor harness
Figure 1 Elevator motor removal
Replacement

REP 7.24 Tray 3 and Tray 4 Elevator Cables (W/TAG 151) 3. Remove the appropriate front elevator cables, Figure 2.
Parts List on PL 7.18. NOTE: The short cable is located over the outer pulley and the long cable is located over
the inner pulley.
Removal
WARNING 1
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Remove the screw, press the legs
customer supply while performing tasks that do not need electricity. Electricity can and remove the pulley carrier from
cause death or injury. Moving parts can cause injury. the appropriate tray (2 places)
WARNING
NOTE: The elevator drives at the front and at the rear are similar for both trays.
1. Remove tray 3 or tray 4, REP 7.2.
2. Release the cables from the appropriate front drive pulley, Figure 1.
2
This illustration shows tray 4 front Remove the short cable
3
Remove the long cable
Tray 4 pulley carriers Tray 3 pulley carriers
2
Remove the cables through
the base of the tray
1
Remove E clip Figure 2 Front elevator cables removal
and keeper plate
4. Release the appropriate paper tray guide, refer to ADJ 7.5.
Figure 1 Front elevator cables release

5. Remove the appropriate rear elevator cable:
Tray 3, Figure 3 4
Tray 4, Figure 4 Remove the screw, press the legs
and remove the pulley carrier
2
Remove the screw, press the legs
and remove the pulley carrier
3
Remove the cable
from the drive pulley
through the cable slot
3
Remove the drive
dog to expose the
cable slot.
4
Remove the cable
2
from the drive pulley Remove the drive
through the cable slot dog to expose the
cable slot.
5
Pass the cable through the 1
base of the tray to remove Remove
the E-clip.
1
Remove 5 Figure 4 Tray 4 rear cable removal
the E-clip. Pass the cable through the
base of the tray to remove

Replacement REP 7.25 Tray 3 and Tray 4 Stack Height Sensor (W/TAG
The replacement is the reverse of the removal procedure. 151)
Tray 3 front cables. Parts List on PL 8.32, PL 8.33.
1. Thread the short cable over the inner groove on the pulley. Removal
2. Thread the long cable over the outer groove on the pulley.
Tray 3 rear cable.
WARNING
Thread the medium length cable over the inner groove on the pulley.
1. Thread the long cable over the inner groove on the pulley. cause death or injury. Moving parts can cause injury.
2. Tread the short cable over the outer groove on the pulley.
Tray 4 rear cable.
Thread the medium length cable over the outer groove on the pulley. WARNING
1. Remove the required paper feed assembly:
Tray 3 paper feed assembly, REP 8.40.
Tray 4 paper feed assembly, REP 8.41.

2. Remove the stack height sensor, Figure 1. REP 7.26 Tray 3 and Tray 4 Home Sensor (W/TAG 151)
Removal
WARNING
WARNING
The removal procedure is the same for tray 3 and tray 4.
1. Pull out tray 3 or tray 4.

3. Pull out the relevant tray by approximately 50mm (2 inches).
4. Remove the tray home sensor and holder, Figure 1.
1
Disconnect the
harness
1
Use a small screwdriver to 3
remove the sensor shim, then Lift the rear of the holder,
press the tabs together to slide the holder forward
2 release the sensor. and remove upwards.
Disconnect the harness
2
Remove the screw.
Figure 1 Stack height sensor removal

Figure 1 Tray home switch and holder
Replacement
The replacement is the reverse of the removal procedure. Install a new sensor shim to lock the
sensor in place.

5. Remove the tray home sensor, Figure 2. REP 7.27 HCF Control PWB (W/TAG 151)
Removal
WARNING
2 Figure 1 ESD Symbol

Press the tabs to release the sensor
CAUTION
Ensure that E.S.D. procedures are observed during the removal and installation of the HCF
Control PWB.
Replacement
2. Remove the HCF control PWB, Figure 2.
Correctly locate the sensor holder, Figure 3.
2
The dowels on the sensor holder must locate
in the holes in the HCF base.
2
Remove
2 screws.
Dowels
Tongue
3
1 Lift the PWB away from
HCF base Disconnect all PJ connectors the bottom mounting
1
Locate the tongue in the slot in Figure 2 HCF control PWB removal
the machine base
Replacement
Figure 3 Holder location 2. After completing the replacement procedure, perform dC604 Registration Setup.

REP 7.28 Tray 3 and Tray 4 Elevate Damper Assembly (W/ 3. Remove the damper from tray 4, Figure 2.
TAG 151)
Removal
WARNING
WARNING
1. Remove tray 3 or tray 4, REP 7.2.
2. Remove the damper from tray 3, Figure 1.
2
Lift the damper to disengage 1
the bottom lugs, then remove Remove two screws.
Replacement
2
Lift the damper
to disengage the the screws.
bottom lugs,
then remove
1
Remove two screws

REP 7.29 Tray 5 Elevator Tray Guides 3. Separate the lift plate from the tray lift top cover, Figure 2.
Parts List on PL 7.70 2

Removal Remove and turn
over the lift plate
WARNING
WARNING
Take care during this procedure. Sharp edges may be present can cause injury.
1. Remove the tray assembly from the tray 5 module, refer to REP 7.21 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 7.21 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 5 and 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 8.1 Tray 1 and Tray 2 Paper Feed Assembly REP 8.2 Tray 3 Paper Feed Assembly (W/O TAG 151)
Parts List on PL 8.26 Parts List on PL 8.30
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove tray 1 or tray 2 as required. 1. Pull out tray 3.
2. Remove tray 1 or tray 2 feed assembly. Figure 1. 2. Remove the rear cover, PL 7.25 Item 1.
3
Remove the screw and remove
tray 1 feed assembly.
2 1
Remove the screw and remove Disconnect the harness.
tray 2 feed assembly.
Figure 1 Remove tray 1 or tray 2 paper feeder
Replacement
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the screws.
2. If new feed rolls are installed reset tray 1 or tray 2 feeds count to zero in the HFSI feature

3. Remove the paper feed assembly, Figure 1. Replacement
NOTE: Note the position of the blue flash on the ribbon cable when connected into Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
PJ399. screws.
1. Refer to the kit instructions and install the spacers on the paper feed assembly.
2. Slide the spacer to the end of the shaft, Figure 2.
1 3 Position of the spacer.

Disconnect 2 PJs. 2
Lift the tab and move the
Disconnect ribbon cable
feed assembly to the left
from PJ399.
and remove.
Figure 1 Tray 3 feed assembly

Figure 2 Location of the spacer

3. Make sure that the feed assembly locates in the stack limiter bracket, Figure 3. REP 8.3 Tray 4 Paper Feed Assembly (W/O TAG 151)
Parts List on PL 8.30, PL 8.31
Removal
WARNING
WARNING
1. Pull out tray 4.
3. Remove the mounting bracket, Figure 1.
Locate the feeder into the stack

limit bracket
Figure 3 Locate the paper feeder assembly
4. Install the paper feed assembly and push the tray in slowly.
NOTE: Check that the tray does not touch the feed assembly.
5. Connect the ribbon cable and the PJs, Figure 1.

6. If a new feed roll assembly is installed, reset the tray 3 feed count to zero in the HFSI fea-
ture screen. Refer to GP 17 High Frequency service Items.
2 1
Remove the Remove 2 screws.
mounting bracket.
Figure 1 Mounting bracket removal

NOTE: Note the position of the blue flash on the ribbon cable when connected into Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
PJ391. screws.
1. Make sure that the feed assembly locates in the stack limiter bracket., Figure 3.
Locate the feeder into the stack

limit bracket.
1
Disconnect ribbon 2 3
cable from PJ391. Disconnect 2 PJs. Lift tab and move the feed
assembly to the left and
remove.
Figure 2 Tray 4 feed assembly

Figure 3 Install the paper feed assembly
2. Install the paper feed assembly and push the tray in slowly.
NOTE: Check that the tray does not touch the feed assembly.
3. Connect the ribbon cable and the PJs, Figure 2.

4. If a new feed roll assembly is installed, reset the tray 4 feeds count to zero in the HFSI

REP 8.4 Registration Transport
Figure 1. Do not damage the temperature/humidity PWB.
Removal
7. Prepare to remove the registration transport, Figure 1.
WARNING 3
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Temperature / Humidity Disconnect the
customer supply while performing tasks that do not need electricity. Electricity can PWB. bias lead.
WARNING
1. Remove the fuser module, PL 10.10 Item 1.
2. Remove the duplex assembly, REP 8.7.
3. Remove the xerographic module, PL 9.20 Item 2.
4. Remove the developer module, REP 9.2.
5. Remove the short paper path assembly, REP 10.1.
6. Open left hand door, PL 7.30 Item 2.
Ground wire.
2
1 Remove 2 screws and the retainer bracket.

8. Remove the registration transport, Figure 2. 9. If required remove the cover from the drive gears, Figure 3.
2
Lift the cover and slide
off the shaft.
1
Release the clip.
2 1 Shaft
Remove the registration transport Move the frame to the front and lift to
through the front of the machine. unlock the transport from the base.
Figure 2 Transport removal Figure 3 Remove the cover

Replacement 3. Ensure that the mylar guide on the registration transport is located on the top of the IOT
frame and not below the frame, Figure 5.
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screw to the retaining bracket.
CAUTION
Ensure that the transport foot is correctly located into the base.
2. Locate the transport foot into the base, Figure 4.
Transport foot
Position the mylar guide on top of the frame.
Figure 5 Mylar guide position
4. Check that the ground wire is secured, Figure 1, when the retainer bracket is reinstalled.
Location hole 5. Go to 01A Ground Distribution RAP. Check the grounding of the registration drive shaft
in the base and the pre-registration drive shaft.
6. After completing the replacement procedure, perform the dC604 Registration Setup.
Figure 4 Transport foot location 7. If a new bias contact is installed, reset the Bias Foam count to zero in the HFSI feature

REP 8.5 Registration Clutch 4. Remove the registration clutch, Figure 2.
Parts List on (35-55 ppm) PL 8.15, (65-90 ppm) PL 8.17

Removal
WARNING
customer supply while performing tasks that do not need electricity. Electricity can Remove the clutch and
gear together.
WARNING
1. Remove the registration transport, REP 8.4.
2. Remove the clutch cover, PL 8.15 Item 24.
3. Prepare to remove the clutch, Figure 1.
1 2
Disconnect the Remove the E-clip. 1
harness. Remove E-clip on the gear.
2
Release the harness Figure 2 Registration clutch removal
from the baffle.

Replacement REP 8.6 Registration Sensor and Wait Sensor (35-55ppm)
Replacement is the reverse of the removal procedure. Parts List on PL 8.15
Check the following: Removal
1. The clutch is located with the key on the frame of the registration transport assembly, Fig-
ure 3.
WARNING
2. The clutch harness is correctly routed and secure, Figure 1.
3. Turn the jam clearance knob 4c to rotate the drive shaft. Ensure that the drive plate on the
clutch rotates without binding on the clutch body, Figure 3.
WARNING
2. Remove the appropriate sensor, Figure 1.
Frame key.
Locate the clutch

onto the key of
the frame.
Clutch drive plate
Clutch body
Registration
1 sensor.
Disconnect
Wait sensor. the harness.
2
Figure 3 Clutch location Release the sensor
and remove.
Figure 1 Sensor location
Replacement

REP 8.7 Duplex Transport Replacement
Parts List on (35-55 ppm) PL 8.22, (65-90 ppm) PL 8.20 1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screw to the duplex transport.
Removal 2. Go to 01A Ground Distribution RAP. Check the grounding of the duplex transport.
3. Check that the duplex transport is located correctly on the metal channel, Figure 2.
WARNING 4. After completing the replacement procedure, perform the dC604 Registration Setup.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the NOTE: Lift the left side of the transport to engage the support pin through the rear frame.
WARNING
Duplex transport.
WARNING
1. Remove the duplex transport, Figure 1.
Duplex transport.
Metal channel.
3 1
Pull out and remove Remove the
the duplex transport. screw.
2
Pull the transport out by 75mm
(3 inches) and disconnect the
harness.
Figure 1 Duplex transport removal

Figure 2 Duplex transport location

REP 8.8 Duplex Motor and Drive Belts NOTE: The duct on the duplex transport is only used on the 65 - 90 ppm machine.
Parts List on (35-55 ppm) PL 8.22, (65-90 ppm) PL 8.20 2. Remove the motor and drive belts, Figure 1.
Removal
5
Remove the
WARNING drive belts.
1
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Disconnect the
customer supply while performing tasks that do not need electricity. Electricity can motor harness.
WARNING
WARNING
1. Remove the duplex transport, REP 8.7.
4
Remove the E-clip. 3
Remove the motor. 2
Remove 2 screws.
Figure 1 Motor and belts removal
Replacement

REP 8.9 Bypass Tray Feed Solenoid REP 8.10 Tray 3 and Tray 4 Transport Motor (W/O TAG 151)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the bypass tray, REP 7.5. 1. Remove HCF rear cover, PL 7.25 Item 1.
CAUTION
Take care not to lose the small spring on the back of the solenoid.
2. Remove the bypass feed solenoid, Figure 1.
2
Remove the spring
(top first).
1
Disconnect
the harness.
3 4
Remove 2 screws. Remove the solenoid.
Figure 1 Solenoid removal
Replacement

2. Remove the Tray 3 and 4 transport motor, Figure 1. REP 8.11 Tray 3 and Tray 4 Transport Drive Gear (W/O TAG
151)
Removal
WARNING
WARNING
2. Remove the tray 3 and 4 transport motor, REP 8.10.
3 2 1
Remove the motor. Remove 2 screws. Disconnect the
motor harness.
Figure 1 Transport motor removal
Replacement
screws.

3. Remove the tray 3 and 4 transport motor bracket, Figure 1. Replacement
CAUTION
The needle clutch in the drive gear can be damaged during removal / replacement. Care must
be taken when removing / replacing the drive gear onto the take away drive shaft.
1. Install the transport drive belt, Figure 2.
Transport 1
drive belt. Position the belt over
2 the tray 3 transport
Slide the belt onto the drive coupling pulley.
drive gear pulley.
Figure 2 Drive belt installation
2 1
Remove the bracket with the Remove 2 screws.
drive gear and the drive belt.
Figure 1 Motor bracket removal

2. Check that the transport motor bracket is located on the stop on the HCF frame, Figure 3. REP 8.12 Tray 1 and Tray 2 Transport Drive Belt
Removal
WARNING
WARNING
2. Remove waste toner bottle, PL 9.10 Item 1.
3. Remove the tray 1 and tray 2 transport drive belt, Figure 1.
HCF frame.
Locate the bracket on the stop to

position the bracket correctly.
Figure 3 Motor bracket location

1
Slip the drive belt
over the idler roll
to remove the
drives belt.
Figure 1 Drive belt removal
Replacement
1. Reverse the removal procedure to replace the transport drives belt.

REP 8.13 Tray 3 Transport Assembly (W/O TAG 151)
Take care to avoid damage to the tray 3 feed sensor flag at the rear of the tray, PL 7.15 Item 9.
Removal
2. Remove tray 3 transport assembly, Figure 2.
WARNING
WARNING
CAUTION
Take care when removing tray 3 support bracket from its snap in mounting. 3
1. Remove tray 3 and tray 4 front covers, Figure 1. Press the rear lug over the post.
Use a small screw driver to remove the

front cover from tray 3.
4
Remove the transport.
1
Remove 2 screws.
2
Apply pressure between
2 transport and tray.
Remove 3 screws.
1 Figure 2 Transport assembly removal
Remove 2 screws.
Replacement
Figure 1 Front covers removal Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.

REP 8.14 Tray 3 Feed Sensor Actuator (W/O TAG 151) REP 8.15 Registration Sensor (65-90 ppm)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove tray 3 transport assembly, REP 8.13. 1. Remove the developer assembly, REP 9.2.
2. Remove tray 3 feed sensor actuator, Figure 1. 2. Remove the xerographic module.
NOTE: Make a note of how the spring is located.
1
Remove the actuator.
2
Remove the actuator spring.
Figure 1 Actuator removal
Replacement
CAUTION
Take care when locating the actuator spring, it can be easily deformed or broken

3. Remove the registration nip assembly, Figure 1 4. Remove the registration sensor and support bracket, Figure 2.
NOTE: To improve the access when removing the screw. Move the xerographic module
latch to the lock position, this changes the position of the developer paddle.
1
Move the
xerographic
module latch 1
to the lock Loosen
position. two
screws.
4
Remove the
registration nip
assembly. 2
Remove the sensor and
support bracket.
2 3 Figure 2 Sensor and bracket removal

Remove the bias lead. Remove the screw.
Figure 1 Registration nip removal

5. Remove the sensor from the support bracket, Figure 3. Replacement
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting
screws.
2. Locate the support bracket on the machine frame and tightened the screws, Figure 4.
1
Locate the tab
on the bracket
in the hole in
the frame.
2
Tighten two
1 screws.
2
Remove the sensor from
the support bracket.
Figure 4 Support bracket position

3. Ensure that the mylar guide is located correctly, Figure 5. REP 8.16 Tray 1 and Tray 2 Transport Rolls and Bearings
Removal
WARNING
WARNING
1. Remove tray 1 and tray 2, PL 7.10.
2. Remove tray 1 and 2 paper feed assembly, REP 8.1.
5. Remove the tray 1 and tray 2 transport drive belt, REP 8.12.
1
Position the mylar guide above
the machine frame.
Figure 5 Mylar guide position

6. Remove the drive shaft and bearings, Figure 1. REP 8.17 Wait Sensor (65-90ppm)
NOTE: The drive pulleys have a built-in one way clutch. Before the drive pulley is Parts List on PL 7.30
removed, mark the pulley to indicate its installed position. The drive shaft rotates when
the pulley is turned in a counter-clockwise direction.
Removal
The removal procedure is the same for the tray 1 and tray 2 transport rolls.
Remove the front bearing when the shaft has been removed. WARNING
WARNING
1. Remove the left hand door, REP 7.5.
2. Prepare to remove the door cover, Figure 1.
4
Move the shaft
3 to the rear and
remove.
Remove
the E-clip.
2
Remove the
drive pulley.
1 1
Remove the E-clip.
Remove 3
Figure 1 Drive shaft removal screws.
Replacement
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting
screws.
2. Ensure that the bearings are located correctly.
3. If a new transport roll is installed, reset the Tray 1 or Tray 2 trans count to zero in the HFSI

3. Remove the door cover, Figure 2. 4. Figure 3 shows the location of the wait sensor.
1
Remove the
cover from the
left hand door
assembly.
1
Wait sensor
Figure 2 Door cover removal Figure 3 Wait sensor location

5. Remove the wait sensor, Figure 4. Replacement
2. Ensure that the cover is located correctly on the left hand door assembly, Figure 5.
1
2
Un-clip and remove the sensor. 1
Door aperture.
Figure 4 Wait sensor removal
2
The lug on the cover must
locate in the door aperture.
Figure 5 Cover location

REP 8.18 Tray 1 and Tray 2 Transport Roll Drives Motor 5. Remove the transport roll drives motor, Figure 2.

Removal
WARNING
WARNING
3. Remove tray 1 and tray 2.
4. Prepare to remove the transport roll drives motor, Figure 1.
1 2 1
Remove the Remove the motor Disconnect the
belt by sliding and ground wire. harness.
it off the idler
pulley
Figure 2 Motor removal
Replacement
screws.
2
3 Remove 2 screws
Remove screw

REP 8.19 Bypass Tray Feed Head 3. Remove the cover from the feed head, Figure 2.

Removal
WARNING
WARNING
1. Remove left hand cover, PL 8.10 Item 3. Use a small screw driver to
release the cover.
CAUTION
Take care not to lose the small spring on the back of the solenoid.
2. Open left hand door and remove the spring from the feed solenoid, Figure 1.
Figure 2 Feed head cover removal
1
Un-clip and
remove the
spring.
Figure 1 Feed solenoid spring removal

4. Release the ribbon cable from the feed head, Figure 3. 5. Remove the feed head, Figure 4.
1
Disconnect the
PJ from the tray
empty sensor.
2
Release the
ribbon cable
from the 2
retainers. Remove the
feed head.
1
Press the tabs and lift the
feed head. Repeat the
action at the rear.
Figure 3 Ribbon cable release Figure 4 Bypass feed head removal

Replacement REP 8.20 Bypass Tray Drive Gear
1. Replacement is the reverse of the removal procedure. Parts List on PL 7.30
2. Before replacement of the feed head ensure that feed roll, pressure plate cam and drive
gear are correctly aligned, Figure 5.
Removal
3. When the feed head is replaced, ensure that the bypass tray empty sensor actuator is
positioned in the slot in the lift plate. Refer to Figure 5.
WARNING
4. Manually rotate the drive gear until the tab on the drive gear is engaged with the armature
on the bypass tray feed solenoid.
Position of the
pressure plate cam. Bypass tray
empty sensor WARNING
actuator.
1. Remove the bypass tray feed head, REP 8.19.
2. Remove the bypass tray drive gear, Figure 1.
Position of the
flat on the feed
roll.
Position of the tab

on the drive gear.
Position of
the nip rolls.
Figure 5 Component alignment 1

Lift the tab to remove the gear.
Figure 1 Drive gear removal

Replacement REP 8.21 Bypass Tray Feed Roll
2. Before replacement of the feed head, ensure that feed roll, pressure plate cam and drive
gear are correctly aligned, Figure 2.
Removal
Bypass tray WARNING

Position of the
pressure plate empty sensor Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
cam. actuator. customer supply while performing tasks that do not need electricity. Electricity can
Position of
the flat on WARNING
the feed roll. Take care during this procedure. Sharp edges may be present that can cause injury.
1. Open the left hand door, PL 7.30 Item 2.
3. Remove the bypass tray drive gear, REP 8.20.
4. Remove the bypass tray feed roll, Figure 1.
Position of the tab

on the drive gear.
Position of
the nip rolls.
1
Remove 2 E-clips.
Figure 2 Component alignment

2
Remove
the E-clip.
3
Slide the shaft out of the
front bearing. Lift the shaft
and remove the feed roll.
Figure 1 Remove the feed roll

Replacement REP 8.22 Bypass Tray Retard Pad
2. Ensure that the bearings at both ends of the shaft are correctly located.
Removal
3. Check the feed head to ensure that the feed roll, pressure plate cam and drive gear are
correctly aligned, Figure 2,
WARNING
Position of the Bypass tray customer supply while performing tasks that do not need electricity. Electricity can
pressure plate empty sensor
cam. actuator.
WARNING
Position of Take care during this procedure. Sharp edges may be present that can cause injury.
the flat on
the feed
roll. 2. Prepare to remove the retard pad, Figure 1.
Position of the tab

on the drive gear.
Position of
the nip rolls.
Figure 2 Component alignment
4. If a new feed roll is installed, reset the Bypass feeds count to zero in the HFSI feature
1
Move the pad to the rear
and allow the pad to
spring up.

3. Remove the retard pad, Figure 2. REP 8.23 Bypass Tray Empty Sensor
Removal
1 WARNING
Insert a screwdriver
between the pad and
holder and twist. customer supply while performing tasks that do not need electricity. Electricity can
WARNING
2. Remove the tray empty sensor, Figure 1.
2
Remove the
retard pad.
Figure 2 Remove the retard pad
Replacement
2. If a new retard pad is installed, reset the Bypass feeds count to zero in the HFSI feature
3
Remove the sensor.
2
1 Push down on the lugs
Disconnect the harness. to release the sensor.
Figure 1 Tray empty sensor
Replacement

REP 8.24 Tray 1 or Tray 2 Feed Sensor 3. Remove the cover from the left hand door assembly, Figure 2.

Removal
WARNING
WARNING
1. Remove the left hand door assembly, REP 7.5.
2. Prepare to remove the left hand door cover, Figure 1.
1
Remove the
cover from the
left hand door
assembly.
Figure 2 Remove the cover
1
Remove three screws.

4. Figure 3 shows the location of tray 1 and tray 2 feed sensors. 5. Remove the feed sensor, Figure 4.
2
Remove 1 screw,
then the sensor.
Wait sensor harness 1
(65-90 ppm). Tray 1 feed sensor. Tray 2 feed sensor.
Figure 4 Remove the feed sensor

Figure 3 Feed sensor locations

Replacement REP 8.25 Tray 5 Feed Sensor
1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the Parts List on PL 8.45
screws.
2. (65-90 ppm Only) Before refitting the left hand door cover, ensure that the wait sensor
Removal
harness is correctly located. Refer to Figure 3.
3. Ensure that the cover is located correctly on the left hand door assembly, Figure 5.
WARNING
WARNING
1. Remove the top cover, PL 7.60 Item 10.
2. Prepare to remove the tray 5 feed sensor, Figure 1.
2
Door aperture
1
The lug on the cover must 3
locate in the door aperture. Lift the bracket
1 2 housing.
Disconnect the harness. Remove eight screws marked A.
Figure 5 Cover location

3. Remove tray 5 feed sensor, Figure 2. 3. Make sure that the spring is positioned on top of the nip roll shaft when the bracket hous-
ing is installed, Figure 4.
Spring position.
Figure 4 Nip roll spring position

2
Press the tabs to 4. Make sure that the spring is positioned on top of the chute upper insert, Figure 5.
release the sensor.
Figure 2 Feed sensor removal
Replacement
the screws.
2. Make sure that the spring on the paper feed assembly is in the correct position, Figure 3.
Place the spring

under the post.
Figure 3 Spring position Position the spring on the top of the

chute upper insert.
Figure 5 Upper insert chute spring
5. Check that the correct screw is used to attach the bracket housing.
6. Check that the harness routing is correct, Figure 1.

REP 8.26 Registration Drive Roll Assembly 3. Remove the lower registration guide, Figure 2.

Removal 1
Remove
2 screws.
WARNING
WARNING
2. Remove the registration nip assembly, Figure 1.
2
Remove the bias guide.
3
Press down and Figure 2 Bias guide removal
slide to release
the nip assembly. 4. Remove the registration clutch, REP 8.27.
5. Prepare to remove the registration drive roll assembly, Figure 3.
2
Remove the screw.
1
1 Remove the E-clip and
Remove the jam clearance bearing.
knob.
Figure 1 Registration nip assembly

2
Remove the E-clip, spring
washer and bearing.

6. Remove the registration drive roll assembly, Figure 4. REP 8.27 Registration Transport Drive Belt
Removal
WARNING
WARNING
2. Remove the drive belt, Figure 1.
1
Remove the registration
drive roll assembly.
Figure 4 Drive roll removal
Replacement
2. Ensure that the ground strap is located between the frame and the bearing. Figure 5.
1
Remove the drive belt.
Replacement
Bearing
Ground strap
Figure 5 Ground strap location

REP 8.28 Tray 3 Feed Sensor (W/O TAG 151) REP 8.29 Tray 3 Takeaway Roll Assembly (W/O TAG151)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Pull out Tray 3. 1. Remove tray 3 transport assembly, REP 8.13.
3. Remove tray 3 feed sensor, Figure 1.
2
Press the tabs together
to release the sensor.
1
Replacement

2. Remove the jam clearance door, Figure 1. 3. Preparation to remove the transport roll assembly, Figure 2.
1
Remove the E-clip.
2
Remove the drive gear and belt.
1
Lift the jam clearance door.
2
Push the tab to release the door
hinge, then remove the door.
Figure 1 Door removal

4. Remove the takeaway roll assembly, Figure 3. 5. Remove the idler roll and shaft, Figure 4.
3
Press the tabs and
push the bearing out.
4
Remove the
takeaway shaft.
1
Move the tabs to remove
the idler rolls and shaft.
Figure 4 Idler roll and shaft removal
Replacement
1 Replacement is the reverse of the removal procedure.
Remove the E-clip.
2
Remove the E-clip.
Figure 3 Takeaway shaft removal

REP 8.30 Tray 3 Transport Roll Assembly (W/O TAG 151) 2. Remove the jam clearance door and drive coupling, Figure 1.

Removal
WARNING
WARNING
1. Remove tray 3 transport assembly, REP 8.13.
1
Remove
the drive
coupling.
2
Lift the jam clearance door.
3
Push the tab to release the door
hinge, then remove the door.
Figure 1 Door and coupling removal

3. Prepare to remove the transport roll assembly, Figure 2. 4. Remove the transport roll assembly, Figure 3.
1
Remove the E-clip.
2
Remove the E-clip
1
Remove the E-clip.
2 3
Remove the coupling. Press the tabs and push
the bearing out.
3
Remove the belt
and drive pulley. 4
Remove the transport
roll assembly.
Figure 2 Preparation Figure 3 Transport roll removal
Replacement

REP 8.31 Tray 3 and Tray 4 Transport Roll (W/O TAG 151) 6. Remove tray 3, REP 7.2.
7. Remove the idler shaft assembly, Figure 2.
Removal
WARNING
WARNING
1. Remove tray 3 and tray 4 transport motor, REP 8.10.
2. Remove Tray 3 and tray 4 transport drive gear, REP 8.11.
3. Remove the left cover, PL 7.25 Item 2.
4. Remove paper tray 2, REP 7.1.
5. (35-55 ppm Only) Remove the ground plate, Figure 1.
1
Remove 2 screws
and the bracket.
2
Remove the ground
plate.
3
Remove the E-clip.
1
2 Remove the springs.
Remove the idler rolls, shaft and
bearings.
Figure 2 Idler shaft removal
Figure 1 Ground plate removal

8. Remove tray 3 and tray 4 transport roll, Figure 3. Replacement
screws.
1. Install the tray 3 and tray 4 transport roll, Figure 4
1
Press the rolls and slide the shaft
2 to the rear until it is released from
Slide the shaft to the front until it is released the front bearing.
from the rear bearing, then remove.
2 1
Press and slide the shaft Locate the shaft in the
Figure 3 Remove the transport roll Front bearing. into the front bearing. bearing at the rear.
Figure 4 Install the transport roll
2. (35-55 ppm Only) Ensure that the ground plate has contact with the transport roll shaft,
refer to Figure 1.
3. If a new tray 3 and tray 4 transport roll is installed, reset the tray 3 / 4 trans count to zero
in the HFSI feature screen. Refer to GP 17 High Frequency service Items.

REP 8.32 Duplex Sensor a. (35-55 ppm). Remove the duplex sensor, Figure 1.

Removal
WARNING
WARNING
WARNING 2
Take care during this procedure. Motors will become hot during normal operation. Press the lugs to
1. Remove the duplex transport, REP 8.7. release the sensor.
NOTE: The duct on the duplex transport is only on the 65 - 90 ppm machine.
2. Identify the speed of the machine and go to the appropriate procedure:
3
1 Remove the sensor.
Figure 1 Duplex sensor (35-55 ppm)

b. (65-90 ppm). Remove the duct from the duplex transport. Remove a duplex sensor, Replacement
Figure 2.
2. If a new duplex sensor is installed, reset the duplex sensor count to zero in the HFSI fea-
3. (65-90 ppm). Check that the tension spring is located correctly on the upper transport
guide. Install the duct on the duplex transport. Check that the sensor wires pass through
the cut-out in the duct and are not caught under the duct. Figure 3.
2
Remove the screw to release
the bracket, then remove the 1
sensor. Disconnect the harness.
Check that the wires pass Check that the
Figure 2 Duplex sensor (65-90 ppm) through the cut out in the duct. tension spring is
located correctly.
Figure 3 Duplex transport duct

REP 8.33 Tray 5 Transport Drive Belt 3. Remove the transport drive belt, Figure 2.

Removal
WARNING
customer supply while performing tasks that do not need electricity. Electricity can 1
cause death or injury. Moving parts can cause injury. Remove the
drive belt.
WARNING
2. Prepare to remove the drive belt, Figure 1.
1
Remove two screws.
2 Figure 2 Drive belt removal

Remove the E-clip.
Replacement
screws.
2. Allow the tension idler to tension the belt and then tighten the screw, Figure 1.
3
Loosen the screw,
move the belt ten-
sioner fully
upward, tighten
the screw.
4
Remove two screws.
5
Release the motor assembly from the drive belt.

REP 8.34 Tray 5 Feed Rolls
Removal
WARNING
WARNING 1 2
Take care during this procedure. Sharp edges may be present that can cause injury. Lift the tab. Lift the guide and slide 1
1. Open the tray 5 door and allow the tray to move down. the nudger and feed roll Lift the tab and slide the retard roll
off the drive shaft. off the drive shaft.
2. Remove the nudger and the feed roll from the front. Slide the tray 5 module away from the
machine and remove the retard roll, Figure 1.
Figure 1 Feed rolls removal
Replacement
NOTE: The feed, retard and nudger rolls W/O TAG P-002 are no longer available as spare
parts. If new rolls are required the only option is to install the feed roll retrofit kit W/TAG P-002,
PL 8.45 Item 22.

2. Ensure that the tabs on the feed roll are located in the drive shaft.
3. Check the registration, refer to dC604 Registration Setup Procedure.
4. If a new nudger, feed and retard roll are installed, reset the tray 5 feeds count to zero in
the HFSI feature screen. Refer to GP 17 High Frequency service Items.

REP 8.35 Tray 1 and Tray 2 Feed Rolls Replacement
Parts List on PL 8.26 1. The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting
the screws.
Removal 2. Make sure that the tabs on the feed roll are located in the drive shaft.
3. Check that the tray empty sensor is located in the cover and that the cover is located cor-
rectly and secure on the feeder frame.
WARNING
customer supply while performing tasks that do not need electricity. Electricity can 5. When new feed rolls are installed, reset tray 1 or tray 2 Feeds count to zero in the HFSI
cause death or injury. Moving parts can cause injury. feature screen. Refer to GP 17 High Frequency service Items.
WARNING
1. Remove tray 1 or tray 2 as required, REP 8.1.
2. Remove tray 1 or tray 2 feed rolls, Figure 1.
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.
1
Un-clip the cover that supports
the tray empty sensor.
4 3 2
Lift the tab and Lift the tab and remove Lift the tab and remove
remove the feed roll. the retard roll. the nudger roll.
Figure 1 Feed rolls removal

REP 8.36 Tray 5 Feed Motor REP 8.37 Tray 5 Transport motor
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the rear cover, PL 7.60 Item 9. 1. Remove the rear cover, PL 7.60 Item 9.
2. Remove tray 5 feed motor, Figure 1. 2. Remove the drives plate, Figure 1.
1
Remove two
1 screws.
Remove
two screws.
2
Remove the
E-clip.
2
Disconnect
the harness. 3
Loosen the
screw, move the
belt tensioner
fully upward,
tighten the screw.
3 4
Remove the motor. 5 Remove 2 screws.
Disconnect both
motor harnesses.
Figure 1 Feed motor removal
Figure 1 Drives plate removal
Replacement
the screws.

3. Remove tray 5 transport motor, Figure 2. REP 8.38 Tray 5 Takeaway Roller
Removal
WARNING
WARNING
2 1. Remove the rear cover, PL 7.60 Item 9.
Remove
the motor. 2. Remove the top cover, PL 7.60 Item 10
3. Remove the transport drive belt, REP 8.33.
1 4. Prepare to remove the lower feed assembly, Figure 1.
Ground wire Remove two screws.
Replacement
the screws.
2. Ensure that the ground wire terminal is located under the motor securing screw, Figure 2.
1
Remove four screws.

5. Remove the lower feed assembly, Figure 2. 7. Remove the takeaway roller, Figure 4.
2
Remove the
lower feed
assembly.
1 2
1 Move the take away Remove the take away roller
Lift the upper feed assembly. roller to the rear. from the lower feed assembly.
Figure 2 Lower feed removal Figure 4 Takeaway roller removal
6. Remove components, Figure 3. Replacement

the screws.
4
2. Check that the cable routing is correct, Figure 1
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 Components removal

REP 8.39 Tray 1 and Tray 2 Retard Roll Friction Clutch REP 8.40 Tray 3 Paper Feed Assembly (W/TAG 151)
Parts List on PL 8.26 Parts List on PL 8.32.
Removal Removal
WARNING WARNING
WARNING WARNING
1. Pull out tray 3.
1. Remove the retard roll, REP 8.35.
2. Remove the clutch coupling, PL 8.26 Item 13.
3. Remove the friction clutch, PL 8.26 Item 2.
Replacement

1. Ensure the support bracket is present on the tray 3 paper feed assembly, Figure 2.
3
Carefully slide out
the paper feed
assembly ensuring
that harnesses are
not damaged
2
Remove
2 screws
Support bracket
1
Disconnect PJ1,
PJ4, PJ10 and the
connector on the
tray 3 home sensor
Figure 2 Support bracket
Figure 1 Feed assembly removal

2. Install the paper feed assembly, Figure 3. REP 8.41 Tray 4 Paper Feed Assembly (W/TAG 151)
Removal
WARNING
1
Locate the tongue
into the frame slot WARNING
1. Pull out tray 4.
2
Install 2
screws
Figure 3 Feed assembly installation
3. Ensure that the tray slide at the rear right of the tray 3 transport assembly, straddles the
support bracket when the paper feed assembly is replaced.
4. Push tray 3 in slowly and check that the tray does not foul the paper feed assembly.
5. Connect the four PJs, refer to Figure 1.
6. The remainder of the replacement is the reverse of the removal procedure. Refer to GP 6
before refitting the screws.
7. If a new paper feed assembly has been installed, reset the tray 3 feeds count to zero in
the HFSI feature screen. Refer to GP 17 High Frequency Service Items.

Paper NOTE: New paper feeder assemblies come ready configured for use in tray 3. When a new
3 feed tray 4 paper feeder is required, follow the steps below.
Carefully slide out the paper feed assembly assembly
ensuring that harnesses are not damaged 1. If a new tray 4 paper feed assembly is being installed, perform steps 2 to 9. If the old tray
4 paper feed assembly is being re-installed, perform steps 5 to 9.
2. Remove the support bracket, Figure 2.
2
Remove 2 2
1 screws Slide the support
Disconnect the 2 in-line connectors bracket rearwards
and the connector on the tray 4 and remove
home sensor
Figure 1 Feed assembly removal
1
Remove the screw
Figure 2 Support bracket removal
3. Remove the tray 3 paper guide, REP 8.55.

4. Install the tray 4 paper guide, REP 8.56.

5. Install the paper feed assembly, Figure 3. REP 8.42 HCF Transport Motor (W/TAG 151)
Removal
WARNING
WARNING
1 1. Remove HCF rear cover, PL 7.25 Item 1.
Locate both
tongues into the
frame slots
2
Install 2
screws
Figure 3 Feed assembly installation
6. Push tray 4 in slowly and check that the tray does not foul the paper feed assembly.
7. Connect the four PJs, refer to Figure 1.
9. If a new paper feed assembly has been installed, reset the tray 4 feeds count to zero in
the HFSI feature screen. Refer to GP 17 High Frequency service Items.

2. Remove the HCF transport motor, Figure 1. REP 8.43 Tray 3 Transport Gear Pulley (W/TAG 151)
Removal
WARNING
WARNING
2. Remove the HCF transport motor (W/TAG 151), REP 8.42.
3. Remove the tray 3 transport gear pulley, Figure 1.
1
1 Remove
Disconnect the 2
Remove 2 screws the KL-clip
motor harness
3
Remove the motor
3 2
Replacement Slide the gear pulley
Remove the gear pulley
1. Replacement is the reverse of the removal procedure. Ensure the at the ground wire is from the belt loop and belt off the shaft
installed between the motor and the frame.
Figure 1 Transport gear removal

Replacement REP 8.44 Tray 3 Transport Assembly (W/TAG 151)
1. Install the tray 3 and tray 4 transport gear pulley, Figure 2. Parts List on PL 8.36.
Removal
WARNING
WARNING
1. Remove tray 3 transport assembly, Figure 1.
1
3 2 Position the gear pulley
Install the Slide the gear pulley in the loop of the belt
KL-clip and belt on to the shaft
Figure 2 Drive belt installation
2. The remainder of the replacement is the reverse of the removal procedure.
3
Remove the transport 2 1
assembly Remove 2 screws Open tray 3
Figure 1 Transport assembly removal
Replacement
1. Ensure that the tray slide at the rear right of the tray straddles the support bracket when
the tray is replaced.

REP 8.45 Tray 3 Exit Sensor (W/TAG 151) REP 8.46 Tray 3 Takeaway Roll Assembly (W/TAG151)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the tray 3 assembly and the tray 4 assembly, REP 7.22. 1. Remove tray 3 transport assembly, REP 8.44.
2. Remove tray 3 exit sensor, Figure 1. 2. Remove the jam clearance door, Figure 1.
1
Lift the jam
clearance door.
3
Remove
the door
Tray 3 paper
feed assembly
3
2 Use a small screwdriver to remove the
1 Disconnect the sensor shim, then press the tabs together 2
Remove the screw to harness. to release the sensor. Push the tab to release
release the bracket the door hinge.
Figure 1 Tray 3 feed sensor removal

Figure 1 jam clearance door removal
Replacement
Replacement is the reverse of the removal procedure. Install a new sensor shim to lock the
sensor in place.

3. Remove the takeaway roll assembly, Figure 2. 4. If required remove the tray 3 transport brace, Figure 3, and the idler rolls, Figure 4.
6
Remove the takeaway
roll shaft.
5
Press the tabs and
push the bearing out.
2
Remove the brace
1
Remove 2 screws
Figure 3 Brace removal
1
Unclip the outer
coupling half 1
2 3 4 Pull back the spring arm, then lift out the idler roll
Remove the Remove the Press the tabs and
E-clip. drive coupling push the bearing out.
Figure 4 Idler rolls removal
Replacement
Figure 2 Takeaway roll removal

REP 8.47 Tray 3 and Tray 4 Transport Roll (W/TAG 151) 5. Prepare to remove the tray 3 and tray 4 transport roll, Figure 2.

Removal
WARNING
WARNING
1. Remove the left cover, PL 7.25 Item 2.
2. Remove tray 3 and tray 4, REP 7.22. 1
Remove the KL-clip
3. Remove the HCF transport motor (W/TAG 151), REP 8.42.
and front bearing.
4. Remove the idler shaft assembly, Figure 1.
2 1
Remove the idler roll assembly Use a spring hook to pull
the spring leg away from
the idler shaft
Figure 1 Idler shaft removal

6. Remove the tray 3 and tray 4 transport roll, Figure 3. Replacement
6 5 CAUTION
Slide the transport roll to Slide the transport roll to the rear to release
the front and remove. the roll from the front of the frame. When installing the gear on the shaft, take care not to damage the one-way clutch in the centre
of the gear.
CAUTION
Before tightening the motor screws, adjust the position of the motor so that there is a very
small amount of backlash between the gears.
the screws.
2. If a new transport roll has been installed, reset the tray 3/4 feeds count to zero in the HFSI
Transport
1 roll
Remove the
KL-clip.
2 4
Remove the Slide the bearing
gear. 3 out of the frame.
Remove the
KL-clip.
Figure 3 Transport roll removal

REP 8.48 Tray 3 Stack Height Sensor (W/TAG 151) REP 8.49 Tray 3 Empty Sensor (W/TAG 151)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the tray 3 paper feed assembly, REP 8.40. 1. Remove the tray 3 paper feed assembly, REP 8.40.
2. Remove tray 3 stack height sensor, Figure 1. 2. Release the sensor mounting, Figure 1.
1 1
3 Use a small screwdriver to
Push the tab to release
Press the tabs together remove the sensor shim
2 the sensor mounting

Figure 1 Sensor mounting release
Replacement
sensor in place.

3. Remove tray 3 empty sensor, Figure 2. REP 8.50 Tray 3 Feed Sensor (W/TAG 151)
Removal
WARNING
WARNING
1. Remove the tray 3 paper feed assembly, REP 8.40.
2. Release the sensor mounting, Figure 1.
2
Pull the tabs apart to
release the sensor
1
Disconnect
the wiring
Replacement
1
the sensor mounting

3. Remove the tray 3 feed sensor, Figure 2. REP 8.51 Tray 4 Stack Height Sensor (W/TAG 151)
Removal
WARNING
WARNING
2. Remove tray 4 stack height sensor, Figure 1.
1
Disconnect
the harness. 2
Pull the tabs apart to
release the sensor.
Replacement
1
3 Use a small screwdriver to
2 Press the tabs together remove the sensor shim
Replacement
sensor in place.

REP 8.52 Tray 4 Empty Sensor (W/TAG 151) 3. Remove tray 4 empty sensor, Figure 2.

Removal
WARNING
WARNING
1 2
Disconnect Pull the tabs apart to
the harness. release the sensor.
Replacement
1
the sensor mounting

REP 8.53 Tray 4 Feed Sensor (W/TAG 151) 3. Remove the tray 4 feed sensor, Figure 2.

Removal
WARNING
WARNING
1
Disconnect
2
the harness. Pull the tabs apart to
release the sensor.
Replacement
1
the sensor mounting

REP 8.54 Tray 3 and Tray 4 Feed Assembly Feed Rolls (W/ 3. Remove the tray 3 feed motor with the bracket, Figure 1.
TAG 151)
Removal
WARNING 2
Remove 3 screws
cause death or injury. Moving parts can cause injury. 1
Remove screw
WARNING
1. Remove the relevant paper feed assembly:
Tray 3 paper feed assembly, REP 8.40
Tray 4 paper feed assembly, REP 8.41
NOTE: This procedure illustrates a tray 3 feed assembly, the procedure for the tray 4
feed assembly is identical.
2. Turn the paper feed assembly upside down and place on a flat work surface.
4 3
Disconnect he harness Remove the motor and bracket
Figure 1 Motor and bracket removal

4. Release the rear fixings, Figure 2. 5. Release the front fixings, Figure 3.
4
Remove
the screw
3 1
2 Remove 2 bearings Remove 2 screws
1 Remove the gear
Remove the KL-clip
Figure 2 Rear fixings Figure 3 Front fixings

6. Separate the upper and lower frames, Figure 4. 7. Remove the plastic cover, Figure 5.
2 1
3 Ensure the Press the fixing to
plastic legs release the cover
Remove the lower frame
disengage
from the
holes
1
Use a small flat bladed screwdriver
to separate the frames
Figure 4 Frame separation Figure 5 Cover removal

8. Remove the nudger roll and feed roll assembly, Figure 6. 9. Remove the retard roller, Figure 7.
2
Use a small screwdriver to push
the shaft through the roller but
leave the shaft engaged in the
pulley and frame
3
Lift the roll assembly
out of the frame
slots and remove
2
Remove the KL-clip
and slide the bearing
out of the frame
3
Separate the retard roll
from the pulley and
remove
1
1 Remove the
Remove the KL-clip and slide KL-clip
the bearing out of the frame
Figure 6 Nudger and feed roll removal Figure 7 Retard roll removal

Replacement 4. Install the nudger roll and feed roll assembly, Figure 9.
1. Install the retard roll by reversing the steps in Figure 7.
2. If necessary refer to Figure 8 for the correct assembly of the retard roll components. 1
Position the roll assembly
above the slots in the frame
and align the dog clutch teeth
Shaft
Belt
Frame
2
Ensure the tang of the 3
feed roll assembly is Push the 4
Washer
positioned under the lift bearing into
Push the bearing
arm, then lower the position and
into position and
feed roll assembly into secure with
KL-clip secure with the
position the KL-clip
KL-clip
Pulley
Retard roll
Figure 9 Nudger and feed roll install
5. Fasten the plastic cover into position ensuring that the wiring is not trapped, refer to Figure 5.
Figure 8 Exploded view of the retard assembly
3. Check that the number of weights on the new nudger roll and feed roll assembly is the
same as on the old assembly, if necessary correct the number of weights, refer to ADJ
8.4.

6. Assemble the two halves of the frame, Figure 10. 7. Align and secure the frame halves, Figure 11.
1 3
Locate the lower frame in Tighten the screw
the rear of the upper frame
2
Ensure the 3
protrusions
are in the
slots
4
Ensure both 1
bearings are Ensure the
correctly Protrusion plastic legs
located are through
the holes
8
Tighten the
machine screw
2
Locate the lower frame in 7
the front of the upper frame Tighten the taptite
screw in the plastic
guide
Figure 10 Frame assembly
Plastic leg
6
Ensure the 2
5 protrusions
are in the slots
Ensure the 2 plastic legs
are through the holes
Figure 11 Final assembly
8. Install the remainder of the removed components.

9. Install the feeder assembly into the machine. Check the feeding performance of the HCF.

REP 8.55 Tray 3 Paper Guide (W/TAG 151) 2. Remove the tray 3 paper guide, Figure 1.

Removal 5
Pivot the guide so it is
clear of the frame at
the front and remove
WARNING
4
Release the central fixing
from the keyhole slot in
the frame
3 Short
Slide the guide to the rear to pin
release the two short pins
from the front frame Short
pin
1
Remove
the screw
2
Loosen the screw by about 3 turns
to allow the frame to spring open
Figure 1 Paper guide removal

Replacement REP 8.56 Tray 4 Paper Guide (W/TAG 151)
1. Install the tray 3 paper guide, Figure 2. Parts List on PL 8.33
Removal
WARNING
1
Locate the two long
pins in the frame rear
2
Align the guide so that the
central fixing drops into the
frame keyhole
4
3 Tighten two
Slide the guide forward screws
to engage the two short
pins in the frame
Figure 2 Paper guide replacement

2. Remove the tray 4 paper guide, Figure 1. Replacement
1. Install the tray 4 paper guide, Figure 2.
5
Pivot the guide
so it is clear of
the frame at the
front and
remove
4
Release the central
fixing from the 1
frame Locate the two long
pins in the frame rear
3
Slide the guide to the
rear to release the
two short pins 2
Short
Short Align the guide so that Short
pin
pin the central fixing drops pin
into the frame keyhole
1 Short
Remove pin 4
the screw Tighten two
screws
2
Loosen the screw by about 3 turns
to allow the frame to spring open 3
Slide the guide forward to engage
the two short pins in the frame
Figure 1 Paper guide removal
Figure 2 Paper guide replacement

REP 8.57 Tray 3 Transport Clutch Drive Assembly (W/TAG
151)
Removal
WARNING
1. Remove tray 3 and tray 4, REP 7.22.
2. Remove the tray 3 transport gear pulley (W/TAG 151), REP 8.43.
3. Remove the tray 3 transport clutch drive assembly, Figure 1.
Tray 3 paper
feed assembly
1
2 Remove the
Remove the clutch drive, spring, E-clip
pulley, belt and flange
Figure 1 Clutch drive removal
Replacement
NOTE: The E-clip is very small, use a small magnetised screwdriver to position the E-clip
whilst pressing the clutch drive against the spring to expose the groove in the shaft.

REP 9.1 Waste Toner Bottle Assembly
Removal 1
Open the waste toner door
WARNING
can cause death or injury. Moving parts can cause injury. 2
Screw the cap onto the bottle
WARNING
1. Remove the rear cover, PL 8.10 Item 1. Remove the waste toner
2. Remove the waste toner bottle and the waste toner door, Figure 1. bottle
4
Press the ends of the strap together to
release the waste toner door
5
Depress the retaining clip on the
hinge block. Remove the waste
toner door
Figure 1 Waste toner door
Replacement

REP 9.2 Developer Assembly 3. Remove the developer module, Figure 2.

Removal
1
Turn the latch
WARNING
WARNING
1. Remove left hand cover, PL 8.10 Item 3.
2. Disconnect PJ93 and the developer bias lead, Figure 1.
3 2
Remove two screws and remove Remove the xerographic module and
the developer module place in a black bag
Figure 2 Remove the developer assembly
2
1 Disconnect developer
Disconnect PJ93 bias lead
Figure 1 Developer bias leads

Replacement REP 9.3 Ozone Fan
2. When installing a new developer module, perform the following:
Removal
NOTE: When replacing the original developer, perform step C only.
a. Follow the developer spares pack instruction sheet to prepare the developer module.
WARNING
b. (65-90 ppm only). Perform ADJ 9.3 Developer Magnetic Seal Brush Adjustment.
c. Lubricate the developer module support pins, ADJ 4.1. from the customer supply while performing tasks that do not need electricity. Electricity
d. (35-55 ppm only). Ensure that the washer and stepped washer are correctly posi- can cause death or injury. Moving parts can cause injury.
tioned, Figure 3.
e. Enter diagnostics, GP 1. Select dC131 location 09-271 developer age and reset to
zero. WARNING
f. Perform the dC905 TC Sensor Calibration. Take care during this procedure. Sharp edges may be present that can cause injury.
g. Perform ADJ 9.2 Image Quality Adjustment Routine. 1. Remove rear cover, PL 8.10 Item 1.
h. If a new developer assembly is installed, reset the Developer count to zero in the 2. Remove the waste toner bottle, REP 9.1.
HFSI feature screen. Refer to GP 17 High Frequency service Items. 3. Remove ozone filter and duct, PL 9.25 Item 2.
Developer assembly
Machine frame Stepped washer

Washer
Figure 3 35-55 ppm developer washer location

REP 9.4 Waste Toner Full Sensor
When the drive gear is removed, the drive pin may fall onto the IOT PWB or LVPS.
Removal
4. Remove the ozone fan, Figure 1.
WARNING
5
Remove the fan, then
disconnect PJ153 on WARNING
the photoreceptor
motor PWB. Take care during this procedure. Sharp edges may be present that can cause injury.
Drive pin 1. Remove the rear cover, PL 8.10 Item 1.
2. Remove the waste toner bottle, PL 9.10 Item 1.
1 4
2 3 Remove 3 screws
Remove 3 screws Remove the collar Remove the drive
and the fly wheel gear
Figure 1 Remove the ozone fan
Replacement
screws.
NOTE: Turn the drive shaft so that the dowel pin is horizontal then locate the drive gear onto
the shaft.

3. Remove the waste toner full sensor, Figure 1. REP 9.5 Toner Dispense Module
Removal
WARNING
1 Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Remove the screw from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
1. Remove the developer assembly, REP 9.2.
2. Remove the toner cartridge.
3. Disconnect the harness PJ97 and PJ75 on the toner dispense module, Figure 1.
4
2 3 Remove the sensor from
Disconnect PJ48 Remove cable-ties the black plastic housing
1 2
Figure 1 Waste toner full sensor Disconnect harness PJ75
Disconnect harness PJ97
Replacement
Figure 1 Disconnect the harness

4. Remove the securing screws from the toner dispense module, Figure 2. 5. Remove the toner dispense module by sliding it of the developer assembly, Figure 3.
Slide the module
Figure 3 Remove the toner dispense module
Replacement
2. Ensure that the harnesses are routed under the support guides on the toner dispense
module, Figure 2.
Support guides
Harness 3. After a new Toner Dispense Module and a Toner Cartridge are installed and the machine
1
Remove 2 screws is powered on. The toner cartridge motor will turn on, the toner bottle will rotate and toner
will be dispense into the toner dispenser sump. Once the toner in the sump reaches the
level of the low toner sensor, the toner bottle will stop turning. The toner must then be
manually run from the toner sump into the developer module.
To run the toner into the Developer Module:
a. Remove the top left cover to access the left side of the Developer Module and moni-
Figure 2 Remove the securing screws
tor the toner concentration sensor voltage output at PJ93 pin 8 (red wire)
b. Enter DC330 code 04-010 main drive motor and 09-040 toner dispense motor.
c. Start the routine. The start will have to be pressed every 5 seconds to restart the
toner dispense motor.
d. Run the routine until the monitored voltage is between 2.2V and 2.8V at PJ93 pin 8.
e. Check the density and image quality. Repeat the procedure if the copies are still
light.

REP 9.6 Xerographic Module Latch 4. Remove the pivot plate to release the developer paddle, Figure 2.
Parts List on (35 ppm) PL 9.22, (40-90 ppm) PL 9.20 NOTE: Observe where the spring is located on the tie bar and on the developer paddle.
Removal
WARNING
WARNING
1. Remove the scanner, REP 14.1.
3. Refer to REP 6.1 and move the ROS to the side, Figure 1.
3
Remove the
pivot plate
1
Support the developer 2
paddle
Remove the screw
Spring
Figure 2 Remove the pivot plate
ROS
Figure 1 Position the ROS

WARNING
Take care when removing the latch. The latch contains a compressed spring, which can
Latch pin
5. Remove the screw from the latch, Figure 3.
Latch plate
1
Remove the screw
2
Remove the latch
Latch handle
Figure 3 Remove the latch
Replacement
Latch pin
2. Apply plastislip grease, PL 26.10 Item 8, to the internal diameter of the bush on the frame
(i.e. the hole the pin fits into) prior to insertion.
3. Refer to Figure 4. Check the following:
a. The latch pin is correctly lined up with the flats on the latch plate.
b. The latch handle and the latch pin are correctly lined up.
c. When reinstalling the developer paddle into the pivot plate, check that the spring is
correctly located on the tie bar and on the feature on the developer paddle, Figure 2.
Figure 4 Latch alignment

REP 9.7 Developer Paddle REP 9.8 Transfer / Detack Harness
Parts List on (35 ppm) PL 9.22, (40-90 ppm) PL 9.20 Parts List on (35 ppm) PL 9.22, (40-90 ppm) PL 9.20
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.
WARNING WARNING
1. Remove the xerographic module latch, REP 9.6. 1. Remove the short paper path assembly, REP 10.1.
2. Remove the developer paddle, Figure 1. 2. Remove the transfer / detack harness, Figure 1.
1
Insert a screwdriver
to flex the frame
1
Remove
spring
2
3 Push down on the harness
Release and remove 2 terminal block to release
the tab Tab on the harness terminal block
the developer paddle Move the developer paddle
Figure 1 Developer paddle Figure 1 Transfer / detack harness
Replacement Replacement
Replacement is the reverse of the removal procedure. Replacement is the reverse of the removal procedure.

REP 9.9 Erase Lamp 4. Remove the erase lamp, Figure 2.
Parts List on (35 ppm) PL 9.22, (40-90 ppm) PL 9.20 Rear location posts Front location posts
Removal
WARNING
WARNING
2
Slide the erase lamp out of
the support
1. Remove the fuser module, PL 10.10 Item 1.
2. Remove the xerographic module, PL 9.20 Item 2. 1
3. Remove the erase lamp support, Figure 1. Lift the tab at the end
of the erase lamp
1 Figure 2 Remove the erase lamp

Remove the screw
Replacement
2. Check that the location posts on the erase lamp (Figure 2), locate in the holes in the
frame, Figure 3.
Location holes
2
Pull out the erase
lamp support
Figure 1 Erase lamp support
Erase lamp connector
Figure 3 Location holes

REP 9.10 Auger Damper 5. Remove the waste toner from the shutter auger tube at the rear of the machine, Figure 2.

Removal
WARNING
WARNING
1. Cam off the developer module.

3. Remove the waste toner from the auger system at the front of the machine, Figure 1.
Place the vacuum cleaner hose over the waste toner tube
and push the shutter to the open position.
Figure 2 Shutter and waste toner auger
6. Remove the ozone filter and the duct, PL 9.25 Item 2.

7. Remove the waste toner full sensor up to step 3, REP 9.4.
1
Vacuum clean the
auger system
Figure 1 Auger system at the front
4. Remove the waste toner bottle assembly, REP 9.1.

8. Remove the shutter assembly and the support bracket, Figure 3. 9. Remove the auger damper, Figure 4.
2
Disconnect PJ97
Pull out the auger damper
Figure 4 Remove the auger damper

3
Remove the
shutter
assembly
and bracket
1
Remove 4 screws
Figure 3 Remove shutter assembly

Replacement 4. Support the auger tube when locating the shutter assembly and bracket onto the auger
tube, Figure 6.
2. Install the new auger damper, Figure 5.
NOTE: The auger damper is longer than the auger spring.
2 1
Ensure that the shutter is positioned Support the auger tube
correctly on the bracket
1
Push and twist the auger damper until it Figure 6 Shutter and bracket position
stops at the end of the auger tube.
Figure 5 Installing the insert
3. Ensure that the shutter assembly is positioned correctly on the support bracket.

REP 10.1 Short Paper Path Assembly 6. Prepare the power and control module, Figure 1.

Removal 1
Remove the
securing screw
WARNING
WARNING
NOTE: The following removal procedure depicts the W/O TAG 114 short paper path assembly.
However, this procedure is also common to the W/TAG 114 short paper path assembly.
1. Remove the fuser assembly, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.
3. Remove the xerographic module and place in a black bag, (35 ppm) PL 9.22 Item 2, (40-
90 ppm) PL 9.20 Item 2.
4. Remove the transfer / detack corotron, (35 ppm) PL 9.22 Item 8, (40-90 ppm) PL 9.20
Item 3.
3 2
Move the module Disconnect the transfer
to the rear and detack leads
Figure 1 Prepare the power and control module

7. Remove the short paper path assembly, Figure 2. Replacement
NOTE: The following replacement procedure depicts the W/O TAG 114 short paper path
assembly. However, this procedure is also common to the W/TAG 114 short paper path assem-
bly.
NOTE: The following replacement procedure must be performed in conjunction with the
related service kit instruction.
screws.
CAUTION
To ensure the transport hinge is located correctly, First install the left hand screw, with the
ground lead, then the right hand screw.
2. Check that the detack wire with the plastic sleeve is routed correctly on the transport
hinge, Figure 3.
1 2 3 4
Remove screw Remove screw Disconnect PJ43 Pass the HT leads
and ground lead through the hole
Figure 2 Remove short paper path assembly
Detack wire with

Transfer wire plastic sleeve
Figure 3 Spiral wrap location

3. Position the ground wire terminal in the left hand screw location on the hinge bracket and REP 10.2 Inverter Assembly
position the HT leads, Figure 4.
4. When locating the hinge bracket to the frame make sure that the hinge is pushed fully
Parts List on PL 10.11, PL 10.20, PL 10.21
against the frame. Removal
5. To ensure that the transport hinge is located correctly, first install the left hand screw, with
the ground wire, then the right hand screw.
WARNING
NOTE: Ensure that both ends of the ground lead are connected to the correct terminals.
WARNING
WARNING
1. Remove the fuser assembly, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.
3. Remove the output device and the right hand cover, PL 8.10 Item 9.
Position of the ground wire tag Position of the HT leads
Figure 4 Ground wire and spiral wrap
6. After completing the replacement procedure, check that the short paper path assembly
latches without excessive force.
7. Raise and lower the latch mechanism of the short paper path assembly, PL 10.25 Item 1,
to ensure that the transfer / detack corotron is parallel to the photoreceptor. If the move-
ment of raising the short paper path assembly is not smooth, check the action of the
corotron carrier PL 10.25 Item 2.

5. (W/O TAG 046, W/O TAG 047 or W/O TAG 148). Remove the inverter support, Figure 1.
6. (W/TAG 046, W/TAG 047 or W/TAG 148). Remove the inverter decurler adjuster and
retaining ring, Figure 2. 3
Remove the
adjuster.
2
Rotate the
inverter support
clockwise to align
both cutouts and
remove
1
Remove 2
screws
2
1 Rotate the inverter decurler retaining
Remove the screw. ring to align both cutouts then remove.
Figure 2 Adjuster and retaining ring
Figure 1 Inverter support

7. Remove the tie bar. Figure 3. 8. Lift the inverter assembly and move to the front, Figure 4.
NOTE: On 65-90 ppm machines W/TAG 120, the thermistor connection PJ76 is not used.
Refer to Figure 3.
4
Rotate the inverter and
then slide the assembly
clear of the machine
4
Remove the tie bar
2
Disconnect harness at 1
PJ49 and PJ76. Remove the support bracket, 1
2 3
screw. (W/TAG 046, W/ TAG 047 Lift the frame Move the inverter
3 and W/TAG 148 machines only) out of the base assembly
1 Disconnect the harness on
Remove 4 screws inverter motor driver PWB
marked A Figure 4 Move the inverter to the front
Figure 3 Tie bar

9. Remove the inverter assembly through the right hand side of the machine, Figure 5. Replacement
2 NOTE: On 65-90 ppm machines W/TAG 120, the thermistor connection PJ76 is not used.
Remove the inverter Refer to Figure 3.
assembly Before installing the inverter assembly check the following:
1. The inverter motor harness is routed correctly. Check that the harness does not get
trapped between the inverter frame and the base, Figure 3.
2. The solenoid harness connector is located at the rear of the inverter frame, Figure 6.
Solenoid harness
connector
1
Ensure the idler shafts at the rear
are clear, before turning the inverter
Figure 5 Remove inverter assembly
Figure 6 Solenoid harness connector

3. The nip roll guide is correctly located in the cut-out at the front and rear of the inverter 5. (W/TAG 046, W/TAG 047 or W/TAG 148). Ensure the gear indexer is set to the neutral
frame, Figure 7. position, Figure 8.
Nip roll guide located

on the inverter frame
Figure 7 Nip roll guide
4. Make sure that the baffle guide, PL 10.13 Item 3 and upper baffle, PL 10.12 Item 14 are
linked correctly. When latch 3d/4d is released, the two baffles must lift together. 1
2 Ensure the flats on the
Engage the detent pin into the 4th/central pivot shaft are horizontal.
detent on the gear indexer.
Figure 8 Initial setup of the gear indexer
6. Replacement of the inverter assembly is the reverse of the removal procedure. Refer to
GP 6 before refitting the screws.
NOTE: When the idler shafts are located, Figure 5. Rotate knob 3C clockwise to engage
the drives coupling between the inverter and the drives plate. This will also allow the
inverter to locate into the base of the machine, Figure 4.
7. If a new inverter assembly is installed, reset the Post Fuser count to zero in the HFSI fea-
8. (W/TAG 046, W/TAG 047 or W/TAG 148). Perform ADJ 10.1 Inverter Decurler Adjust-
ment.

REP 10.3 Inverter Motor 2. Remove the inverter motor, Figure 1.

Removal
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord 3
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. inverter motor
WARNING
WARNING
1. Remove the inverter assembly, REP 10.2. 2
Remove 2 screws
1
Un-clip the support
arm from the shaft
Figure 1 Inverter motor
Replacement

REP 10.4 Inverter Path Solenoid Replacement
Parts List on PL 10.11 1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.
Removal 2. Check that the solenoid harness connector is located at the rear of the inverter frame as
in Figure 1.
3. Make sure that the link arm is connected to the solenoid armature. Manually operate the
WARNING
solenoid armature and check that the inverter gate operates correctly.
WARNING
1. Remove the inverter assembly, REP 10.2.
2. Remove upper baffle assembly, REP 10.7.
3. Remove the diverter solenoid, Figure 1.
3
Remove the solenoid
1
Disconnect
solenoid
harness
2
Remove 2 screws
Figure 1 Inverter path solenoid

REP 10.5 Inverter Nip Solenoid REP 10.6 Nip Roll Guide
Removal Purpose
This procedure is used to repair the following:
Single exit nip roll, PL 10.11 Item 7.
WARNING
Double exit nip roll, PL 10.11 Item 8.
Nip roll guide, PL 10.11 Item 10.
can cause death or injury. Moving parts can cause injury. Removal
WARNING WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
1. Remove the inverter assembly, REP 10.2. from the customer supply while performing tasks that do not need electricity. Electricity
2. Remove the inverter nip solenoid, Figure 1.
3 WARNING
Remove the solenoid
2 1
Remove 2 screws Disconnect the harness
Figure 1 Inverter nip solenoid
Replacement
screws.

3. Remove the tie bar, Figure 1. 4. Remove the nip roll guide, Figure 2.
1 1
Remove 4 screws 3
Remove two screws
2 Remove tie bar
2 3
Disconnect harness from
Disconnect the harness Remove the
inverter motor driver PWB
from the exit sensor and nip roll guide
from the nip roll guide
Figure 1 Remove tie bar Figure 2 Nip roll guide
5. Remove the following components from the nip roll guide as required:
IOT exit sensor.
Single exit nip roll.
Double exit nip roll.

Replacement REP 10.7 Upper Baffle Assembly
screws.
Removal
CAUTION
Check that the inverter path solenoid harness is not trapped between the nip roll guide and the WARNING
support bracket, Figure 3. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
2. Ensure that the ground connection is secured by the nip roll guide front fixing screw. from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
Nip roll guide 1. Remove the inverter assembly, REP 10.2.
Support bracket
Harness
Figure 3 Inverter path solenoid Harness

2. Remove the upper baffle assembly. REP 10.8 Nip Split Shaft Assembly
(35-55 ppm). Complete the procedure in Figure 1.
(65-90 ppm). Remove the inverter sensor, REP 10.20. Then complete the procedure
in Figure 1. Removal
WARNING
WARNING
Solenoid 2. Remove the rear cover, PL 8.10 Item 1.
harness
3. Remove the tie bar, Figure 1.
connector
3
Remove the
shaft and
the baffle
1
Lift the upper baffle
to vertical position 2
Remove 2 E-clips
Figure 1 Upper baffle assembly
Replacement
1. The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting 1
the screws. Remove 4 screws
2. Check that the solenoid harness connector is located at the rear of the inverter frame,
3
Remove the tie bar
refer to Figure 1.
3. Make sure that the two upper baffles are linked correctly. When the latch 3d/4d is
released, the two baffles lift together. 2
Disconnect harness on
Figure 1 Tie bar

4. Remove the nip split shaft assembly, Figure 2. Replacement
screws.
2. Check that both springs are positioned correctly, Figure 3.
Spring position
2 1
Release both springs Figure 3 Location of the spring
Remove nip split
shaft assembly
3. If a nip slit shaft assembly is installed, reset the nip split shaft count to zero in the HFSI
Figure 2 Nip split shaft assembly

REP 10.9 Shaft Actuator Replacement
Parts List on PL 10.11 1. Replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the
screws.
Removal 2. Check that both springs are positioned correctly, Figure 2.
WARNING
WARNING
2. Remove the inverter nip solenoid, REP 10.5.
3. Remove the shaft actuator, Figure 1.
Spring position
Figure 2 Location of the spring
2 1
Remove the shaft actuator Unclip both springs
Figure 1 Shaft actuator

REP 10.10 Fuser Latch
Parts List on (35-55 ppm) PL 10.8, (65-90 ppm) PL 10.10 WARNING
Removal Take care when removing the latch. The latch contains a compressed spring, which can
4. Hold the fuser latch pin in position with a screw driver and remove the screw at the back
WARNING of the latch to release the fuser latch, latch pin and spring, Figure 2.
from the customer supply while performing tasks that do not need electricity. Electricity 1
can cause death or injury. Moving parts can cause injury. Remove screw
WARNING
2. Remove the scanner, REP 14.1.
3. Refer to REP 6.1 and move the ROS to the side, Figure 1. 4
Remove latch
and stop
ROS
3
Remove
spring
Fuser
latch
2
Remove latch
pin
Figure 2 Remove the fuser latch
Figure 1 Move the ROS

Replacement REP 10.11 Inverter Gate
screws.
2. Ensure that the latch stop is seated over the locator post on the machine frame, Figure 3.
Removal
Locator post WARNING

Screw
WARNING
1. Remove the inverter path solenoid, REP 10.4.
Latch stop 2. Remove the jam clearance lever 3a, Figure 1.
NOTE: To remove the inverter gate, remove two nuts, Figure 2 and flex the bracket. If the
repair is used with REP 10.12, the jam clearance lever 3a, Figure 1 and the inverter
assembly bracket, Figure 2, must be removed.
Spring
Use a small screwdriver to

release the jam clearance
lever 3a.
Fuser latch Latch pin
Figure 3 Locate the latch stop
Figure 1 Jam clearance lever 3a

4. Remove the inverter path solenoid link, Figure 3.
CAUTION NOTE: When the link arm has been removed, a new link arm must be installed, PL 10.11
Take care not break the inverter assembly bracket. Item 1.
3. Carefully unlatch the inverter assembly bracket from the inverter assembly, Figure 2.
1
Use a screwdriver
to remove the link
1
Remove 2 nuts
Figure 3 Inverter path solenoid link
2
Use a screwdriver to
unlatch the clip on the
inverter assembly
bracket from the tie bar Inverter assembly
bracket
Figure 2 Inverter assembly bracket

5. Remove the inverter gate, Figure 4. REP 10.12 Tri-Roll Shaft Assembly
1 Removal
Rotate and then remove the inverter gate
WARNING
WARNING
1. Remove the inverter gate, REP 10.11.
2. Remove the tri-roll jam clearance knob 3c, Figure 1.
Use a small screwdriver

to release the clip on the
tri-roll jam clearance
knob 3c
Figure 4 Inverter gate
Replacement
Re-install the remainder of the removed components. Replacement is the reverse of the
removal procedure. Refer to GP 6 before refitting the screws.
Figure 1 Tri-roll knob

3. Remove the tri-roll, fuser exit and exit shaft bearings, Figure 2. Remove the duct (65-90 4. Remove the securing screw and tri-roll drive gear, Figure 3.
ppm) or the baffle guide (35-55 ppm), PL 10.13.
1
1 Remove the screw
Remove the E-clip and bearing
2
Remove screw 2
Raise the tang
to remove the
tri-roll gear.
3 3
Remove the E-clip Remove the
bearing behind
the gear
4
Remove the bearing
from the tri-roll shaft
Figure 3 Tri-roll drive gear

5. Remove the tri-roll guide, Figure 4.
5
Remove 2 screws
6
Remove the E-clip and bearing
on post fuser exit roll
2
1 To remove the tri-roll guide,
lift and twist the guide
Pull the side plate to
release the tri-roll guide
Figure 4 Tri-roll guide removal

6. Remove the tri-roll shaft, Figure 5.
NOTE: Note the orientation of the tri-roll shaft.
1
Install the guide so that the fingers
wrap around the tri-roll shaft.
Rear
location
hole
2
Locate the fingers on the guide at the
rear and then move to the front.
Ensure that the posts on the guide
are located in the holes in the frame
Front location
hole
1
Move the shaft to the front, Figure 6 Install tri-roll guide
lift and remove the shaft
c. Tri-roll gear and the securing screw., Figure 3.
Figure 5 Tri-roll shaft removal Ensure that the post is located in the hole on the frame.
d. The tri-roll bearing and E-clip, Figure 2.
Replacement e. The exit shaft bearing and E-clip
Refer to GP 6 before refitting the screws. i. Locate the duct (65-90 ppm) or baffle guide (35-55 ppm) on the exit shaft, PL
10.13.
1. Re-install the following components:
ii. Install the bearing and E-clip on the exit shaft, Figure 2.
a. Tri-roll shaft, Figure 5
iii. Ensure the nip roll guide is located correctly, REP 10.2 and refer to Figure 6.
b. Tri-roll guide. The guide locates on the tri-roll shaft in front of the bearing. Locate the
f. Install bearing and E-clip on the post fuser exit roll, Figure 2.
post on the tri-roll guide into the location holes in the front and rear frame. Figure 6.
g. Complete the steps in REP 10.12.
h. Install the inverter gate. Make sure that the inverter assembly support bracket is
installed correctly. Refer to the replacement procedure in REP 10.11.
2. If a new tri-roll shaft assembly is installed, reset the Post Fuser count to zero in the HFSI

REP 10.13 Fuser Web Motor Assembly
Removal 2
Remove the fuser
web assembly
WARNING
WARNING
1. Remove the main drive module, (35-55 ppm) REP 4.1, (65-90 ppm) REP 4.5.
2. Disconnect PJ154 on the main drive PWB and remove the fuser web motor assembly,
(35-55 ppm) Figure 1, (65-90 ppm) Figure 2.
1
2 Remove
Remove the fuser 3 screws
web assembly
Figure 2 Drives module 65-90 ppm
1
Remove
3 screws
Figure 1 Drives module 35-55 ppm

3. Remove the fuser connector assembly from the fuser web motor assembly, Figure 3. REP 10.14 Exit Shaft Assembly
Removal
WARNING
1 from the customer supply while performing tasks that do not need electricity. Electricity
Remove 2 screws can cause death or injury. Moving parts can cause injury.
WARNING
2
Remove the
fuser connector 2. Remove the exit shaft assembly, (35-55 ppm) Figure 1, (65-90 ppm) Figure 2.
assembly
Figure 3 Fuser web motor assembly
Replacement
2
Remove circlip, drive
gear and bearing
1
Remove the circlip
and bearing
3
Remove the exit shaft
Figure 1 Exit shaft assembly 35-55 ppm

REP 10.15 Intermediate Drive Belt (W/O TAG 114)
Removal
WARNING
WARNING
1. Remove the short paper path assembly, REP 10.1.

2. Release the transfer / detack corotron harness from the supports, Figure 1.
2
Remove circlip, drive
gear and bearing
1
Remove the circlip 3
and bearing Remove the exit shaft
Figure 2 Exit shaft assembly 65-90 ppm
Replacement
2. Ensure that the bearings locate into the baffle guide and that the baffle guide is linked with
the upper baffle. Both baffles are lifted together when clearing a post fuser jam.
1
Release the harness
Figure 1 Transfer / detack corotron harness

3. Remove the securing screw to release the drives assembly, Figure 2. 4. Remove the vacuum fan, Figure 3.
Corotron carrier
2
Drives assembly Remove the
vacuum fan
1
Remove screw
1
Remove 2 screws
Figure 2 Short paper path assembly Figure 3 Remove vacuum fan

5. Remove the intermediate drive assembly, Figure 4. 6. Remove the intermediate drive belt, Figure 5.
2
1 Remove drive belt
Remove snap on washer
Figure 5 Remove the drive belt
1
Lift the drive Replacement
gear assembly
2 2. Check that the transfer / detack HT leads are correctly positioned at the rear of the short
Move the drive gear assembly to release paper path assembly, Figure 1.
the catch and remove the assembly
Figure 4 Remove the drive assembly

REP 10.16 Fuser Exit Switch 2. Remove the top cover from the fuser module, Figure 1.

1
Removal Remove
4 screws
WARNING
WARNING
WARNING
1. Remove the fuser module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.
2
Remove the top cover
Figure 1 Remove the top cover

3. Remove the upper paper guide assembly, Figure 2. 4. Release the harness and remove the fuser exit switch, Figure 3.
3
Remove the
upper guide
1
Remove the
screw
3
Remove the
switch
2
Release the harness
Figure 3 Fuser exit switch removal

1
Disconnect the harness
2
Remove 2 screws
Figure 2 Upper guide removal

Replacement REP 10.17 IOT Exit Sensor
1. The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting Parts List on PL 10.11
the screws.
2. On 65-90 ppm machines, make sure that the harness and the connector are routed away
Removal
from the spring, Figure 4.
WARNING
Anti-rotation bracket Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
Harness Take care during this procedure. Sharp edges may be present that can cause injury.
connector 1. Remove the output device.
3. Remove the tie bar, Figure 1.
Harness
Spring
Figure 4 Harness location 65-90 ppm
3. On all machines. Check for 5mm clearance between the anti-rotation bracket and the 3
heater lamp wires, Figure 4. Inspect the heater lamp wires for damage. If the wires are Remove the tie bar
damaged install a new fuser module. 1
Remove 4 screws
2
Disconnect the harness from the
Figure 1 Remove the tie bar

4. Release the nip roll guide, Figure 2. 5. Remove the IOT exit sensor, Figure 3.
2 2
1 Lift the guide to release 1 Press the lugs down to
Remove two screws the nip roll guide Disconnect the harness release the IOT sensor
Figure 2 Release the nip roll guide Figure 3 Remove the IOT sensor

Replacement REP 10.18 Inverter Output Guide Assembly
The replacement is the reverse of the removal procedure. Refer to GP 6 before refitting the Parts List on PL 10.11
screws to the output guide.
Removal
CAUTION WARNING
Check that the inverter path solenoid harness is not caught between the nip roll guide and the
support bracket, Figure 4.
WARNING
Nip roll
guide 1. Remove the inverter assembly, REP 10.2.
2. Release the nip roll guide, Figure 1.
Support
bracket
Inverter path solenoid harness
Figure 4 Inverter path solenoid harness

1
Disconnect the
3 harness
Lift the guide to release 2
the nip roll guide
Remove two screws
Figure 1 Release nip roll guide

3. Remove the output guide, Figure 2. Replacement
screws.
CAUTION
Check that the inverter path solenoid harness is not caught between the nip roll guide and the
support bracket, Figure 3.
Nip roll guide
2
Remove two screws Support bracket
Inverter path
solenoid
harness
1 3
Remove two screws Flex the side plates to
release the output guide Figure 3 Inverter path solenoid harness
Figure 2 Remove the output guide

REP 10.19 Tri-Roll Nip Split Solenoid Replacement
the screws.
Removal 2. Before the inverter is installed, manually operate the solenoid and check that the nip rolls
operate correctly.
3. Check that the wires to the solenoid are free to move and not trapped by the plastic guide,
WARNING
Figure 2.
WARNING Plastic guide

2. Remove the tri-roll nip split solenoid, Figure 1.
The wires are not

trapped by the plastic
guide
Figure 2 Route solenoid wires
1 2 3 4
Remove screw and Disconnect Remove Flex the actuator bar to
plastic guide the harness two screws remove the solenoid
Figure 1 Remove the solenoid

REP 10.20 Inverter Sensor Replacement
the screws.
Removal 2. Route the harness under the tab on the upper baffle, Figure 1.
3. Make sure that the upper baffle and the inverter assembly duct are linked correctly. When
the latch 3d/4d is released, the two items lift together.
WARNING
WARNING
2. Remove the inverter sensor, Figure 1.
1
Follow the sequence
to remove the sensor
2
Disconnect the har-
ness from the sensor
Tab to secure the

harness
Figure 1 Remove the inverter sensor

REP 11.1-110 2K LCSS Covers NOTE: Removing the top cover first will allow easy removal of the front and rear covers.

Removal 1
Open the exit cover,
remove two screws.
6
WARNING Remove the
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord rear cover
from the customer supply while performing tasks that do not need electricity. Electricity assembly.
Remove
the top
cover.
WARNING
1. Remove the covers, Figure 1.
5
4 Remove two
3 Remove the
screws.
Open the front
front door cover
door, remove
assembly.
four screws.
Figure 1 Removing the covers
Replacement
Reverse the removal procedure to replace the covers.

Xerox WorkCentre 5790 Family 4-245 REP 11.1-110
REP 11.2-110 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 11.4-110.
5. Tighten the motor screws and re-connect the harness.
WARNING
6. Install the 2K LCSS rear cover, REP 11.1-110.
WARNING
1. Remove the 2K LCSS rear cover, REP 11.1-110.
2. Remove the motor and drive belt, Figure 1.
4
Remove the
drive belt.
3
Remove 2
screws and
motor
2 1
Disconnect the Remove the
motor harness. spring.
Figure 1 Removing the drive belt

REP 11.2-110 4-246 Xerox WorkCentre 5790 Family
REP 11.3-110 Intermediate Paper Drive Belt Replacement
Parts List on PL 11.22. 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 2K LCSS rear cover REP 11.1-110.
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 11.4-110 Paper Output Drive Belt and Paper Transport
Exit Motor 4
Remove the
Parts List on PL 11.22. motor and
Removal belt.
WARNING
WARNING
1. Remove the 2K LCSS rear cover, REP 11.1-110. Support the
motor and
2. Remove the intermediate drive belt, REP 11.3-110. remove three
3. Remove the output drive belt and motor, Figure 1. screws.
2
Remove
the belt
tensioner
spring.
1
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 11.4-110. Tighten the
screws.
6. Install the intermediate drive belt, REP 11.3-110.

REP 11.5-110 Bin 1 Drive Belts
Removal
WARNING
WARNING
1. Remove the 2K LCSS front and rear covers, REP 11.1-110.
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
8 and middle PWB
Move motor assembly standoffs, leaving the
to the right PWB attached by only
the top standoff.
9
Remove 2 screws and
upper pulley.
5
10 Release the
Disconnect PJ316 and release the belt tensioner
from behind the PWB and drive pulley. spring.
11 4
1 Fully lower bin 1.
Remove screw and Disconnect PJ318.
remove the belt clamp.
3
Remove 3 screws,
12 remove bracket
Remove 2 screws, lower with motor.
pulley and drive belt. 2
Remove E-clip and bearing.
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 2K LCSS.
1
If not already lowered, fully lower bin 1, refer 1. Reverse the removal procedure to replace the bin 1 drive belts.
to figure 1.
NOTE: The bin 1 level can critically affect the overall stack registration. Refer to ADJ
11.1-110 if adjustment is necessary.
2. Install the front and rear covers REP 11.1-110.
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 11.6-110 Tamper Assembly
Removal
WARNING
WARNING
1. Remove the 2K LCSS covers REP 11.1-110.
2. Prepare to remove the tamper assembly Figure 1.
3 1
4 Remove
Release the harness Release the harness from the retainer 2 screws
from all retainers along next to the paddle motor assembly, PL
the tamper assembly. 11.8 Item 10 2
Lift the tamper
assembly upwards
and remove from the
2K LCSS
Figure 2 Removing the tamper assembly

2 1
Disconnect the tamper
Disconnect 3 sensor harnesses and Replacement
motors harnesses.
release the harnesses from the retainers.
Reverse the removal procedure to replace the tamper assembly.
NOTE: Ensure that:

Figure 1 Preparing the tamper assembly
The slots in the tamper assembly locate correctly in the 2K LCSS frame.
3. Remove the tamper assembly, Figure 2. The sensors are correctly located in the tamper assembly, they are easily mis-located
when being re-connected to the harnesses.
All connectors in the harness over the tamper assembly are securely connected.

REP 11.7-110 Hole Punch Unit, Motor and Sensors
Removal
WARNING
WARNING
1. Remove the 2K LCSS covers, REP 11.1-110.
2. Remove and empty the chad bin, PL 11.6 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. Disconnect harnesses.
Disconnect the harnesses and remove the the PJ.
bracket assembly. 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 REP 11.8-110 Stapler Traverse Assembly
1. Reverse the removal procedure to replace the hole punch unit, motor assembly and sen- Parts List on PL 11.20.
sors.
2. If necessary, perform ADJ 11.3-110 Hole Punch Position.
Removal
NOTE: When installing the hole punch motor assembly, ensure that the belt tensioner arm
does not get trapped behind the motor assembly plate. WARNING
NOTE: Refer to IQS 6 Copy / Print Defects for hole punch performance specifications. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
WARNING
Take care not to topple the 2K LCSS. The 2K LCSS is unstable when un-docked from the
machine. Do not show the customer how to un-dock the 2K LCSS.
1. Un-dock the 2K LCSS, REP 11.13-110.
2. Remove the rear cover and front door cover assembly, REP 11.1-110.
3. Manually move the ejector, PL 11.18 Item 1 fully to the right.

Xerox WorkCentre 5790 Family 4-255 REP 11.7-110, REP 11.8-110
4. Disconnect the harness, Figure 1.
CAUTION
When removing and replacing the stapler traverse assembly, support the weight of the assem-
bly underneath the stapler and take care not to damage wiring.
5. Remove the stapler traverse assembly, Figure 2.
NOTE. For clarity the entry

guide cover is omitted
2 1
Remove 2 screws. Remove screw.
1 See CAUTION See CAUTION
Disconnect the group
of 4 connectors.
Figure 1 Harness disconnection
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 11.9-110 Staple Head Unit 3. Remove the staple head unit from the stapling unit Figure 1.

Removal 1
Remove 2
screws, remove
stapler cover.
WARNING
WARNING
1. Remove the stapler traverse assembly, REP 11.8-110.
2. Place the stapler traverse unit upside-down
2
Disconnect the
harness
3
Remove two screws and
remove the staple head unit.
Figure 1 Removing the staple head unit
Replacement
Reverse the removal procedure to replace the staple head unit.

REP 11.10-110 Ejector Assembly Sensors
Removal
WARNING Ejector motor encoder

Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord sensor. Remove 2
from the customer supply while performing tasks that do not need electricity. Electricity screws and cover to
can cause death or injury. Moving parts can cause injury. access the sensor
WARNING
WARNING
1. Disconnect the two harnesses between the 2K LCSS and the machine.
2. Un-dock the 2K LCSS, REP 11.13-110 and move it away from the machine.
3. Ensure the stapling unit is at the home position. Ejector out sensor
Q11-322
4. If necessary, manually move the ejector to the left position.
5. Remove the ejector assembly, Figure 1.
Ejector home
sensor Q11-320
1
Disconnect 2 bulkhead
connectors.
3
Lower the ejector
assembly, disengage
the dowels from the
mounting blocks and
remove.
2
Remove 3 screws.
Figure 1 Removing the ejector assembly
6. Remove the appropriate sensor by releasing the sensor tabs and disconnecting the
harness.

Replacement REP 11.11-110 Bin 1 Level Sensors
CAUTION Removal
When installing the ejector assembly onto the 2K 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. WARNING
WARNING
1. Remove the ejector assembly, REP 11.10-110.

2. Remove the stacker level sensors Figure 1. REP 11.12-110 Paddle Wheel Shaft Assembly
Removal
3
Remove 2
screws, remove WARNING
sensor support
assembly. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
1. Remove the stapler traverse assembly, REP 11.8-110.
4 2. Remove the tamper assembly, REP 11.6-110.
Release the sensors and
disconnect harnesses. 3. Remove bin 1, PL 11.2 Item 10.
2
Disconnect 2
connectors.
1
Remove two
screws and
harness
retainers.
Figure 1 Removing the stacker level sensors
Replacement
Reverse the removal procedures to replace the bin 1 level sensors.

REP 11.11-110, REP 11.12-110 4-260 Xerox WorkCentre 5790 Family
4. Remove the paddle motor assembly, Figure 1. 5. Prepare the rear components, Figure 2
1
Disconnect 2
harnesses
3
Remove the E-clip
and bearing
2
Remove the
gear assembly
4 3 2
Remove the Remove 2 Release the
paddle screws harness
motor from the
assembly retainer 1
Remove the E-clip
4 and flag
Remove 3 screws
Figure 2 Rear preparation
Figure 1 Paddle motor assembly

6. Prepare the front components, Figure 3. 8. Remove the paddle wheel shaft assembly, Figure 4
2
Slide the shaft
4 assembly to the
Remove the screw rear
3 and remove the
Disconnect the harness switch bracket
5
Remove 2 screws
3
Remove the
shaft assembly
2
Release the spring and
remove the switch actuator
1
Remove the E-clip
Figure 3 Front preparation
7. Ensure that the compiler ejector is in the home position (fully to the left).
1
Move the output
cover to the right
Figure 4 Paddle wheel shaft removal

Replacement REP 11.13-110 2K LCSS Un-Docking
1. Install the paddle wheel shaft, ensure that the pin on the rear of the safety gate switch Parts List on PL 11.4
cam, Figure 3, locates in the safety gate. Install the front E-clip.
2. Install the output cover, Figure 4, ensuring that the safety gate is aligned with the slots in
Removal
the output cover.
3. Install the rear bearing and E-clip.
WARNING
4. Install the switch bracket, 1 screw, connect the harness, Figure 3.
5. Install the gear assembly, ensuring that it locates onto the large D flat, Figure 2. from the customer supply while performing tasks that do not need electricity. Electricity
6. Install the flag and E-clip, ensuring that the flag locates on the small D flat, Figure 2. can cause death or injury. Moving parts can cause injury.
7. Ensure the paddles and flag are correctly aligned Figure 5. Install the motor assembly,
Figure 1.
WARNING
1 Take care during this procedure. Sharp edges may be present that can cause injury.
Align the paddles with the output cover
WARNING
1. If necessary, disconnect the harnesses between the 2K LCSS and the machine.
2. Open the 2K LCSS front door.
2
Ensure the
encoder flag is
within the sensor
Figure 5 Paddle alignment
8. Test the operation of the paddle roll, enter dC330, output code 11-025. 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.

3. Release the 2K LCSS link bracket assembly, Figure 1. REP 11.14-110 2K LCSS PWB
Removal
WARNING
WARNING
1. Remove the 2K LCSS rear cover assembly, REP 11.1-110.
1 2. Disconnect all harness connectors from the 2K LCSS PWB.
Press the latch block 3. Remove the three screws and release the three standoffs securing the 2K LCSS PWB.
forward to release both
latches.
Replacement
NOTE: Before replacing the 2K LCSS rear cover assembly, perform 11F-110 2K LCSS PWB
DIP Switch Settings RAP.
Reverse the removal procedure to replace the 2K LCSS PWB.
2
Roll the 2K LCSS away
from the machine.
Figure 1 2K LCSS link bracket assembly
Replacement
Line up the 2K LCSS latches to the machine apertures then push the two units firmly together
until they latch.

REP 11.15-110 Entry Guide Cover 4. Remove the entry guide cover, Figure 1

Removal
WARNING
Remove the cover
WARNING
WARNING
1. Remove the 2K LCSS front cover and 2K LCSS rear cover, REP 11.1-110.
2
2. Un-dock the 2K LCSS, REP 11.13-110. Remove 2 screws
3. Disconnect the harness to the entry sensor, PL 11.24 Item 3, at the rear frame.
1
Remove 2 screws
Figure 1 Entry guide cover removal

Replacement REP 11.16-110 Docking Latch Assembly
Refer to GP 6 before refitting the screws. Parts List on PL 11.4.
1. Bias the entry guide cover away from the paper guide when you tighten the screws. Removal
2. The clearance between the entry guide cover and the paper guide must be a minimum of
1mm. Refer to Figure 2.
WARNING
NOTE: If the clearance is less than 1mm, then install a new entry guide cover. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Check for a minimum can cause death or injury. Moving parts can cause injury.
clearance of 1mm
between the entry
guide cover and the WARNING
paper guide
WARNING
1. Remove the front and rear covers, REP 11.1-110.
2. Un-dock the 2K LCSS, REP 11.13-110.
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.

3. Prepare to remove the docking latch assembly, Figure 1. 4. Remove the docking latch assembly, Figure 2.
1
Release the
harness
retainer
2
Disconnect
the switch
harness
2 Flanged
Remove 2 screws
hole
Flanged hole 3
Remove 2
screws
1
Disconnect P/J302 4
Remove the latch assembly
Figure 1 Prepare to remove the latch 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.

REP 11.17-110 Ejector Belt 2. Remove the ejector belt, Figure 1.

Removal
WARNING
WARNING
1. Remove the ejector assembly, refer to REP 11.10-110. 1
Belt grip. Remove the clip.
3
Remove the pulley
then the ejector belt.
2
Remove the E-clip.
Figure 1 Remove the ejector belt
Replacement
2. Ensure that the ejector belt is correctly engaged with the belt grip on the ejector assembly
before the clip is reinstalled. Refer to Figure 1.

REP 11.1-120 1K LCSS Covers NOTE: Removing the top cover first will allow easy removal of the front and rear covers.

Removal
4
Remove the front door
WARNING cover assembly.
3
Open the front door,
WARNING remove three screws.
1. Remove the covers, Figure 1.
1
Open the exit cover.
Remove two screws,
then the top cover.
2
Remove two screws,
then the rear cover.
Figure 1 Removing the covers
Replacement
Reverse the removal procedure to replace the covers.

REP 11.2-120 Input Drive Belt and Transport Motor 1 Replacement
Parts List on PL 11.110. 1. Place the belt around the pulleys.
Removal NOTE: Ensure that the shoulder screw is installed in the correct position. Refer to Figure
1.
2. Install the motor screws, but do not tighten.

WARNING
3. Install the spring.
4. Rotate the shaft by hand to ensure the belt runs smoothly over the pulleys and allow the
spring to tension the belt, ADJ 11.2-120.
5. Tighten the motor screws and re-connect the harness.
WARNING
2. Remove transport motor 1 and the input drive belt, Figure 1.
4
Remove the drive belt.
3
transport motor 1.
Shoulder screw.
2
Remove the spring.
1
Disconnect PJ17.

REP 11.3-120 1K LCSS Stability Foot 2. Remove the stability foot, Figure 1.

Removal
WARNING
Locating pin
WARNING
1. Remove the 1K LCSS, REP 11.11-120. 2
Push down the front locking
tab. Remove the stability foot.
Locating pin
1
Push down the rear locking
tab. Release the rear of the
stability foot.
Figure 1 Removal
Replacement
Align the slots in the stability foot with the locating pins under the machine. Firmly push the sta-
bility foot into position.

REP 11.4-120 Paper Output Drive Belt and Transport Motor 4. Remove transport motor 2, Figure 2.
2
Parts List on PL 11.120. 3
Removal Remove transport
motor 2.
WARNING
WARNING
1. Remove the 1K LCSS top cover and rear cover, REP 11.1-120.
2. Remove the intermediate drive belt, PL 11.118 Item 4.
3. Remove the paper output drive belt, Figure 1.
2
Remove 2 screws.
1
Loosen the screw.
2
Release the tension on
the paper output drive
belt. Re-tighten the
screw.
3 1
Remove the paper Disconnect the in-
output drive belt. line PJ.
Figure 2 Removing transport motor 2
Replacement
2. Manually rotate the paper output drive belt to allow the spring to tension the belt, ADJ
11.2-120.
Figure 1 Removing the paper output drive belt

REP 11.5-120 Bin 1 Drive Belts NOTE: Keep all of the components removed as a set. The set of rear frame components
are different from the front frame set.
Parts List on PL 11.106. 5. Prepare to remove the rear bin 1 drive belt, Figure 1.
Removal
WARNING
5
Remove the bin 1
elevator motor and
bracket.
WARNING
1. Enter dC330, code 11-032, bin 1 elevator motor down. Fully lower bin 1.
2. Open the 1K LCSS front door, PL 11.100 Item 4.
3. Switch off the machine.
4. Remove the 1K LCSS rear cover and front cover, REP 11.1-120.
4
Remove 3 screws.
3
Remove the E-clip and
bearing.
1 2
Release the tensioner spring. Disconnect PJ6, PJ4, PJ1, PJ3 and
PJ12. Release the harnesses from
the 2 cable clamps.

6. Remove the rear bin 1 drive belt, Figure 2. 7. Remove the bin 1 drive belt (front) Figure 3.
4 3
Remove two screws
Remove 2 screws then
then the upper pul-
the upper pulley.
ley.
4
Remove screw and front
belt clamp. Remove the
belt.
Standoff.
3
Disconnect PJ.
1
Release the tensioner
spring.
2
Remove 3 screws
marked A. Release 1
standoff.
1 2
5 Remove 2 screws then the lower pulley. Remove two screws then
Remove 1 screw from the belt clamp. the lower pulley.
Remove the belt.
Figure 2 Bin 1 drive belt removal (rear) Figure 3 Bin 1 drive belt (front)
Replacement
NOTE: Ensure the correct set of components are used for each side of the 1K LCSS.
1. Reverse the removal procedure to replace the bin 1 drive belts.
NOTE: Bin 1 level can critically affect the overall stack registration. Refer to ADJ 11.1-120
if adjustment is necessary.

REP 11.6-120 Tamper Assembly 2. Prepare to remove the tamper assembly, Figure 1.

1
Removal Disconnect 3 sensor harnesses
and release the harnesses from
the retainers.
WARNING
WARNING
1. Remove the 1K LCSS covers REP 11.1-120.
4
Release the harness from the
retainer next to the paddle
motor assembly, PL 11.104
Item 10.
2 3
Disconnect the tamper Release the harness from all retainers
motors harnesses. along the tamper assembly.
Figure 1 Preparing the tamper assembly

3. Figure 2, remove the tamper assembly. REP 11.7-120 Stapler Assembly and SH1 Paper Sensor
Removal
WARNING
WARNING
1. Remove the 1K LCSS covers, REP 11.1-120.
2. Manually move the ejector, PL 11.114 Item 1 fully to the right (out position).
3. Prepare to remove the staple head unit and mounting bracket, Figure 1.
1
Remove 2 screws 1
Remove 2 screws.
2
Lift the tamper assembly upwards and
remove from the 1K LCSS.
Figure 2 Removing the tamper assembly
Replacement 2
Reverse the removal procedure to replace the tamper assembly. Disconnect the bulk-
head connector.
NOTE: Ensure that:
The slots in the tamper assembly locate correctly in the 1K LCSS frame.
The sensors are correctly located in the tamper assembly, they are easily mis-located
when being disconnected and re-connected to the harnesses.
All connectors in the harness over the tamper assembly are securely connected.

CAUTION CAUTION
When removing and replacing the stapler assembly, support the weight of the assembly under- When removing the SH1 paper sensor, do not damage the actuator for the SH1 cartridge sen-
neath the stapler and take care not to damage wiring. sor, Figure 3.
4. Remove the stapler assembly, Figure 2. 5. Remove the SH1 paper sensor, Figure 3.
3
Remove the SH1
paper sensor.
SH1 cartridge
sensor actuator
2
Remove 3 screws.
1
Remove 2 screws.
1
Disconnect the PJ.
2
Remove the stapler assembly.
See CAUTION.
Figure 2 Removal Figure 3 SH1 paper sensor removal
Replacement
Reverse the removal procedure to replace the staple head unit.

REP 11.8-120 Ejector Assembly and Sensors 3. Remove the ejector assembly, Figure 1

Removal
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Ejector motor encoder sensor.
WARNING
Remove 2 screws and
1. If necessary, manually move the ejector to the right (out position).
cover to access the sensor.
2. Remove the docking latch, REP 11.14-120.
NOTE: Do not disconnect the docking interlock switch.
Ejector out sensor

Q11-322
Ejector home
sensor Q11-320
1
Disconnect 2 bulkhead
connectors.
2
Remove 3 screws.
3
Lower the ejector assembly,
disengage the dowels from the
mounting blocks and remove.
Figure 1 Removing the ejector assembly
4. Remove the appropriate sensor by releasing the sensor tabs and disconnecting the harness.

Replacement REP 11.9-120 Bin 1 Upper Level Sensor
CAUTION Removal
When installing the ejector assembly onto the 1K 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. WARNING
WARNING
1. Remove the ejector assembly, REP 11.8-120.
2. Remove the bin 1 upper level sensor, Figure 1.
3
Unclip the sensor.
2 1
Remove two screws, then the Disconnect the harness.
sensor support.
Figure 1 Removing the stacker level sensors
Replacement
Reverse the removal procedures to replace the bin 1 upper level sensor.

REP 11.10-120 Paddle Wheel Shaft Assembly 2. Remove the paddle motor assembly, Figure 1.

Removal 2
Disconnect PJ.
WARNING
WARNING
1. Remove the tamper assembly, REP 11.6-120.
3
Remove 2 screws.
4
1 Remove motor
Disconnect PJ14. assembly.
Figure 1 Paddle motor assembly

3. Prepare the rear components, Figure 2. 4. Prepare the front components, Figure 3.
3
Remove 3 screws 2
marked A. Remove 3 screws
marked A.
1 2
Remove E-clip and Remove E-clip and bearing 1
flag. Remove E-clip and bearing.
Figure 2 Rear preparation Figure 3 Front preparation
5. Ensure that the compiler ejector is fully to the left (home position).

6. Remove the paddle wheel shaft assembly, Figure 4. Replacement
1. The replacement is the reverse of the removal procedure. Ensure the paddles and flag
are correctly aligned, refer to Figure 5.
1
Remove the output
cover. 1
2 Align paddles with the output cover.
Remove the shaft assembly. 2
Ensure the encoder flag is within the sensor.
Figure 4 Paddle wheel shaft removal
Figure 5 Paddle alignment
2. Test the operation of the paddle roll, enter dC330, output code 11-025. 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 11.11-120 1K LCSS Removal
Removal
WARNING
WARNING
WARNING
Use safe handling procedures when removing the module, GP 16. The module is heavy.
NOTE: The 1K LCSS weight is 21Kg (46lb).
1. Disconnect the harnesses between the 1K LCSS and the machine.

2. Remove the 1K LCSS bin 1, PL 11.100 Item 10.
2
3. Remove the 1K LCSS top cover, refer to REP 11.1-120.
Pull the latch block forward to
4. Open the 1K LCSS front door. release both latches.
5. Prepare to remove the 1K LCSS, Figure 1.
1
Remove 2 thumb-
screws from under-
neath the 1K LCSS.
Figure 1 1K LCSS link bracket assembly
6. Close the 1K LCSS front door.

7. Remove the 1K LCSS, Figure 2. REP 11.12-120 1K LCSS PWB
1 Removal
Slide the 1K LCSS away from the
machine to disengage the latches and
bottom bracket.
WARNING
WARNING
2. Disconnect all harness connectors from the 1K LCSS PWB.
3. Remove the three screws and release the three standoffs securing the 1K LCSS PWB.
Replacement
1. Reverse the removal procedure to replace the 1K LCSS PWB.
2. Before replacing the 1K LCSS rear cover, perform the 11F-120 1K LCSS PWB DIP Switch
Settings RAP.
2
Use the lifting handles to
remove the 1K LCSS from
the mounting bracket.
Support pins (front and

rear)
Docking latch (front

and rear) Bottom bracket
Figure 2 1K LCSS removal
Replacement
2. Ensure that the bottom bracket on the 1K LCSS is located over the support pins. Line up
the 1K LCSS latches to the machine apertures then push the two units firmly together
until they latch.

REP 11.13-120 Entry Guide Cover
Removal
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity Remove 2 screws
WARNING
1. Remove the 1K LCSS, REP 11.11-120.
2. Remove the 1K LCSS front cover and rear cover, REP 11.1-120.
3. Remove the entry guide cover, Figure 1.
1
Disconnect the
bulkhead connector
4
Remove the cover
3
Remove 2 screws
Figure 1 Entry guide cover removal

Replacement REP 11.14-120 Docking Latch Assembly and Docking
Refer to GP 6 before refitting the screws. Interlock Switch
1. Bias the entry guide cover away from the paper guide when you tighten the screws. Parts List on PL 11.102.
2. The clearance between the entry guide cover and the paper guide must be a minimum of Removal
1mm. Refer to Figure 2.
NOTE: If the clearance is less than 1mm, install a new entry guide cover.
WARNING
Check for a minimum
clearance of 1mm
between the entry
guide cover and the WARNING
paper guide Take care during this procedure. Sharp edges may be present that can cause injury.
1. Remove the 1K LCSS, REP 11.11-120.
2. Prepare to remove the docking latch assembly, Figure 1.
4
Remove 2 screws
2
Release 2 harness
retainers.
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.
3
Pull the harness
through the flanged
hole.
1
Disconnect PJ6.

3. Remove the docking latch assembly, Figure 2. REP 11.15-120 Ejector Belt
Removal
WARNING
3
Remove the latch
assembly
WARNING
1. Remove the ejector assembly, refer to REP 11.8-120.
1
Release the harness
retainer
2
Remove 2 screws
Figure 2 Latch assembly removal
4. Remove the sensor cover, PL 11.102 Item 1.

5. Release the docking interlock switch from the sensor cover.
Replacement
Reverse the removal procedure to replace the docking latch assembly.
CAUTION
Ensure that the harness is put through the flanged hole, refer to Figure 1.

2. Remove the ejector belt, Figure 1.
1
Belt grip. Remove the clip.
.
3
Remove the pulley
then the ejector belt.
2
Remove the E-clip.
Figure 1 Remove the ejector belt
Replacement
2. Ensure the ejector belt is correctly engaged with the belt grip on the ejector assembly
before the clip is reinstalled. Refer to Figure 1.

REP 11.1-171 HVF Covers
Removal
WARNING
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 hinge pin.
Remove the HVF covers as follows:
1. Remove the front door, Figure 1. If required, remove 5 screws to separate the door sup-
port from the front door.
2
Remove the hinge pins (2 places).
Figure 1 Front door removal

2. Remove the top cover, Figure 2. 3. Remove the front cover, Figure 3.
NOTE: If an inserter is installed, remove the inserter, REP 11.82-171. NOTE: The top cover must be removed before removing the front cover.
4
Remove 2 screws.
3
Lift the top tray.
5
2 Remove the top cover.
Remove 2 screws. 1
1
Remove the inserter cover or 3 2 Remove 6 screws.
inserter, see NOTE. Remove the front cover. Lift the cover to disengage the
bottom locating tabs form the
frame.
Figure 2 Top cover removal Figure 3 Front cover removal

4. Remove the rear cover, Figure 4.
NOTE: The top cover must be removed before removing the rear cover.
1
Remove 6 screws,
then the vent cover.
2
Remove 3
screws.
1
Remove 2 2
screws. Remove 3 screws,
then the foot cover.
3
4 Lift the rear cover to disengage
Figure 5 Vent and foot covers removal
Remove the rear cover. the bottom locating tabs from
the frame.
Replacement
Figure 4 Rear cover removal 1. Reverse the removal procedure to reinstall the HVF covers.
2. Depending on the installed options and the covers removed, refit covers in the following
5. Remove the vent cover and foot cover, Figure 5. To provide enough room to remove the
sequence:
vent cover, undock the HVF, REP 11.13-171.
a. Vent cover.
NOTE: The top front cover and rear cover must be removed before removing the vent b. Foot cover (if a tri-folder is not installed).
cover and foot cover.
c. Rear cover.
NOTE: The foot cover in not installed if a tri-folder is installed. d. Front cover
e. Top cover.
f. Inserter cover (if a inserter so not installed).
g. Front door.

REP 11.2-171 HVF Stapler Assembly 6. Figure 1. At the rear of the HVF, disconnect three connectors and remove one screw
securing the grounding strap.
Removal
WARNING
WARNING
1. Slide the HVF away from the IOT.
2. Remove the HVF front door, REP 11.1-171.
3. Remove the HVF top cover, REP 11.1-171.
4. Remove the HVF front cover, REP 11.1-171.
5. Remove the rear cover, REP 11.1-171.
1
Disconnect three PJs
2
Remove grounding
strip screw
REAR VIEW
Figure 1 Disconnect PJs and remove screw

7. Figure 2. With the power cord disconnected, it is possible to reach behind the stapler and 8. Figure 3. At the HVF rear, turn the back stop latch as indicated, to release the back stop.
move the ejector unit to the out position, by turning the encoder of the ejector unit motor, The back stop will move in the outboard direction.
MOT11-020 in the direction indicated.
Backstop
Turn the latch
Turn the encoder wheel

Stapler (shown
in faint lines)
REAR VIEW
Figure 3 Releasing the back stop

Figure 2 Move ejector to the out position

9. Remove the stapler assembly, Figure 4. REP 11.3-171 Top Tray
Removal
WARNING
WARNING
Remove the top tray as follows:
1 1. If fitted, undock the inserter, REP 11.82-171.
Remove the screw 2. Remove the top and rear covers REP 11.1-171.
3. Disconnect the links from the tray, Figure 1.
2
Slide the stapler
assembly forward
Figure 4 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. At the HVF rear, pull the back stop to the rear and hold it there while turning the back stop
latch clockwise. Release the back stop, which should slide forward until stopped by the
latch.
3. Reconnect all PJs and re-install the screws.
1
Lift the tray and pull the
link eyes from the lugs 2
on the tray Remove the pin
and spring
Figure 1 Link disconnection

4. Remove the bias spring and pin, Figure 1. REP 11.4-171 Bin 1 Removal
5. Remove the shaft front and rear circlips and bushes. Lift the top tray from the shaft, Figure
2.
Removal
NOTE: Remove the idler pulley to avoid straining the drive belt when removing the shaft
drive pulley.
WARNING
5 4 Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Remove the top tray. Remove the E-clip and from the customer supply while performing tasks that do not need electricity. Electricity
bearing. can cause death or injury. Moving parts can cause injury.
WARNING
1. Remove the E-clip and lift bin 1 to release bin 1 from the lift bar. Figure 1
3
Remove the E-clip
and bearing.
2
Remove the
inner belt idler
and pulley.
1
Remove the E-clip
and outer pulley.
Figure 2 Shaft drive and support bushes
Replacement
Reverse the removal procedure to reinstall the HVF top tray.

REP 11.5-171 Right Side-Cover Removal
Removal
WARNING
WARNING
1. With the machine powered, use the PTU or control code 11-032 to lower Bin 1.
2. Remove bin 1, REP 11.4-171, then remove the right side cover, Figure 1.
2
Lift bin 1 to release the
bin from the lifting bar
1
Remove the E-clip
Figure 1 Bin 1 removal
Replacement
Reverse the removal procedures to reinstall bin 1.

3. Remove 6 screws then remove the right side-cover, Figure 1. REP 11.6-171 HVF Ejector Assembly Removal
Removal
WARNING
1
Lower the lifting bar
WARNING
1. Remove bin 1, REP 11.4-171.
2. Remove the right side-cover, REP 11.5-171.
3. Remove the front door, top cover, front cover and rear cover, REP 11.1-171.
4. Remove the front and rear pressing plate fingers, REP 11.7-171.
5. Remove the front tamper motor assembly, REP 11.11-171.
6. Remove the front tamper arm, PL 11.153 Item 5.
2
Remove 6
screws
Figure 1 Right side cover
Replacement
Reverse the removal procedures to reinstall the right side cover.

7. Remove the ejector front cover, Figure 1. 8. Prepare to remove the belt cover, Figure 2.
2
Disconnect the PJ to the
bin 1 rear wall sensor,
Q11-196.
1
2 Remove 2 screws.
Remove the ejector
front cover. 1
Remove 2 screws.
FRONT VIEW
Figure 1 Ejector front cover Figure 2 Belt cover

9. Remove the belt cover and pressing plate bracket, Figure 3. 10. Prepare to remove the ejector module, Figure 4.
1
Note the routing of the
ejector assembly harness.
2 1 3 2
Flex the ejector cover from the shaft Remove 2 screws. Remove the pressing plate Disconnect the ejector assembly
of the support finger drive gear. bracket. harness, 4 connectors.
REAR VIEW
Figure 3 Pressing plate bracket removal Figure 4 Disconnect the harness

11. Remove the ejector assembly, Figure 5. Replacement
NOTE: Set the front and rear support fingers so that their ends are aligned when extended.
Refer to REP 11.8-171.
1. Prepare to reinstall the ejector assembly, Figure 6.

2. Reverse the removal procedures to reinstall the ejector assembly.
Location slot Offset module 1

Route the harness under
the rear tamper assembly.
2 1
Remove the ejector Remove 2 screws
assembly and the earth wire
2 Ejector assembly
Figure 5 Ejector assembly removal Ensure the base plate location tab is inserted
through the location slot in the offset module. Base plate location tab
Figure 6 Reinstall the ejector assembly
3. When reinstalling the front tamper and the ejector front cover make sure that the correct
screws are used and that the screws are not overtightened GP 6.
4. When refitting the pressing plate, the shaft of the front support finger drive gear must fit
into the ejector assembly cover, refer to Figure 3.

REP 11.7-171 Pressing Plate Fingers REP 11.8-171 Front and Rear Support Fingers
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the right side-cover REP 11.5-171. 1. Remove the right side cover REP 11.5-171.
2. Remove the screws then lower the pressing plate fingers through the cover slots, Figure 2. Remove the ejector assembly REP 11.6-171.
1. 3. Remove the ejector front plate and support finger assembly, Figure 1.
Rear Pressing
Plate Finger
Front Pressing
Plate Finger 2 1
Remove the fingers Remove 2 screws
Front Tamper Base. Ejector front plate
Figure 1 Pressing plate fingers
Replacement Figure 1 Ejector front plate

Reverse the removal procedures to replace the front and rear pressing plate fingers.

4. Remove the front tamper base and front support finger, Figure 2. 5. Remove the guide and the rear support finger, Figure 3.
Rotate the finger to disen-

gage the pin from the guide
slot.
1 Front Tamper Finger Guide 2

Remove the screw Base Rotate the finger to dis-
and clip engage the pin from the Rear support finger guide
guide slot.
Figure 2 Front support finger Figure 3 Rear support finger

Replacement REP 11.9-171 HVF Offset Motor Assembly
1. Reverse the removal procedure to replace the front or rear support fingers. Parts List on PL 11.140
NOTE: Set the front and rear support fingers so that their ends are aligned when extended. Removal
Refer to Figure 4.
2. With the pressing plate installed, set the front and rear support finger alignment, Figure 4.
If the fingers are not aligned, the compiler output will be uneven and cause exit jams. WARNING
WARNING
1. Remove the right side cover REP 11.5-171.
2. Remove the offset motor and gear assembly, Figure 1.
3 2 1
Rotate the encoder Remove the clip and Remove the rear Encoder Wheel
wheel until the finger disengage the gear. pressing plate finger 1
ends align. Disconnect the
grounding wire
2
Disconnect the
CORRECT INCORRECT motor PJ.
3
Remove the
bracket front and
rear screws
4 5
Re-engage the gear and Replace rear pressing
refit the circlip plate finger
Figure 1 Offset motor and gears
Figure 4 Support finger end alignment

Replacement
Reverse the removal procedures to reinstall the offset motor assembly.

REP 11.10-171 Stacker Idler Rolls Replacement
Parts List on PL 11.145 1. Refer to Figure 2. Ensure the sprung brackets are parallel and re-install the idler rolls in
the sprung brackets.
Removal
WARNING
WARNING Incorrect Correct

1. Lift the top tray.
2. Refer to Figure 1. Raise the paper pusher and remove the four stacker idler rolls. Figure 2 Correct spring bracket position
2. Check that the rolls are held securely.
1
Raise the paper
pusher
Idler rolls
3
Remove the roll
2
Ease spring brackets
outwards
Figure 1 Paper pusher and idler rolls

REP 11.11-171 Front Tamper Motor Assembly
3
Parts List on PL 11.140 Disconnect the
Removal motor harness.
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity Remove 3
can cause death or injury. Moving parts can cause injury. screws.
WARNING
1. Remove the front door and front cover REP 11.1-171.
2. Remove the front tamper motor assembly, Figure 1.
5
Remove the front
tamper motor
assembly.
2 1
Disconnect the 2 sensor harnesses. Remove screw to release
the front tamper arm.
Figure 1 Front tamper motor assembly
Replacement
Reverse the removal procedures to reinstall the front tamper drive assembly.

REP 11.12-171 Bin 1 Elevator Motor Assembly NOTE: The pulley pin may fall when the pulley is removed.

7 1
Removal Release
Remove the
the wiring
motor assembly
from the
WARNING clamps
WARNING
1. Remove the front and rear covers, REP 11.1-171.
2. Remove the rear drive belt lower pulley to relieve the belt tension.
3. Remove the bin 1 elevator motor assembly, Figure 1.
6
Remove 2 screws
4 2
Remove the pin Remove the circlip and
and the bearing the upper pulley
5 3
Disconnect T211 (bin 1 elevator motor harness) Remove 2 screws
and T601 (bin 1 encoder sensor)
Figure 1 Bin 1 elevator motor assembly
Replacement
1. Reverse the removal procedures to reinstall the stacker motor gearbox assembly.
NOTE: Check that the flats on the shaft bearing align with the cut-outs in the bracket.
2. Check that the bin 1 lift bar is level before refitting the stacker belt lower pulley.

REP 11.13-171 HVF and HVF BM Un-Docking
Removal
WARNING
WARNING
CAUTION
Do not show the customer how to un-dock the HVF or HVF BM. 1
Pull the lever forward to release both latches
1. Open the front door.
2. Release the docking latch and move the HVF or HVF BM to the right, away from the IOT,
Figure 1.
2
Roll the HVF to the right
away from the IOT
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 IOT and the HVF or HVF BM if necessary.
Replacement
CAUTION
Take care to align the HVF to the right side of the IOT before rolling the HVF into position. Mis-
alignment will damage or break the interlock actuator.
Reverse the removal procedure to dock the HVF or HVF BM.

REP 11.14-171 HVF Top Jam Clearance Guide Assembly 3. Remove the inboard pivot screw, Figure 2.

Removal
WARNING
WARNING
1. Remove the HVF front door, top cover, front cover and rear cover, REP 11.1-171.
2. .Remove the outboard pivot screw, Figure 1.
Remove the inboard

pivot screw
REAR VIEW
Figure 2 Inboard pivot screw
Remove the outboard

pivot screw
Figure 1 Outboard pivot screw

4. Remove the jam clearance assembly, Figure 3. REP 11.15-171 HVF Rear Tamper Assembly
Removal
WARNING
WARNING
1. Remove the rear cover REP 11.1-171.
2. Remove the right side cover REP 11.5-171.
3. Remove the ejector assembly REP 11.6-171.
4. Remove the support finger motor assembly, PL 11.140 Item 9.
Twist the assembly

and lift upwards
Figure 3 Assembly removal
Replacement
The replacement procedure is the reverse of the removal procedure.

5. Remove the rear tamper assembly, Figure 1. Replacement
CAUTION
Check that the Ejector cable harnesses are routed below rear tamper assembly and do not
obstruct any moving parts.
1. Reverse the removal procedures to reinstall the rear tamper assembly.
2. Turn the offset drive gear to position the offset carriage so that the rear tamper assembly
can be positioned on the locating pins.
1
Disconnect 3 PJs.
4 3 2
Remove the rear tamper Remove 2 screws. Disen- Turn the offset motor gear to
assembly through the gage the 2 locating pins on move the offset carriage to the
opening created by the left side. front.
removing the ejector (see
NOTE).
Figure 1 Rear tamper assembly
NOTE: To ease the removal of the rear tamper assembly, remove the cable clamps that
secure the pressing and support encoder sensor harness to the rear tamper assembly.
Also, turn the offset motor gear to move the offset carriage to the rear.

REP 11.16-171 BM Flapper 2. Remove the BM flapper bracket assembly, Figure 1.

Removal
WARNING
WARNING
1. Open the HVF BM front door and fully pull out the BM module.
2
Disengage the
drive belt. 1
3 Remove 4 screws
4 and the ground
Remove the BM Disconnect the
BM flapper roll wire.
flapper bracket
assembly. home sensor.
Figure 1 Remove the BM flapper bracket

3. Remove the BM flapper assembly, Figure 2. REP 11.17-171 BM PWB
Removal
WARNING
WARNING
1. Remove the top cover, then the rear cover, REP 11.1-171.
2
1 Remove the BM flapper
Remove the KL-clip and assembly.
the bearing.
Figure 2 BM flapper assembly removal
4. Remove the BM flapper, Figure 3.
1
2 Remove the E-
3 Remove the KL-clip, then clip, pin, then the
Remove the KL-clip, then the bearing. pulley.
the bearing.
Figure 3 BM flapper removal
Replacement

2. Remove the BM PWB, Figure 1. Replacement
CAUTION
Figure 1, 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 booklet maker 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 Finisher /
DFA Location 12.
Check and perform the adjustments that follow:
ADJ 11.5-171 Booklet Tamping
ADJ 11.6-171 Booklet Compiling Position.
ADJ 11.7-171 Booklet Crease Position
ADJ 11.8-171 Booklet Staple Position
Bin 2 harness
Harness retainers 1
Disconnect all PJs
BM harnesses
2
3 Remove 8 screws and
If necessary, release harnesses remove the PWB
from the retainers to allow the
PWB to be removed
Figure 1 PWB removal

REP 11.18-171 BM Crease Blade Motor
Purpose
This procedure is used to repair the following components:
BM crease blade motor encoder sensor, PL 11.165 Item 1.
Motor encoder, PL 11.165 Item 4.
Bearing, PL 11.165 Item 7.
Crank, PL 11.165 Item 8.
Removal
WARNING
WARNING
2. Remove the crease blade knob (6d), PL 11.161 Item 4.
3. Remove the crease roll handle (6c), PL 11.161 Item 5.
4. Remove the BM front cover, PL 11.161 Item 3.
5. Remove the left frame plate, PL 11.162 Item 2.
6. Remove the motor cover, PL 11.165 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. Remove the BM crease blade motor assembly, Figure 1.
7
Remove the motor
assembly from the frame
3
Remove the circlip, rear
crank and bearing
2
Remove the E-clip and
bearing, release the con-
necting rod
6 5 4
Disconnect the Remove circlip, Remove E-clip and
motor harness front crank and bearing, release the
bearing connecting rod
1
Remove 4 screws
Figure 1 Removing the motor assembly

8. Remove the BM crease blade motor, Figure 2. REP 11.19-171 BM Crease Roll Motor
Removal
WARNING
1 WARNING
Support the encoder
and slide out the shaft
3 1. Remove the top cover, then the rear cover, REP 11.1-171.
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.

3. Remove the motor assembly, Figure 1. REP 11.20-171 BM Backstop Motor Assembly
NOTE: As necessary, cut any tie wraps securing the crease roll motor harness. Parts List on PL 11.163
Purpose
Ground wire, PL 11.163 Item 1.
Motor damper, PL 11.163 Item 3.
BM backstop motor, PL 11.163 Item 4.
BM backstop drive belt, PL 11.163 Item 11.
Removal
WARNING
WARNING
5
Pull the motor
assembly off
the shaft
4
Remove the
1 encoder disc
Remove 3
screws
3
Disconnect
the motor
harness
2
Remove the circlip
Replacement
Reverse the removal procedure to replace the BM crease roll motor.

2. Remove the BM backstop motor, Figure 1. REP 11.21-171 BM Backstop Assembly
1 Removal
Remove
allen key
and spring
WARNING
2
Remove WARNING
4 screws Take care during this procedure. Sharp edges may be present that can cause injury.
1. Remove the booklet maker, REP 11.61-171.
2. Rotate the crease roll handle (6c), fully counter clockwise.
3 5. Remove the BM front cover, PL 11.161 Item 3.
Disconnect the
motor harness
6
Remove 2 screws to release the motor
from the bracket, remove 2 screws to
remove the motor and ground wire from
the damper
5
Remove the belt
4
Free the motor pulley from the belt
and lift out the motor assembly
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.

7. Remove the belt clamp, Figure 2.
CAUTION
The BM harnesses and the backstop assembly harnesses are connected with a catch. Ensure
the catch is released when disconnecting the solenoid harnesses.
6. Remove the two harness clamps, Figure 1.
1
Remove 2 screws
Lay down the BM assembly to access the
backstop assembly.
1
Use a flat blade screwdriver
to push out the harness
clamp.
2
Remove the belt clamp
Figure 2 Belt clamp

2
Use a flat blade screwdriver
8. Use the allen key, PL 11.163 Item 9 to remove the 2 screws and remove shaft support, PL
to push out the harness
clamp. 11.164 Item 10.
9. Prepare to remove the shaft from the frame, Figure 3.
Frame locator
Figure 1 Remove the two harness clamps
2
Remove the E-clip
1
Move the shaft
10. Move the backstop assembly to the bottom of the BM assembly.

11. Remove the shaft from the BM backstop assembly, Figure 4. Replacement
1. Reverse the removal procedure to replace the backstop assembly.
2. When installing the shaft ensure that the anti-play shoe has not moved out of position,
Figure 6.
Correct position of the anti-play

shoe.
Ensure that the shaft is gripped
securely.
1
Remove the shaft through the BM backstop assembly
bottom of the BM assembly Incorrect position of the anti-play
shoe.
Figure 4 Remove the shaft
12. Remove the BM backstop assembly, Figure 5.
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
11.163 Item 9.
6. Go to ADJ 11.9-171 and complete the adjustments.
1 2 3
Flex the belt Rotate the BM back- Slide the BM backstop under
upwards stop into this position the belt
Figure 5 Remove the backstop assembly

REP 11.22-171 BM Entry Roll 5. Remove the BM Entry Roll, Figure 1.

Purpose 1
This procedure is used to repair the following components: Remove E-clip, bearing,
BM entry roll pulley, PL 11.161 Item 14. pulley and belt.
BM entry roll, PL 11.161 Item 15.
Removal
WARNING
WARNING
3. Remove the crease roll handle (6c), PL 11.161 Item 5. 2
4. Remove the BM front cover, PL 11.161 Item 3. 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 11.10-171.

REP 11.23-171 BM Entry Sensor
Removal
WARNING
WARNING
5. Remove the BM entry sensor, Figure 1.

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 11.24-171 BM Crease Roll Gate Motor REP 11.25-171 BM Compiler Motor and BM Flapper Motor
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the top cover, then the rear cover, REP 11.1-171. 1. Remove the top cover, then the rear cover, REP 11.1-171.
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
2 motor assembly
Remove 2
screws
3
Disconnect the
motor harness
3
Remove 3 screws
2
Disconnect the
ground strap
4
Remove the 1
motor assembly Disconnect the
harness
Figure 1 Motor assembly removal Figure 1 Motor assembly removal
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 11.26-171 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 11.163 Item 15. and pulley
BM backstop link, PL 11.163 Item 16.
BM backstop drive shaft, PL 11.164 Item 14.
BM backstop belt, PL 11.163 Item 7.
BM back stop bearing, PL 11.163 Item 11.
BM back stop idler bracket, PL 11.163 Item 12.
Removal
WARNING
WARNING
5. Remove the LH frame plate, PL 11.162 Item 2.
6. Remove the BM tamper assembly, REP 11.30-171.
7. Remove the backstop motor assembly, REP 11.20-171.
8. Remove the backstop assembly, REP 11.21-171.
9. Remove the crease blade assembly, REP 11.36-171. 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 11.27-171 BM Staple Heads
1 Removal
Remove KL-clip, tensioner
link and bearing
2 WARNING
Slide the shaft
to one side Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
1. Fully pull out the BM module.
2. Remove the relevant staple head cover, PL 11.168 Item 14.
3. Pull the stapler bracket handle, PL 11.168 Item 9. Open the staplers fully.
3
Remove the belt NOTE: If a 5.5 mm socket and short extension is not available or access to the staple head
securing screws is difficult, remove the BM stapler bracket assembly, REP 11.28-171, then
remove the relevant staple head.
Figure 4 Backstop belt removal 4. Figure 1, remove the relevant staple head.
Replacement
1. Reverse the removal procedure to replace the removed components.
2. Allow the BM backstop belt to be tensioned correctly before the bracket assembly secur-
ing screws are tightened. Refer to Figure 3.

REP 11.28-171 BM Stapler Bracket Assembly
Purpose
This procedure is used to repair the following parts:
Front follower, PL 11.168 Item 1.
Actuator, PL 11.168 Item 2.
Rear follower, PL 11.168 Item 3.
Spring, PL 11.168 Item 4.
BM paper present sensor Q11-190, PL 11.168 Item 5.
Latch slide, PL 11.168 Item 6.
Staple bracket handle, PL 11.168 Item 9.
Stapler bracket assembly, PL 11.168 Item 10.
2
Loosen 1 screw Torsion spring, PL 11.168 Item 11.
using a 5.5mm Bearing, PL 11.168 Item 12.
socket and Spring, PL 11.168 Item 13.
ratchet driver
BM stapler head carrier closed sensor Q11-421, PL 11.168 Item 18.
Lower shaft, PL 11.168 Item 19.
Upper shaft, PL 11.168 Item 20.
Removal
WARNING
WARNING
2. Remove 4 screws securing the BM PWB mounting plate to the frame, allow the PWB and
3 mounting plate to hang down, giving access to the BM staple head carrier closed sensor.
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
Replacement
1. Reverse the removal procedure to replace the BM staple heads.
2. Perform ADJ 11.3-171 Stapler Anvil Alignment.

3. Figure 1, remove the BM staple head carrier closed sensor actuator. 10. Figure 2, lower the stapler bracket.
2
Remove
the KL-clip
3
Remove the
actuator
1
Remove the
sensor 2 1
Pull the stapler bracket Release the rear follower
handle to open the staplers from the slot using a
fully screwdriver
Figure 1 Actuator removal Figure 2 Lowering stapler bracket
4. Temporarily attach the PWB mounting plate using only the top two screws.
9. Remove both staple head covers, PL 11.168 Item 14.

11. Figure 3, remove the latch shaft.
1
Remove KL-clip and pull shaft forward
50mm (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 11.29-171 BM Conveyor Belts
Removal
1
Lever out
the bearing WARNING
using a Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
screwdriver
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. Remove the BM bin 2 extension by aligning the pivot pins with the cutouts and snapping
2 the extension out of engagement.
Remove the
3. Turn over bin 2 and remove the base pan, 3 screws.
bracket
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.
3 1
Push the other bearing Release belt from the drive pulley
though the frame to
remove the idler roller
2
Push out 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 11.30-171 BM Tamper Assembly and Tamper 1 Motor 6. Figure 1, remove the tamper assembly.

3 4
Purpose Remove 2 screws Remove 2 screws
This procedure is used to repair the following components: and earth connector
BM rear tamper arm, PL 11.162 Item 5.
BM front tamper arm, PL 11.162 Item 6.
BM rear tamper rack, PL 11.162 Item 7.
BM front tamper rack, PL 11.162 Item 8.
BM rear tamper assembly, PL 11.162 Item 9.
BM front tamper assembly, PL 11.162 Item 10.
BM tamper gear,PL 11.162 Item 11.
BM tamper bracket, PL 11.162 Item 12.
BM tamper rack guide, PL 11.162 Item 13.
BM tamper guide plate, PL 11.162 Item 15.
BM rear tamper finger, PL 11.162 Item 16.
BM front tamper finger, PL 11.162 Item 17.
Removal
WARNING
can cause death or injury. Moving parts can cause injury. 2 1
If necessary, remove 2 Remove the cover and 5
screws to remove the disconnect the harness Remove 2 screws
motor
WARNING
2. Remove the crease blade knob (6d), PL 11.161 Item 4. 6
3. Remove the crease roll handle (6c), PL 11.161 Item 5. Move the tampers to align with the
slots to release each tamper from the
slot
5. Remove the left frame plate, PL 11.163 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 End stop
Pull out both tamper 4 screws 3
assemblies Remove the BM
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 11.5-171 Booklet Tamping.

REP 11.31-171 HVF Buffer Guide Assembly 6. Figure 2. Remove the pivot screw.

Removal
WARNING
WARNING
1. Remove the HVF front door, REP 11.1-171.
2. Remove the HVF top cover, REP 11.1-171.
3. Remove the HVF front cover, REP 11.1-171. Remove the
4. Remove the HVF rear cover, REP 11.1-171. 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
procedure is the reverse of the removal procedure.
Disconnect the
two PJs
REAR VIEW
Figure 1 Disconnecting PJs

REP 11.32-171 HVF Input Jam Clearance Guide REP 11.33-171 Buffer Pocket Jam Clearance Guide
Parts List on PL 11.153 Assembly
Removal Parts List on PL 11.153
Removal
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord WARNING
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury. WARNING
1. Remove the HVF front door, REP 11.1-171. Take care during this procedure. Sharp edges may be present that can cause injury.
2. Remove the HVF top cover, REP 11.1-171. 1. Remove the HVF front door, REP 11.1-171.
3. Remove the HVF front cover, REP 11.1-171. 2. Remove the HVF top cover, REP 11.1-171.
4. Figure 1. Remove the pivot screw at the front of the input guide. 3. Remove the HVF front cover, REP 11.1-171.
4. Remove the HVF rear cover, REP 11.1-171.
5. Remove the buffer pocket roll, REP 11.42-171.
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.

6. Figure 1. At the rear of the HVF, prepare to remove the buffer pocket jam clearance guide. 7. Figure 2. At the front of the HVF, remove the buffer pocket jam clearance guide.
2 1
Remove the buffer pocket Remove 3 screws.
Bypass feed motor
(MOT 11-080) ref. only jam clearance guide.
1
REAR VIEW Remove 3 screws.
Figure 1 Rear screw removal Figure 2 Guide removal
Replacement

REP 11.34-171 Inserter Jam Clearance Guide Assembly REP 11.35-171 Diverter Exit Gate
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the HVF front door, top cover and front cover, REP 11.1-171. 1. Remove the HVF front door, top cover, front cover and rear cover, REP 11.1-171.
2. Figure 1. Remove the pivot screw from the front end of the inserter jam clearance guide. 2. 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
Remove the pivot Remove the bush from the shaft
screw

2
Remove the K-L clip
3. Remove the guide through the front opening.
Replacement REAR VIEW
Figure 1 Removal preparation

3. Figure 2. Remove the diverter exit gate. REP 11.36-171 Crease Blade Assembly
Diverter Purpose
3 Connecting rod, PL 11.165 Item 9.
Remove the
diverter Crease blade assembly, PL 11.165 Item 13.
Crease blade support guide, PL 11.165 Item 14.
Removal
WARNING
Remove the from the customer supply while performing tasks that do not need electricity. Electricity
pivot screw can cause death or injury. Moving parts can cause injury.
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. 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 out from Remove 4 screws
under the front and rear supports
Figure 1 Crease blade 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 screw,
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 11.37-171 Stacker Driving Shaft Bearings NOTE: The upper pulley pin may fall when the pulley is removed.
Parts List on PL 11.145 4. Remove the stacker shaft front bearings, Figure 2.
Removal
5
WARNING Remove the
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord circlip and
from the customer supply while performing tasks that do not need electricity. Electricity inner bearing
WARNING
1. Remove the front and rear covers REP 11.1-171.
2. Remove the stacker motor and gear assembly REP 11.12-171.
4
Remove two
3. Remove the shaft rear bearing, Figure 1. screws and the
support bracket
4
Remove the bear-
ing 3
Remove the
outer bearing
3
Remove the thrust
washer
1 2
Remove the circlip Remove the pulley pin
2 and upper pulley
Remove the circlip
Figure 2 Stacker shaft front bearings

1
Remove the circlip Replacement
and gear Reverse the removal procedures to reinstall the stacker driving shaft front and rear bearings.
NOTE: Make sure that the flats on the bearing align with the cut-outs in the bracket or frame.
Figure 1 Stacker shaft rear bearing

REP 11.38-171 HVF Stacker Bin 1 Main Drive Belts 3. Remove the driving belt from the upper pulley and idler, Figure 1.

Removal
WARNING
Remove the upper pulley
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord 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 11.1-171.
2. Remove the stacker bin 1 tray, REP 11.4-171.
1
Remove the screw
and belt clamp
2
Remove the circlip
and lower pulley
Figure 1 Main drive belt removal
Replacement
Reverse the removal procedures to reinstall the front and rear stacker driving belts.
NOTE: Check that the bin 1 lift bar is level before fitting the belt clamp.

REP 11.39-171 HVF BM Diverter Gate 3. Figure 2. Remove the BM diverter gate.

Removal
WARNING 1
Open Guide 5b
WARNING
1. Remove the HVF front door, top cover, front cover and rear cover, REP 11.1-171. Remove the
diverter gate
2. Remove the rear components, Figure 1.
3
Remove the bush
2
Remove the
pivot screw
1
Pull the solenoid arm Figure 2 Diverter removal
from the shaft
Replacement
2
Remove the K-L clip
REAR VIEW
Figure 1 Rear components removal

REP 11.40-171 HVF Input Roll 3. Figure 2. At the front of the HVF, remove the circlip and bush.

Removal
WARNING
WARNING
2. Figure 1. Remove the black plastic cover.
2
Lift out the cover
Remove the circlip

and bush
1 Figure 2 Circlip and bush removal

Press in the catches,
(2 places)
Figure 1 Cover removal

4. Figure 3. At the rear of the HVF, remove the input roll. REP 11.41-171 HVF Inserter Guide Roll
Removal
WARNING
Remove the input roll from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
4
Remove the pulley and Take care during this procedure. Sharp edges may be present that can cause injury.
the bush 1. Remove the HVF front door, top cover, front cover and rear cover, REP 11.1-171.
2. Open guide 8a.
3. Figure 1. At the front of the HVF, remove the circlip and the bush.
3
Lift the shaft and remove
the belt from the pulley
2
Slide the pulley and the
bush along the shaft
1
Remove the circlip
REAR VIEW
Figure 3 Input roll removal
Replacement 1
The replacement procedure is the reverse of the removal procedure. Remove the circlip
and the bush
Figure 1 Circlip and bush removal

4. Figure 2. At the rear of the HVF, remove the inserter guide roll. REP 11.42-171 HVF Buffer Pocket Roll
Removal
1
Remove the circlip
WARNING
Slide the pulley and the
3 WARNING
Slip the belt off of Take care during this procedure. Sharp edges may be present that can cause injury.
the pulley
2. Remove the punch unit, or the punch unit guide, as appropriate.
3. Figure 1. At the front of the HVF, remove the circlip and bush.
4
Remove the pulley and
the bush
5
Remove the inserter
guide roll
REAR VIEW
Figure 2 Inserter guide roll removal
Replacement
1
Remove the circlip
and the bush

4. At the rear of the HVF, remove the buffer pocket roll. The bracket can be moved if neces- REP 11.43-171 HVF Booklet Entrance Roll
sary, to improve access, (two screws), Figure 2.
1 Removal
Remove
the circlip
WARNING
Slide the pulley can cause death or injury. Moving parts can cause injury.
and the bush
along the shaft
WARNING
3 1. Remove the HVF front door, top cover front cover and rear cover, REP 11.1-171.
Slip the belt off 2. Figure 1. Remove the circlip and bush at the outboard end of the roll.
the pulley
4
Remove the
pulley and
the bush
5
Bracket Remove the buffer
REAR VIEW pocket roll
Figure 2 Buffer pocket roll removal

1
Replacement Remove the circlip
The replacement procedure is the reverse of the removal procedure. and the bush

3. Figure 2. At the rear of the HVF, remove the booklet entrance roll. REP 11.44-171 HVF Buffer Lower Roll
Removal
5
Remove
the booklet WARNING
entrance
roll Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
2. Open jam clearance guide 5b.
3. Figure 1. Remove the circlip and the bush from the outboard end of the roll.
4
Remove the
1 pulley and
Remove the bush
the circlip
2 3
Slide the pulley and the Slip the belt off the pulley
REAR VIEW
Figure 2 Booklet entrance roll removal

1
Remove the circlip
Replacement and the bush

4. Figure 2. At the rear of the HVF, remove the buffer lower roll. REP 11.45-171 HVF Buffer Upper Roll
5
Remove the buffer lower roll Removal
WARNING
4 can cause death or injury. Moving parts can cause injury.
Remove the pulley
and the bush
WARNING
3
Slip the belt off the pulley 1. Remove the HVF front door, top cover, front cover and rear cover, REP 11.1-171.
2. Figure 1. Remove the circlip and the bush.
1 2
Remove the circlip Slide the pulley and the bush along the shaft Fixed guide
1
REAR VIEW Remove the circlip and the bush
Figure 2 Buffer lower roll removal

2
Replacement Remove the screw
3
Loosen screw

3. Figure 2. Remove the buffer upper roll. REP 11.46-171 HVF Stacker Exit Feed Roll
Remove the circlip Removal
2
Slide the pulley and the bush along the shaft
WARNING
Slip the belt off the pulley from the customer supply while performing tasks that do not need electricity. Electricity
4
Remove the pulley and the bush
WARNING
Remove the screw
6 2. Figure 1. Remove the circlip and bush
Loosen the screw
7
Pull the upper part of the fixed guide to
the left and remove the buffer upper roll
REAR VIEW
Figure 2 Buffer upper roll removal
Replacement
1
Remove the circlip
and the bush

3. Figure 2. Remove the stacker exit feed roll. REP 11.47-171 HVF Top Exit Feed Roll
Removal
1
Remove the idler, (1 screw) WARNING
2 can cause death or injury. Moving parts can cause injury.
Remove the circlip, pulley and bush
WARNING
Remove the stacker exit feed roll
1. If fitted, undock the inserter, REP 11.82-171.
3. Figure 1. Raise the top tray and lower the plate beneath it.
REAR VIEW 1
Release the
Figure 2 Stacker exit feed roll removal two links
Replacement
2
Lower the plate
Figure 1 Lowering the plate

4. Figure 2. Remove the circlip and bush. Remove the front magnet bracket screws. 5. 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

6. Figure 4. Remove the top exit feed roll. REP 11.48-171 Paddle Module Driving 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
Replacement Remove the 2
3 bracket screws
Remove the paddle module
driving motor assembly.
Replacement
Reverse the removal procedures to replace the compiler paddle module driving motor assem-
bly.

REP 11.49-171 Compiler Paddle Module 4. Remove the compiler paddle module, Figure 1.

Removal
WARNING
WARNING
1. Remove the front, rear and top covers REP 11.1-171.
2. Remove the HVF stapler assembly, REP 11.2-171.
3. Remove the paddle module driving motor assembly, REP 11.48-171.
NOTE: The motor coupler should detach with the motor assembly. If the coupler fails to 2
detach, remove the coupler from the paddle module assembly. Remove 2 1
screws
Disconnect the paddle
module cable connectors,
remove 2 screws and
pass the connector
assembly through the
frame aperture
3
Remove 2 screws
and ground strap
4
Manoeuvre the module
downwards, Remove the
module through the stapler
aperture
Figure 1 Paddle module attachment
Replacement
CAUTION
Do not damage or strain the paddle module ribbon cables or connectors
1. Reverse the removal procedures to replace the compiler paddle module.
2. Use the correct screws to secure the compiler paddle module; do not overtighten GP 6.

REP 11.50-171 BM Exit Sensor REP 11.51-171 Compiler Paper Pusher Motor Assembly
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the BM right hand cover, REP 11.56-171. 1. Remove the top and rear covers REP 11.1-171.
2. Remove the upper static eliminator (3 screws), PL 11.168 Item 18. 2. Remove the paper pusher motor assembly, Figure 1.
3. Figure 1, remove the BM exit sensor.
2
Disconnect
the harness
and remove
the sensor
1
Remove the rear screw
1
Remove the 2
screw then slide
Remove 2 screws
out the sensor
3
Disconnect the PJ, remove the motor and bracket
Figure 1 Paper pusher motor assembly
Reverse the removal procedure to replace the BM exit sensor. Reverse the removal procedures to reinstall the compiler paper pusher motor assembly.

REP 11.52-171 BM Crease Rolls, Gears, Clutch and 8. Figure 1, remove the rear bearings.
Bearings
Removal
WARNING
WARNING
2. Release the crease roll nip pressure by fully rotating the crease roll handle (6c) counter-
clockwise.
6. Remove the BM right hand cover, REP 11.56-171.
7. Remove the BM crease roll motor, REP 11.19-171, but do not disconnect the motor har- 2
ness or remove the motor from the mounting plate. 1 Remove 2 bearings.
Remove 2 circlips.
Figure 1 Rear bearing removal
9. Temporarily attach the BM crease roll motor using only the top screw.
10. Temporarily attach the PWB mounting plate using only the top two screws.
11. Fully pull out the BM module.

12. Figure 2, prepare to remove the upper crease roll. 13. Figure 3, remove the upper crease roll.
1
Slide the upper crease
roll to the rear, remove
from the front.
3 2 1
Remove the upper Remove the upper Remove the circlip.
crease roll bearing. crease roll gear.
Figure 2 Preparation Figure 3 Upper crease roll removal

14. Figure 4, remove the lower crease roll and clutch assembly. Replacement
1 CAUTION
Pull the lower crease roll and Do not remove the crease roll and clutch assembly if they are secure on the shaft.
clutch assembly to the front to
release the bearing. 1. Install the lower crease roll and clutch assembly and bearings.
2. Check if the lower crease roll gear and clutch assembly are secure on the shaft. If the
lower crease roll gear and clutch assembly wobble, perform the following:
a. Figure 5, remove the clutch.
1
Remove the screw and
the retainer.
2
Remove the 9 nine
clutch plates and the
lower crease roll gear.
Figure 5 Clutch removal
2 3
Slide the front of the lower Remove the lower crease roll
crease roll and clutch assem- and clutch assembly.
bly out of the slot.
Figure 4 Lower crease roll and clutch assembly

b. Figure 6, carefully identify the lower crease roll gear and clutch assembly compo-
nents. Reassemble the components on the lower crease roll shaft in sequence from
1 to 12. Ensure the following points are followed:
Components are orientated correctly as shown in Figure 6.
The shallow grooves in the bore of the gear face towards the rear and mate
with the teeth of the clutch plate installed on the shaft.
The deep grooves in the bore of the gear face towards the front and mate with
the teeth of the clutch plates subsequently installed on the shaft.
The spring retainer is installed over the end the shaft.
Lower crease roll gear

Retainer (note the Gear keyed clutch (note the orientation)
orientation) plate
Gear keyed clutch

plate
Screw Shaft keyed clutch Shaft keyed clutch

plate plate Bearing Lower crease roll shaft
Figure 6 Clutch components

c. Figure 7, Ensure that the tabs of the outer gear keyed clutch plate are not outside of REP 11.53-171 Compiler Paper Pusher
the grooves in the gear.
Removal
WARNING
Outer gear keyed
clutch plate
WARNING
Tabs Take care during this procedure. Sharp edges may be present that can cause injury.
1. Remove the front, rear and top covers REP 11.1-171.
2. Remove the stacker motor gearbox, REP 11.12-171.
3. Remove components, Figure 1.
Grooves
5
Remove 2 screws
Figure 7 Outer gear keyed clutch plate
d. Figure 8, ensure that the final shaft keyed clutch plate does not come off of the shaft
during installation.
4
Remove 2 screws
3
Remove the bracket
and bearing
Final shaft keyed
clutch plate
2
Remove E-clip and
pulley
1
Remove 2 screws
Figure 8 Outer gear keyed clutch plate
e. Tighten the screw on the front end of the shaft until it reaches a hard stop.
f. Check that the lower crease roll gear and clutch assembly is secure on the shaft. If Figure 1 Components removal
necessary, repeat steps A to D.
3. Install the remainder of the removed components by reversing the removal procedure. 4. Remove the pusher driving motor assembly, REP 11.51-171.

5. Remove the pusher sensor assembly, REP 11.54-171. REP 11.54-171 Sensor Assembly
6. Remove the pusher module, Figure 2. The mylar strips and dampers are attached to the
pusher module.
Removal
1
Remove circlip and
bearing WARNING
5
Lift the pusher module can cause death or injury. Moving parts can cause injury.
out of the guides
WARNING
Remove the pinion
shaft 1. Remove the HVF top cover REP 11.1-171.
2. Remove the sensor assembly, Figure 1.
3
Push the left edge of
the exit upper guide
downward, away
from the pinion shaft
2
Remove the
2 screw, then
Remove circlip, remove the
bearing and thrust sensor
washers assembly
Figure 2 Pusher module removal
Replacement
Reverse the removal procedures to reinstall the compiler paper pusher.
1
Disconnect the two PJs
Figure 1 Sensor assembly
Replacement
Reverse the removal procedures to replace the sensor assembly.

REP 11.55-171 HVF Power Supply Unit
Removal
WARNING
WARNING
1. Remove the HVF front and rear covers REP 11.1-171.
2. Remove the HVF power supply unit, Figure 1.
2
remove the power supply
unit
1
Disconnect the
grounding strap and
the two PJs
Figure 1 HVF PSU
Replacement
Reverse the removal procedures to replace the HVF power supply unit.

REP 11.56-171 BM Right Hand Cover
Removal
WARNING
WARNING
2. Open the BM front door and fully pull out the BM module.
6. Figure 1, Prepare to remove the BM right hand cover.

1
Push the BM fully home
2
Remove
3 screws
3 4
Fully pull out the BM module Remove 3 screws

7. Figure 2, remove the BM right hand cover. REP 11.57-171 HVF Main PWB
2
Disconnect the Removal
harness
WARNING
WARNING
2. Disconnect the PJs, remove 9 screws and remove the PWB assembly, Figure 1.
1
Lever the cover
free of the detents
and remove the
cover
Figure 2 Cover removal
Replacement
Reverse the removal procedure to replace the BM right hand cover.
Figure 1 HVF main PWB
Replacement
Reverse the removal procedures to replace the HVF main PWB.

REP 11.58-171 BM Crease Nip Springs 6. Figure 1, remove the front lower linkage.

Removal
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. KL-clip
WARNING
1. Open the BM front door and fully pull out the BM.
2. Rotate the crease roll handle (6c) fully counterclockwise.
2
3 Slide the linkage off the shafts
Release the linkage from
the spring hook
Figure 1 Front linkage removal

7. Figure 2, remove the front spring.
1
Move the spring to the corner cutout
2
Flex the spring
slightly and slide out
of the hole
4
Release the linkage
from the spring hook
3
Slide the linkage from
the shafts
Figure 2 Front spring removal
8. Remove the top cover, then the rear cover, REP 11.1-171. 2
9. Fully push in the BM. Remove the E-clip
10. 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 rear nip spring and linkage.
1
11. Figure 3, remove the rear lower linkage.
Remove the KL-clip
Figure 3 Rear linkage removal

12. Figure 4, remove the rear spring. REP 11.59-171 Crease Roll Gate Assembly
Purpose
Crease roll gate rack gear, PL 11.167 Item 8.
Crease roll gate rack drive gear, PL 11.167 Item 13.
Crease roll gate rack, PL 11.167 Item 14.
Crease roll gate front guide, PL 11.167 Item 15.
Crease roll gate rear guide, PL 11.167 Item 16.
Crease roll gate, PL 11.167 Item 19.
Removal
WARNING
2 1 Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
Flex the spring slightly Move the spring to from the customer supply while performing tasks that do not need electricity. Electricity
and slide out of the hole the corner cutout can cause death or injury. Moving parts can cause injury.
WARNING
1. Open the HVF BM front door and fully pull out the BM.
Figure 4 Rear spring removal 6. Remove the crease roll gate motor, REP 11.24-171.
Replacement
Reverse the removal procedure to replace the BM crease roll nip front spring.

7. Figure 1, remove the crease roll gate rack drive gear and both crease roll gate rack gears. 8. 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

9. Figure 3, remove the crease roll gate. 10. 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
Hold the baffle 4
away from the Remove
guide the guide
Figure 3 Gate removal

2
Remove screw
1
Remove two
screws
Figure 4 Front guide removal

11. Figure 5, remove the grease roll gate rear guide. Replacement
Reverse the removal procedure to replace the crease roll gate assembly.
CAUTION
Ensure that the crease roll gate shaft is positioned centrally within the crease roll gate.
4 3
Remove Hold the baffle
the guide away from the
guide
2
Remove
screw
1
Remove two screws
Figure 5 Rear guide removal
12. Loosen 3 screws to remove the crease roll gate shaft from the crease roll gate.

REP 11.60-171 BM Paper Guide Assembly 6. Figure 1, remove the front bearing.

Purpose 1
Remove
the E-clip
Paper guide, PL 11.161 Item 7.
Nip spring, PL 11.161 Item 9.
Nip roll, PL 11.161 Item 10.
Nip shaft, PL 11.161 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
2. Rotate the crease roll handle (6c) fully counterclockwise. Remove the bearing
Figure 1 Front bearing removal

7. Figure 2, remove the rear bearing. 8. Figure 3, remove the BM paper guide assembly.
1
Remove the
E-clip, then
the bearing.
3
Pivot the BM flapper assembly
2 down to rest on the crease
Remove 4 screws. Disconnect the blade.
ground harness.
4
Lift out the BM paper
Figure 2 Rear bearing removal guide assembly.
1
Pull out the 2 harness supports.
Figure 3 Paper guide assembly removal

9. Figure 4, remove the components from the BM paper guide assembly. REP 11.61-171 BM Module
4 Removal
Carefully disengage the
spring legs from the
guide and remove the
shaft assembly WARNING
Mandatory safety warning. This procedure must be performed by two people. The mod-
1 ule is heavy.
Release the nip
springs to
remove the nip
shaft and nip rolls WARNING
WARNING
WARNING
Do not undock the HVFBM from the machine. The machine maintains the stability of the
HVFBM.
3
Remove E-clip
and front latch
2
Remove E-clip and
rear latch
Figure 4 Paper guide dismantling
Replacement
Reverse the removal procedure to replace the BM paper guide assembly.

2. Figure 1, disconnect PJ562 and PJ559 from the BM PWB. 3. Figure 2, disconnect the harness from bin 2.
1
1 2 Remove 2 screws.
Disconnect PJ562 and Disconnect the harness. Secure the
PJ559. harness to the harness retainers.
Figure 2 Disconnect the harness
2
Release the harness from
the retainers.
Figure 1 Disconnect the PJs

4. Figure 3, prepare to remove the BM module. 5. Figure 4, prepare to remove the BM module.
1
Fully pull out the BM
module.
2
Disconnect the ground harness.
Secure the harness to the har-
ness retainers.
1
2 Align approximately two
Make sure that the top of the paper reams of paper against the
stack is level with the base of the BM edge of the HVF BM.
module.

6. Figure 5, Release the latches.
WARNING
Use safe handling procedures, GP 16 when removing this module. The module is heavy.
CAUTION
Do not damage the BM front cover when the BM module is removed.
NOTE: The BM module weight is 27 Kg (59.5 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.
2
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

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.
One person must lift the 4. Figure 7, prepare to install the BM module.
BM module by the left side
cross member.
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

REP 11.62-171 BM Slide Assembly
Removal
WARNING
WARNING
2 1. Remove the BM module, REP 11.61-171.
Carefully push the BM module into 2. Remove the BM front cover, PL 11.161 Item 3.
the HVF BM until the catch is held
under the guide. Do not push the 3. Figure 1, Remove the slide assembly from the HVF BM frame.
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 11D-171 Booklet Quality RAP.

4. Figure 2. Remove the bracket and the slide rail from the right side of the BM module.
3 2 1
Cut the four cable ties Remove four screws
Remove the bracket and the
slide rail to release the harness
1
Figure 2 Remove the bracket and the slide rail
Remove screw
2
1 Move the slide to the
2 Remove screw rear and remove the
Move the slide to the rear and slide assembly
remove the slide assembly
Figure 1 Remove the slide assembly

5. Figure 3. Remove the two brackets from the slide rail. 7. Figure 5. Remove the two brackets from the slide rail
1
3 Remove screw
Remove screw 1 3
Remove screw Remove screw
2 4 2
4 Remove the bracket Remove the bracket from the
Remove the bracket from Remove the bracket from
from the slide rail slide rail the slide rail
the slide rail
Figure 3 Remove the bracket from the slide rail Figure 5 Remove the bracket from the slide rail
6. Figure 4. Remove the bracket and the slide rail from the left side of the BM module. 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.
2 1
3 Cut the five cable ties to Remove four screws
Remove the bracket release the harness
and the slide rail
Figure 4 Remove the bracket and slide rail

REP 11.63-171 Entry Feed Motor 1 REP 11.64-171 Bypass Feed Motor
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the rear cover REP 11.1-171. 1. Remove the rear cover REP 11.1-171.
2. Remove entry feed motor 1 and bracket assembly, Figure 1. 2. Remove the bypass feed motor and bracket assembly, Figure 1.
1 1
Remove the 2 Remove the pivot and
bracket screws 2 bracket screws
2
Remove the pivot
screw
2
Disconnect the
3 motor PJ.
Disconnect the
motor PJ.
Tension Spring
Tension Spring
Figure 1 Bypass feed motor and bracket
Figure 1 Entry feed motor and bracket
3. Remove 2 screws and the grounding wire to remove the motor and damper from the
bracket.
bracket.
1. Reverse the removal procedures to replace the bypass feed motor.
1. Reverse the removal procedures to replace entry feed motor 1.
2. Set the belt tension, ADJ 11.10-171.
2. Set the belt tension ADJ 11.10-171.

REP 11.65-171 Buffer Feed Motor REP 11.66-171 Exit Feed Motor 2
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the rear cover REP 11.1-171. 1. Remove the rear cover, REP 11.1-171.
2. Remove the buffer feed motor and bracket assembly, Figure 1. 2. Remove exit feed motor 2 and bracket assembly, Figure 1.
1
Remove the
pivot and 2
bracket screws 1
Remove the
pivot and 2
bracket screws
2
Disconnect the
motor PJ.
2
Disconnect the
motor PJ.
Tension Spring
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
1. Reverse the removal procedures to replace the buffer feed motor.
Replacement
2. Fit the pivot screw and set the belt tension, ADJ 11.10-171. Do not tighten the motor 1. Reverse the removal procedures to replace exit feed motor 2.
bracket screws fully until the belt is tensioned by the spring. 2. Fit the bracket pivot screw and set the belt tension, ADJ 11.10-171.

REP 11.67-171 Tri-Folder Covers 2. Remove the rear cover, the top cover and the right side cover as necessary, Figure 2.
Parts List on PL 11.190 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).
from the customer supply while performing tasks that do not need electricity. Electricity 1
can cause death or injury. Moving parts can cause injury. Remove the rear cover
(4 screws).
WARNING
1. Remove the front door then the front cover, Figure 1.
1
Remove 1 screw
then the front door
hinge pin.
3
Open the front door to
access the top cover front 2
fasteners. Remove the right hand side cover (5 screws).
Figure 2 Top, rear and right side covers
Replacement
Reverse the removal procedures to reinstall the tri-folder covers.
3 2
Remove 4 screws Remove the door from the
then the front cover. upper pivot.
Figure 1 Tri-folder front door and cover

REP 11.68-171 Tri-Folder Drive Assembly 4. If necessary, remove the circlip then remove the drive coupler, refer to Figure 1.
Parts List on PL 11.193 Replacement

1. Detach the coupler alignment tool from the drive unit, refer to Figure 1.
Removal
2. Install the drive assembly, Figure 2.
WARNING
WARNING
1. Remove the HVF rear cover, REP 11.1-171. 1
Slide out the booklet
2. Remove the tri-folder rear cover REP 11.67-171. maker.
3. Remove the tri-folder drive assembly, Figure 1.
Circlip
Drive coupler
Coupler alignment tool
1 2
Release the coupler
Attach the drive assembly, (4 screws).
drive belt tension, then
remove the belt.
Figure 2 Attach the drive assembly
2
Drive assembly Remove 4 screws,
then the tri-folder drive
assembly.
Figure 1 Drive assembly

3. Centralise the coupler alignment tool onto the crease roll encoder disc, PL 11.166 Item 13 5. Slacken off the drive unit retaining screws, Figure 4.
and Figure 3.
Drive unit
1
Position the coupler
alignment tool onto
the crease roll
encoder disc.
2 1
Loosen 4 screws.
Carefully slide the BM towards the
drive assembly.
Figure 4 Loosen the drive unit

Figure 3 Centralise the alignment tool
4. Prepare to centralise the drive coupler, refer to Figure 1, with the HVF BM crease roll
encoder disc, Figure 3.

6. Centralise the coupler alignment tool with the drive unit coupler, Figure 5. 7. Secure the drive unit in the centralised position, Figure 6.
Alignment tool
2
Drive coupler Slide out the
BM and remove
the coupler
alignment tool.
2 1
Ensure the drive coupler is centralised Secure the drive unit,
with the alignment tool. tighten 4 screws.
1
Adjust the position of the drive unit.
Figure 5 Centralise 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 11.69-171 Drive Coupling Assembly
Removal
1
Remove the
drive belt.
WARNING
2
Remove the
driven pulley and
WARNING gear.
1. Remove the tri-folder rear cover, REP 11.67-171.
NOTE: Access is improved if the top cover is removed also.

2. Remove the drive coupling assembly bracket, Figure 1.
3
Remove the feed and
the exit roll drive gear
then the bearing.
4
Remove 5 screws,
then the drive coupling
assembly bracket
5
Slacken the tensioner lock screw
then move the crease roll tensioner
pulley to the left. Tighten the lock
screw.
Figure 1 Drive coupling assembly

3. Remove the clutch and bearing from the idler bracket, Figure 2. REP 11.70-171 Tri-Folder Feed Roller and Drive Belt
Removal
WARNING
WARNING
Clutch torque arm 1. Undock the tri-folder from the HVF then move the unit to the right to access the left side of
the frame, refer to REP 11.73-171.
2. Remove the drive belt, Figure 1.
1 Feed Roller
Disconnect the
clutch connector.
Bearing
3
Pull the roller shaft
2 through the frame bearing
Remove the idler and remove the drive belt.
assembly.
1
Crease roll belt Release the belt
Idler tension.
Figure 2 Idler assembly and crease roll clutch

Driven pulley
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 2
idler, then fit the drive belt over the clutch gear. Refer to Figure 2. Remove the shaft circlip and move the feed roller shaft
toward the front to remove the driven pulley.
3. Position the clutch torque arm in the slot in the idler bracket. Refer to Figure 2.
4. Perform ADJ 11.10-171 Motor Drive Belt Tensioning.
3. If necessary, remove the feed roller shaft front circlip and bearing, then remove the feed
roller assembly from the Tri Folder. Refer to Figure 1.
Replacement
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 11.10-171 Motor Drive Belt Tensioning.

REP 11.71-171 Tri-Folder Assist Gate Solenoid REP 11.72-171 Crease Roll Springs
Removal Removal
WARNING WARNING
WARNING WARNING
1. Open the front door, or remove the bin 2 assembly. Remove the tri-folder rear cover, REP 1. Remove the front door, front cover and rear cover, REP 11.67-171.
11.67-171. 2. Remove the circlip then remove the front or rear spring, Figure 1.
2. Remove the assist gate solenoid, Figure 1.
3
Remove the
assist gate
solenoid.
Front crease roll spring Rear crease roll spring
2 1
Remove 2 screws. Disconnect the connector.
Figure 1 Crease roll springs

Figure 1 Assist gate solenoid
Replacement
Replacement
Reverse the removal procedures to replace the front or rear crease roll spring.
Reverse the removal procedures to replace the assist gate solenoid.

REP 11.73-171 Tri-Folder Top Door Cover and Idler NOTE: Control the movement of the torsion spring.
Assemblies
Removal
WARNING
WARNING
1. Undock the tri-folder from the HVF, then move it to the right to gain access to the left side
of the tri-folder frame,REP 11.99-171.
NOTE: The wiring harnesses to the HVF do not need to be disconnected.

2. Remove the top door cover assembly, Figure 1.
2 4 Torsion Spring
3
Remove the clip. Release the front of the top Remove the
door cover assembly, then front screw.
1 remove.
Remove the rear screw.
Figure 1 Top cover removal

3. Remove idler assemblies, Figure 2. REP 11.74-171 Tri-Folder Roller Assembly and Diverter
Solenoid
Remove the top cover
(5 screws). Removal
WARNING
WARNING
2 1. Undock the tri-folder assembly from the HVF, REP 11.73-171. Position and support the tri-
Release the springs, then folder so that it is safely accessible from the front, rear and left side.
remove the idler assembly. 2. Release the crease roll drive belt tension, REP 11.69-171. Disconnect the harness from
the diverter and assist gate solenoids.
3. Remove the tri-folder roller assembly, Figure 1.
NOTE: If not supported, the roller assembly will fall inside the tri-folder frame.
Figure 2 Idler assembly removal
Replacement
1. Reverse the removal procedures to reinstall the idler assembly and top door cover
assembly.
2. Make sure that the correct self-tapping screws are used to replace the cover base. Do not
overtighten the screws, refer to GP 6.
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 then 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.

4. Remove the diverter gate solenoid or crease roll pulleys as necessary, Figure 2.
2
Remove the upper screws.
Diverter gate
lever
1
Remove 2
screws.
1
Disconnect
the assist 2
gate sensor. Remove the
diverter gate
solenoid.
Crease roll
pulleys
Figure 2 Solenoid and pulleys removal
4 Replacement
3
Support the roller assembly, then Remove the roller assembly 1. Reverse the removal procedures to reinstall the pulleys, diverter gate solenoid and tri-
remove the lower screws, see NOTE. through the front door. folder roller assembly.
2. Before replacing the roller assembly set the diverter operating lever to the forward posi-
tion (solenoid armature extended) to engage with the right side of the diverter shaft lever.
Refer to Figure 2.
3. Check that the diverter gate operates correctly before tensioning the crease roll drive belt.
Figure 1 Roller assembly removal

REP 11.75-171 Bin 1 Limit Switches 2. Remove the relevant limit switch, Figure 1.

Removal
WARNING
WARNING
1. Remove the HVF rear cover, REP 11.1-171. 1
Remove 1 screw, then the
upper limit switch.
2
Remove 1 screw, then the
lower limit switch.
Figure 1 Bin 1 limit switches
Replacement
Reverse the removal procedures to replace the Bin 1 upper and lower limit switches.

REP 11.76-171 Bin 1 Upper Level Sensor REP 11.77-171 Tri-Folder Door Interlock Switches and
Parts List on PL 11.140 Sensor
Removal Parts List on PL 11.190, PL 11.197
Removal
WARNING
from the customer supply while performing tasks that do not need electricity. Electricity Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
can cause death or injury. Moving parts can cause injury. from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
1. Remove the HVF front and rear covers, REP 11.1-171. Take care during this procedure. Sharp edges may be present that can cause injury.
2. Disconnect the connector, then remove the transmitter or receiver as necessary, Figure 1. 1. Remove the tri-folder front and top covers, REP 11.67-171.
2. Disconnect, then remove the relevant interlock switch or top cover sensor, Figure 1.
Top cover sensor

Receiver Top cover interlock switch
Transmitter
Front door interlock switch
Figure 1 Bin 1 upper level sensor removal

Figure 1 Switches and sensor removal
Reverse the removal procedures to replace the transmitter or receiver of the bin 1 upper level Reverse the removal procedures to replace the front door and top cover interlock switches and
sensor. the top access cover sensor.

REP 11.78-171 Tri-Folder Entry and Assist Gate Sensors REP 11.79-171 Tri Folder Exit Sensor
Removal Removal
WARNING WARNING
WARNING WARNING
1. Undock the tri-folder unit from the HVF, refer to REP 11.73-171. 1. Remove the tri-folder top cover, REP 11.67-171.
2. Disconnect, then remove the relevant sensor, Figure 1. 2. Remove the exit sensor, Figure 1.
1
Disconnect, then remove
the exit sensor.
Entry sensor Assist gate sensor
LEFT SIDE VIEW
Figure 1 Sensor removal Figure 1 Exit sensor removal
Reverse the removal procedures to replace the entry and assist gate sensors. Reverse the removal procedures to replace the exit sensor.

REP 11.80-171 Tri-Folder Control PWB REP 11.81-171 Tri-Folder and Bin 2 Tray Harnesses
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the tri-folder rear cover, REP 11.67-171. 1. Remove the tri-folder rear cover, REP 11.67-171. If removing the tri folder harness,
2. Disconnect the PJs, then remove the PWB, Figure 1. remove the HVF rear cover, REP 11.1-171.
1
Disconnect all
connectors from
the PWB.
2
Remove 4 screws, then the PWB.
Replacement
Reverse the removal procedures to replace the tri-folder control PWB.

2. Disconnect, then remove the relevant harness, Figure 1. REP 11.82-171 Inserter Undocking
Removal
WARNING
WARNING
CAUTION
Place the inserter on a suitable surface. Do not damage the inserter locating pins.
Tri folder harness
CAUTION
Bin 2 Harness Do not show the customer how to undock the inserter.
1. Open the HVF front door.
Bin 2 Harness PJ
Figure 1 Harness removal
Replacement
Reverse the removal procedures to replace the main and bin 2 tray harnesses.

2. Undock the inserter, Figure 1. REP 11.83-171 Inserter Front and Rear Covers
Removal
WARNING
Lift the inserter vertically from can cause death or injury. Moving parts can cause injury.
the HVF and put it on a suitable
surface.
WARNING
1. Undock the inserter and put it on a suitable surface, REP 11.82-171.
2. Remove the lower screw and release the upper tab. Move the cover to release the right
side tab from the frame, Figure 1.
2
1 Release the upper tab, then
Move the white latch handle to the rear. the side tab. Remove the front
cover.
Locating Pins
Figure 1 Inserter undocking
Replacement
1. Reverse the removal procedures to dock the inserter.
2. Lock the inserter onto the HVF by sliding the latch handle towards the front, Figure 1.
1 3
Remove 1 screw. Remove 1 screw.
4
Release the upper tab, then
the side tab. Remove the rear
cover.
Figure 1 Covers removal
Replacement
Reverse the removal procedures to replace the inserter front and rear covers.

REP 11.84-171 Inserter Motor REP 11.85-171 Inserter PWB
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the inserter rear cover, REP 11.83-171. 1. Remove the inserter rear cover, REP 11.83-171.
2. Remove the inserter motor and bracket, Figure 1. 2. Remove the inserter PWB, Figure 1.
1
2 3 Open the top 1 2
Disconnect the Remove 3 screws, then left door. Disconnect all connectors Remove 4 screws, then the
connector. the inserter motor.
on the inserter PWB. inserter PWB.
Figure 1 Inserter motor removal
Replacement Figure 1 Inserter PWB

1. Reverse the removal procedures to replace the inserter motor.
Replacement
2. Make sure that the correct screws are used to replace the inserter motor, GP 6.
Reverse the removal procedures to replace the inserter PWB.

REP 11.86-171 Inserter Clutch Replacement
Parts List on PL 11.179 1. Reverse the removal procedures to replace the inserter clutch.
2. When replacing the bracket, check that the clutch torque arm locates in the locating tab.
Removal Put the reverse roll drive belt over the drive idler and check that the reverse roll idler gear
shaft locates properly into the frame.
3. 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 rear cover, REP 11.83-171.
2. Remove the clutch, Figure 1.
NOTE: The reverse roll drive idler and the drive belt are not attached to the clutch bracket
or the inserter frame.
1 2
Remove the E-clip Remove 4 screws, then the bracket.
and bearing.
3
Disconnect the
connector, then
remove the clutch.
Reverse roll drive

belt
FOR CLARITY
INSERTER MOTOR
Reverse roll drive Reverse roll drive
NOT SHOWN
idler pulley
Figure 1 Inserter clutch removal

REP 11.87-171 Inserter Top Cover Interlock Switch REP 11.88-171 Left Hand Door Interlock Switch
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the inserter front cover, REP 11.83-171. 1. Remove the inserter front and rear covers, REP 11.83-171.
2. Disconnect the PJs and remove the 2 screws securing the top cover interlock switch, Fig- 2. Remove the inserter motor, REP 11.84-171.
ure 1. 3. Remove the rear pivot screw and remove the top cover, Figure 1.
1
Disconnect the connectors.
2
Remove 2 screws, then the
top cover interlock switch.
Replacement
Reverse the removal procedures to replace the inserter top cover interlock switch.

REP 11.89-171 Main Tray and Paper Length Sensors
3 2 1 Parts List on PL 11.175
Remove 3 screws from Remove 2 latch pins. Remove the rear
the rear. pivot screw, then
Removal
the top cover.
WARNING
WARNING
1. Remove the main tray or relevant sensor, Figure 1
3
Remove the relevant
paper length sensor.
4
Remove 3 screws
from the front. 2
Remove 2
5 screws, then the
cover plate.
Release the cable harness 6
clips and lift the top-inside Remove the left hand
cover. door interlock switch.
1
Pull the lug on one side of
the tray to disconnect from
4. Remove the door latch pins then remove 4 screws holding the top inside cover, Figure 1. the frame pivot.
5. Release the cable harness clips and lift the top-inside cover. Disconnect the PJs and
remove the top left door interlock switch.
Figure 1 Main tray assembly removal
Replacement
1. Reverse the removal procedures to replace the left hand cover interlock switch. Replacement
2. When reinstalling the inside top cover and the top cover make sure that the correct Reverse the removal procedures to replace the inserter main tray and paper length sensors.
screws are used and that the screws are not overtightened GP 6

REP 11.90-171 Bottom Tray and Paper Sensors
Parts List on PL 11.175 2
3 Remove the
Removal Remove the pivot shaft. circlip and
bearing.
WARNING
WARNING
1. Undock the inserter, REP 11.82-171. Release the front and rear pivot tabs then lift the bot- Paper width
tom tray. Control the movement of the bottom tray springs. sensors
2. Remove the relevant sensor, Figure 1.
4
Remove 2 screws,
then the sensor
bracket.
1
5 Unit empty sensor Release the front and rear
Remove the relevant pivot tabs.
sensor.
Figure 1 Bottom tray and sensors removal
Replacement
1. Reverse the removal procedure to replace the bottom tray and paper sensors.
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-
tally in the frame.
3. Make sure that the bottom tray springs are correctly aligned before engaging the front and
rear pivot tabs.

REP 11.91-171 Inserter Top Cover and IDG Pickup Sensor REP 11.92-171 Inserter Top Left Door and Acceleration
Parts List on PL 11.179 Sensor
Removal
WARNING
WARNING
1. Remove the inserter front cover, REP 11.83-171. Take care during this procedure. Sharp edges may be present that can cause injury.
2. Remove the top cover pivot screw. Move the rear top guide to disengage the pivots then 1. Remove the front and rear covers, REP 11.83-171.
remove the sensor bracket and disconnect the sensor PJ, Figure 1.
1
Remove the top cover pivot screw.
2
Move the rear
top guide to
disengage
the pivots.
3
Remove the sensor bracket,
then the sensor.
Figure 1 Top cover and sensor removal
Replacement
Reverse the removal procedure to replace the IDG pickup sensor and top cover.

2. Remove the acceleration sensor, Figure 1. REP 11.93-171 LE and TE Sensors
Removal
WARNING
WARNING
1. Remove the inserter front and rear covers, REP 11.83-171.
2. Remove the inserter motor, REP 11.84-171.
3. Remove the pickup roll assembly, REP 11.95-171.
4. Remove the top cover, REP 11.91-171.
2 5. Remove the top inside cover, refer to REP 11.88-171.
the guide plate.
1 3
Remove the front
Remove the
and rear door
acceleration
stop and door
sensor.
pivot screws.
Replacement
Reverse the removal procedure to replace the inserter top left door and the acceleration sensor.

6. Remove the relevant sensor, Figure 1. REP 11.94-171 Inserter Bottom Plate Sensor
Removal
WARNING
WARNING
1. Undock the inserter, REP 11.82-171.
2. Release the front and rear pivot tabs, then lift the bottom tray. Control the movement of
the bottom tray springs.
3. Remove the sensor from the bracket, Figure 1.
1
Release the harness
clips.
3 2
Remove 1 screw, then Bottom Tray
Disconnect, then remove
the relevant sensor. the bracket.
Replacement
1. Reverse the removal procedure to replace the LE and TE sensors.
2. When replacing the top inside cover, and the top cover make sure that the correct screws
are used and that the screws are not overtightened, GP 6
1
Disconnect, then
remove the sensor.

Replacement
Reverse the removal procedure to replace the inserter bottom plate sensor.

REP 11.95-171 Inserter Pickup Assembly and Reverse
2
Feed Roller Remove the Link Arm
Parts List on PL 11.179 plastic clip.
Removal
1
WARNING Raise the inserter top
cover.
WARNING
1. Remove the pickup assembly from the inserter, Figure 1.
3 4
Pull the pickup assembly towards the front to Disengage the shaft from
disengage the roller shaft from the drive cou- the drive coupling.
pling and the link arm.
5
Remove the pickup
assembly.
Figure 1 Pickup roller assembly removal

2. Remove the reverse roller shaft, Figure 2. REP 11.96-171 HVF Fixed and Adjustable Casters
For clarity the top
cover is not shown. 1 Removal
Release the tab
then remove the
retard cover.
WARNING
Mandatory safety warning. This procedure must be performed by 2 people. The module
is heavy.
WARNING
WARNING
CAUTION
Do not remove more than one castor 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.).
2 3 1. If installed, undock the tri-folder from the HVF, REP 11.82-171.
Remove the clip. Remove the reverse roller.
2. If installed, undock the inserter from the HVF, REP 11.82-171.
3. Undock the HVF, REP 11.13-171.
Figure 2 Reverse roller removal 4. Remove the HVF front and rear covers, REP 11.1-171.
5. Lift and support the HVF frame securely at a position close to where the castor is to be
Replacement removed, GP 16. Support the frame approximately 4 inches (approximately 2 reams of
1. Reverse the removal procedure to replace the reverse feed roller and the pickup assem- paper) above the floor so that the castor is not supporting the unit.
bly.
2. After replacing the pickup assembly, close the inserter top cover fully to engage the link
arm with the pickup roller.

6. Remove the fixed castor, Figure 1. 7. Support the HVF frame. Remove the adjustable castor from the frame, Figure 2.
2
1 Rotate the castor adjustment
1 Remove the screw and wheel to unscrew the castor
stop plate. from the frame
the fixed castor.
Figure 1 Fixed castor removal Figure 2 Adjustable castor removal
Replacement
Reverse the removal procedure to replace the HVF fixed and adjustable casters.

REP 11.97-171 Pause to Unload PWB REP 11.98-171 Inserter Idle Roller Assembly
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the HVF Front door, front cover and top cover, REP 11.1-171. 1. Remove the inserter front and rear covers, REP 11.83-171.
2. Remove the pause to unload PWB and bracket, Figure 1. 2. Remove the inserter motor, REP 11.84-171.
3. Remove the inserter clutch, REP 11.86-171.
4. Remove the top cover assembly, REP 11.91-171.
5. Remove the inside top cover and top left door interlock switch, REP 11.88-171.
Bracket
1 2
Disconnect the connector. Remove the pause to unload PWB.
Replacement
Reverse the removal procedure to replace the pause to unload PWB.

6. Prepare to remove the idle roller assembly, Figure 1. 7. Remove the idle roller assembly from the frame, Figure 2.
NOTE: Check that the loading gear remains engaged with the loading shaft gear.
5
Remove the idle roller assembly.
1
Disconnect the
connector. Unclip
the connector
from the frame.
2
Remove 3 screws
marked A.
4
Remove 2 screws
marked B.
3
Turn the loading
bracket
3
Remove 2 screws at
the rear of the idle
roller assembly.
2 1
Remove 2 circlips then the driven and Release the torsion spring tension.
idler gears. Loading Lever
Figure 2 Idle roller assembly
Replacement
1. Reverse the removal procedure to replace the Idle roller assembly.
2. 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 correctly if it is not supported horizontally in the inserter frame.

REP 11.99-171 Tri-Folder Removal 5. Disconnect the HVF to tri-folder bin 2 tray harness from the tri-folder module, REP 11.81-171.
6. Disconnect the tri-folder harness from PJ553 and PJ563 on the BM PWB, PL 11.166 Item 10.
7. Undock the tri-folder from the HVF
Removal
Replacement
Reverse the removal procedures to replace the tri-folder module.
WARNING
WARNING
2. Remove the tri-folder rear cover, REP 11.67-171.
3. Remove the coupler drive belt, REP 11.68-171.
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 11.100-171 Ejector Paddle Assembly (W/TAG V-007) Replacement
Parts List on PL 11.140 1. Rotate the paddle shaft to ensure that the locating tab is uppermost, Figure 2.
2. Hold the paddle assembly by the two short tabs and clip onto the shaft.
Removal
NOTE: Ensure that the paddle assembly is correctly oriented to fit onto the plastic locat-
ing tab.
WARNING
WARNING
1. Rotate the ejector paddle assembly until the two short tabs are visible. Paddle locating tab
2. Remove the ejector paddle assembly, Figure 1.
Figure 2 Paddle locating tab
1
Squeeze the two short tabs
together and pull to remove
the ejector paddle assembly
Figure 1 Ejector paddle assembly

REP 11.101-171 Paddle Wheel
Removal
WARNING
WARNING
NOTE: This procedure shows the replacement of the paddle wheels with the paddle module
assembly installed. If necessary, remove the paddle unit assembly before replacing the paddle
wheels. Refer to REP 11.49-171.
1. 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.
2. Remove one paddle wheel at a time from the shaft, Figure 1.
1
Squeeze the two rubber
blades together and pull to
remove one paddle wheel
at a time from the shaft
Figure 1 Paddle removal
Replacement
1. Hold the paddle wheel by the two rubber blades and clip onto the shaft one at a time to
ensure that all four new paddles are in the same orientation as the old four paddles.

REP 12.1 OCT Fingers Install CAUTION
Make sure that the OCT fingers are installed in the correct position. Each of the three fingers is
Parts List on PL 12.10 marked.
Installation 4. Install three OCT fingers on to the exit shaft assembly, Figure 2.
WARNING
CAUTION
Do not install the OCT fingers on 65 -90 ppm machines.
1. Remove the OCT, PL 12.10 Item 1.
3. Remove lug 1 and lug 2 from the rear of the right hand cover, Figure 1.
Finger 1
Finger 2
Finger 3
Figure 2 Finger install

Lug 1 (1st in from the right Right side of cover.
Lug 2 (5th in from the right side of the cover). 5. Remove the fuser module, (35-55 ppm) PL 10.8 Item 1, (65-90ppm) PL 10.10 Item 1.
side of the cover).
Figure 1 Lug removal

6. Manually feed a sheet of A4 or 8.5 x 11 inch paper, long edge feed, through the paper
path, Figure 3.
CAUTION
NOTE: This is necessary to make sure that the OCT fingers are fully raised when the right When the right cover is installed, make sure that the OCT fingers extend through the hole in
hand cover is installed. the right hand cover. Refer to Figure 4.
7. Install the right hand cover, Figure 4.
OCT fingers.
3
2 1 Rotate the jam clear-
Insert a sheet of paper Release the jam clearance handle 3c counter Figure 4 Finger check
in to the paper path. ance handle 3d/4d. clockwise.
8. Remove the piece of paper from the paper path. Make sure that the OCT fingers fall freely
under their own weight.
9. Re-install the fuser and then the OCT.
Figure 3 Inserting paper

REP 14.1 Scanner 5. Remove the rear cover, PL 8.10 Item 1.
6. Remove the user interface, REP 2.1.
Parts List on PL 14.20 (W/O TAG 150), PL 14.10 (W/TAG 150)
7. Remove the left hand cover, PL 8.10 Item 3.
Removal 8. Remove the right hand cover, PL 8.10 Item 4.
9. Remove the xerographic module. Put the module in a black bag.
WARNING
Use safe handling procedures, GP 16 when removing the module. The module is heavy.
NOTE: The scanner weight is 16.5 kg (36lb.).
WARNING 10. Figure 2. Stand at the rear of the machine and remove the scanner.
1. Remove the OCT, PL 12.10 Item 1, or perform the following:
REP 11.12-120 1K LCSS Removal.
REP 11.13-110 2K LCSS Undocking.
REP 11.13-171 HVF and HVF BM Undocking.
2. Lock the scan carriage, Figure 1.
a. Disconnect the following connectors from the power distribution PWB:
PJ136
PJ135
PJ133
PJ131
PJ132
b. Disconnect the following connectors from the single board controller PWB:
PJ101
PJ102
PJ103
PJ104 1
PJ105 Remove the transport screw from the storage
PJ107 position. Use the transport screw to lock the
scan carriage.
PJ109
PJ113
PJ114
PJ152 (connection on the rear of the module to DADH) Figure 1 Scan carriage locking
c. (W/TAG 150), disconnect PJ4 and PJ6 from the scanner daughter PWB, PL 3.24
Item 20.
d. Remove the cable clamp, PL 3.24 Item 10.
e. Release the harnesses from the single board controller PWB module.
f. Release the catch on the single board controller PWB module, then remove the sin-
gle board controller PWB module.

Replacement
4 1. The replacement procedure is the reverse of the removal procedure.
Raise the scanner and release the harness 2. Ensure that the receptacle on the base of the scanner is correctly installed onto the
from beneath the scanner. tongue on the machine frame. Refer to Figure 2.
Tongue
2
W/TAG 150 Only,
Remove 1 screw
and 1 spacer.
Receptacle (2 positions)
5
Remove the scanner.
3
Push the scanner towards
the rear of the machine.
Tongue
1
Remove 2 screws and 2 spacers.
2
Remove 1 screw and 1 spacer.
Figure 2 Scanner removal

REP 14.2 Exposure Lamp Inverter and Fuse (W/O TAG 150) Replacement
Parts List on PL 14.25 1. Reverse the removal procedure to replace the exposure lamp inverter and fuse.
2. When re-connecting the ribbon cable into PJ463, the blue band printed on the cable must
Removal face to the left, when viewed as shown in Figure 1.
3. Figure 1, ensure the ribbon cable is folded correctly in the cable clamp. Engage two of the
cable clamp clips in the carriage holes. Bend the clamp to engage the third clip.
WARNING
1. Remove the CVT glass and document glass, REP 14.6.
2. Remove the exposure lamp inverter and fuse, Figure 1.
5 4
Remove the inverter and fuse. Disconnect 2
connectors.
PJ464
3
Note the orientation
of the ribbon cable,
blue stripe to the
left.
Fuse
1 PJ463
Remove 2 screws
2
Place fingers under the carriage to hold
the cable clamp, then release the 3 clips
from above while pulling the clamp down.
Figure 1 Inverter and fuse

REP 14.3 Document Size Sensors (W/O TAG 150) REP 14.4 DADH Closed Switch
Parts List on PL 14.25 Parts List on PL 14.25 (W/O TAG 150), PL 14.15 (W/TAG 150)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the CVT glass and document glass, REP 14.6. 1. Remove the DADH, REP 5.19.
2. For document size sensor 2 only, remove the PWB cover (3 screws), PL 14.25 Item 1. 2. Remove the user interface assembly, REP 2.1.
3. Remove the document size sensor 1 and / or 2, Figure 1. 3. Remove the scanner top cover, PL 14.20 Item 3 (W/O TAG 150), PL 14.10 Item 3 (W/TAG
150).
1 4. Remove the DADH closed switch, Figure 1.
Pinch the tabs together to
release the sensor.
2
Remove 2
screws.
3
Remove the
switch.
2 1
Disconnect the harness. Release the catch and disconnect
Figure 1 Document size sensor 1 the bulkhead connector.
NOTE: Figure 1 shows document size sensor 1. The fastening for the document size sen-
sor 2 is the same as for 1. Figure 1 DADH closed switch
Reverse the removal procedure to replace the document size 1 and 2 sensors. Reverse the removal procedure to replace the DADH closed switch.

REP 14.5 Scanner PWB (W/O TAG 150) Replacement
Parts List on PL 14.25 1. Reverse the removal procedure to replace the scanner PWB.
2. When re-connecting the ribbon cable to PJ456 ensure that the blue band printed on the
Removal cable faces the front of the machine.
WARNING
WARNING
2. Remove the scanner PWB cover, PL 14.25 Item 1. Release the document size sensor
from the cover, REP 14.3.
3. Remove the scanner PWB, Figure 1.
1
Disconnect all
harnesses.
3
Remove the scanner 2
PWB. Release 4 standoffs.
Figure 1 Scanner PWB

REP 14.6 CVT Glass, Document Glass and CVT Ramp
Removal
WARNING
Remove 2 screws.
WARNING
2. Remove the user interface assembly, REP 2.1.
3. Remove the scanner top cover, REP 14.14.
CAUTION
Contamination in the optics cavity can cause image quality defects. Do not allow the optics
cavity to become contaminated.
4. Remove the CVT glass and document glass, Figure 1.
Replacement
1. Clean the underside of the CVT glass and document glass, ADJ 14.1.
NOTE: Ensure that the white stripes on both the CVT glass and the document glass, are
at the front of the machine and on the underside of the glass. 2
2. Reverse the removal procedure to replace the CVT glass and document glass. Lift off the CVT glass
and store carefully.
3. Clean the upper side of the CVT glass and document glass, ADJ 14.1 (W/O TAG 150), 3
ADJ 14.2 (W/TAG 150). Lift off the document
glass and store carefully.
Figure 1 Document glass and CVT glass

REP 14.7 Scan Carriage Home Sensor
Parts List on PL 14.25 (W/O TAG 150), PL 14.15 (W/TAG 150) CAUTION
Do not remove the document glass. Do not loosen the two screws securing the setting plate,
Removal
shown in Figure 1.
4. Remove the scan carriage home sensor, Figure 1.
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord Dowel DO NOT LOOSEN
THESE SCREWS.
WARNING
Setting
1. Remove the DADH, REP 5.19. plate
2. Remove the user interface assembly, REP 2.1.
3. Remove the scanner top cover, PL 14.20 Item 3 (W/O TAG 150), PL 14.10 Item 3 (W/TAG
150). 1
Peel back
the adhesive
tape.
Lugs
3
Remove the
screw. Discon-
nect the harness
and remove the
sensor.
2
Remove screw and release the sensor mounting plate to Location hole
reveal the sensor.
Figure 1 Scan carriage home sensor
Replacement
1. Reverse the removal procedure to replace the scan carriage home sensor.
2. Figure 1, when mounting the sensor, ensure that the location hole in the sensor mounting
plate is located over the dowel of the setting plate.
3. When replacing the scan carriage home sensor, ensure that the lugs are located in the
slot of the sensor mounting plate before tightening the screw.
4. Ensure that the adhesive tape is re-installed so that it entirely covers the aperture. If nec-
essary install new adhesive tape.

REP 14.8 Input Module Angle Sensor REP 14.9 Exposure Lamp
Parts List on PL 14.25 (W/O TAG 150), PL 14.15 (W/TAG 150) Parts List on PL 14.25 (W/O TAG 150), PL 14.15 (W/TAG 150)
Removal Removal
WARNING WARNING
WARNING WARNING
1. Remove the DADH, REP 5.19. 1. Remove the CVT glass and document glass, REP 14.6.
2. Remove the user interface assembly, REP 2.1. 2. Manually move the Scan carriage to align with the cut-outs in the frame.
3. Remove the scanner top cover, PL 14.20 Item 3 (W/O TAG 150), PL 14.10 Item 3 (W/TAG 3. Remove the exposure lamp with the end blocks, Figure 1.
150).
4. Remove the input module angle sensor, Figure 1.
2 3
Depress the actuator Release the lamp
to release the sensor. mounting block from
the carriage at both
ends. Remove the lamp
and end blocks.
1
Disconnect the PJ through
the access hole, then
release the lamp harness
retainer.
2
Press the catch and slide the
mounting block upwards at both
3 1 ends of the lamp.
Disconnect the sensor from the harness. Remove the screw.
Figure 1 Input module angle sensor
Replacement
Figure 1 Releasing lamp fasteners
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.

4. Remove the end blocks from the exposure lamp, Figure 2. REP 14.10 Scan Idler Pulleys
Removal
WARNING
Slide the end block
from the lugs. from the customer supply while performing tasks that do not need electricity. Electricity
WARNING
2. Carefully move the scan carriage to the left side of the scanner module.
3. Remove the scan idler pulleys, Figure 1.
2 NOTE: Figure 1 and Figure 2 show the rear scan idler pulley. The procedure for the front
Remove the end block from the scan idler pulley is similar.
other end of the exposure
lamp.
2
Hold the tension in the cable and
slide the pulley off of the shaft.
Figure 2 Removing end blocks
Replacement
Reverse the removal procedure to replace the exposure lamp.
1
Remove the
E-clip.
3
Maintain the tension in the cable and
remove the pulley from the cable loop.
Figure 1 Scan idler pulley removal

Replacement REP 14.11 Scan Motor (W/O TAG 150)
1. Reverse the removal procedure to replace the scan idler pulleys. Parts List on PL 14.25
2. Make sure the scan idler pulleys are installed correctly, Figure 2.
Removal
1
Maintain the tension in the WARNING
cable and place the pulley
in the cable loop. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
WARNING
2. Mark the position of the scan motor bracket, Figure 1.
3 2
Install the E-clip. Slide the pulley onto the
shaft.
Figure 2 Scan idler pulley replacement
Scribe a line.
Figure 1 Motor bracket position

3. Remove the scan motor and then remove the weight (35 ppm only), Figure 2. REP 14.12 Scan Cables
3 4 Weight (35 ppm
Loosen 2 grub screws and then only) Removal
Remove the motor
and bracket. remove the flywheel.
WARNING
WARNING
CAUTION
When moving the scan carriages, hold them by the metal parts only, to avoid damaging the
lamp or mirrors.
3. Figure 1 shows the arrangement of the scan cables. Refer to Figure 1 when installing the
cables.
2
Remove 2
5
screws. Remove 2 screws and then
remove the motor from the
1 bracket.
Disconnect
PJ456.
Replacement
1. Re-assemble the motor onto the bracket and fully tighten the screws.
2. Replace motor / bracket assembly into the optics cavity, engage the motor pulley with the
drive belt and install the two screws, but do not tighten.
3. Move the motor / bracket assembly to the right until the bracket aligns with the scribe line,
Figure 1, then fully tighten the screws.
4. Re-install the flywheel and tighten the 2 screws.
5. Re-install the CVT glass and document glass.
6. Ensure that the weight (35 ppm only) is fitted onto the new motor.

Capstan
Drive shaft Anchor ball
Rear cable (silver cable)
End ball
Fly-wheel weight, W/O TAG 150 Scan carriage

machines only. clamp
Half rate scan carriage

pulleys
Anchor ball
End ball
Scan carriage
clamp
Capstan
Half rate scan carriage

pulleys Fixed pulley
Front cable (dark cable)
Tab to secure the spring

to the frame
Fixed pulley
Figure 1 Scan cables arrangement

4. Move the scan carriage to the position shown in Figure 2, with the exposure lamp at the Replacement
left end of the frame cut-outs, then mark the position of the half rate scan carriage. The
anchor balls should be in the position shown in Figure 1. NOTE: The replacement procedure is made easy by holding the windings on the capstan in
place with tape at all times, until each cable is fully installed. Keep the cable tight to prevent it
unwinding.
1. Prepare several short lengths of adhesive tape.

Scan carriage Frame cut-out
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 scan carriage is in the start position, as in Figure 2.
3. Place the rear cable in the position shown in Figure 3. Hold in place on the capstan with
adhesive tape.
Silver cable
rear
End ball
Exposure lamp Half rate scan
carriage
Figure 2 Carriage start position
5. (W/TAG 150) remove the document size sensor cover, refer to REP 14.20.
6. Remove the cable clamps, with captive screws, from the scan carriage. Move the cables
Dark cable
clear of the scan carriage, then lift the scan carriage out through the cut-outs in the frame. Front
Rest the scan carriage out of the way of the cables. It is not necessary to disconnect the
ribbon cable. Store the cable clamps for later use.
7. Unhook the tension spring from the rear cable. Remove the spring from the cable and Figure 3 Winding start position
store the spring for later use.
8. Remove the rear cable completely by unhooking the end ball from its retaining bracket 4. Starting with the end-ball end of the cable, wind on three turns, stopping at each turn to
and unwind the cable from the capstan. hold the cable to the capstan with adhesive tape. If necessary, use a fresh length of adhe-
9. Repeat steps 7 and 8 for the front cable. sive each time to ensure the cable is held tightly.
5. Hold the capstans in position, then tape the top of the fly-wheel weight (W/O TAG 150) or
the drive shaft (W/TAG 150) onto the top left of the scanner frame. 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 REP 14.13 Scanner Drive Belt (W/O TAG 150)
the end ball holding bracket. If the winding is correct, the end ball will fit tightly onto the
bracket. Parts List on PL 14.25
7. Wind the loop end of the cable round the capstan three times, as shown in Figure 1, stop- Removal
ping at each turn to hold the cable to the capstan with adhesive tape. If necessary, use a
fresh length of adhesive tape 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 WARNING
scan pulley. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
9. Attach the spring to the cable loop and hook the spring to its tab on the frame. from the customer supply while performing tasks that do not need electricity. Electricity
10. Ensure all the adhesive tape is removed from the scanner. can cause death or injury. Moving parts can cause injury.
11. Repeat steps 2 to 10 for the front cable.
12. Fit the scan carriage through the slots in the frame and position the ribbon cable round the WARNING
guide on the half rate scan carriage.
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.
CAUTION
When moving the scan carriages, hold them by the metal parts only, to avoid damaging the
lamp or mirrors.
1. Remove the front scan cable, REP 14.12.
Cable
Scan carriage front
Scan carriage rear Cable
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 following: DADH, REP 5.19. Reinstall the CVT glass and document glass,
REP 14.6.
(W/TAG 150) Document size sensor cover, REP 14.20.
DADH, REP 5.19
CVT glass and document glass, REP 14.6

2. Figure 1. Remove the scanner motor flywheel. REP 14.14 Top Cover
Drive belt
Removal
WARNING
WARNING
2. Remove the user interface assembly, REP 2.1. It is not necessary to disconnect the PJ.
Bearing
Circlip 1 3. Figure 1, remove the top cover.
Loosen 2 allen
screws.
3
4 Remove
2 Lift off the top cover. three
Drive shaft Remove the screws.
flywheel.
Figure 1 Flywheel removal and component location
3. Remove the circlip from the front end of the scanner drive shaft.
4. Push the drive shaft inboard and remove the bearing.
5. Remove the drive belt from the motor shaft.
6. Remove the drive belt from the drive shaft.
Replacement
1. The replacement procedure is the reverse of the removal procedure.
2
1 Loosen three screws.
Remove one
screw.
Figure 1 Top cover removal
Replacement
2. Perform ADJ 14.1 (W/O TAG 150), ADJ 14.2 (W/TAG 150) Optics Cleaning.

REP 14.15 Scan Motor (W/TAG 150) REP 14.16 Scan Motor and Scan Carriage Drive Belts (W/
Parts List on PL 14.15 TAG 150)
Removal
WARNING
1. Remove the CVT and document glass, REP 14.6. can cause death or injury. Moving parts can cause injury.
2. Figure 1. Remove the scan motor.
WARNING
1. Remove the CVT glass, document glass and CVT ramp, REP 14.6.
2. Remove five screws securing the PWB cover, PL 14.15 Item 1.
3. Lift the PWB cover and disconnect PJ923 on the scanner PWB, PL 14.15 Item 4.
4. Remove the scan motor, REP 14.15.
4
Disconnect the motor
harness and then
remove the motor.
1 2 3
Scribe a line round the Remove 3 screws. Remove the scan motor
motor bracket. drive belt.
Figure 1 Scan motor
Replacement
2. Ensure the motor bracket is aligned with the scribe line on the base of the scanner, Figure 1.

5. Prepare to remove the belts, Figure 1. 6. Release the scan carriage drive shaft, Figure 2.
1
Remove the E-clip
1
2 Scribe around the intermediate
Remove 2 screws pulley bracket
Figure 1 Preparation Figure 2 Release the scan shaft

7. Remove the drive belts, Figure 3. REP 14.17 Exposure Lamp Inverter (W/TAG 150)
2 1
Move the scan carriage drive Carefully hold the scan cable on the Removal
shaft towards the front pulley to maintain cable tension
WARNING
WARNING
1. Remove the CVT glass, REP 14.6.
2. Remove the CVT ramp and document glass, REP 14.6.
3. Release the exposure lamp inverter PWB, Figure 1.
3
Slip the scan 5
4 Remove the E-clip and bearing. Push
carriage drive Slide the scan carriage
belt over the the shaft rearwards to release the rear
drive shaft rearwards bearing, lift the intermediate pulley
scan carriage into its bearing to
pulley and shaft , remove the drive belts
maintain cable tension
1 2
Remove 2 screws. Place fingers under the carriage to hold the
Figure 3 Remove scan belt cable clamp, then release the 3 clips from
above while pulling the clamp down.
Replacement
CAUTION Figure 1 Release the inverter

Ensure that the intermediate pulley bracket and scan motor bracket are aligned with the
scribed marks.

4. Remove the exposure lamp inverter, Figure 2. Replacement
1. Reverse the removal procedure to replace the exposure lamp inverter PWB.
3 2. When re-connecting the ribbon harness, the blue band printed on the cable must face as
Remove the exposure shown in Figure 3.
lamp inverter PWB. 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.
Blue tab on the scan carriage

ribbon harness.
1 2
Disconnect the lamp harness. Disconnect the scan carriage rib-
bon harness.
Make a note of the orientation of
the blue tab on the harness.
Figure 3 Ribbon harness
Figure 2 Remove the inverter

REP 14.18 Scan Carriage Ribbon Harness (W/TAG 150) 7. Disconnect and remove the exposure lamp ribbon harness, Figure 1.

Removal
WARNING
WARNING
1. Remove the CVT glass, REP 14.6.
2. Remove the CVT ramp and document glass assembly, REP 14.6.
3. Remove five screws securing the scanner PWB cover.
4. Lift the PWB cover and disconnect PJ923 on the scanner PWB, PL 14.15 Item 4.
5. Disconnect the ribbon harness from the exposure lamp inverter, REP 14.17.
6. Release the ribbon harness from the half rate scan carriage.
1 2 3
Remove 4 screws, 2 on Disconnect the ribbon Lift the lens carriage and
each side of the lens car- harness at PJ926. release the ribbon harness.
riage assembly.
Figure 1 Release the ribbon harness
Replacement
2. Perform ADJ 14.2 Optics Cleaning.

REP 14.19 Scanner PWB (W/TAG 150) REP 14.20 Document Size Sensor 1 and Document Size
Parts List on PL 14.15 Sensor 2 (W/TAG 150)
Removal
WARNING
WARNING
1. Remove the CVT glass, REP 14.6. Take care during this procedure. Sharp edges may be present that can cause injury.
2. Remove the CVT ramp and document glass assembly, REP 14.6. 1. Remove the CVT glass, REP 14.6.
3. Remove five screws securing the scanner PWB cover. 2. Remove the CVT ramp and document glass assembly, REP 14.6.
4. Lift the PWB cover and disconnect PJ923 on the scanner PWB, PL 14.15 Item 4. 3. Remove four screws securing PWB cover.
5. Disconnect all of the harness connectors from the scanner PWB, PL 14.15. 4. Lift the PWB cover and disconnect PJ923 on the scanner PWB, PL 14.15 Item 4.
6. Remove four screws securing the scanner PWB. 5. Remove document size sensor 1 (Q14-315) or document size sensor 2 (Q14-320), Figure 1.
7. Remove the scanner PWB.
Replacement

NOTE: The removal of document size sensor 1 and document size sensor 2 is identical.
Size sensor 1
Q14-315
Size sensor 2
Q14-320
2 1
Press the side of the sensor to Disconnect the harness from
release the sensor from the bracket. the document size sensor.
Figure 1 Remove document size sensor
Replacement

ADJ 3.1 Registration Setup ADJ 3.2 Magnification Adjustment
Purpose Purpose
To measure and adjust image to paper registration. Go to dC604 Registration Setup. To adjust the machine magnification to 100%
Adjustment
WARNING
NOTE: There are no across process direction adjustments.
1. Select 100% magnification.

2. Use the internal registration test pattern.
3. Make a copy from the document glass or through the DADH.
4. Measure the process direction dimension, IQS 8 Magnification.
5. Enter dC131, select either:
(W/O TAG 150) 05-009 DADH Mag (copy mode)
(W/TAG 150) 14-169 DADH Mag
14-027 Scanner Mag Adj
NOTE: An entry of less than the default value will increase the dimension B.
6. Repeat the above steps until the dimension on the copy is the same as on the print.
7. If the across process dimension is not within the tolerances specified and the customer is
dissatisfied, install a new scanner module, (W/O TAG 150) PL 14.20 Item 1 or (W/TAG
150) PL 14.10 Item 1.

Xerox WorkCentre 5790 Family 4-443 ADJ 3.1, ADJ 3.2
ADJ 3.1, ADJ 3.2 4-444 Xerox WorkCentre 5790 Family
ADJ 4.1 Machine Lubrication Tray 3 and 4 Transport Roll and Bearings
Purpose Parts list on: PL 8.30 (W/O TAG 151), PL 8.32 (W/TAG 151).
To correctly lubricate the machine to prevent noise and wear.
1. Remove the tray 3 and 4 transport roll, REP 8.31 (W/O TAG 151) or REP 8.47 (W/TAG
151).
Lubrication
2. Apply plastislip grease, PL 26.10 Item 8, to lubricate the ends of the transport roll, where
Refer to GP 18 Machine Lubrication for general guidance on the use of lubricants. the bearings locate.
3. Reinstall the tray 3 and 4 transport roll, REP 8.31 (W/O TAG 151) or REP 8.47 (W/TAG
151).
WARNING
Tray 3 and 4 Elevator Drives Gear Coupling
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Parts list on: PL 7.17 (W/O TAG 151), PL 7.19 (W/TAG 151).
The following list gives the parts of the machine where lubrication is permitted. Go to the rele- 1. Pull out tray 3 and tray 4.
vant procedure: 2. Apply plastislip grease, PL 26.10 Item 8, to lubricate the coupling on the elevator motor
Tray 3 and 4 Transport Roll and Bearings. and the coupling on the back of the tray.
Tray 3 and 4 Elevator Drives Gear Coupling. 3. Push home tray 3 and tray 4
Bypass Feed Roll Shaft.
Tray 1 and 2 Support Slides.
Tray 3 Takeaway Roll Assembly.
Tray 3 Transport Roll Assembly.
Registration Transport Gears.
Developer Module Support Pins.
1K LCSS Drive Belt Tensioners.
1K LCSS Bin 1 Drive Belt Pulleys and Idler.
2K LCSS Drive Belt Tensioners.
2K LCSS Bin 1 Drive Belt Pulleys and Idler.
1K and 2K LCSS Bin 1 Elevator Motor Worm and Gear.
1K and 2K LCSS Tamper Assembly.
HVF BM Support Pin.

Xerox WorkCentre 5790 Family 4-445 ADJ 4.1
Bypass Feed Roll Shaft Tray 1 and 2 Support Slides
1. Remove the bypass tray drive gear, REP 8.20. 1. Remove tray 1 and 2, REP 7.1.
2. Figure 1, plastislip grease, PL 26.10 Item 8, to lubricate the shaft. 2. Figure 2, plastislip grease, PL 26.10 Item 8, to lubricate the support slides.
3
Slide the shaft to the rear to expose the areas of the shaft
normally located within the rear and front bearings. Apply
grease to these newly exposed areas.
2
Remove E-clip
Apply grease to the upper Apply grease to the upper

surface of the left slides surface of the right slides
1
Remove the E-clips
Figure 1 Bypass feed shaft Figure 2 Tray 1 and 2 support slides
3. Return the feed roll shaft to the original position and install the E-clips, Figure 1. 3. Lubricate the stack height mechanism actuator located at the rear left side of the tray and
4. Install the bypass tray drive gear and feed head, REP 8.20. the paper width guides.
4. Re-install tray 1 and 2, REP 7.1.
Tray 3 Takeaway Roll Assembly
Parts list on: PL 8.35 Item 2 (W/O TAG 151), PL 8.36 Item 2 (W/TAG 151).
1. Remove the tray 3 takeaway roll assembly, REP 8.29 (W/O TAG 151) or REP 8.46 (W/
TAG 151).
2. Use plastislip grease, PL 26.10 Item 8, to lubricate the two areas of the shaft normally
located within the bearings.
3. Re-install the tray 3 takeaway roll assembly. REP 8.29 (W/O TAG 151), REP 8.46 (W/TAG
151).

ADJ 4.1 4-446 Xerox WorkCentre 5790 Family
Tray 3 Transport Roll Assembly Registration Transport Gears
Parts list on: PL 8.35 Item 11 (W/O TAG 151). Parts list on: PL 8.15.
1. Remove the tray 3 transport assembly, REP 8.13. 1. Remove the registration clutch, REP 8.5.
2. Figure 3, plastislip grease, PL 26.10 Item 8, to lubricate the tray 3 transport roll assembly. 2. Use plastislip grease, PL 26.10 Item 8, to lubricate the following parts:
Registration clutch, PL 8.15 Item 7. Lubricate the gear teeth only.
Gear (22T/28T), PL 8.15 Item 17. Lubricate the gear teeth only.
Gear (23T), PL 8.15 Item 18. Lubricate the gear teeth and the bore of the gear.
5
Apply grease to the 2 areas of 3. Re-install the removed components, REP 8.5.
4 the shaft that are normally inside Developer Module Support Pins
Remove E-clip, slide the bearings
shaft to the rear
2. Figure 4, use plastislip grease, PL 26.10 Item 8, to lubricate the developer assembly sup-
port pins at the front and rear.
3 1
2 Spring open the legs and Front pins Rear pins
Slide pulley and Remove E-clip and remove the outer coupling
belt from the shaft. inner coupling
Figure 4 Developer assembly support pins
Figure 3 Transport roll removal 3. Re-install the developer assembly, REP 9.2.
3. Re-install the tray 3 transport roll assembly.

4. Re-install the tray 3 transport assembly, REP 8.13.

1K LCSS Drive Belt Tensioners 1K and 2K LCSS Bin 1 Elevator Motor Worm and Gear
1. Remove the 1K LCSS top cover and rear cover, REP 11.1-120. 1. Remove the 1K LCSS top cover and rear cover, REP 11.1-120 or the 2K LCSS top cover
2. Remove the relevant belt tensioner: and rear cover, REP 11.1-110.
Bin 1 drive belt tensioner, PL 11.106 Item 15. 2. Figure 5, use plastislip grease, PL 26.10 Item 8, to lubricate the worm and gear.
Intermediate paper drive belt tensioner, PL 11.118 Item 14. NOTE: The lubrication procedure is the same for the 1K LCSS and the 2K LCSS. The 1K
Paper output drive belt, PL 11.120 Item 8. LCSS is shown in Figure 5.
3. Remove the E-clip and pulley from the belt tensioner. Apply plastislip grease, PL 26.10
Item 8 to the shaft and pulley bore. Re-assemble the pulley and E-clip on the belt ten-
sioner.
4. (Bin 1 drive belt tensioner only) Clean off the old lubricant and any contamination from
the belt tensioner and 1K LCSS frame using a micro fiber wiper, PL 26.10 Item 13. Apply
plastislip grease, PL 26.10 Item 8, to the whole contact face of the belt tensioner.
5. Reinstall the belt tensioner.
1K LCSS Bin 1 Drive Belt Pulleys and Idler
2. If necessary, remove the 1K LCSS PWB, REP 11.12-120.
3. Remove the relevant pulley or idler:
Bin 1 drive belt idler, PL 11.106 Item 17.
Bin 1 drive belt pulleys, PL 11.106 Item 6.
4. Remove the E-clip and pulley or idler from the belt tensioner. Apply plastislip grease, PL
26.10 Item 8 to the shaft and pulley or idler bore. Re-assemble the pulley or idler and E-
clip on the belt tensioner.
2K LCSS Drive Belt Tensioners
2. Remove the relevant belt tensioner:
Intermediate paper drive belt tensioner, PL 11.22 Item 17.
Bin 1 drive belt tensioner, PL 11.10 Item 13. Apply grease
to the worm
3. Remove the E-clip and pulley from the belt tensioner. Apply plastislip grease, PL 26.10 and gear
Item 8 to the shaft and pulley bore. Re-assemble the pulley and E-clip on the belt ten-
sioner.
4. Clean off the old lubricant and any contamination from the belt tensioner and 2K LCSS
frame using a micro fiber wiper, PL 26.10 Item 13. Apply plastislip grease, PL 26.10 Item Figure 5 Lower vertical slides
8, to the whole contact face of the belt tensioner.
2K LCSS Bin 1 Drive Belt Pulleys and Idler
2. If necessary, remove the 1K LCSS PWB, REP 11.14-110.
3. Remove the relevant pulley or idler:
Bin 1 drive belt idler, PL 11.10 Item 15.
Bin 1 drive belt pulleys, PL 11.10 Item 6.
4. Remove the E-clip and pulley or idler from the belt tensioner. Apply plastislip grease, PL
26.10 Item 8 to the shaft and pulley or idler bore. Re-assemble the pulley or idler and E-
clip on the belt tensioner.

1K and 2K LCSS Tamper Assembly HVF BM Support Pin
1. Remove the 1K LCSS top cover, REP 11.1-120 or the 2K LCSS top cover, REP 11.1-110. 1. Open the BM front door.
2. Figure 6, use plastislip grease, PL 26.10 Item 8, to lubricate the tamper assembly. 2. Fully pull out the BM unit.
3. Figure 7, use plastislip grease, PL 26.10 Item 8, to lubricate the BM support pin.
NOTE: The lubrication procedure is the same for the 1K LCSS and the 2K LCSS.
Apply grease to the pin
Figure 7 Support pin lubrication
4. Fully push in the BM unit and close the HVF BM front door.
Apply grease to the

shaft
Figure 6 Lower vertical slides

ADJ 5.1 DADH Drive Belt Adjustment 2. Adjust the correct motor drive belt, Figure 1. When the feed motor is adjusted, correctly
engage the gears on the feed motor and the feed clutch. Check that the pitch rings just
Parts List on PL 5.25 and PL 5.35 touch.
Purpose
To correctly set the tension of the feed motor and the CVT motor drive belts.
Adjustment
WARNING
CAUTION
Before this adjustment is performed, make sure all components removed in the repair proce-
dure are installed correctly.
NOTE: The same adjustment applies to the feed motor and the CVT motor. This procedure 1
Feed motor Pitch rings Loosen the 3
shows how to adjust the feed motor. The green spring applies tension to the feed motor drive
screws.
belt. The silver spring applies tension to the CVT motor drive belt.
Feed motor CVT motor
3 2
Tighten the 3 screws. Allow the spring to apply the tension to the drive belt.
Figure 1 Drive belt

ADJ 5.2 DADH Height Adjustment
Parts List on PL 5.10 and PL 5.25
Purpose
To correctly set the distance between the scanner module and the DADH.
Check Front DADH standoff.
WARNING CVT glass.

NOTE: The DADH standoffs include the CVT roll bearings, PL 5.25 Item 4 and PL 5.25 Item
13.
1. Check the height of the DADH. The two standoffs touch the CVT glass when the DADH is
closed, Figure 1. Check that the DADH is parallel to the scanner module. Perform the
steps that follow. Refer to Figure 2:
a. Put a strip of paper on the CVT glass below the back DADH standoff.
b. Close the DADH.
c. Carefully pull the paper. Make sure that the paper was pressed between the CVT
glass and back DADH standoff.
d. Repeat A to C for the front DADH standoff.
2. If the DADH height is incorrect, perform the Adjustment.
Back DADH standoff.
CVT glass.
Figure 1 DADH standoffs

Adjustment
CVT glass. Back DADH standoff. NOTE: The factory setting of the counterbalances is approximately 3mm (0.125 inch), refer to
Figure 3. The same adjustment applies to the left counterbalance and right counterbalance.
Adjust the two counterbalances.
1. If the height of the DADH is wrong, adjust the counterbalances, Figure 3.
2
Use an allen key to adjust the setting screw to raise
or lower the DADH.
Lower the DADH.
1
Loosen the lock nut.
3
Tighten the lock nut.
Approximately 3mm
(0.125 inch)
Strip of paper.
Figure 2 Clearance check
Raise the DADH.
Figure 3 Counterbalances
2. If mis-registration is found after the DADH is set to the correct height, go to ADJ 5.5
DADH Registration Adjustment.

ADJ 5.3 DADH Skew Adjustment 3. Adjust the setting screw on the right counterbalance to correct the skew, Figure 1.

1
Purpose Loosen the lock nut.
To correct document feed skew induced by the DADH.
3
Preparation Tighten the lock nut.
1. Clean the CVT glass. Refer to ADJ 5.4 DADH cleaning procedure.
2. Check that the document width guides are adjusted correctly.
3. Make sure that the DADH is set to the correct height. Go to ADJ 5.2 DADH Height Adjust-
ment.
4. Check the document path for obstructions or foreign objects.
5. Perform the Skew Check.
Skew Check
1. Use the DADH to make 5 copies. Check the skew, refer to IQS 5 Skew.
NOTE: Skew is always measured on the lead edge, irrespective of paper orientation.
2. If necessary, perform the Adjustment.

Adjustment
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do 2
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Adjust the setting
death or injury. Moving parts can cause injury. screw (see NOTE).
1. Raise the DADH.
2. Loosen both DADH thumbscrews, PL 5.10 Item 12. Figure 1 Skew adjustment
NOTE: Turn the setting screw in direction A to move the right side of the DADH to the
front. Turn the setting screw in direction B to move the right side of the DADH to the rear.
4. Pull the DADH forward, then tighten the thumbscrews.

5. Perform again the Skew Check.
6. When the DADH skew is good, check the DADH registration. Go to ADJ 5.5 DADH regis-
tration Adjustment.

ADJ 5.4 DADH Cleaning Procedure
When the under side of the input tray is cleaned, do not damage the restack arm, PL 5.35 Item 3.
Purpose
14. Clean the input tray and the exit area below the input tray with a micro fiber wiper and
This procedure describes how to clean the DADH. The wear of the feed rolls, paper dust and
antistatic fluid.
dirt in the environment can cause the copy quality defects.
15. Clean the CVT glass and the document glass. Refer to (W/O TAG 150) ADJ 14.1 Optics
The tools required: Cleaning Procedure or (W/TAG 150) ADJ 14.2 Optics Cleaning Procedure.
5.5mm nut driver
The supplies required:
Dry micro fiber wiper, PL 26.10 Item 13.
Brush
Cleaning fluid, PL 26.10 Item 2.
Antistatic fluid, PL 26.10 Item 19.
Adjustment
WARNING
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Key Retard roll
1. Use a brush to clean the document length sensors, PL 5.35 Item 8.
3. Use a dry micro fiber wiper, or brush to clean the document path area, top and bottom.
Remove all loose material.
4. Clean the CVT roll, PL 5.25 Item 5 with a micro fiber wiper and water. Figure 1 Retard roll position
5. Clean the CVT idlers and the takeaway idlers, PL 5.20 Item 3 with a micro fiber wiper and
water.
6. Remove the DADH rear cover, rotate the takeaway rolls.
7. Clean the takeaway rolls, PL 5.35 Item 6 with a micro fiber wiper and water.
CAUTION
When the feed rolls are installed, make sure the lowest roll, (retard roll), is correctly positioned
on the assembly as shown in Figure 1.
8. Remove the feed roll assembly, REP 5.14. Clean the 3 rolls and the pad, PL 5.35 Item 2
with a micro fiber wiper and water. Use a brush to clean the paper dust from the assembly
and from the area around the assembly. Install the feed roll assembly.
9. Leave the top cover open and raise the DADH assembly.
10. Lower the baffle assembly, PL 5.30 Item 5. Clean the four CVT idler rolls with a micro fiber
wiper and water.
11. Clean the exit roll idlers, PL 5.30 Item 8 and the takeaway roll, PL 5.35 Item 6 with a micro
fiber wiper and water.
12. Clean the document pad with a micro fiber wiper and water.
13. Lower the DADH assembly. Install the DADH rear cover.

ADJ 5.5 DADH Registration Adjustment ADJ 5.6 DADH Document Pad
Purpose Purpose
To measure and adjust the image to paper registration. To correctly align the DADH document pad with the document glass.
Adjustment Adjustment
Reset the DADH registration. Go to dC604 Registration Setup Procedure.
WARNING
NOTE: If a new document pad is installed, make sure that the protective paper is removed
from the adhesive pads.
1. Raise the DADH. Put the document pad with the adhesive pads face-up on the document
glass.
2. Align the document pad with the document registration guides as shown in Figure 1.
Document registration
guides
Document pad
Figure 1 Document pad alignment
3. Carefully lower then raise the DADH. Make sure the document pad is attached correctly.

ADJ 6.1 ROS Window Cleaning Procedure 2. Using a clean, dry cotton tip, very carefully clean the underside of the ROS widow, Figure 1.
Purpose
To improve the image quality.
NOTE: Only perform this procedure if directed to it from an Image Quality RAP.
Procedure
WARNING
WARNING
Do not break the glass. Broken glass can cause injury.
CAUTION
The ROS window is secured by 2 clips, 1 at the front and 1 at the rear. If too much pressure is
applied when cleaning the ROS window, the glass will flex and may break.
1. Remove the xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL 9.20 Item 2.
1
Insert the cotton tip through
the aperture on the bottom of
the ROS.
NOTE: The ROS window is

positioned 12mm (0.5 inch)
above the aperture.
2
Very carefully clean the
ROS window.
Figure 1 ROS window cleaning

ADJ 6.2 ROS Cleaning Procedure NOTE: Carefully rotate the polygon mirror for access to all sides.
Purpose 4. Install the ROS top cover.

To improve the image quality. 5. Install the ROS, REP 6.1.
Cleaning Methods
NOTE: Only perform this procedure if directed to from an Image Quality RAP.
Procedure
WARNING
Do not break the glass. Broken glass can cause injury.
WARNING
Ensure that the electricity to the machine is switched off while performing tasks that do CAUTION
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause Do not use the toner vacuum cleaner near the ROS window. The glass is flexible and can
death or injury. Moving parts can cause injury. break.
1. Use a toner vacuum cleaner to carefully clean metalwork inside of the ROS.
WARNING 2. Use a clean, dry cotton tip to remove the contamination from glass components.
3. If the contamination remains, use a cotton tip dampened with film remover, PL 26.10 Item
4.
4. Start from the center of each component and carefully clean towards the outside edge.
ROS window ROS laser diode.

See CAUTION. See CAUTION.
Mirrors.
CAUTION
Ensure that E.S.D. procedures are observed during this procedure.
CAUTION
When rotating the polygon mirror, do not press down on the polygon mirror. Do not move any
other components. The components are aligned during manufacture.
CAUTION
Contamination of the inside of the ROS can cause image quality defects. Ensure the inside of
the ROS is clean before the top cover is replaced.
1. Remove the ROS, REP 6.1.
2. Remove the top cover from the ROS (5 torx head screws). Lens.
CAUTION
Do not attempt to clean the ROS laser diode. Polygon mirror.
See CAUTION.
3. Refer to Figure 1. Refer to Cleaning Methods. Inspect the inside of the ROS. As neces-
sary, clean the inside of the ROS, the mirrors, the polygon mirror, the lens and the surface
of all glass components
Figure 1 ROS component location

ADJ 7.1 Tray 3 and Tray 4 Paper Tray Guide Setting (W/O 3. To reset the paper tray guide:
Refer to Figure 2 to set the paper tray guide to A4 paper size and reposition the
TAG 151) retaining clips.
Parts List on PL 7.17 Refer to Figure 3 to set the paper tray guide to 8.5 x 11 inch paper size and reposi-
Purpose tion the retaining clips.
To adjust the paper tray guides in tray 3 and tray 4 for A4 or 8.5 x 11 inch paper.
Retaining clips.
Adjustment
WARNING
1. Pull out the tray to be adjusted and remove the paper from the tray.
2. Push in the retaining clips and remove the paper tray guide, PL 7.15 Item 20, Figure 1.
Retaining clips.
Figure 2 Set the paper guide to A4 size
Figure 1 Remove the paper guide

ADJ 7.2 Tray 5 Paper Tray Guide Setting
Retaining clips.
Purpose
To adjust the paper tray guides in tray 5 for A4 / A3 or 8.5 x 11 / 11 x 17 inch paper.
Adjustment
WARNING
1. Open tray 5 door and allow the tray to lower and remove the paper stack.
2. Adjust the paper guide to the required paper size, Figure 1.
To set the paper tray guide to A4 / A3 paper size, move the paper guide to the outer
position.
To set the paper tray guide to 8.5 x 11 / 11 x 17 inch paper size, move the paper
guide to the inner position.
Figure 3 Set the paper tray guide to 8.5 x 11 size
4. To lock the paper tray guide in position, push the retaining clips in the reverse direction to
that shown in Figure 1.

ADJ 7.3 Tray 5 Module to Machine Alignment
Paper size indicator window
Purpose
To correctly align the tray 5 module to achieve correct top edge registration and reliable trans-
fer of paper from the tray 5 module to the machine.
1
Move the handle up to
release the lock on the Adjustment
paper guide.
WARNING
2 not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
Use the handle to move the death or injury. Moving parts can cause injury.
paper guide to the required Machines W/O TAG P-001. The adjustment must be performed in the following order:
paper size.
1. Figure 1, turn the hand wheel above the front castor at the left of the tray 5 module to set
tray 5 level with the left hand door. The measurement between the left hand door and tray
5 should be equal at the front and the rear. This is the nominal position for tray 5 and the
3 image registration and hole punching should need little or no correction.
Move the handle down to
lock the paper guide.
Figure 1 Paper guide adjustment

NOTE: Before each adjustment or measurement, un-dock and re-dock the module to Machines W/TAG P-001. The adjustment must be performed in the following order:
reset the tray 5 position.
1. Figure 2, turn the hand wheel in the centre of the tray 5 module to raise the casters off the
floor.
Ensure edges are

parallel.
1
Turn the wheel at the front Turn the hand wheel to obtain
to obtain the alignment. alignment.
- +
2
Raise front and rear casters off of the floor.
Figure 1 Tray 5 alignment W/O TAG P-001

Figure 2 Tray 5 alignment W/TAG P-001
2. Make prints to check for image registration and correct hole punching. If necessary, con-
tinue to step 3.
3. Figure 1, turn the wheel as necessary. The + direction moves the paper towards the front
of the machine. The - direction moves the paper towards the rear of the machine.

ADJ 7.4 Tray 5 Module Tray Alignment 2. Turn the adjusting screw to move the docking pin bracket to the front or to the rear, Figure 2

Purpose
To align the tray 5 module paper tray with the paper trays in the IOT module. Use this adjust-
ment when the top edge registration cannot be achieved using the NVM values in dC604 Reg-
istration Setup Procedure. 1
Turn the adjusting
NOTE: Perform ADJ 7.3, Tray 5 Module to Machine Alignment, before starting this adjustment screw as necessary.
procedure. Use both ADJ 7.3 and this adjustment to achieve correct hole punch alignment.
Before performing this adjustment return the NVM values for tray 5 to the nominal values.
Adjustment
WARNING 2
Ensure that the electricity to the machine is switched off while performing tasks that do The bracket moves.
Make a sample print and determine which way and how far the tray needs to be moved. After
the adjustment is made, take a sample print.
Figure 2 Adjusting screw
1. Loosen the two screws on the docking pin bracket, Figure 1.
3. Use the scribed indicator to determine the amount of movement, Figure 3.
Use the scribed indicators to

determine the amount of adjust-
ment required.
The indicator is in 1mm incre-
ments.
1
Loosen two screws.
Figure 1 Docking pin bracket

Figure 3 Adjustment indicator

4. Secure the docking pin bracket, Figure 4. ADJ 7.5 Tray 3 and Tray 4 Paper Tray Guide Setting (W/TAG 151)
Purpose
To adjust the paper tray guides in tray 3 and tray 4 for A4 or 8.5 x 11 inch paper.
Adjustment
WARNING
1. Pull out the tray to be adjusted and remove the paper from the tray.
2. To reset the paper tray guides:
1 Refer to Figure 1 and Figure 2 to change the paper tray guides and paper guides
Tighten two screws. from A4 paper size to 8.5x11 inch paper size.
Refer to Figure 3 and Figure 4 to change the paper tray guides and paper guides
from 8.5x11 inch paper size to A4 paper size.
Top location points

Figure 4 Secure the docking pin bracket
5. Make sample prints and check the top edge registration.

6. Enter dC604 Registration Setup Procedure and set the top edge registration.
7. If the top edge registration is still out of range, then repeat the adjustment.
4
Push in 2
retaining
clips.
1
Pull out 2
retaining
clips.
Bottom location points

2
Lift the paper
3
tray guide Engage the paper tray guide with the
forward location points, top and bottom
Figure 1 Paper tray guide re-position

1 5 Top location points
Release the top Move the front
fixing from the tray paper guide to
the front position
6
Press the
paper guide
into position
4
Push in 2
retaining
clips.
1
Pull out 2
retaining
clips.
Bottom location points
4 2 3
2 3 Engage the paper tray guide with the
Move the rear paper Press the paper Release the top Lift the paper
tray guide rearward location points, top and bottom
guide to the rear position guide into position fixing from the tray
Figure 2 Paper guides re-position Figure 3 Paper tray guide re-position

ADJ 7.6 Tray 5 Stack Height Sensor and Retard Shield
1 5
Release the top Move the front Parts List on PL 8.45, PL 26.11
fixing from the tray paper guide to Purpose
the rear position
To enable the stack height sensor and retard shield to be set to their optimum positions on W/
TAG P-050 and W/TAG P-051 tray 5 modules only. Thus extending the life of the feed, nudger
and retard rolls.
6
Press the NOTE: Manufacturing failed to strike the Mod/Tag plate on a quantity of tray 5 modules manu-
paper guide factured with the adjustable stack height sensor (W/TAG P-050) and retard shield (W/TAG P-
into position 051). These adjustable tray 5 modules can be identified by an externally visible retard shield,
refer to Figure 6.
NOTE: In the service engineering community tray 5 is also referred to as the PFP (Paper Feed
Platform).
Preparation
WARNING
Special tool required - PFP setting tool, PL 26.11 Item 6 and Figure 1.
4 1. Remove the following components from the upper feed assembly drive shafts;
2 3
Move the rear paper Press the paper Release the top Feed roll, REP 8.34.
guide to the front position guide into position fixing from the tray Clutch, PL 8.45 Item 13.
One way coupling, PL 8.45 Item 4.
Figure 4 Paper guides re-position
Bearing, PL 8.45 Item 8.
Roller belt, PL 8.45 Item 15.
Nudger roll, REP 8.34.
One way gear, PL 8.45 Item 3.
Retard roll, REP 8.34.
Clutch coupling, PL 8.47 Item 11.
Clutch, PL 8.47 Item 7.
2. Remove 2 screws then the top cover, PL 7.60 Item 10.

3. Prepare to locate the PFP setting tool onto the upper feed assembly, Figure 1. 4. Install the PFP setting tool, Figure 2.
Nudger roll shaft.
Setting tool
flange.
Hole for feed

roll shaft.
Location slot.
PFP setting tool correctly orientated for posi-

1
Locate the PFP setting tool onto the feed roll
tioning onto the upper feeder assembly.
shaft, so that the nudger roll shaft rests on
top of the setting tool flange.
Figure 1 Tool orientation Figure 2 Setting tool location

5. Engage the tab in the setting tool location slot, Figure 3. 6. Check that the tool is correctly located, as shown in Figure 4.
NOTE: In Figure 4, the spring loaded access cover is shown in ghosted form for clarity.
Nudger roll shaft.
1
Ensure that the location
slot of the PFP setting
tool slides onto and fully
locates on the tab of the
upper feed assembly.
Upper feed
assembly tab.
Tab in the location slot.
Figure 4 Correct tool location
Figure 3 Tab location

Retard Shield Check and Adjustment 3. Prepare to adjust the position of the retard shield, Figure 6.
1. Check the position of the retard shield, Figure 5.
Retard shield.
1 1
Setting Attempt to feed a strip of standard xerox
Retard tool Loosen the retard shield retaining nut.
Paper 80gsm (20lb) paper between the lower
strip. shield. flange. side of the PFP setting tool flange and
the retard shield.
Figure 5 Retard shield check
2. If the paper strip does not feed between the flange of the PFP setting tool and the retard
shield then retard shield is positioned correctly, proceed to Stack Height Sensor Check
and Adjustment.
If the paper strip does feed between the flange of the PFP setting tool and the retard
shield then the retard shield requires adjustment, continue at step 3.

4. Adjust the position of the retard shield, Figure 7. Stack Height Sensor Check and Adjustment
NOTE: Take care not to move the PFP setting tool as the retard shield is repositioned. 1. Ensure the machine is switched on with the PFP door open so that the paper tray travels
Ensure the retard shield remains parallel to the upper feed assembly. to and remains at the lowest position.
2. Enter dC330 code 07-402 tray 5 stack height sensor. Press Start. The display should read
low.
3. Check the position of the stack height sensor, Figure 8.
1
2 Raise the retard shield until it just
Re-tighten the retaining butts against the underside of the 1
nut, refer to Figure 5. Tray 5 Sensor
PFP setting tool. NOTE: The sensor flag Rest a finger lightly on the flag of the
stack flag.
is part of the upper feed stack height sensor and check the
assembly top cover. height
display has changed from low to high.
Figure 7 Retard shield adjustment sensor.
5. Re-check the position of the retard shield, Figure 5. If necessary repeat the adjustment of
the retard shield. Figure 8 Sensor check
4. If the display has changed from low to high the sensor is positioned correctly. Proceed to
step 7.
NOTE: The change of state of the sensor may be accompanied by an audible buzzer.
If the display does not change from low to high the sensor will require adjustment, con-
tinue at step 5.

5. Adjust the position of the stack height sensor, Figure 9.
2 1 3
Carefully reposition the sensor to the point where Loosen Tighten the screw.
the display just changes from low to high. the screw.
Figure 9 Sensor adjustment
6. Check the position of the stack height sensor, Figure 7. If necessary repeat the adjust-
ment of the stack height sensor.
7. The adjustments are now complete, remove the PFP setting tool.
8. Install all the removed PFP components, refer to Preparation steps 1 and 2. Replacement
is the reverse of the removal procedure.
9. Ensure Mod/Tag 050 and 051 are marked off on the tray 5 Mod/Tag plate.

ADJ 8.1 Registration Setup ADJ 8.2 Simplex and Duplex Buckle Timing
Purpose Purpose
To measure and adjust the image to paper registration. Refer to dC604 Registration Setup. To check and adjust the buckle timing on the simplex and duplex transport assemblies.
Simplex Buckle Timing

Check
Go to dC131, select location 08-152 (LeRegSnrToClutchOn). The value should be set in the
region of 10 to 30 below the default value shown in Table 1.
Table 1 Simplex
Machine speed Default Value Adjust to between
35 ppm 630 600 to 620
40 to 55 ppm 440 410 to 430
65 to 90 ppm 290 260 to 280
Adjustment
1. Adjust the simplex buckle timing NVM value in increments of 10 in accordance with Table
1.
2. Print internal test pattern number 16, dC606. Run 20 copies of test pattern number 16 in
simplex mode and then check the copies for cockle deletions, Figure 1.
3. If necessary repeat steps 1 and 2.
4. Record the new values in the machine log book.
5. Check the duplex buckle timing.
Duplex Buckle Timing
Check
Go to dC131, select location 08-148 (Le Dup Snr To Clh On). The value should be set in the
region of 10 to 30 below the default value shown in Table 2.
Table 2 Duplex
Machine speed Default Value Adjust to between
35 ppm 496 466 to 486
40 to 55 ppm 343 313 to 333
65 to 90 ppm 256 226 to 246
Adjustment
1. Adjust the duplex buckle timing NVM value in increments of 10 in accordance with Table
2.
2. Print internal test pattern number 16, dC606. Run 20 copies of test pattern number 16 in
duplex mode and then check the copies for cockle deletions, Figure 1.
3. If necessary repeat steps 1 and 2.
4. Record the new values in the machine log book.
5. Perform NVM Save and Restore, GP 5.

Purpose
Lead edge of test To adjust the nip pressure of the retard roll.
pattern 16
Reducing the nip pressure will make the retard action less aggressive and may improve mis-
feeds.
Increasing the nip pressure will make the retard action more aggressive and may improve
multi-feeds.
Check
Remove the relevant feed head. Refer to Figure 1, Check the position of the spring seat.
Typical areas of image

deletion
Figure 1 Cockle deletion

Retard roll frame Retard roll spring Adjustable spring seat
Figure 1 Spring seat position
Adjustment
NOTE: The feeders have the spring seat set in the nominal (1mm) position during manufac-
ture, Figure 2.
1. Figure 2, change the position of the spring seat to adjust the nip pressure of the retard
roll:
Change the spring seat to the 2mm position to increase the retard roll pressure
Change the spring seat to the 0mm position to decrease the retard roll pressure

ADJ 8.4 Tray 3 and Tray 4 Nudger Roll Pressure (W/Tag
151)
Purpose
To adjust the downward pressure of the nudger roll.
Reducing the downward pressure will make the nudging action less aggressive and may
0mm position Pip reduce the tendency of some papers from feeding more than one sheet from the top of the
stack.
To release the spring seat from this position, press down the pip and slide the spring
seat away from the frame hole
To locate the spring seat in this position, slide the spring seat along the slot until the Increasing the downward pressure will make the nudging action more aggressive and may
pip drops into the frame hole improve the feeding of glossy paper and thin paper.
Check
Remove the relevant feed head. Refer to Figure 1, Check the number of weights.
Nominal 1mm position

To release the spring seat from this position, lift up the base of the spring and slide the
spring seat away from the spring position
To locate the spring seat in this position, lift the base of the spring and slide the spring
seat along the slot until the thin end is located under the spring
6 weights are fitted

as standard
Nudger roll weights
2mm position
To release the spring seat from this position, lift up the base of the spring and slide the
spring seat away from the spring position
To locate the spring seat in this position, lift the base of the spring and slide the spring
seat along the slot until the thick end is located under the spring
Nudger roll
Figure 1 Weights position

Figure 2 Spring seat adjustment
2. Install the feed head and check the paper feeding performance.

Adjustment 2. Figure 3, change the number of weights to adjust the downward pressure of the nudger
roll.
1. Figure 2, shows the location of the spare weights.
1
Remove the nut
3
Install and
tighten the nut
2
Storage position of Change the number
the spare weights of weights
Figure 3 Spring seat adjustment

Figure 2 Weights location
3. Install the feed head and check the paper feeding performance.

ADJ 9.1 Corotron Cleaning ADJ 9.2 Image Quality Adjustment Routine
Parts List on (35 ppm) PL 9.22, (40-90 ppm) PL 9.20. Purpose
Purpose The Image Quality Adjustment (IQA) feature allows adjustment of the image quality by adjust-
ment of the Grid Voltage and ROS Exposure levels. This is achieved by running an Image
To clean the corotrons.
Quality Adjustment routine from within SAKO tools. This routine can be performed at any stage
of the machines operational life by the key operator.
Adjustment
Adjustment
WARNING The adjustment routine consists of the steps that follow:
1. Load A4 (8.5x11 inch) white paper LEF in the Bypass Tray.
death or injury. Moving parts can cause injury. 2. Turn off or reset to nominal all image enhance features.
1. (35 ppm) Remove the transfer/detack corotron, PL 9.22 Item 8, from the short paper path 3. Enter Customer Administration Tools, GP 24.
assembly, PL 10.25 Item 1. 4. Select the Troubleshooting tab.
2. Use a soft small brush to remove any small particle that may be on the corotron wire. 5. Select Image Quality Adjustments.
3. Reinstall the transfer/detack corotron in the short paper path. 6. Follow the prompts in the image quality adjustment window.
4. (40-90 ppm) These machines have a cleaning device for the transfer/detack corotron. 7. Example of the IQA test pattern is shown in Figure 1.
Move the device back and forward to clean the transfer/detack wires. If the transfer/ 8. When the test pattern image is scanned, the following sequence of events occur:
detack corotron is heavily contaminated then the corotron assembly can be removed and a. The average image density (grey level measured on a grey scale; 0 = black, 255 =
cleaned with a brush. white) of the shadow and highlight is measured to obtain two respective averages. If
5. Raise and lower the latch mechanism of the short paper path assembly, PL 10.25 Item 1, the average for either the highlight or shadow is out of range, the image cannot be
to ensure that the transfer/detack corotron is parallel to the photoreceptor. If the move- used reliably and the routine is terminated with an appropriate message displayed
ment of raising the short paper path assembly is not smooth, check the action of the push on the GUI.
rod, PL 10.25 Item 13, REP 10.1. b. Once the validity of the test pattern has been confirmed the measured average grey
NOTE: Do not attempt to clean the corotron wires with any solvents or wipe clean using paper. levels of the shadow and highlights are compared against shadow and highlight
If necessary install a new transfer/detack corotron, PL 10.25 Item 11. Grey Level reference values contained in NVM, producing a shadow error and high-
light error.
c. These errors are then used together with pre-stored IQA factors to determine a Grid
Voltage Offset and a ROS exposure Offset.
d. Range checking and capping is then performed to limit any unexpected behavior.
e. The SIP sends these offsets to the IOT to be stored in IOT NVM.
f. The Grid Voltage and ROS exposure are then adjusted by applying the relevant off-
set to the nominal setting after any other adjustments are applied (e.g. calibration or
Process Control adjustments etc.).
9. If a fault occurs on completion of the routine then refer to the relevant RAP.

ADJ 9.3 Developer Magnetic Seal Brush Adjustment
Purpose
To check and maintain an effective seal on the 65, 75 and 90 ppm machine developer module.
Adjustment
WARNING
2. Use a flashlight to examine the condition of the seal, Figure 1.
3. Check for the following:
The seal for damage.
The halo guide, transfer and detack corotron, PL 9.20 Item 8, for contamination.
If either or both above are true, continue below.
1. Remove the developer module, PL 9.15 Item 2. Place the developer module, left side
Figure 1 IQA test pattern down, on a suitable surface.
2. Check the shutter assembly seal for damage, Figure 2. If necessary install a new shutter
3. Remove contamination from the following:
Above and below the developer roll area.
Registration guide and the halo guide.
The floor pan.
Transfer corotron, detack corotron and the duplex paper path.
4. Restore the magnetic seal brush. Go to Magnetic Seal Loading.
5. Reinstall the developer module and the xerographic module.
6. Make 50 prints.
7. Remove the xerographic module.
8. Use a flashlight to check the halo guide, transfer corotron, detack corotron and the duplex
paper path for contamination of toner and developer beads.
9. If there is contamination, repeat steps 1 through to 9.
10. If contamination persists, install a new developer module, PL 9.15 Item 2.

Magnetic seal brush. To be
effective this must have a
uniform profile the full
length of the magnet.
Check the seal for torn fabric, broken edges and

delamination from the main fabric.
Figure 1 Magnetic seal brush Figure 2 Shutter assembly seal
Magnetic Seal Loading

1. Use a brush to remove the residual magnetic seal brush.
2. Use the curved edge of the magnetic seal repair tool, PL 26.10 Item 23, to remove devel-
oper from the rear of the magnetic roll, Figure 3. The correct quantity of toner that should
be removed from the magnetic roll is shown in Figure 4.

1 Correct quantity of developer
Hold the tool against the rear
edge of magnetic roll as
shown.
2
Lean the tool toward the bottom
of the developer until it is in line
with lower lip.
Figure 4 Developer quantity
3
Keeping the tool at this
angle, push the tool up the
magnetic roll to remove
developer.
4
When the tool is in line with
upper seal, lean back, then
carefully lift the tool. Ensure
the maximum amount of
developer is removed.
5
Use the upper seal to keep the
material on the tool.
Figure 3 Developer removal

3. Apply the developer evenly to the magnetic strip to form the seal. Gently shake the tool as
developer is applied to aid distribution, Figure 5.
CAUTION
Ensure the developer is evenly distributed across the magnetic seal. Too much developer will
cause beads on prints, too little will not form a good seal.
4. Use a flat edge of the tool to distribute the developer across the width of the magnetic
strip, Figure 6.
1
Start at the inboard end of
the magnetic strip.
1
Distribute the developer
across the width of the
magnetic strip.
2
Apply the developer evenly to
the magnetic strip to form the
seal. One scoop of developer
should cover half the magnetic
strip.
Figure 6 Distributing developer
5. Repeat steps 2 to 4 for the front of the magnetic roll.

Figure 5 Applying developer
NOTE: Two scoops of developer is the optimum amount to form a good seal. Do not use
more than three scoops.

6. An example of a good magnetic seal is shown in Figure 7. ADJ 9.4 Xerographics Cleaning
Purpose
To clean the xerographics area.
Adjustment
WARNING
1. Remove the erase lamp assembly, PL 9.20 Item 1. Use a dry micro fiber wiper, PL 26.10
Item 13, to clean the erase lamp assembly. Ensure the electrical contacts at the rear of
the erase lamp assembly and on the chassis are clean before re-installing the assembly.
2. Check that the transfer/detack corotron end block covers are properly seated and
securely clipped onto the corotron end blocks. Check that the halo guide is properly
seated and firmly attached to the transfer/detack corotron.
3. Clean the detack/transfer corotron assembly, ADJ 9.1 Corotron Cleaning. Ensure the
electrical contacts at the rear of the transfer / detack corotron assembly and on the chas-
sis are clean before re-installing the assembly.
4. (35 ppm). Clean the charge scorotron by carefully pulling out the cleaning rod on the front
1 of the xerographic module as far as it will go and then pushing it fully home. Repeat nine
A good magnetic seal should be an times.
even distribution of material along 5. (40-90 ppm) Clean the charge scorotron. Perform the following:
the length of the magnetic seal.
a. Press the Log in/out (key symbol) button on the key pad or select Guest on the UI.
b. Enter User Name admin (case sensitive). Select Next.
c. Enter the Password 1111 (default setting). Select Next.
d. Select the Xerographic Module Cleaning routine. Repeat the routine two times.
Figure 7 A good magnetic seal
NOTE: The routine completes four cleaning cycles of the charge scorotron. If the
charge scorotron cleaner fails to work, go to the 09-341, 09-342 Scorotron Cleaning
Failure RAP.
6. Clean the waste toner bottle area, refer to the OF11 Waste Toner Contamination RAP.
7. Check and clean the following areas for toner and developer bead contamination, Figure 1.
The developer roll area, above the roll and in the recesses below the roll.
Developer beads hanging from the developer roll and the lower lip.
The halo guide, registration guide and the registration cover.
The duplex paper path.
8. (65-90 ppm) Perform ADJ 9.3 Developer Magnetic Seal Brush Adjustment.
9. Refer to the checkouts in IQ3 Xerographic RAP.

ADJ 9.5 Optimize Dark and Light Grey Image
Purpose
Developer roll and lower lip Use this adjustment if the dark greys are too dark and / or light greys are too light.
Use this adjustment in combination with the changes made in IQ10 Image Quality Improve-
ment RAP.
NOTE: This procedure will only make a slight improvement to the image quality.
Initial Actions
Halo guide
WARNING
Registration death or injury. Moving parts can cause injury.
guide Perform IQ3 Xerographics RAP before starting this adjustment.
Ensure that all the image quality settings on the UI are at default.
Make a copy of the customer document that shows the defect and keep as a reference.
Enter dC606 Print Test Patterns and print internal test pattern 15.
Transfer corotron
Exit diagnostics, GP 1.
Place the test pattern 15 on the platen glass with the dark bands to the right and the light
band to the left. Make a copy.
Compare the copy with the test pattern 15, Figure 1.
Detack corotron If the sections 5 - 7 look the same as each other then the machine has a problem
with poor shadows / dark greys. Go to the Poor Shadows Adjustment.
If section 1 looks white then the machine has a problem with poor highlights / light
greys. Go to the Poor Highlights Adjustment.
Registration roll cover
For 35 ppm machines only. Some machines suffer from poor shadows and poor high-
lights. In such cases install the ROS filter and optimize poor shadows first. Installation of
the ROS filter will improve dark grey performance at the expense of slight degradation of
the light grey performance.
Then perform the poor highlights adjustment which, will attempt to restore the highlights.
If the highlights are unacceptable, then do not install the ROS filter.

Poor Shadows Adjustment Final Image Quality Check
1. Enter dC131 NVM Read / Write location 06-001 Light Level and reduce the value by 200. 1. Enter dC606 Print Test Patterns and print internal test pattern 15.
35 ppm machines. Ensure that the value is between 3000 and 6000. 2. Exit diagnostics, GP 1.
40-55 ppm machines. Ensure that the value is between 1500 and 3050. 3. Place the new printed test pattern 15 on the platen glass and make one copy. The image
65-90 ppm machines. Ensure that the value is between 1500 and 3200. quality is optimized.
2. Enter dC606 Print Test Patterns and print test pattern 15. 4. Make a copy of the customer document and compare it with the initial copy. Check that
the image quality has improved.
3. Exit diagnostics, GP 1.
5. Run a variety of jobs to confirm that the changes made have not introduced other copy
4. Place the new printed test pattern 15 on the platen glass and make one copy.
quality problems.
5. If the copy has poor shadows, then go to the next step.
6. Record any NVM changes in the machine log book.
If the copy has good shadows, then go to the Poor Highlights Adjustment.
7. Perform NVM Save and Restore, GP 5.
6. Enter dC131 NVM Read / Write at location 06-001 Light Level and reduce the value by
200. Reduce the value in increments of 200 until good shadow is achieved.
35 ppm machines. Do not reduce the value below 3000.
40-55 ppm machines. Do not reduce the value below 1500.
65-90 ppm machines. Do not reduce the value below 1500.
7. Enter dC606 Print Test Patterns and print internal test pattern 15
9. If the copy has poor highlights, then go to the Poor Highlights Adjustment.
If the highlights are good, then go to the Final Image Quality Check.
Poor Highlights Adjustment
1. Enter dC131 NVM location 09-003 Charge Grid and reduce the value by 25.
35 ppm machines. Ensure that the value is between 370 and 470.
40-55 ppm machines. Ensure that the value is between 380 and 480.
65-90 ppm machines. Ensure that the value is between 370 and 470.
2. Enter dC606 Print Test Patterns and print internal test pattern 15.
4. Place the new printed test pattern 15 on the platen glass and make one copy.
5. If the copy has poor highlights, then go to the next step.
If the highlights are good, then go to the Final Image Quality Check.
6. Enter dC131 NVM. Location 09-003 Charge Grid and reduce the value by 25. Reduce the Figure 1 Test pattern 15
value in increments of 25 until good highlights is achieved.
Do not reduce the value below 350.
7. Enter dC606 Print Test Patterns and print internal test pattern 15.
9. Place the new printed test pattern 15 on the platen glass and make one copy. The copy
quality is optimized.

ADJ 10.1 Inverter Decurler Adjustment
Parts List on PL 10.20 Adjuster slot
Purpose
Indicator
Use this adjustment to increase or decrease the output curl on prints from the IOT on machines
W/TAG 046, W/TAG 047 or W/TAG 148.
2
Align the adjuster slot with the
indicator on the retaining ring.
WARNING
1
Loosen the screw.
Check
1. Enter dC131a NVM Read/Write, scroll to 10-028 and 10-029 and ensure that the temper-
ature values are set to default.
2. Perform the procedures in IQ5 Print Damage RAP.
3
Tighten the screw.
3. Check the machine is otherwise functioning correctly, refer to SCP 1 Initial Actions.
If the machine is fitted with a 1K or 2K LCSS, make sure the software timing patch is
enabled:
Figure 1 Initial calibration
a. Press the Machine Status button.
b. Select the Tools tab. The Device Settings screen will display. NOTE: After the adjuster slot is set central to the indicator on the retaining ring, it will only
c. Select the Option Enablement. be possible to make adjustments of 1 increment in either the clockwise or counter clock-
d. Use the numerical keypad to enter the following code: *3386787231. wise directions.
The asterisk must be entered before the number. Press Enter. 2. Adjust the initial calibration of the inverter decurler:
e. Switch off, then switch on the machine, GP 14. a. Adjust the initial calibration, Figure 2.
NOTE: To disable the timing patch, perform step 3 again but enter *3386787230 at the step d. b. Run 20 duplex copies of the customers preferred print media or A4 / 8.5x11 inch
paper.
Adjustment
1. Initial calibration of the inverter decurler:
NOTE: The initial calibration procedure should give acceptable results for 80gsm paper
and most other print media. However, for non-Xerox paper, pre-printed paper and card it
may be necessary to adjust the initial calibration, Figure 2 or reset the inverter decurler
retaining ring, Figure 3.
Align the slot of the adjuster slot with the retaining ring, Figure 1.

1 2
Turn the adjuster 1 increment
Insert a coin into the
clockwise to increase down curl.
slot of the adjuster.
3
Align the indicator on the retaining
ring with the adjuster slot.
4
Tighten the screw.
1
Loosen the screw.
Figure 3 Increase down curl
3. Reset the inverter decurler retaining ring:

After the retaining ring is reset adjustments of a further 2 increments are enabled, 1 in
2 either direction.
Turn the adjuster 1 increment clockwise to
increase down curl, or turn the adjuster 1 a. Reset the position of the retaining ring. To increase the down curl on output copies,
increment counter-clockwise to decrease see Figure 3. To decrease the down curl on output copies, see Figure 4.
down curl.
2
Turn the adjuster 1 increment
Figure 2 Adjust the initial calibration counter-clockwise to decrease
down curl.
c. Assess the copies for curl, refer to IQ5. If output curl is evident then reset the inverter
decurler retaining ring to allow for further adjustment, refer to Figure 3 and Figure 4.
3
Align the indicator on the retaining
ring, central with the adjuster slot.
4
Tighten the screw.
1
Loosen the screw.
Figure 4 Decrease down curl
b. Run 20 duplex copies of the customers preferred print media or A4 / 8.5x11 inch
paper.
c. Assess the copies for curl, refer to IQ5.

ADJ 11.1-110 2K LCSS Bin 1 Level ADJ 11.2-110 Machine to 2K LCSS Alignment
Purpose Purpose
To ensure bin 1 is level, and achieve the best stacking performance. To correctly align the 2K LCSS to achieve reliable transfer of paper from the machine to the 2K
LCSS.
Adjustment
Adjustment
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
1. Remove the bin 1 motor, refer to REP 11.5-110. death or injury. Moving parts can cause injury.
2. Move bin 1 to the lowest position. 1. Figure 1, turn both right hand wheels in the same direction to adjust the vertical alignment
between the 2K LCSS and the machine viewed from the front or rear.
3. Slacken the screw on each belt clamp and adjust the position they sit on the belts to level
the tray. Lock the clamps.
4. Re-install the bin 1 motor, refer to REP 11.5-110.
6. Enter dC330 code 11-033, Bin 1 Elevator Motor Cycle. Check that bin 1 cycles without
giving any fault indications.
Figure 1 Machine to 2K LCSS alignment

Xerox WorkCentre 5790 Family 4-487 ADJ 11.1-110, ADJ 11.2-110
ADJ 11.3-110 Hole Punch Position Adjustment
Purpose WARNING
To optimize the position of the hole punch. Ensure that the electricity to the machine is switched off while performing tasks that do
Check death or injury. Moving parts can cause injury.
1. Ask the customer which trays are used to feed from for hole punching. 1. Remove the chad bin and unscrew the thumb screw retaining the hole punch assembly.
2. Load the indicated trays with A4 (8.5x11 inch) paper. 2. Pull out the hole punch assembly a short distance to access the spacer, if installed, refer
3. Make a set of five punched copies or prints from each of the indicated trays. Mark the top to Figure 2. The following settings can be made:
edge (towards the front of the machine) of each set to indicate the tray from which it was NOTE: If the spacer cannot be found, suitable washers up to a total thickness of 2mm
fed. (0.080 inches) may be used.
4. Evaluate the average hole positions in each set, referring to Figure 1. The distances
shown should be equal at the top and bottom of the sheet. If the distances are different by With no spacer installed the holes are punched closest to the bottom of the sheet.
more than 1mm (0.040 inches), perform the adjustment. With the spacer installed unfolded the holes are punched 1mm (0.040 inches) closer
to the top of the sheet.
With the spacer installed folded the holes are punched is 2mm (0.080 inches) closer
to the top of the sheet.
Spacer unfolded to give Spacer folded to give 2mm

1mm (0.040 inches) offset (0.080 inches) offset
towards the top towards the top
Figure 1 Hole positions
Figure 2 Hole punch spacer

ADJ 11.3-110 4-488 Xerox WorkCentre 5790 Family
3. Evaluate the movement needed and re-position the hole punch assembly. If the spacer is ADJ 11.4-110 Motor Drive Belt Tensioning
removed, tape it next to the TAG label on the 2K LCSS frame for future use.
4. Make sets from each of the indicated trays once more and ensure that the hole alignment
Purpose
is now optimized, make further adjustment if necessary. To set the tension of directly or indirectly driven belts that are tensioned by a spring attached to
the motor.
5. If necessary, re-load the paper trays as they were before the adjustment was performed.
Check
1. The shafts and pulleys are installed and properly located.
2. The drive belt is undamaged and correctly routed.
3. The adjustable motor or tensioning pulley bracket is positioned with fastening screws not
tightened fully.
NOTE: For motors with pivoted brackets, the pivot screw must be fitted and tightened.
4. The tensioning spring is fitted between the bracket and frame locating point.
Adjustment
WARNING
1. Figure 1 shows a typical arrangement. Press the belt midway between pulleys and check
that the bracket moves in the direction of the spring pull; slacken the bracket screws if
necessary.
2. Release the belt and allow the spring to pull the bracket and tension the drive belt then
tighten the lock and bracket screws.

NOTE: Check the belt condition and routing if the tension spring is not extended or the
locking screw is at the end of the bracket adjustment slot.
Drive belt
Pivot Screw
Bracket
Tension spring
Adjustment slot Lock screw
Typical spring tensioning arrangement
Figure 1 Drive belt tensioning

ADJ 11.1-120 1K LCSS Bin 1 Level ADJ 11.2-120 Motor Drive Belt Tensioning
Parts List on PL 11.106 Purpose
Purpose To set the tension of directly or indirectly driven belts that are tensioned by a spring attached to
the motor.
To ensure bin 1 is level, and achieve the best stacking performance.
Adjustment Check
WARNING 3. The adjustable motor or tensioning pulley bracket is positioned with fastening screws not
Ensure that the electricity to the machine is switched off while performing tasks that do tightened fully.
1. Remove the bin 1 elevator motor, refer to REP 11.5-120. 4. The tensioning spring is fitted between the bracket and frame locating point.
2. Move bin 1 to the lowest position. Adjustment
3. Slacken the screw on each belt clamp and adjust the position they sit on the belts to level
the tray. Lock the clamps.
4. Re-install the bin 1 elevator motor, refer to REP 11.5-120. WARNING
5. Switch on the machine, GP 14. Ensure that the electricity to the machine is switched off while performing tasks that do
6. Enter dC330, code 11-033, Bin 1 Elevator Motor Cycle. Check that bin 1 cycles without not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
giving any fault indications.
necessary.

NOTE: Check the belt condition and routing if the tension spring is not extended or the
Drive belt
Pivot Screw
Bracket
Tension spring

ADJ 11.1-171 Machine to HVF/HVF BM, HVF BM to Tri- 2. Figure 2, turn both adjustable castors in the same direction to adjust the vertical alignment
between the tri-folder and the HVF/HVF BM.
folder Alignment
Purpose
To correctly align the HVF or HVF BM, to achieve reliable transfer of paper from the machine to
the output tray.
To correctly align the tri-folder, to achieve reliable transfer of paper from the HVF BM to the out-
putray.
Check
Ensure the HVF/HVF BM is aligned both vertically and horizontally with the machine. If
necessary perform the adjustment.
Ensure the Tri-folder is aligned vertically and horizontally with the HVF/HVF BM. If neces-
sary perform the adjustment.
Adjustment
WARNING
1. Figure 1, turn both adjustable castors in the same direction to adjust the vertical alignment 2
between the HVF/HVF BM and the machine. Ensure the tri-folder
1 is aligned vertically
and horizontally with
Rotate the adjustable
the HVF BM.
castors.
Figure 2 Tri-Folder to HVF BM alignment
1 2
Rotate the adjustable castors. Ensure the HVF/HVF BM is aligned ver-
tically and horizontally with the machine.
Figure 1 Machine to HVF/HVF BM alignment

Xerox WorkCentre 5790 Family 4-493 ADJ 11.1-171
ADJ 11.2-171 Tri-Folder Paper Size Setting
Purpose
To set the tri-folder to correctly fold 8.5 x 11 inch or A4 paper.
Check
1. Ensure that the tri-folder is at the same height as the HVF, ADJ 11.1-171.
2. Run a copy job 4 sheets and check that the folds are in the correct place.
3. The paper should be folded into three equal parts and the folds parallel to the edge of the
paper. If necessary perform the adjustment.
Adjustment
WARNING
NOTE: Figure 1 shows the tri-folder front and rear paper setting adjusters in the 8.5 x11 inch
(LTR) position.
1 2 2
Move the adjuster
1
1. Remove the front door, PL 11.190, front cover PL 11.190 and the rear cover PL 11.190. Loosen the Move the adjuster Loosen the
Check that the front and rear paper setting adjusters are in position for the appropriate screw screw
size of paper, Figure 1. 3
Fasten the screw 3
Fasten the screw
Front Rear
Figure 1 Tri-Folder paper setting
2. Set the front and rear paper setting adjusters to the A4 or 8.5 x 11 inch (LTR) position,
Figure 1.
NOTE: Do not over loosen the adjuster screws. The adjusters can detach from the back-
stop. Make sure the position of the backstop changes when the adjusters are moved.
3. Ensure the front door interlock switch is cheated, PL 11.197 Item 2. Run a four sheet C
fold and Z fold copy job. Check that the copies are folded into three approximately equal
parts, with the folds parallel to the edge of the paper.
4. Check the C and Z folded copies meet the customer requirements. If necessary make fine
adjustments to the position of the folds, ADJ 11.12-171 Tri-Folder Fold Adjustment.

ADJ 11.3-171 Stapler Anvil Alignment 3. Insert the alignment tool, Figure 1.

Purpose
To ensure the correct alignment of the stapler anvil to the stapler throat.
Special Tools Required

Stapler alignment tool, supplied with the HVF BM, located on the left of the BM frame.
NOTE: This procedure illustrates the front stapler. The procedure for adjusting the rear stapler
is identical.
Adjustment
WARNING
WARNING
1
Insert the stapler
1. To improve the access to the two clamp screws for the anvil, remove the tamper assem- 2 alignment tool into
bly, REP 11.30-171. Press the tool firmly into the stapler throat
2. Fully pull out the BM module. Remove the stapler cover(s), one screw on each. Pull the place and slowly close
stapler bracket handle and swing open the stapler bracket. the stapler bracket
Figure 1 Alignment tool insertion

4. Loosen the anvil, Figure 2.
Loosen 2 clamp screws so

that the anvil can move freely,
see note
Figure 2 Loosening the anvil
NOTE: Take great care not to drop the anvil, spacer or clamp plate, Figure 3, as they can
fall to the bottom of the BM module. If parts need to be retrieved from the bottom of the
BM module it may be necessary to tilt the whole HVF BM to make the loose parts slide to
the centre of the base, from where they can be easily removed.
5. Close the stapler, Figure 3.

2
Continue to rotate the
stapler gear so that the
two protrusions on the
tool engage with the
depressions in the
anvil. Move the anvil if
necessary using the
two clamp screws
Anvil
Spacer Clamp plate
1
Rotate the stapler gear counterclockwise
to begin closing the stapler
3
Continue to rotate the stapler gear
until the anvil is tightly clamped by
the alignment tool and the stapler
will close no further
4
Tighten the two screws alternately a little at a time, while
holding the free screw with a finger. Ensure that the anvil
does not move as the screws are tightened
Figure 3 Closing the stapler
6. Open the stapler fully by use of the stapler gear, Figure 3, then remove the alignment tool. 8. Check the operation of the stapler by making a few stapled sets using 2 sheets of 80gsm
7. Perform the adjustment on the other stapler anvil if necessary. (20 pound) paper. check the quality of the staple clinch.

ADJ 11.4-171 Crease Blade Position 9. Position the crease blade setup tools on the crease roll shafts, Figure 1.
Purpose
One tool is shown located on
To correctly position the crease blade to ensure accurate booklet creasing. the front of the crease rolls.
Locate the second tool on the
Special Tools Required rear of the crease rolls in the
Crease blade setup tools (2), supplied with the HVF BM, located on the left of the frame. same manner.
Adjustment
WARNING
WARNING
Crease blade setup tool
5. Re-install the crease blade knob and crease roll handle.
7. Rotate the crease roll handle fully counter clockwise to open the crease roll nip. Rotate
the crease roll handle clockwise until the crease rolls are just touching.
8. Ensure the crease blade is fully retracted by positioning the crease blade knob with the
arrow in the up position.
Crease roll shafts
Figure 1 Setup tool positioning

10. Lock the crease gate in the open position, Figure 2. 11. Loosen the crease blade screws, Figure 3.
2
Insert an interlock cheater in
the teeth as shown to prevent
the gate from falling.
1
Lift the gate to the highest
position.
Loosen 10 screws marked A.
Figure 2 Lock the crease gate Figure 3 Blade loosening
12. Fully insert the crease blade by positioning the crease blade knob (6d), PL 11.161 Item 4,
with the arrow in the down position.
13. Set the crease blade in the correct position, Figure 4.

2 1
Push the rear of the Push the front of the
crease blade forward to crease blade forward to
contact the setup tool contact the setup tool
4
3 Tighten 2 screws
Tighten 2 screws
Crease blade
Setup tool
Figure 4 Blade positioning
14. Fully retract the crease blade by positioning the crease blade knob (6d), PL 11.161 Item
4, with the arrow in the up position.
15. Tighten the six remaining crease blade clamp screws, refer to Figure 3.
16. Remove both crease blade setup tools and return them to the storage position.
17. Install all of the removed components and check the operation of the BM module.

ADJ 11.5-171 Booklet Tamping e. Select 12Finisher/DFA.
f. Select 12-006 BookMkrTampRdyOff-set.
Purpose
g. Select Read/Write and increase the value by 8.
To set the tamper travel to give neat booklets without edge damage.
h. Select Save, select OK, select Close, select Exit.
Procedure Adjustment
Go to the appropriate check and adjustment from the following options: 1. Do the following:
If only A4 paper is available, go to A4 Paper Procedure. a. Enter dC131.
If only 8.5 X 11 inch paper is available, go to 8.5 X 11 Inch Procedure. b. Select Diagnostic Routines.
A4 Paper Procedure c. Select Copier Routines.
d. Select dC131 NVM Read/Write.
Check
e. Select 12Finisher/DFA.
1. Open the HVF BM front door and insert an interlock cheater into the front door interlock
switch.
g. Select Read/Write and enter the new value to correct the error found during the
2. Fully pull out the BM module and release the jam clearance handle PL 11.161 Item 8, fully
open the paper guide, PL 11.161 Item 7. check. Increasing the value lengthens the tamping stroke (tamps to a narrower
dimension between the tampers. Decreasing the value shortens the tamping stroke
3. Do the following:
(tamps to a wider dimension between the tampers). One step = 0.53mm.
a. Enter dC131.
b. Select Diagnostic Routines.
2. Repeat the check to ensure the tampers are set correctly.
c. Select Copier Routines.
3. When the tamper travel is correct, do the following:
a. Enter dC131.
g. Select Read/Write and reduce the original value by 8.
4. Enter dC330 code 11-065 BM Backstop Motor, select Start, allow the backstop to raise to
the receive position (where it will pause), select Stop.
5. Enter dC330 code 11-066 BM tamper 1 motor. Select Start to energize the tamper motor,
allow the tampers to move into the tamped position (where they will pause), select Stop.
4. Switch the machine off then on, GP 14.
6. Insert a single sheet of A4 paper, short edge downward into the booklet maker compiling
area, so that it rests on the backstop and is located between the two tampers 8.5 X 11 Inch Procedure
7. Bias the sheet towards the rear of the machine until the sheet touches the rear tamper, Check
Figure 1.
8. Observe the position of the sheet between the tampers, Figure 1. switch.
If the sheet cannot reach the backstop because the tampers are too close together, 2. Fully pull out the booklet maker and release the jam clearance handle PL 11.161 Item 8,
the NVM value will need to be decreased to move the tampers further apart, perform fully open the paper guide PL 11.161 Item 7.
the adjustment.
If the front tamper is not within 0.5mm (0.02 inch) of the sheet edge without touching
a. Enter dC131.
the sheet, the NVM value will need to be increased to move the tampers closer
together, perform the adjustment.
If the tampers are in the correct position, within 0.5mm (0.02 inch) of the sheet edge
without touching the sheet, do the following: d. Select dC131 NVM Read/Write.
a. Enter dC131. e. Select 12Finisher/DFA.
b. Select Diagnostic Routines. f. Select 12-006 BookMkrTampRdyOff-set.
c. Select Copier Routines. g. Select Read/Write and reduce the original value by 19.
d. Select dC131 NVM Read/Write. h. Select Save, select OK, select Close, select Exit.

4. Enter dC330 code 11-065 BM Backstop Motor, select Start, allow the backstop to raise to f. Select 12-006 BookMkrTampRdyOff-set.
the receive position (where it will pause), select Stop. g. Select Read/Write and increase the value by 19.
5. Enter dC330 code 11-066 BM tamper 1 motor. Select Start to energize the tamper motor, h. Select Save, select OK, select Close, select Exit.
allow the tampers to move into the tamped position (where they will pause), select Stop.
4. Switch the machine off then on, GP 14.
6. Insert a single sheet of 8.5 X 11 inch paper, short edge downward into the booklet maker
compiling area, so that it rests on the backstop and is located between the two tampers
7. Bias the sheet towards the rear of the machine until the sheet touches the rear tamper,
Figure 1.
8. Observe the position of the sheet between the tampers, Figure 1.
If the sheet cannot reach the backstop because the tampers are too close together,
the NVM value will need to be decreased to move the tampers further apart, perform
the adjustment.
If the front tamper is not within 0.5mm (0.02 inch) of the sheet edge without touching
the sheet, the NVM value will need to be increased to move the tampers closer
together, perform the adjustment. Front tamper Paper sheet Paper sheet Rear tamper
If the tampers are in the correct position, within 0.5mm (0.02 inch) of the sheet edge
without touching the sheet, do the following:
a. Enter dC131.
Adjustment
a. Enter dC131.
g. Select Read/Write and enter the new value to correct the error found during the
check. Increasing the value lengthens the tamping stroke (tamps to a narrower
dimension between the tampers. Decreasing the value shortens the tamping stroke Booklet maker staplers
(tamps to a wider dimension between the tampers). One step = 0.53mm.
2. Repeat the check to ensure the tampers are set correctly.
3. When the tamper travel is correct, do the following:
a. Enter dC131.
b. Select Diagnostic Routines. Figure 1 Observing the tamper positions

ADJ 11.6-171 Booklet Compiling Position
Purpose
To set the compiling position to ensure correct compiling without damage. When the compiling
position is correctly set, each sheet is fed behind the BM entry roll to rest against the right side
of the compiler.
Procedure
Go to the appropriate check and adjustment from the following options:
If only A4 paper is available, go to A4 Paper Procedure. Top of sheet must align
If only 8.5 X 11 inch paper is available, go to 8.5 X 11 Inch Procedure. with the 0 mark on the
B scale
A4 Paper Procedure
Check
switch.
2. Fully pull out the BM module and release the jam clearance handle PL 11.161 Item 8, fully
open the paper guide PL 11.161 Item 7.
4. Insert a single sheet of A4 paper short edge downward into the booklet maker compiling
area, so that it rests on the backstop and is approximately central front to back. Tuck the
top of the sheet behind the BM entry roll, PL 11.161 Item 15.
5. If the BM right hand cover does not have a viewing hole, remove the BM right hand cover,
REP 11.56-171.
6. Figure 1, check the alignment of the sheet against the scale.
Figure 1 Top edge alignment
7. If the sheet is correctly aligned, exit diagnostics and re-install the BM right hand cover, if
removed in step 5. If the sheet is not correctly aligned, perform the adjustment.

Adjustment
1. Do the following
a. Enter dC131.
f. Select 12-003 BookMkrCompileOff-set.
g. Select Read/Write and enter the new value to correct the error found during the Top of sheet must align
check. Increasing the value will raise the sheet. Decreasing the value will lower the with the bottom mark
on the B scale
sheet. One step = 0.1137mm.
2. Repeat the Check to ensure the compiling position is correctly set.
3. When the compiling position is correct, switch the machine off then on, GP 14.
8.5 X 11 Inch Procedure
Check
switch.
2. Fully pull out the BM module and release the jam clearance handle PL 11.161 Item 8. fully
open the paper guide PL 11.161 Item 7.
3. Do the following
a. Enter dC131.
g. Select Read/Write and increase the original value by 80.
5. Insert a single sheet of 8.5 X 11 inch paper short edge downward into the booklet maker
compiling area, so that it rests on the backstop and is approximately central front to back.
Tuck the top of the sheet behind the BM entry roll, PL 11.161 Item 15.
6. If the BM right hand cover does not have a viewing hole, remove the BM right hand cover,
REP 11.56-171. Figure 2 Top edge alignment
7. Figure 2, check the alignment of the sheet against the scale.
8. If the sheet is correctly aligned, do the following:
a. Enter dC131.

g. Select Read/Write and decrease the value by 80, this will return the NVM value to ADJ 11.7-171 Booklet Crease Position
the original setting.
Purpose
i. Re-install the BM right hand cover, if removed in step 5. To set the crease position of the booklet in relation to the left edge of the top sheet of the book-
let.
9. If the sheet is not correctly aligned, perform the adjustment.
Adjustment Check
1. Do the following 1. Run a copy job of 3 stapled 4 sheet booklets.
a. Enter dC131. 2. Observe the position of the crease in relation to the open end of the booklet. The fold
b. Select Diagnostic Routines. should be central, so that the open end of the booklet pages are equal from the fold. If
c. Select Copier Routines. necessary perform the adjustment.
d. Select dC131 NVM Read/Write. Adjustment
e. Select 12Finisher/DFA. 1. Perform the following:
f. Select 12-003 BookMkrCompileOff-set. a. Enter dC131.
g. Select Read/Write and enter the new value to correct the error found during the b. Select Diagnostic Routines.
check. Increasing the value will raise the sheet. Decreasing the value will lower the c. Select Copier Routines.
sheet. One step = 0.1137mm.
d. Select 131 NVM Read/Write...
e. Select 12Finisher/DFA...
2. Repeat the Check to ensure the compiling position is correctly set.
f. Select 12-005 BookMrkFoldOffset.
g. Select Read/Write.
a. Enter dC131.
h. Enter the new value to correct the error found during the check.
NOTE: Increasing the value increases the width of the top sheet of the booklet
(moves the fold away from the left edge). Decreasing the value decreases the width
of the top sheet of the booklet (moves the fold towards the left edge). One step =
e. Select 12Finisher/DFA. 0.1137mm.
i. Select Save, then OK.
g. Select Read/Write and decrease the value by 80.
2. Select Save, then select OK.
3. When the crease position is correct, switch the machine off then on, GP 14.
i. Re-install the BM right hand cover, if removed in step 5.
4. When the compiling position is correct, switch the machine off then on, GP 14.

ADJ 11.8-171 Booklet Staple Position ADJ 11.9-171 Booklet Maker Skew
Purpose Purpose
To set the position of the staples so that they are positioned on the fold of the booklet. To adjust the skew of the booklet crease.
Check Check and complete the following adjustments:

1. Run a copy job of 3 stapled 4 sheet booklets. ADJ 11.6-171 Booklet compiling position.
2. Observe the position of the staple in relation to the fold of the booklet. The staple should ADJ 11.8-171 Booklet staple position.
be positioned in the middle of the fold. If necessary perform the adjustment. ADJ 11.7-171 Booklet crease position.
Adjustment Check
1. Perform the following: 1. Run a copy job of 3 stapled 4 sheet booklets.
a. Enter dC131. 2. Observe the position of the crease in relation to the open end of the booklet. The fold
b. Select Diagnostic Routines. should be central, so that the open end of the booklet pages are equal from the fold. If
c. Select Copier Routines. necessary perform the adjustment.
d. Select 131 NVM Read/Write... Adjustment

e. Select 12Finisher/DFA...
f. Select 12-004 BookMrkStapleOffset.
WARNING
g. Select Read/Write.
h. Enter the new value to correct the error found during the check. not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
i. Select Save, then OK. death or injury. Moving parts can cause injury.
j. Select 12-005 BookMrkFoldOffset. 1. Slide out the booklet maker and locate the adjustment screw on the booklet backstop,
k. Select Read/Write. Figure 1.
l. Change the value by the same amount as the 12-004 BookMrkStapleOffset value. 2. Use a 2.5mm allen head driver and turn the adjustment screw as follows:
Turn the screw clockwise to rotate the crease clockwise relative to the centre line.
NOTE: Increasing both values moves the staple position toward the left edge of the
top sheet. Decreasing both values moves the staple position away from the left edge Turn the screw anti-clockwise to rotate the crease anti-clockwise relative to the cen-
of the top sheet. One step = 0.1137mm. Changing only the 12-004 BookMrkStaple- tre line.
Offset value will move the staple position and fold position the same amount. One half turn of the adjustment screw will change the crease angle approximately 3
to 4mm over the length of the crease.
m. Select Save, then OK.
3. Run a copy job of 3 stapled 4 sheet booklets to check that the crease is in the centre of
2. Select Save, then select OK. the book. Repeat the adjustment if necessary.
3. Repeat the Check to ensure the staple position is correct.
4. When the staple position is correct, switch the machine off then on, GP 14.

ADJ 11.8-171, ADJ 11.9-171 4-506 Xerox WorkCentre 5790 Family
ADJ 11.10-171 Motor Drive Belt Tensioning
Correct position of the Purpose
crease blade fold To set the tension of belts that are tensioned by a spring attached to a motor. See also ADJ
11.11-171 Idler Drive Belt Tensioning.
Check
3. The adjustable motor or tensioning pulley bracket is positioned with fastening screws not
tightened fully.
Angle of adjustment
4. The tensioning spring is fitted between the bracket and frame locating point.
Adjustment
WARNING
Adjustment screw
necessary.
Figure 1 Booklet crease adjustment

NOTE: Check the belt condition and routing if the tension spring is not extended or the ADJ 11.11-171 Idler Drive Belt Tensioning
Purpose
To set the tension of drive belts that are tensioned by a spring attached to an idler. See also
ADJ 11.10-171 Motor Drive Belt Tensioning.
Drive belt Check

3. The tensioning spring is fitted between the idler bracket and frame locating point.
Adjustment
Pivot Screw
WARNING
Bracket not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
1. Figure 1 shows a typical arrangement. Loosen the adjustment screw and allow the spring
to tension the belt.
2. Tighten the adjustment screw.
Tension spring 3. If no more adjustment is available, install new components as necessary.
Adjustment slot Tension spring
Locking screw
Bracket
Typical idler tensioning arrangement

ADJ 11.12-171 Tri-Folder Fold Adjustment Adjustment
Purpose
To adjust C or Z folded copies in accordance with the customer requirements. WARNING
Check not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause
1. Ensure the tri-folder and the HVF BM are aligned correctly, ADJ 11.1-171 Machine to death or injury. Moving parts can cause injury.
HVF/HVF BM, HVF BM to Tri-Folder Alignment. 1. Perform the adjustments that follow as necessary to meet with the customer C fold and Z
2. Ensure the tri-folder is set for the correct size of paper, ADJ 11.2-171 Tri-Folder Paper fold requirements, Figure 2.
Size Setting.
3. The NVM settings. Enter dC131 then check that codes values for 12-009 (C folds), 12-
010 (Z folds) and 12-011 (Tri-fold de-skew) are set in accordance with the values on the
HVF/BM label, Figure 1.
If necessary, enter dC131 and change the NVM values for codes 12-009, 12-010
and 12-011 to match with the values on the HVF BM label.
4. Ensure the front door interlock switch is cheated, PL 11.197 Item 2. Run a four sheet C
fold and Z fold copy job. Check that the copies are folded into three approximately equal
parts, with the folds parallel to the edge of the paper.
5. Check that the C and Z folded copies meet with the customer requirements. If necessary
make fine adjustments to the length of folds A and/or B. Figure 3.
C Fold profile Z Fold profile

1
Open the HVF BM front door, then pull
out the booklet maker module from the
HVF BM. Figure 2 C folded and Z folded output copy profiles
NOTE: Figure 3 shows the orientation of a C and Z folded copy on the tri-folder output tray, as
viewed from the front of the machine.
A Folds
Figure 3. The folds marked A are created within the booklet maker module. The length of the A
fold is determined by the NVM values in dC131. An increase to the NVM value by 30 will
decrease the A fold by 1mm. A decrease to the NVM value by 30 will increase the A fold by
1mm.
MOD. TAG Matrix Use dC131 code 12-009 to make adjustments to C folded copies.
Use dC131 code 12-010 to make adjustments to Z folded copies.
2
Check that the values on the HVF/BM label Booklet maker B Folds
match the NVM values. Figure 3. The folds marked B are created within the tri-folder module. The length of the B fold is
determined by the position of the paper setting adjusters. If necessary remove the front door,
PL 11.190, front cover PL 11.190 and the rear cover PL 11.190, then reposition the paper set-
Figure 1 HVF/BM NVM value label location ting adjusters. Figure 2. An adjustment of 1 graduation on the paper size adjuster scale will
adjust the position of fold B by 1mm.
Raise the paper setting adjusters to decrease fold B.

Lower the paper setting adjusters to increase fold B.

ADJ 11.13-171 HVF Performance Improvement (W/TAG V-
006)
Purpose
To improve the overall performance and reliability of the HVF finisher module.
Adjustment
WARNING
Perform the following 10 remedial procedures in consecutive order to accomplish the HVF per-
formance improvement adjustment W/TAG V-006.
1. Hole Punch Blanking Assembly Modification.
2. Hole Punch Blanking Assembly to HVF Frame Modification.
3. Check for Wear on the Upper Paddles.
4. Check the Front and Rear Tampers for Scoring.
2 2 5. Check the Spacing Between the Front and Rear Tampers.
Move the adjuster Move the adjuster
6. Buffer Pocket Jam Clearance Guide Modification.
3 3 7. Check for Wear on the Lower Paddles.
Fasten the screw Fasten the screw 8. Check the Position of the Ejector Assembly.
1 1
9. Chamfered Staple Cartridge Installation.
Loosen the screw Loosen the screw
10. Customer Awareness Instruction on Bin 1 Obstructions.
11. BM Diverter Solenoid Position.
Figure 3 Set the paper size adjusters

Procedures Hole Punch Blanking Assembly to HVF Frame Modification
Hole Punch Blanking Assembly Modification The right angled tab on the HVF Rear frame can obstruct the hole punch blanking assembly
from reaching the home position. This causes the top section of the assembly to bend forward
The hole punch blanking assembly heats up as copies pass through. The increase in tempera-
and reduce the paper path gap through the assembly, resulting in paper jams and misfeeds.
ture causes the hole punch blanking assembly to bow. This bowing effect causes a reduction of
the paper path gap through the assembly, resulting in paper jams and misfeeds. 1. Remove then reinstall the hole punch blanking assembly, PL 11.153 Item 4. Check if the
1. Remove the hole punch blanking assembly, PL 11.153 Item 4. assembly collides with the tab, refer to Figure 3.
2. Figure 1. Dismantle the hole punch blanking assembly.

HVF Rear frame
1
Bend the tab upwards to between 90
and 95 degrees.
Hole punch blanking assembly
1 2
Remove the shoulder Remove the screw then
screw. separate the assembly.
Figure 1 Hole punch blanking assembly
3. Figure 2. Form a slot to allow translational movement (inboard to outboard) during expan-
sion and contraction of the hole punch blanking assembly. Figure 3 HVF rear frame
2. Figure 3. If necessary bend the tab.

3. Reinstall the hole punch blanking assembly. Ensure the assembly is not obstructed by the
tab.
4. Proceed to Check for Wear on the Upper Paddles.
Check for Wear on the Upper Paddles
Wear of the upper paddles will cause the failure of sheets 2 to 100 in the compile area to regis-
ter against the back stops. This can lead to mis-registered or mis-stapled sheets in a set.
NOTE: Check the serial number of the machine, if the serial number is before either of the fol-
lowing, install a new set of four paddle wheels, PL 11.145 Item 28 to maintain good reliability:
2mm
HVF YFV005294 (manufacture date 17th March 2009)
HVF/BM YFW02881 (manufacture date 19th November 2009)
1
File the screw hole towards the front
by 2mm to form a clearance slot.
Figure 2 Hole punch blanking assembly
4. Reinstall the hole punch blanking assembly then proceed to Hole Punch Blanking Assem-
bly to HVF Frame Modification.

1. Figure 4. Check the paddle wheels of the paddle module assembly for wear. Check the Front and Rear Tampers for Scoring
Deep scores in the front and rear tampers can cause the paper to catch and fail to register in
the compiler area.
Paddle module assembly
1. Figure 5. Check the tampers for scoring. If scoring is evident install a new metal pin rein-
forced tamper set, PL 11.140 Item 22.
1.5mm The paddle wheels should

be in good condition with
a thickness not less than
1.5mm.
Typical areas of possible scoring for front

and rear tampers (rear tamper shown).
1.5mm
Figure 5 Rear tamper

Paddle wheel 4 places
2. In extreme cases where abrasive paper is being used, scoring can still occur with the new
metal pin reinforced tampers. This scoring can be seen especially on the rear tamper,
Figure 4 Paddle module assembly underneath the left pin. if necessary, install a new metal pin reinforced tamper set, PL
11.140 Item 22.
2. Run 50 sets of 3 documents in A4 or 8.5 x 11 inch LEF simplex and stapled mode. Check 3. Proceed to Check the Spacing Between the Front and Rear Tampers.
for mis-registered or mis-stapled sets in the direction of paper feed on the 2nd and 3rd
sheets of each set. If any sets are mis-registered or mis-stapled install new paddle
wheels, refer to REP 11.49-171 and REP 11.101-171.
3. Proceed to Check the Front and Rear Tampers for Scoring.

Check the Spacing Between the Front and Rear Tampers Buffer Pocket Jam Clearance Guide Modification
The spring loaded diverter gate shaft can bind to the buffer pocket jam clearance guide. As a
result the diverter gate becomes slow in its movement causing 11-142-171 and 11-140-171
CAUTION
paper jam faults.
The use of shim stock packing between the HVF frame and the front tamper motor assembly.
1. Remove the buffer pocket jam clearance guide, REP 11.33-171.
must not exceed a total thickness of 2mm. Exceeding the 2mm limit will impede the operation
of the HVF front door. 2. Figure 7. Cut away the guide.
Incorrect spacing between the tampers can cause the paper to buckle between the tampers.
This can cause mis-stacking, mis-stapling and/or upper and lower paper grooves in one or Buffer pocket jam clearance guide
more of the tampers.
1. Run 50 sets of 3 documents in A4 or 8.5 x 11 inch LEF simplex and stapled mode. Ribs
2. Check during the upper paddle operation that the tampers come to a closed position with
un-buckled paper in between.
Shaft
3. Check for mis-compiling in the direction of feed. If mis-compiling is evident and greater
than 1.2mm continue with steps 4 to 6. If there is no mis-compiling or mis-compiling less
than 1.2mm proceed to Buffer Pocket Jam Clearance Guide Modification.
4. Figure 6. In small increments position the front tamper motor assembly up to 2mm away
from the front frame with spacers made from shim stock (600T41512).
1
Cut away the ribs of the guide to
increase shaft clearance (2
places).
1
Loosen the 3 screws.
2 Figure 7 Buffer pocket jam clearance guide

Pack shim stock between the HVF
frame and the tamper motor assembly 3. Replace the buffer pocket jam clearance guide, REP 11.33-171.
4. Proceed to Check for Wear on the Lower Paddles.
3
Tighten the 3 screws.
HVF frame Tamper motor assembly
Figure 6 Tamper motor assembly
5. Re-run the test job (step 1) and check for improvements.

6. Repeat steps 4 and 5 as necessary, then proceed to Buffer Pocket Jam Clearance Guide
Modification.

Check for Wear on the Lower Paddles Check the Position of the Ejector Assembly
Wear on the lower paddle on the ejector assembly will cause the top sheet of a stacked set to If the ejector assembly has been removed after manufacturing it may have been replaced
mis-stack, mis-staple or not staple. incorrectly. A incorrectly positioned ejector assembly will cause miss-compiling and premature
1. Figure 8. Check the lower paddle for wear. wear of components.
1. Figure 9. Check the ejector module is located correctly, refer to REP 11.6-171.
1 1
Ejector assembly Location slot Offset module
. Route the harness under
the rear tamper assembly.
Extensive wear
Paddles subject to extensive

wear will form pointed ends, Formation of
as indicated by the shaded pointed end
areas.
2 Ejector assembly
Lower paddle Ensure the base plate location tab is inserted
through the location slot in the offset module. Base plate location tab
Figure 8 Lower paddle

Figure 9 Ejector assembly
NOTE: On W/O Tag V-007 machines, the lower paddle is not a spared item.
2. Proceed to Chamfered Staple Cartridge Installation.
2. Perform one of the following:
If wear on the lower paddle is evident on a W/O Tag V-007 machine, install a new W/
Tag V-007 ejector assembly, PL 11.14 Item 2.
If wear on the lower paddle is evident on a W/Tag V-007 machine, install a new ejec-
tor paddle assembly, PL 11.140 Item 26.
3. Proceed to Check the Position of the Ejector Assembly.

Chamfered Staple Cartridge Installation
The surface area of the 100 sheet staple cartridge can protrude slightly, where the corner of Raised surface area.
the output sets are positioned for stapling. This raised area can catch the first 5 sheets in a out-
put set, then cause the set to mis-compile, mis-staple and/or create dog ears.
1. Figure 10. Check the staple cartridge for a raised surface.
Raised surface area.

1
File the raised surface area until it
is level with the metal plate.
Metal plate.
Figure 11 Staple cartridge
4. Proceed to Customer Awareness Instruction on Bin 1 Obstructions

Customer Awareness Instruction on Bin 1 Obstructions
It is not always obvious to customers that bin 1 will lower almost to the base of the HVF finisher
Figure 10 Staple cartridge when the stacker tray is at full capacity. If bin 1 is obstructed as it descends the elevator motor
will continue to try and drive bin 1 downwards. This type of incident can cause elevator motor
2. Check if the customer ever runs more than 50 sheet staple sets. (11-460-171) faults.
3. In accordance with the customer requirements either; 1. Advise the customer that items should never be placed in the area under bin 1, and that
Fit a 50 sheet capacity staple cartridge, which has a chamfered surface. obstruction of bin 1 will cause premature elevator motor failure.
Figure 11. Hand file a chamfer on a 100 sheet capacity staple cartridge. 2. Mark off the HVF module modification tag number 006, refer to Tags.
NOTE: Check the serial number of the machine, if the serial number is before either of the fol-
lowing, install a new stacker motor gearbox, PL 11.135 Item 10 to maintain good reliability:
HVF YFV005294 (manufacture date 17th March 2009)
HVF/BM YFW02881 (manufacture date 19th November 2009)
BM Diverter Solenoid Position

The booklet maker diverter gate is susceptible to breakage if the diverter gate solenoid travel is
not arrested by the stop washer pressing against the solenoid body, but by the diverter gate
reaching the end of its travel.
Perform ADJ 11.14-171 BM Diverter Solenoid Position.

ADJ 11.14-171 BM Diverter Solenoid Position Adjustment
Purpose
To correctly position the BM diverter solenoid. The booklet maker diverter gate is susceptible to WARNING
breakage if the diverter gate solenoid travel is not arrested by the stop washer pressing against
the solenoid body, but by the diverter gate reaching the end of its travel.
Check
1. Figure 2, adjust the position of the solenoid.
2. Enter the dC330 output code 11-074 to energize the BM diverter solenoid.
1
3. Figure 1, check the position of the solenoid. Loosen screw
When the solenoid is

energized the rubber
washer must be pinched
between the E-clip and 2
the solenoid body
Move the solenoid to
eliminate any gap
under the washer
3
Tighten the screw
Figure 1 Solenoid position check 6 4

Tighten the 2 5
Loosen 2 screws
4. If the condition stated in Figure 1 is not met, perform the adjustment. screws Move the solenoid fully
to the left in the bracket
Figure 2 Solenoid position adjustment
2. If there is not enough movement in the solenoid mounting position to eliminate any gap
under the washer, install a spacer washer/shim between the E-clip and rubber washer to
eliminate the gap.
3. Enter the dC330 output code 11-074 to energize the BM diverter solenoid to check that
the rubber washer is now pinched between the E-clip and the solenoid body.
4. Make prints or copies to both the booklet maker and to bin 1 to ensure that the BM
diverter is operating correctly.

ADJ 14.1 Optics Cleaning Procedure (W/O TAG 150) ADJ 14.2 Optics Cleaning Procedure (W/TAG 150)
Purpose Purpose
To clean the optics components of the scanner ensuring optimum image quality. To clean the optical components of the scanner ensuring optimum image quality.
NOTE: This adjustment must only be performed if directed to from an Image Quality RAP, or if NOTE: This adjustment must only be performed if directed to it from an Image Quality RAP, or
the optics cavity was opened to install a new component and contamination can be seen on if the optics cavity was opened to install a new component and contamination can be seen.
the optics components.
Procedure
Procedure
WARNING
CAUTION
CAUTION Observe ESD precautions during this procedure.
Observe ESD precautions during this procedure. 1. Remove the DADH, REP 5.19.
1. Remove the CVT glass and document glass, REP 14.6. 2. Remove the CVT glass and document glass, REP 14.6.
2. Inspect the cleanliness of the optics mirrors, if necessary, clean them as follows: 3. Inspect the cleanliness of the exposure lamp, lens and mirror and if necessary, clean
a. Vacuum clean the area to remove all visible contamination, taking care not to touch them as follows:
the mirrors with the cleaning nozzle. It may be necessary to move the carriages to a. Vacuum clean the area as necessary to remove all visible contamination, taking care
gain reasonable access, do this by hand rotation of the flywheel on the capstan not to touch the mirror, exposure lamp or lens with the cleaning nozzle. It may be
shaft. necessary to move the carriage gently to the left. It is advisable to leave it in this
b. Wash your hands. position, but it can be returned to the home position by depressing slightly to allow
c. Carefully clean the mirrors using a dry micro fiber wiper, PL 26.10 Item 13. It may be the flag to enter the gap in the scan carriage home sensor.
necessary to use a cleaning cloth dampened with film remover, PL 26.10 Item 4 on b. Wash your hands.
stubborn contamination. c. Carefully clean the exposure lamp, the top of the full width array and the mirror with a
d. Polish the mirrors with a dry micro fiber wiper, PL 26.10 Item 13. micro fiber wiper, PL 26.10 Item 13, dampened with antistatic fluid, PL 26.10 Item 19.
e. Check that the mirror surfaces are now clean. Repeat the cleaning operation if nec- d. Polish the lamp, array top and mirror with a dry micro fiber wiper, PL 26.10 Item 13.
essary. 4. Examine the lenses of the document size sensors, PL 14.15 Item 3, and clean if neces-
3. Inspect the cleanliness of the document glass and CVT glass, if necessary, clean them as sary with a micro fiber wiper, PL 26.10 Item 13.
follows:
5. Inspect the document glass and CVT glass and if necessary, clean them as follows:
a. Clean the under side of document glass and CVT glass using a micro fiber wiper, PL
a. Clean the under side of document glass and CVT glass using a micro fiber wiper, PL
26.10 Item 13, dampened with film remover, PL 26.10 Item 4.
26.10 Item 13, dampened with antistatic fluid, PL 26.10 Item 19.
b. Polish the under side of document glass and CVT glass with a dry micro fiber wiper.
b. Polish the under side of document glass and CVT glass with a dry micro fiber wiper,
c. Install the document glass and CVT glass, taking care not to smear the cleaned PL 26.10 Item 13.
underside, REP 14.6
c. Install the document glass and CVT glass, taking care not to smear the cleaned
NOTE: . Ensure that the CVT glass is installed as far to the right as possible. underside, REP 14.6.
NOTE: . Ensure that the white stripes on both the CVT glass and the document NOTE: . Ensure that the white AGC strip on both the CVT glass and the document
glass, are at the front of the machine and on the underside of the glass. glass, are at the front of the machine and on the underside of the glass.
d. Clean the upper side of document glass and CVT glass using a micro fiber wiper,PL d. Clean the upper side of document glass and CVT glass using a micro fiber wiper,
26.10 Item 13, dampened with film remover, PL 26.10 Item 4. dampened with film remover, PL 26.10 Item 4.
e. Polish the upper side of document glass and CVT glass using a dry micro fiber e. Polish the upper side of document glass and CVT glass using a dry, micro fiber
wiper, PL 26.10 Item 13. wiper.
4. Re-install the remainder of the removed components. 6. Re-install the remainder of the removed components.

5 Parts Lists
PL 1 - Standby Power PL 8 - Paper Transport
PL 1.10 Power and Control Assembly............................................................................. 5-3 PL 8.10 Main Covers....................................................................................................... 5-37
PL 1.15 Main Power Cables............................................................................................ 5-4 PL 8.11 Front Door Assembly (65-90 ppm) (2 of 3) ........................................................ 5-38
PL 8.15 Registration Transport (35-55 ppm)................................................................... 5-39
PL 2 - User Interface PL 8.17 Registration Transport (65-90 ppm)................................................................... 5-40
PL 2.10 User Interface .................................................................................................... 5-5 PL 8.20 Duplex Transport (65-90 ppm)........................................................................... 5-41
PL 3 - Machine Run Control PL 8.22 Duplex Transport (35-55 ppm)........................................................................... 5-42
PL 8.25 Tray 1 and 2 Paper Feed Assembly (1 of 2) ...................................................... 5-43
PL 3.22 Single Board Controller PWB Module (1 of 2) ................................................... 5-6
PL 3.24 Single Board Controller PWB Module (2 of 2) ................................................... 5-7 PL 8.26 Tray 1 and 2 Paper Feed Assembly (2 of 2) ...................................................... 5-44
PL 8.30 Tray 3 Paper Feed Assembly (W/O TAG 151) .................................................. 5-45
PL 4 - Main Drive Assembly PL 8.31 Tray 4 Paper Feed Assembly (W/O TAG 151) .................................................. 5-46
PL 4.10 Main Drive Module (65-90 ppm) (1 of 2) ............................................................ 5-8 PL 8.32 Tray 3 Paper Feed Assembly (W/TAG 151) ...................................................... 5-47
PL 4.12 Main Drive Module (65-90 ppm) (2 of 2) ............................................................ 5-9 PL 8.33 Tray 4 Paper Feed Assembly (W/TAG 151) ...................................................... 5-48
PL 4.15 Main Drive Module (35-55 ppm) (1 of 2) ............................................................ 5-10 PL 8.35 Tray 3 Transport Assembly (W/O TAG 151)...................................................... 5-49
PL 4.17 Main Drive Module (35-55 ppm) (2 of 2) ............................................................ 5-11 PL 8.36 Tray 3 Transport Assembly (W/TAG 151).......................................................... 5-50
PL 8.40 Tray 5 Feed Assembly (1 of 3)........................................................................... 5-51
PL 5 - DADH PL 8.45 Tray 5 Feed Assembly (2 of 3)........................................................................... 5-52
PL 5.10 DADH (Complete), Covers, DADH PWB ........................................................... 5-12 PL 8.47 Tray 5 Feed Assembly (3 of 3)........................................................................... 5-53
PL 5.15 Feed Assembly (35 ppm)................................................................................... 5-13
PL 5.17 Feed Assembly (40-90 ppm).............................................................................. 5-14 PL 9 - Xerographics
PL 5.20 Top Cover Assembly.......................................................................................... 5-15 PL 9.10 Waste Toner Bottle Assembly............................................................................ 5-54
PL 5.25 CVT.................................................................................................................... 5-16 PL 9.15 Developer Assembly (65-90 ppm) ..................................................................... 5-55
PL 5.30 Baffle Assembly ................................................................................................. 5-17 PL 9.17 Developer Assembly (35-55 ppm) ..................................................................... 5-56
PL 5.35 Input Tray Assembly .......................................................................................... 5-18 PL 9.20 Xerographic Module and Short Paper Path Assembly (40-90 ppm) .................. 5-57
PL 5.40 Document Cover ................................................................................................ 5-19 PL 9.22 Xerographic Module and Short Paper Path Assembly (35 ppm) ....................... 5-58
PL 9.25 Ozone Fan and Photoreceptor Fan ................................................................... 5-59
PL 6 - ROS
PL 6.10 ROS ................................................................................................................... 5-20 PL 10 - Copy Transportation and Fusing
PL 10.8 Fuser Module Assembly (35-55 ppm)................................................................ 5-60
PL 7 - Paper Supply PL 10.10 Fuser Module Assembly (65-90 ppm).............................................................. 5-61
PL 7.10 Tray 1 and 2 Assembly ...................................................................................... 5-21 PL 10.11 Inverter Assembly (1 of 4)................................................................................ 5-62
PL 7.15 HCF Tray 3 and 4 Assembly (W/O TAG 151) (1 of 2) ....................................... 5-22 PL 10.12 Inverter Assembly (2 of 4)................................................................................ 5-63
PL 7.17 HCF Tray 3 and 4 Assembly (W/O TAG 151) (2 of 2) ....................................... 5-23 PL 10.13 Inverter Assembly (3 of 4)................................................................................ 5-64
PL 7.18 HCF Tray 3 and 4 Assembly (W/TAG 151) (1 of 2) ........................................... 5-24 PL 10.14 Inverter Assembly (4 of 4)................................................................................ 5-65
PL 7.19 HCF Tray 3 and 4 Assembly (W/TAG 151) (2 of 2) ........................................... 5-25 PL 10.15 Inverter Drive Gears and Jam Clearance Knobs ............................................. 5-66
PL 7.20 Elevator Motor and Control PWB (W/O TAG 151)............................................. 5-26 PL 10.20 Inverter Decurler Assembly W/TAG 046/047................................................... 5-67
PL 7.21 Elevator Motor and Control PWB (W/TAG 151)................................................. 5-27 PL 10.21 OCT Inverter Decurler Assembly W/TAG 148 ................................................. 5-68
PL 7.25 HCF Covers (W/O TAG 151) ............................................................................. 5-28 PL 10.25 Short Paper Path Assembly............................................................................. 5-69
PL 7.26 HCF Covers (W/TAG 151) ................................................................................. 5-29
PL 7.30 Bypass Tray and Left Door Assembly................................................................ 5-30 PL 11 - 2K LCSS
PL 7.40 Stand Assembly ................................................................................................. 5-31 PL 11.2 2K LCSS Covers................................................................................................ 5-70
PL 7.60 Tray 5 Covers .................................................................................................... 5-32 PL 11.4 2K LCSS Docking Latch .................................................................................... 5-71
PL 7.62 Tray 5 Base........................................................................................................ 5-33 PL 11.6 2K LCSS Hole Punch Unit ................................................................................. 5-72
PL 7.64 Tray 5 Guides .................................................................................................... 5-34 PL 11.8 2K LCSS Paddle Wheel/Safety Gate................................................................. 5-73
PL 7.68 Tray 5 Lift assembly (1 of 2) .............................................................................. 5-35 PL 11.10 2K LCSS Bin 1 Control Components (1 of 2)................................................... 5-74
PL 7.70 Tray 5 Lift assembly (2 of 2) .............................................................................. 5-36 PL 11.12 2K LCSS Bin 1 Control Components (2 of 2)................................................... 5-75
PL 11.14 2K LCSS Paper Entry Transport...................................................................... 5-76
PL 11.16 2K LCSS Tamper Assembly ............................................................................ 5-77
November 2014 Parts Lists

PL 11.18 2K LCSS Ejector Assembly ............................................................................. 5-78 PL 11 - Tri-Folder
PL 11.20 2K LCSS Staple Head Unit/Traverse Assembly .............................................. 5-79 PL 11.190 Tri-Folder Covers ........................................................................................... 5-119
PL 11.22 2K LCSS Bin 0 Entry ....................................................................................... 5-80 PL 11.193 Tri-Folder Drives module ............................................................................... 5-120
PL 11.23 2K LCSS Bin 1 Entry ....................................................................................... 5-81 PL 11.195 Tri-Folder Top Door Cover Assembly ............................................................ 5-121
PL 11.24 2K LCSS Entry Guide Cover/Jam Clearance Guide........................................ 5-82 PL 11.197 Tri-Folder Main Drives Assembly................................................................... 5-122
PL 11.26 2K LCSS Electrical .......................................................................................... 5-83
PL 12 - OCT
PL 11 - 1K LCSS PL 12.10 OCT ................................................................................................................. 5-123
PL 11.100 1K LCSS Covers............................................................................................ 5-84
PL 11.102 1K LCSS Docking Latch ................................................................................ 5-85 PL 14 - Scanner
PL 11.104 1K LCSS Paddle Wheel/Safety Gate............................................................. 5-86 PL 14.10 Scanner Module, CVT/Document Glass (W/TAG 150).................................... 5-124
PL 11.106 1K LCSS Bin 1 Control Components ............................................................. 5-87 PL 14.15 Electrical Components (W/TAG 150)............................................................... 5-125
PL 11.110 1K LCSS Paper Entry Transport.................................................................... 5-88 PL 14.20 Scanner Module, CVT/Document Glass (W/O TAG 150)................................ 5-126
PL 11.112 1K LCSS Tamper Assembly .......................................................................... 5-89 PL 14.25 Electrical Components (W/O TAG 150)........................................................... 5-127
PL 11.114 1K LCSS Ejector Assembly ........................................................................... 5-90
PL 17 - Secure Access
PL 11.116 1K LCSS Staple Head Assembly................................................................... 5-91
PL 17.00 Secure Access Additions ................................................................................. 5-128
PL 11.118 1K LCSS Bin 0 Entry ..................................................................................... 5-92
PL 11.120 1K LCSS Bin 1 Entry ..................................................................................... 5-93 PL 20 - Fax
PL 11.122 1K LCSS Entry Guide Cover/Jam Clearance Guide...................................... 5-94 PL 20.10 Fax PWBs ........................................................................................................ 5-129
PL 11.124 1K LCSS Electrical ........................................................................................ 5-95
PL 25 - Accessories
PL 11 - HVF PL 25.10 Convenience Stapler ....................................................................................... 5-130
PL 11.130 HVF Covers and Docking .............................................................................. 5-96
PL 11.135 HVF Stacker .................................................................................................. 5-97 PL 26 - Consumables and Tools
PL 11.140 HVF Ejector, Pressing and Support (1 of 2) .................................................. 5-98 PL 26.10 Consumables and Tools (1 of 2)...................................................................... 5-131
PL 11.145 HVF Ejector, Pressing and Support (2 of 2) .................................................. 5-99 PL 26.11 Consumables and Tools (2 of 2)...................................................................... 5-132
PL 11.150 HVF Main Drives............................................................................................ 5-100
PL 11.153 HVF Feed Assembly and Punch (1 of 3) ....................................................... 5-101
PL 28 - Covers
PL 11.155 HVF Feed Assembly and Punch (2 of 3) ....................................................... 5-102 PL 28.10 Covers ............................................................................................................. 5-133
PL 11.156 HVF Feed Assembly and Punch (3 of 3) ....................................................... 5-103 PL 31 - Maintenance/Installation/Removal Kits
PL 11.157 HVF Power and Control ................................................................................. 5-104 PL 31.10 Maintenance/Installation/Removal Kits (1 of 5) ............................................... 5-134
PL 11 - HVF Booklet Maker PL 31.11 Maintenance/Installation/Removal Kits (2 of 5) ............................................... 5-135
PL 11.160 HVF BM Module (Complete).......................................................................... 5-105 PL 31.12 Maintenance/Installation/Removal Kits (3 of 5) ............................................... 5-136
PL 31.13 Maintenance/Installation/Removal Kits (4 of 5) ............................................... 5-137
PL 11.161 HVF BM Entry and Front Cover..................................................................... 5-106
PL 31.14 Maintenance/Installation/Removal Kits (5 of 5) ............................................... 5-138
PL 11.162 HVF BM Tamper Assembly ........................................................................... 5-107
PL 11.163 HVF BM Back Stop Motor.............................................................................. 5-108 PL 31.35 Line 1 Fax Kits ................................................................................................. 5-139
PL 31.40 Line 2 Fax Kits ................................................................................................. 5-140
PL 11.164 HVF BM Back Stop assembly........................................................................ 5-109
Common Hardware ......................................................................................................... 5-141
PL 11.165 HVF BM Crease Blade Motor ........................................................................ 5-110
PL 11.166 HVF BM Crease Rolls Motor and PWB ......................................................... 5-111
PL 11.167 HVF BM Crease Rolls and Support Leg ........................................................ 5-112
PL 11.168 HVF BM Stapler Assemblies ......................................................................... 5-113
PL 11.169 HVF BM Bin 2 ................................................................................................ 5-114
PL 11 - Inserter
PL 11.175 Inserter Covers .............................................................................................. 5-115
PL 11.177 Inserter Main Drives (1 of 3) .......................................................................... 5-116
Parts Lists November 2014

PL 1.10 Power and Control Assembly
Item Part Description
1 Power and control assembly
(USSG/XCL) (Not Spared) (65-
90ppm) (REP 1.1)
Power and control assembly (XE)
(Not Spared) (65-90ppm) (REP 1.1)
2 604K84470 IOT PWB (NOTE 2) (REP 3.1)
3 LVPS and base module (see below
for variants) (REP 1.9)
105K35817 35-55 ppm
105K36412 65-90 ppm (XE)
105K36402 65-90 ppm (USSG/XCL)
4 Shield (Not Spared)
5 105K29563 HVPS (35 ppm) (REP 1.10)
105K29553 HVPS (40-90 ppm)
6 Locking screw (Not Spared)
7 110K14020 Door interlock switch (S01-300)
(NOTE) (REP 1.8)
8 110K14030 On/Off switch
9 108E06730 In-line fuse (2.5A slow blow)
10 Main power cord (REF: PL 1.15
Item 1)
11 Not used
12 962K34760 IOT-HVPS harness (35 ppm)
962K27020 IOT - HVPS harness (40-90 ppm)
13 962K49460 IOT - Finisher Harness
14 962K63630 IOT internal tray 5 harness
NOTE: 1. For the left door interlock (S01-305), refer to PL

7.30 Item 3.
NOTE: 2. For additional information about the IOT PWB,

refer to TAG 155 and TAG 156.

Xerox WorkCentre 5790 Family 5-3 PL 1.10
PL 1.15 Main Power Cables
1 Main power cord (see below for
variants)
152S06414 United Kingdom (35-55ppm)
152S06407 United Kingdom (65-90 ppm)
152S06410 Europe (35-55 ppm)
152S06413 Europe (Alternate) (35-55 ppm)
152S06406 Europe (65-90 ppm)
152S06400 USSG/XCL (35-55 ppm)
152S06401 USSG/XCL (65-90 ppm)
152S06415 Denmark (35-55 ppm)
152S06404 Denmark (65-90 ppm)
152S06416 Switzerland (35-55 ppm)
152S06420 Switzerland (65-90 ppm)
152S06402 Argentina (35-55 ppm)
152S06403 Argentina (65-90 ppm)
152S06405 South Africa (65-90 ppm)
2 117E36280 20A power cord
NOTE: This power cord can also be ordered as part of PL

31.14 Item 13.

PL 1.15 5-4 Xerox WorkCentre 5790 Family
PL 2.10 User Interface
1. User interface assembly (USSG/
XCL) (Not Spared) (USSG/XCL)
(35-55 ppm) (REP 2.1)
User interface assembly (XE) (Not
Spared) (35-55 ppm) (REP 2.1)
User interface assembly (USSG/
XCL) (Not Spared) (65-90 ppm)
(REP 2.1)
User interface assembly (XE) (Not
Spared) (65-90 ppm) (REP 2.1)
2. 868E60561 UI screen clamp
3. UI Harness (P/O PL 2.10 Item 10)
(PJ81, PJ130) (W/TAG 150)
UI Harness (W/O TAG 150)
4. 604K67750 Overlay label kit (French/Canadian)
(35-55ppm)
604K67760 Overlay label kit (French/Canadian)
(65-90ppm)
5. 123K08651 UI touch screen (REP 2.4)
6. 960K59860 UI touch screen PWB (REP 2.2)
7. 848K48822 User interface housing (USSG/
XCL) (35-55 ppm)
848K48812 User interface housing (XE) (35-55
ppm)
848K48842 User interace housing (USSG/XCL)
(65-90 ppm)
848K48832 User interface housing (XE) (65-90
ppm)
8. Name plate label (see below for
variants)
897E70180 35 ppm
897E70170 40 ppm
897E70160 45 ppm
897E70150 55 ppm
897E70140 65 ppm
897E70130 75 ppm
897E70120 90 ppm
9. UI Internal USB cable (P/O PL 2.10
Item 10)
10. 962K82370 UI/USB harness pack
11. 960K59842 UI Control PWB (REP 2.3)
12. 960K59850 UI Status PWB
13. Control to status PWB harness (P/
O PL 2.10 Item 12) (PJ909)
14. UI touch screen ribbon cable (40
way) (P/O PL 2.10 Item 6) (PJ944,
PJ907)
15. UI touch screen ribbon cable (12
way) (P/O PL 2.10 Item 6) (PJ942,
PJ906)
16. Safety cover (Not Spared)
(MEXICO)

PL 3.22 Single Board Controller PWB
Module (1 of 2)
1 952K00790 Riser PWB/Power distribution
harness
2 Hard disk drive (SATA) (P/O PL
31.13 Item 23) (REP 3.2)
3 960K72210 Riser PWB (REP 3.4)
4 960K27451 Foreign device interface PWB
5 962K82620 Foreign device interface harness
6 019E67610 Fax mounting bracket
7 HDD mounting bracket (P/O PL
31.13 Item 23)
8 HDD thumb screw (Not Spared)
9 813W25205 Locking screw
10 952K39410 HDD power/data harness
11 Not used
12 Foreign device interface kit (REF:
PL 31.14 Item 2)

PL 3.24 Single Board Controller PWB
Module (2 of 2)
1 Single board controller PWB
module (Not Spared)
2 127K56210 Cooling fan
3 960K59806 Single board controller PWB (35-55
ppm) (W/TAG 150) (REP 3.4)
960K71893 Single board controller PWB
(Mono) (35-55 ppm) (W/O TAG
150)
960K59816 Single board controller PWB (65-90
ppm) (W/TAG 150) (REP 3.4)
4 952K26710 Single board controller PWB /
Power distribution harness
5 960K59830 Power distribution PWB
6 962K33461 DADH/power distribution PWB
harness
7 Single board controller module/
scanner driver PWB/CCD PWB
harness (REF: PL 14.25 Item 13)
(W/O TAG 150)
Single board controller PWB/DADH
comms/scanner power harness
(REF: PL 14.15 Item 5) (W/TAG
150)
8 960K65035 Software module (REP 3.3)
9 Single board controller/CCD PWB
harness (REF: PL 14.25 Item 5)
10 Cable clamp (Not Spared)
11 Single board controller module/user
interface harness (Not Spared)
12 960K52410 Memory module (1Gb)
13 813W25205 Locking screw
14 962K49410 Single board controller module/
LVPS/IOT PWB harness (PJ131-
PJ25 & PJ105-PJ1)
15 962K76580 ROS data cable (PJ113-PJ122)
16 UI video cable (Not Spared)
17 Thumbscrew (Not Spared)
18 Extension bracket (Not Spared)
19 014E68681 Spacer
20 960K59821 Scanner daughter PWB (W/TAG
150)
21 Scanner daughter PWB/scanner
PWB video PWB harness (REF: PL
14.15 Item 13) (PJ6)
22 105K36240 Battery

PL 4.10 Main Drive Module (65-90
ppm) (1 of 2)
1 007K14324 Main drive module (REP 4.5)
2 Flywheel (P/O PL 4.10 Item 1)
3 807E09920 Photoreceptor drive gear (REP 4.4)
4 Dowel pin (P/O PL 4.10 Item 1)
5 Main drive (P/O PL 4.10 Item 1)
6 Main drive motor and PWB
assembly (P/O PL 4.10 Item 1)
(NOTE) (REP 4.6)
7 Ozone fan (REF: PL 9.25 Item 1)
8 130E10530 Waste toner door switch (S09-380)
9 114E18630 Fuser connector assembly
10 Spring (P/O PL 4.10 Item 1)
11 604K24650 Auger damper kit (REP 9.10)
12 Mounting bracket (P/O PL 4.10
Item 1)
13 055K36090 Shutter assembly (REP 9.10)
14 Washer (P/O PL 4.10 Item 1)
15 Screw (P/O PL 4.10 Item 1)
16 Waste toner full sensor (REF: PL
9.10 Item 2)
17 Photoreceptor drive motor (09-010)
(P/O PL 4.10 Item 1)
NOTE: The main drive motor is an integral part of the main

drive PWB.

ppm) (2 of 2)
1 127K55430 Fuser web motor assembly
(MOT10-010)
2 Ozone seal (P/O PL 31.10 Item 6)
3 Not used
4 Xerographic CRUM connector (P/O
PL 4.10 Item 1)
5 Xerographic CRUM connector
screw (P/O PL 4.10 Item 1)
7 807E09930 Output paper path drive gear (REP
4.7)
8 807E09940 Intermediate drive gear (REP 4.7)
9 023E25040 Main drive belt 2 (REP 4.7)
10 807E06462 Fuser drive gear/pulley assembly
(REP 4.7)
11 Bearing (P/O PL 4.12 Item 10)
12 114E18810 Fuser CRUM connector
14 Support plate (P/O PL 4.10 Item 1)
15 807E05670 Registration transport drive pulley
(REP 4.7)
17 Developer drive gear/pulley
(REP 4.7)
18 023E25050 Main drive belt 1 (REP 4.7)
19 Scorotron cleaner home sensor
(Q09-070) (P/O PL 4.10 Item 1)
20 Charge scorotron harness (P/O PL
4.10 Item 1)
21 Charge scorotron grid harness (P/O
PL 4.10 Item 1)
22 Auto cleaner harness (P/O PL 4.10
Item 1)
23 Idler (P/O PL 4.10 Item 1)

ppm) (1 of 2)
1 007K14316 Main drive module (35 ppm) (REP
4.1)
007K14337 Main drive module (40-55 ppm)
(REP 4.1)
2 Flywheel (P/O PL 4.15 Item 1)
3 807E06600 Photoreceptor drive gear (REP 4.4)
5 Main drive (P/O PL 4.15 Item 1)
6 127K55411 Main drive motor and PWB
assembly (35 ppm) (NOTE) (REP
4.2)
127K55421 Main drive motor and PWB
assembly (40-55 ppm) (NOTE)
(REP 4.2)
7 Ozone fan (REF: PL 9.25 Item 1)
8 130E10530 Waste toner door switch (S09-380)
9 114E18630 Fuser connector assembly
11 055K36090 Shutter assembly (REP 9.10)
12 Waste toner full sensor (P/O PL
9.10 Item 2)
13 604K24650 Auger damper kit (REP 9.10)
Item 1)
17 Photoreceptor drive motor (MOT09-
010) (P/O PL 4.15 Item 1)
NOTE: The main drive motor is an integral part of the main
drive PWB.

ppm) (2 of 2)
1 127K55430 Fuser web motor assembly
(MOT10-010)
2 Ozone seal (P/O PL 31.10 Item 6)
3 Not used
4 Xerographic CRUM connector (P/O
PL 4.15 Item 1)
5 Xerographic CRUM connector
screw (P/O PL 4.15 Item 1)
7 807E09930 Output paper path drive gear (REP
4.3)
8 807E09940 Intermediate drive gear (REP 4.3)
9 023E30740 Main drive belt (REP 4.3)
10 007K13202 Fuser drive gear (REP 4.3)
12 114E18810 Fuser CRUM connector
14 807E05670 Registration transport drive pulley
(REP 4.3)
15 007K21830 Developer drive gear (White) (55
ppm) (REP 4.3)
807E05680 Developer drive gear (Black) (35
ppm)
16 Scorotron cleaner home sensor
(Q09-070) (P/O PL 4.15 Item 1)
17 Auto cleaner harness (P/O PL 4.15
Item 1)
18 Charge scorotron harness (P/O PL
4.15 Item 1)
19 Charge scorotron grid harness (P/O
PL 4.15 Item 1)
20 Idler (P/O PL 4.15 Item 1)

PL 5.10 DADH (Complete), Covers,
DADH PWB
1 Rear cover (P/O PL 5.10 Item 9)
2 036K01701 Right counterbalance (REP 5.12,
ADJ 5.2, ADJ 5.5)
3 Document pad (Not Spared) (ADJ
5.6)
4 036K01630 Left counterbalance (REP 5.12,
ADJ 5.2, ADJ 5.5)
5 960K34852 DADH PWB (35 ppm)
960K51763 DADH PWB (40-90 ppm) (W/TAG
D-002)
6 962K62932 Communication/power cable
7 Harness support (P/O PL 5.10 Item
9)
8 Top cover (REF: PL 5.20 Item 15)
9 084K42640 DADH (35 ppm) (REP 5.19, ADJ
5.2, ADJ 5.5)
084K36766 DADH (40-90 ppm) (REP 5.19, ADJ
5.2, ADJ 5.5)
10 DADH Closed switch magnet (Not
Spared) (NOTE 1)
11 DADH ground harness (P/O PL
5.10 Item 9)
12 803E13680 Thumbscrew (40-90 ppm)
003K20000 Thumbscrew (35 ppm)
13 Bracket (P/O PL 5.10 Item 9)
14 CVT Cleaning label (Not Spared)
15 End stop (Not Spared)
16 Mylar guide (P/O PL 5.10 Item 17)
17 Mylar guide kit (REF: PL 31.14 Item
9)
NOTE: 1. For the DADH closed switch (Q05-300), refer to PL

14.15 - W/TAG 150 or PL 14.25 - W/O TAG 150.
NOTE: 2. To clean the DADH, refer to ADJ 5.4.

PL 5.15 Feed Assembly (35 ppm)
1 113R00717 Feed roll assembly (See NOTE 1)
(REP 5.14)
2 130K73950 Feed sensor (Q05-330)
3 Front cover (P/O PL 5.15 Item 18)
4 Feed housing (P/O PL 5.15 Item
18)
5 121K44530 Feed solenoid (SOL05-010)
6 Feed yoke (P/O PL 5.15 Item 18)
9 005K12600 Feed clutch (CL05-025)
11 110E13480 Top cover interlock switch (S05-
305)
12 Document present sensor actuator
(Not Spared)
13 130K73890 Document present sensor (Q05-
310)
14 125E00430 Static eliminator
15 Gear (P/O PL 5.15 Item 26)
16 127K53770 Feed motor (MOT05-020) (See
NOTE 2) (ADJ 5.1)
17 Feed motor tension spring (red) (P/
O PL 5.10 Item 9)
18 059K58961 Feed assembly (complete) (REP
5.3)
19 Shaft (P/O PL 5.15 Item 26)
21 Feed roll assembly cover (Not
Spared)
22 Intermediate feed bearing (P/O PL
5.15 Item 26)
24 004E22560 Feed motor bracket
25 Ground harness (P/O PL 5.15 Item
18)
26 604K42680 DADH feed bearing kit (Complete)
NOTE: 1. HFSI. To reset the HFSI count, refer to GP 17.
NOTE: 2.For the feed motor drive belt, refer to PL 5.35 Item 5.

PL 5.17 Feed Assembly (40-90 ppm)
1 113R00718 Feed roll assembly (See NOTE 1)
(REP 5.14)
2 130E11200 Feed sensor (Q05-330)
3 Front cover (P/O PL 5.17 Item 18)
4 Feed housing (P/O PL 5.17 Item 18)
5 127K75140 Nudger motor (MOT05-010)
6 Feed yoke (P/O PL 5.17 Item 28)
9 005K12600 Feed clutch (CL05-025) (W/O TAG
D-005)
Feed clutch (P/O PL 5.17 Item 30)
(W/TAG D-005)
11 110E13480 Top cover interlock switch (S05-
305)
12 Front feed gate (P/O PL 5.17 Item
18)
13 Rear feed gate (P/O PL 5.17 Item
18)
16 127K53770 Feed motor (MOT05-020) (See
NOTE 2) (ADJ 5.1)
17 Feed motor tension spring (red) (P/
O PL 5.10 Item 9)
18 059K58412 Feed assembly (complete) (W/O
TAG D-002) (REP 5.3)
Feed assembly (complete) (REF:
PL 31.11 Item 8) (W/TAG D-002,
TAG D-006) (REP 5.3)
21 802E87730 Feed roll assembly cover
22 Intermediate feed bearing (P/O PL
5.17 Item 26)
24 004E22560 Feed motor bracket
25 Ground harness (P/O PL 5.17 Item
18)
26 604K42680 DADH feed bearing kit (Complete)
27 Nudger motor bracket (P/O PL 5.17
Item 5)
28 604K54340 Lever arm CRU spares kit
29 Shim kit (Not Spared) (W/TAG D-003)
30 604K61440 Feed clutch and spacer kit (W/TAG
D-005)
31 Spacer (P/O PL 5.17 Item 30)
NOTE: 2. For the feed motor drive belt, refer to PL 5.35 Item
5.

PL 5.20 Top Cover Assembly
1 Hinge (P/O PL 5.20 Item 16)
2 Bushing (P/O PL 5.20 Item 16)
3 022E25061 CVT/Takeaway idler
4 806E19680 Shaft
5 Torsion spring (green) (P/O PL 5.20
Item 17)
6 038E22914 Base
8 Torsion spring (silver) (P/O PL 5.20
Item 17)
9 029E37810 Latch pin
10 Spring plate (P/O PL 5.20 Item 17)
11 130K73960 Takeaway sensor (Q05-335) (REP
5.8)
12 130K73970 CVT Sensor (Q05-350) (REP 5.8)
13 Sensor support (P/O PL 5.20 Item
17)
14 Shaft securing bracket (P/O PL
5.20 Item 17)
15 802K62453 Top cover
16 055K37584 Top cover assembly (REP 5.1)
17 055K37570 Top access cover assembly (35-55
ppm) (REP 5.2)
055K36650 Top access cover assembly (60-90
ppm) (REP 5.2)
NOTE: For the top cover interlock switch (S05-305), refer to

PL 5.17 Item 11.

PL 5.25 CVT
1 130K73980 Registration sensor (Q05-340)
(REP 5.10)
2 Sensor support (P/O PL 5.10 Item
9)
3 Torsion spring (P/O PL 5.10 Item 9)
4 013E21103 Front CVT roll bearing
5 CVT Roll (P/O PL 5.25 Item 17)
(REP 5.15)
6 022E25061 Pre-scan idler
7 Base (P/O PL 5.10 Item 9)
8 Shaft (Not Spared)
9 127K53780 CVT Motor (MOT05-030) (ADJ 5.1)
10 CVT Motor tension spring (silver)
11 023E25420 CVT Motor drive belt (REP 5.15,
ADJ 5.1)
12 050E14972 Duplex gate (REP 5.15)
13 013E21094 Rear CVT roll bearing
14 Spacer (white) (P/O PL 5.10 Item 9)
15 004E22560 CVT Motor bracket
16 Ground harness (Not Spared)
17 604K55240 CVT roll kit (white) (W/TAG D-004)
604K48370 CVT roll kit (grey) (W/O TAG D-
004)

PL 5.30 Baffle Assembly
1 Lower cover (P/O PL 5.30 Item 5)
2 130K73990 Exit sensor (Q05-345) (35 ppm)
(REP 5.11)
130E19340 Exit sensor (Q05-345) (40-90 ppm)
(REP 5.11)
3 038E34361 Baffle assembly
4 121E20060 Duplex solenoid (SOL05-050) (REP
5.7)
5 055K36641 Baffle assembly (complete) (REP
5.5)
6 022E25061 Post scan idlers
7 806E19680 Shaft
8 059K50770 Exit roll idlers (35 ppm) (REP 5.18)
059K43910 Exit roll idlers (REP 5.18)
10 Document finger (P/O PL 5.30 Item
5)
12 Lift bar (P/O PL 5.30 Item 5)
13 Link arm (P/O PL 5.30 Item 5)
14 604K48160 Mylar guide strip (REP 5.20)
15 Not used
16 Not used
17 Not used
19 Duplex solenoid assembly

PL 5.35 Input Tray Assembly
1 Input tray assembly (complete)
(REP 5.14)
2 004K00971 Pad
3 031E11310 Restack arm
4 050E22922 Input tray
5 423W00949 Feed motor drive belt (ADJ 5.1)
6 059K84630 Takeaway roll assembly (REP 5.6)
7 125E00430 Static eliminator (small) (REP 5.17)
8 130E19340 DADH Length sensor 1 (Q05-315)/
DADH Length sensor 2 (Q05-320)
(See NOTE) (W/TAG D-007) (REP
5.9)
9 Lower cover (right) (P/O PL 5.35
Item 18) (40-90 ppm)
10 115K02540 Static eliminator (large)
115K02160 Static eliminator (large)(low
humidity conditions) (NOTE 2)
11 103K01511 Document width sensor (Q05-325)
(REP 5.16)
13 014E61020 Spacer (black)
14 Spacer (white) (P/O PL 5.35 Item 1)
15 Pulley (P/O PL 5.35 Item 1)
16 Sensor bracket (P/O PL 5.35 Item
1)
17 059K43920 Exit roll assembly (REP 5.13)
18 Not used
19 130E11200 Document present sensor (Q05-
310) (40-90 ppm)
20 Lower cover (Left) (P/O PL 5.35
Item 1) (40-90 ppm)
(35 ppm)
NOTE: 1.This part is also spared as part of a kit PL 31.13
Item 3 containing 2 sensors.
NOTE: 2. Use this part to eliminate stacking problems in low

humidity conditions.

PL 5.40 Document Cover
1 848K06210 Document cover assembly
2 Document cover (P/O PL 5.40 Item
1)
3 Counter balance (P/O PL 5.40 Item
2)
4 Document pad (Not Spared)
5 Counterbalance support (Not
Spared)
6 Document cover bracket (Not
Spared)
7 803E13680 Thumbscrew
8 LH Adaptor plate (P/O PL 5.40 Item
1)
9 RH Adaptor plate (P/O PL 5.40
Item 1)
10 Platen cover handle (P/O PL 5.40
Item 1)
11 Magnetic interlock (P/O PL 5.40
Item 2)
12 Cover platen (P/O PL 5.40 Item 2)

PL 6.10 ROS
1 Scanner (W/TAG 150)(REF: PL
14.10 Item 1),(W/O TAG 150)(REF:
PL 14.20 Item 1)
2 Spacer (Not Spared)
3 Grommet (Not Spared)
4 ROS spares kit (REF: PL 31.11
Item 12) (35 ppm) (NOTE)
ROS spares kit (REF: PL 31.11
Item 12) (40-55 ppm) (NOTE)
ROS spares kit (REF: PL 31.11
Item 12) (65-90 ppm) (NOTE)
5 962K12184 ROS Power distribution (PJ120-
PJ18)/Communication (PJ121-PJ2
& PJ122-PJ109) harness (35-55
ppm)
ROS Power distribution (PJ120-
PJ18)/communication (PJ121-PJ2
& PJ122-PJ228) harness (Not
Spared) (65-90 ppm)
6 Scanner frame securing bracket
(Not Spared)
8 ROS (P/O PL 6.10 Item 4)
NOTE: The replacement part may differ in appearance to the

part that is being replaced, this is due to a design change.

PL 7.10 Tray 1 and 2 Assembly
1 Tray housing (P/O PL 7.10 Item 26,
PL 7.10 Item 27) (W/TAG 001)
2 960K42122 Tray 1 and 2 control PWB
3 809E84170 Leaf spring (REP 7.12)
4 059K59261 Paper guide latch assembly (REP
7.6)
5 Label tray 1 (P/O PL 7.10 Item 26)
6 Label tray 2 (P/O PL 7.10 Item 27)
7 059K59230 Cam assembly (REP 7.12)
8 Tray home cam (P/O PL 7.10 Item
7)
9 Paper size cam (P/O PL 7.10 Item
7)
10 Retaining plate (Not Spared)
11 Paper guide (P/O PL 8.26 Item 1)
12 MAX Fill label (P/O PL 7.10 Item 4)
13 Tray 1 and 2 paper lift plate (P/O PL
7.10 Item 26, PL 7.10 Item 27)
14 059K59270 Paper stop assembly
15 059K59221 Lift gear kit (REP 7.20)
16 IOT-PFM Harness (PJ7-PJ382)
(Not Spared) (REP 7.13)
17 Paper tray 1 & 2 lift arm (P/O PL
7.10 Item 26, PL 7.10 Item 27)
18 Bearing (P/O PL 7.10 Item 26, PL
7.10 Item 27)
19 Quadrant gear (60T) (P/O PL 7.10
Item 15)
20 Gear (13T) (P/O PL 7.10 Item 15)
21 Not used
22 Lift arm pin (P/O PL 7.10 Item 15)
23 Paper tray lip (P/O PL 7.10 Item 24)
24 604K48700 Paper tray lip kit (W/TAG 002)
25 Gear (60T) (P/O PL 7.10 Item 15)
26 050K68570 Tray 1 assembly (See NOTE) (W/
TAG 001) (REP 7.1)
27 050K68580 Tray 2 assembly (See NOTE) (W/
TAG 001) (REP 7.1)
28 Lift arm bracket (P/O PL 7.10 Item
26, PL 7.10 Item 27)
NOTE: 1. For the envelope tray feeding kit please refer to PL

31.13 Item 18.

PL 7.15 HCF Tray 3 and 4 Assembly
(W/O TAG 151) (1 of 2)
1 022E27180 Tray hoist pulley
2 050K59433 Tray 4 assembly (NOTE 1) (REP
7.2)
3 050K59422 Tray 3 assembly (NOTE 1) (REP
7.2)
4 Front short elevator cable (P/O PL
7.15 Item 10, PL 7.15 Item 11)
5 Rear elevator cable (tray 4) (P/O
PL 7.15 Item 11)
PL 7.15 Item 10)
7 Front long elevator cable (P/O PL
7.15 Item 10, PL 7.15 Item 11)
8 HCF (complete) (Not Spared)
9 130K67521 Tray 3 feed sensor actuator (REP
8.14)
10 012K05690 Tray 3 elevator cable assembly
(REP 7.4)
11 012K05701 Tray 4 elevator cable assembly
(REP 7.4)
12 849E21140 Pulley carrier
13 Tray 3 feed sensor actuator spring
14 004K07330 Tray 4 elevate damper assembly
(REP 7.11)
(REP 7.11)
16 038E30370 Tray lift guide
17 019E73940 Retard pad (cork)
18 Separation strip (7 off) (P/O PL 7.15
Item 19)
19 801K20310 Separation strip kit
20 Paper tray guide (P/O PL 7.15 Item
2, 3) (ADJ 7.1)
21 807E22950 Gear (REP 7.11)
22 801E11400 Corner separation strip
23 019E75120 Retard pad (Metamoll)
NOTE: 1. Refer to ADJ 7.1 to set the tray 3 and tray 4 paper
guides.
NOTE: 2. To repair or prevent paper cut damage to the front

edge of the tray assembly, use the rib protector kit PL 31.11
Item 5.

(W/O TAG 151) (2 of 2)
1 Tray 4 assembly (REF: PL 7.15
Item 2)
Item 3)
3 049K00300 Tray 3 and 4 clamp kit
4 Side clamp (2 off) (P/O PL 7.17
Item 3)
5 Center clamp (P/O PL 7.17 Item 3)
6 604K18182 Tray 3 & 4 mylar retainer clip kit
7 Retainer clip (Wide) (6 off) (P/O PL
7.17 Item 6)
8 Retainer clip (Narrow) (2 off) (P/O
PL 7.17 Item 6)
9 Not used
10 Paper tray guide (Not Spared) (ADJ
7.1)
11 Flexure spring (Not Spared)
12 009K02380 Top edge flexure spring
13 Retaining clips (Not Spared)
14 019K06030 HCF Tray alignment clip kit
15 Front clip (P/O PL 7.17 Item 14)
16 Rear clip (P/O PL 7.17 Item 14)
17 Alignment locking clip (P/O PL
31.12 Item 1)
18 807E47310 Elevator drives gear coupling (REP
7.4)

(W/TAG 151) (1 of 2)
1 Tray hoist pulley (Not Spared)
2 050K77170 Tray 4 assembly (REP 7.22)
3 050K77160 Tray 3 assembly (REP 7.22)
4 Front short elevator cable (tray 4)
(P/O PL 7.18 Item 10) (REP 7.24)
PL 7.18 Item 10) (REP 7.24)
PL 7.18 Item 9) (REP 7.24)
7 Front long elevator cable (tray 4)
(P/O PL 7.18 Item 10) (REP 7.24)
8 Front long elevator cable (tray 3)
(P/O PL 7.18 Item 9) (REP 7.24)
9 604K84081 Tray 3 elevator cable kit (REP 7.24)
10 604K84091 Tray 4 elevator cable kit (REP 7.24)
11 Pulley carrier (P/O PL 7.18 Item 9,
PL 7.18 Item 10)
(REP 7.28)
(REP 7.28)
14 Retard pad (Not Spared)
15 868E87140 Tray 3 skew bracket (NOTE 1) (W/
TAG 153)
16 868E87150 Tray 4 skew bracket (NOTE 1) (W/
TAG 153)
17 Front short elevator cable (tray 3)
(P/O PL 7.18 Item 9) (REP 7.24)
NOTE: 1.This part is also suplied as part of PL 31.14 Item 16
and PL 31.12 Item 20. .
NOTE: 2. To repair or prevent paper cut damage to the front

edge of the tray assembly, use the rib protector kit PL 31.11
Item 5.

(W/TAG 151) (2 of 2)
Item 2)
Item 3)
3 604K83671 Tray 3 and 4 clamp kit
4 Side clamp (2 off) (P/O PL 7.19
Item 3)
5 Centre clamp (P/O PL 7.19 Item 3)
6 Tray 4 paper tray guide (P/O PL
7.18 Item 2)
7 Tray 3 paper tray guide (P/O PL
7.18 Item 3)
8 019E74532 Retaining clips
9 819E20420 Front clip
10 807E47310 Elevator drives gear coupling (REP
7.4)
11 Tray 4 paper guide (P/O PL 7.18
Item 2)
Item 3)
13 815E92301 Separation strip

PL 7.20 Elevator Motor and Control
PWB (W/O TAG 151)
1 127K78350 Tray 3 elevator motor (MOT07-
030), Tray 4 elevator motor
(MOT07-040) (REP 7.3)
2 960K41522 HCF control PWB (REP 7.10)
3 019E63410 Switch holder
4 130E10570 Tray 3 home switch (S07-303), Tray
4 home switch (S07-304) (REP 7.9)
5 Not used
6 120E25810 Tray 4 stack limiter (REP 7.8)
7 868E11660 Tray 3 stack limiter bracket
8 120E25800 Tray 3 stack limiter (REP 7.8)
9 868E11670 Tray 4 stack limiter bracket

PL 7.21 Elevator Motor and Control
PWB (W/TAG 151)
1 127K78350 Tray 3 elevator motor (MOT07-
030)/ Tray 4 elevator motor
(MOT07-040) (REP 7.23)
2 960K84461 HCF control PWB (REP 7.27)
604K95330 HCF control PWB (NOTE) (W/TAG
158) (REP 7.27)
3 019E87841 Sensor holder (REP 7.26)
4 Tray 3 home sensor (Q07-303)/
Tray 4 home sensor (Q07-304) (P/
O PL 31.13 Item 21) (REP 7.26)
NOTE: Install only when noise reduction is required due to
noisy tray 3 and 4 feed motors and HCF motor.

PL 7.25 HCF Covers (W/O TAG 151)
1 802K48781 Rear cover
2 848K12270 Left cover
3 859K03060 Castor (locking)
4 848E17500 Tray 4 front cover
5 848E17490 Tray 3 front cover
6 826E20970 Screw (M6 x 30)
7 822E26820 Right cover
8 Cover infill 1 (P/O PL 7.25 Item 10)
10 848E17510 Cover infill kit
11 Castor (Not Spared)

PL 7.26 HCF Covers (W/TAG 151)
1 848E63675 Rear cover
2 822E26830 Left cover
4 604K83651 Tray 4 front cover
5 604K83660 Tray 3 front cover

PL 7.30 Bypass Tray and Left Door
Assembly
1. 050K67883 Bypass tray and left door assembly
(35-55 ppm) (REP 7.5)
050K67893 Bypass tray and left hand door
assembly (65-90 ppm) (REP 7.5)
2. Left hand door (P/O PL 7.30 Item 1, PL
7.30 Item 27)
3. 110E19990 Left hand door interlock (S01-305)
4. 121E25680 Feed solenoid (SOL08-050) (REP 8.9)
5. Feed head assembly (P/O PL 7.30
Item 1, PL 7.30 Item 27) (REP 8.19)
6. Feed head (P/O PL 7.30 Item 5)
7. 130E20360 Bypass tray empty sensor (Q07-335)
(REP 8.23)
8. Hinge pin (Not Spared)
9. Spring retainer (P/O PL 7.30 Item 11)
10. 809E57640 Spring drive gear
11. 807E05311 Drive gear assembly (REP 8.20)
12. Bypass tray (P/O PL 7.30 Item 1)
13. Ground spring (P/O PL 7.30 Item 5)
14. Feed head top cover (P/O PL 7.30 Item
5)
15. Feed roll (P/O PL 7.30 Item 21) (REP
8.21)
16. Nip roll (P/O PL 7.30 Item 5)
17. Left hand door cover (P/O PL 7.30 Item
2)
18. Retard pad bracket (P/O PL 7.30 Item
21)
19. Retard pad assembly (P/O PL 7.30
Item 21)
20. Retard pad spring (P/O PL 7.30 Item 21)
21. 059K39862 Feed roll and retard pad assembly (See
NOTE 2) (REP 8.22)
22. Solenoid spring (P/O PL 7.30 Item 4)
23. 003E78141 Interlock cover
24. 130E12770 Tray 1 feed sensor (Q08-101), Tray 2
feed sensor (Q08-102) (65-90 ppm)
(130E12130) (REP 8.24)
25. 130E11610 Wait Sensor (Q08-100, Q08-110) (65-
90 ppm) (See NOTE 1) (REP 8.17)
26. Nip roll (Not Spared)
27. Not used
28. Pre-reg nip roll spring (P/O PL 7.30
Item 29)
29. 604K55500 Skew bypass tray spares kit (x2 spring)
(W/TAG 048)
30. Nip roller (Not Spared)
31. Shaft (Not Spared)
32. Lower cover (Not Spared)
33. Front pre-nip roll spring (Not Spared)
34. Middle pre-nip roll spring (Not Spared)
NOTE: . 1.Refer to PL 8.15 Item 3 for the 35-55 ppm wait sensor.
NOTE: . 2.HFSI. To reset the HFSI count, refer to GP 17.

PL 7.40 Stand Assembly
1 Stand unit (complete) (Not Spared)
2 802K48582 Front door (NOTE)
5 802K48781 Rear cover
6 Stand base (Not Spared)
7 826E20970 Screw (M6x30)
8 Door hinge pin (P/O PL 7.40 Item 2)
12 848K12270 Left cover
NOTE: Hinge pins (PL 7.40 Item 8) are supplied with the front
door.

PL 7.60 Tray 5 Covers
1 802K93561 Front door assembly
2 Front door hinge (P/O PL 7.60 Item
1)
3 Front door hinge pin (P/O PL 7.60
Item 1)
4 Trail edge guide assembly (P/O PL
7.60 Item 1)
5 Front door latch (P/O PL 7.60 Item
1)
6 110E20570 Front door interlock switch (S07-
306)
110E07300 Front door interlock switch (See
Note)
7 Interlock switch plate (Not Spared)
8 848K19110 Front cover
10 802E82363 Top cover
11 Cable clamp (P/O PL 7.60 Item 9)
12 848E05863 Base knuckle cover
13 Front door interlock harness (Not
Spared)
14 Tamper guide lever (P/O PL 7.60
Item 1)
15 Tamper lever compression spring
16 Label (Tray 5) (P/O PL 7.60 Item 8)
17 Label (Max) (P/O PL 7.60 Item 8)
NOTE: For use with all Tray 5 SEF option kits

PL 7.62 Tray 5 Base
1 Adjustable castor (P/O PL 31.14
Item 18)
3 Platform assembly (Not Spared)
4 009E74211 Spring bias
5 003E76870 Latch bias
6 003E78020 Docking latch
7 Docking latch spring (P/O PL 7.62
Item 16)
8 Docking latch bracket (P/O PL 7.62
Item 16)
9 Docking latch main bracket (P/O PL
7.62 Item 16)
10 803E13680 Docking latch thumb screw (See
NOTE)
11 068K54920 Docking plate (See NOTE)
12 Slide assembly (Not Spared)
13 Docking guides (P/O PL 7.62 Item
16)
14 Slide assembly locking nut (Not
Spared)
15 Docking plate assembly (P/O PL
31.11 Item 11)
16 003K20681 Latch assembly
NOTE: This part is can also be ordered as part of a kit PL

31.11 Item 11.

PL 7.64 Tray 5 Guides
1 110E07300 Docking interlock switch (S07-372)
2 Handle latch (Not Spared)
3 Latch spacer (Not Spared)
4 Slide latch (Not Spared)
5 Spring leaf (Not Spared)
6 Rear guide (P/O PL 7.64 Item 12)
7 Front guide assembly (Not Spared)
8 038E34402 Guide strip
9 Adjustment plate (P/O PL 7.64 Item
13)
10 Docking pin (P/O PL 7.64 Item 13)
11 Rear guide assembly spring (P/O
PL 7.64 Item 12)
12 038K16403 Rear guide assembly
13 029K04680 Docking pin assembly

PL 7.68 Tray 5 Lift assembly (1 of 2)
1 Tray assembly (complete) (REF: PL
7.70 Item 1)
2 Crash bar (Not Spared)
3 Frame top brace (Not Spared)
4 Elevator motor (MOT07-373) (P/O
PL 7.68 Item 24) (REP 7.16)
5 130K74380 Elevator motor encoder sensor
(Q07-406) (REP 7.16)
6 Elevator motor bracket (P/O PL
7.68 Item 24)
7 Elevator motor shaft (Not Spared)
8 960K35024 Control PWB
9 130K75511 Stack down sensor (Q07-405)
(REP 7.15)
10 Standoff (Not Spared)
11 Tray level drive gear clip (Not
Spared)
12 110E06961 Upper limit switch (S07-412) (REP
7.17)
13 Rear elevator rack (P/O PL 7.68
Item 25) (REP 7.21)
14 Front elevator rack (P/O PL 7.68
Item 25) (REP 7.21)
15 Retard roller shield (P/O PL 8.47
Item 1)
16 003K20950 Shipping handle assembly
17 Shipping pin bearing (P/O PL 7.68
Item 16)
18 Shipping pin spring (P/O PL 7.68
Item 16)
19 Shipping pin (P/O PL 7.68 Item 16)
20 Shipping pin handle (P/O PL 7.68
Item 16)
21 Cable tie (Not Spared)
22 Clinch stud (Not Spared)
23 Cable holder (Not Spared)
24 127K56330 Elevator motor assembly (REP
7.16)
25 007K19660 Elevator rack assembly (REP 7.21)
26 Upper limit switch actuator (Not
Spared)
27 Tray level drive gear (P/O PL 7.68
Item 25) (REP 7.21)
28 Actuator spring (Not Spared)

PL 7.70 Tray 5 Lift assembly (2 of 2)
1 Tray lift assembly (Not Spared)
2 110E06961 Tray down limit switch (S07-415)
3 025E06871 Lower safety bar
4 Lift plate (Not Spared)
5 Fixing plate (Not Spared)
6 Infill plate (P/O PL 7.70 Item 19)
7 019K13470 Cork pad
8 Tray lift top cover (Not Spared)
9 Lift plate crash bar actuator 2 (Not
Spared)
10 Lift plate crash bar actuator 1 (Not
Spared)
11 Crash bar actuator spring (Not
Spared)
12 Not Used
13 Infill actuator arm (P/O PL 7.70
Item 19)
14 Infill actuator arm spring (P/O PL
7.70 Item 19)
15 Infill actuator arm pin (P/O PL 7.70
Item 19)
16 Infill plate spring (P/O PL 7.70 Item
19)
17 Lower safety spring (Not Spared)
18 612W25655 Tray down limit switch screw
19 815K11380 Infill plate assembly
20 962K50461 Tray 5 elevator harness
21 032E29800 Rear elevator tray guide (REP 7.29)
22 032E29790 Front elevator tray guide (REP
7.29)

PL 8.10 Main Covers
2 Not used
3 802E93211 Left hand cover
4 802E93202 Right hand cover (W/O TAG 046,
TAG 047, TAG 148)
848E46340 Right hand cover (P/O PL 10.20
Item 1) (W/TAG 046, TAG 047)
Right hand cover (P/O PL 10.21
Item 1) (WARNING) (W/TAG 148)
5 Filter (Not Spared)
6 Filter cover (Not Spared)
7 826E49310 Thumbscrew
8 Work shelf (P/O PL 8.10 Item 11)
9 Work shelf bracket (P/O PL 8.10
Item 11)
10 848K48881 Front door assembly (35-55 ppm)
848K48893 Front door assembly (REF: PL 8.11
Item 10) (65-90 ppm)
11 Work shelf assembly kit
12 014E67571 Stand off cable holder (NOTE)
NOTE: This part can also be ordered as part of PL 31.14 Item

13

PL 8.11 Front Door Assembly (65-90
ppm) (2 of 3)
1 Internal cover (P/O PL 8.11 Item 10)
2 Grill (P/O PL 8.11 Item 10)
3 Paper path cooling fan 1 (P/O PL
8.11 Item 10)
4 Cooling duct (P/O PL 8.11 Item 10)
5 Foam seal (P/O PL 8.11 Item 10)
6 Paper path cooling fan 2 (P/O PL
8.11 Item 10)
7 Harness (P/O PL 8.11 Item 10)
8 Front door (P/O PL 8.11 Item 10)
9 Logo badge (P/O PL 8.11 Item 10)
10 848K48893 Front door assembly
11 Door hinge pin (P/O PL 8.11 Item 10)

PL 8.15 Registration Transport (35-55
ppm)
1 059K60041 Registration transport assembly
(REP 8.4, ADJ 8.1)
2 Retainer bracket (Not Spared)
3 130E11430 Wait sensor (Q08-100),
Registration sensor (Q08-150)
(NOTE 2) (REP 8.6)
4 Registration transport guide (P/O
PL 8.15 Item 1)
5 059K52341 Registration nip assembly
6 028E16630 Snap on washer (M6)
7 Registration clutch (CL08-070) (P/
O PL 31.12 Item 13) (REP 8.5, ADJ
8.1, ADJ 4.1)
8 013E36980 Bearing
9 806E18030 Drive roll assembly (REP 8.26)
10 Jam clearance knob (P/O PL 8.15
Item 1)
11 Gear (26T) (P/O PL 8.15 Item 1)
12 Spring arm (P/O PL 8.15 Item 1)
14 Gear (28T) (P/O PL 8.15 Item 1)
15 Ring pitch (P/O PL 8.15 Item 1)
16 Black nylon washer (P/O PL 8.15
Item 1)
17 Gear (22G/28T) (P/O PL 8.15 Item
1) (ADJ 4.1)
18 Gear (23T) (P/O PL 8.15 Item 1)
(ADJ 4.1)
1)
20 Drive belt (P/O PL 8.15 Item 1)
(REP 8.27)
21 Spring arm pin (P/O PL 8.15 Item 1)
22 Lower bias guide (P/O PL 8.15 Item
1)
23 835E05350 Bias contact (NOTE 1)
24 Clutch cover (P/O PL 31.12 Item
13)
25 Drive shaft (P/O PL 8.15 Item 26)
26 604K55571 Drive roll repair kit (W/TAG 051)
NOTE: 1. This is a HFSI. Refer to GP 17 and reset the bias

foam count to zero in the feature screen.
NOTE: 2. Sensor reference Q08-110 may also be seen when

the tray 5 is present.

PL 8.17 Registration Transport (65-90
ppm)
1 059K60051 Registration transport assembly
(REP 8.4, ADJ 8.1)
2 Retainer bracket (Not Spared)
3 130E11610 Registration sensor (Q08-150)
(REP 8.15)
4 Registration transport guide (P/O
PL 8.17 Item 1)
5 059K52341 Registration nip assembly
7 Registration clutch (CL08-070) (P/
O PL 31.12 Item 13) (REP 8.5, ADJ
8.1, ADJ 4.1)
8 013E36980 Bearing
9 806E18030 Drive roll assembly (REP 8.26)
10 Jam clearance knob (P/O PL 8.17
Item 1)
11 Gear (26T) (P/O PL 8.17 Item 1)
12 Spring arm (P/O PL 8.17 Item 1)
14 Gear (28T) (P/O PL 8.17 Item 1)
15 Ring pitch (P/O PL 8.17 Item 1)
16 Black nylon washer (P/O PL 8.17
Item 1)
1) (ADJ 4.1)
18 Gear (23T) (P/O PL 8.17 Item 1)
(ADJ 4.1)
1)
(REP 8.27)
21 Spring arm pin (P/O PL 8.17 Item 1)
22 Lower bias guide (P/O PL 8.17 Item
1)
23 835E05350 Bias contact (NOTE)
24 Clutch cover (P/O PL 31.12 Item
13)
25 Registration sensor bracket (Not
Spared)
26 Drive shaft (P/O PL 8.17 Item 27)
NOTE: This is a HFSI. Refer to GP 17 and reset the bias

foam count to zero in the feature screen.

PL 8.20 Duplex Transport (65-90 ppm)
1 059K64151 Duplex transport (REP 8.7)
2 Drive belt (76T) (P/O PL 8.20 Item
1) (REP 8.8)
1) (REP 8.8)
4 130E11610 Duplex sensor (Q08-160) (See
NOTE) (REP 8.32)
5 003K20760 Jam clearance latch
7 Nip roll shaft (P/O PL 8.20 Item 1)
8 127K62340 Duplex motor (MOT08-060) (REP
8.8)
9 960K32880 Duplex motor driver PWB (REP
8.8)
10 Drive pulley (P/O PL 8.20 Item 1)
12 Duplex duct (P/O PL 8.20 Item 1)
13 Duplex nip roll shaft (P/O PL 8.20
Item 1)
14 059K49400 Nip roll assembly
16 Duplex drive roll shaft (P/O PL 8.20
Item 17) (W/O TAG 051)
Duplex drive roll shaft (P/O PL 8.20
Item 17) (W/TAG 051)
NOTE: HFSI. To reset the HFSI count, refer to GP 17.

PL 8.22 Duplex Transport (35-55 ppm)
1 059K59433 Duplex transport (REP 8.7)
1) (REP 8.8)
1) (REP 8.8)
4 130E12070 Duplex sensor (Q08-160) (NOTE)
(REP 8.32)
5 003K20760 Jam clearance latch
7 Nip roll shaft (P/O PL 8.22 Item 1)
8 127K53190 Duplex motor (MOT08-060) (REP
8.8)
9 960K52720 Duplex motor driver PWB (REP
8.8)
10 Drive pulley (P/O PL 8.22 Item 1)
12 Duplex nip roll shaft (P/O PL 8.22
Item 1)
13 059K49400 Nip roll assembly
15 Duplex drive roll shaft (P/O PL 8.22
Item 16) (W/O TAG 051)

PL 8.25 Tray 1 and 2 Paper Feed
Assembly (1 of 2)
1 Tray 1 or 2 paper feed assembly (P/
O PL 8.26 Item 1)
2 023E31270 Transport drive belt (REP 8.12)
3 020E54150 Pulley
4 020E48680 Pulley idler
5 127K61842 Transport roll drives motor
(MOT08-025)
6 013E37480 Rear transport roll bearing (REP
8.16)
7 013E37490 Front transport roll bearing (REP
8.16)
8 059K70070 Transport roll (NOTE)
9 962K64030 Power harness
10 962K64020 Signal harness
11 120E36130 Cable holder
12 962K64040 Connection harness

PL 8.26 Tray 1 and 2 Paper Feed
Assembly (2 of 2)
1 604K61761 Tray 1 or 2 paper feed assembly
(REP 8.1)
2 005K12242 Friction clutch (REP 8.39)
3 059K69800 Roll assembly (3 rolls) (See NOTE)
(REP 8.35)
4 Retard roll (P/O PL 8.26 Item 3)
5 Feed Nudger roll assembly (P/O PL
8.26 Item 3)
6 127K61850 Feed/elevator motor (MOT08-010,
MOT08-020)
7 130E12770 Tray empty sensor (Q07-331, Q07-
342)
8 130E12790 Tray 1 stack height sensor (Q07-
336)/ Tray 2 stack height sensor
(Q07-337)
9 Guide (P/O PL 8.26 Item 1)
10 014E67650 Shim sensor
11 809E84180 Retard roll gate spring
12 Retard roll gate (P/O PL 8.26 Item
1)
13 Clutch coupling (P/O PL 8.26 Item
1) (REP 8.39)

PL 8.30 Tray 3 Paper Feed Assembly (W/
O TAG 151)
1. 604K53950 Tray 3 and 4 paper feed assembly kit
(REP 8.2, REP 8.3)
2. Tray 3 paper feeder (P/O PL 8.30 Item
1) (See NOTE 2)
3. Spacer tool (P/O PL 8.30 Item 1)
4. Feeder spacer (Tray 3 only) (P/O PL
8.30 Item 1)
5. Tray 3 feeder label (P/O PL 8.30 Item 1)
6. 059K43730 Feed roll assembly (W/O TAG 110)
Feed roll assembly (P/O PL 8.30 Item
24) (W/TAG 110)
7. 127K42880 Tray 3 and 4 transport motor (MOT08-
045) (P/O PL 8.30 Item 23) (REP 8.10)
127K53380 Tray 3 and 4 transport motor (MOT08-
045) (Alternative) (REP 8.10)
8. 807E06210 Tray 3 and 4 transport drive gear (Non-
conductive) (35-55 ppm)
Tray 3 and 4 transport drive gear (Con-
ductive) (P/O PL 8.30 Item 23) (65-90
ppm) (REP 8.11)
9. Transport drive belt (P/O PL 8.30 Item 16)
10. Flange (P/O PL 8.30 Item 16)
11. Pulley (P/O PL 8.30 Item 16)
12. Spring (P/O PL 8.30 Item 16)
13. Drive coupling (P/O PL 8.30 Item 16)
14. Tray 3 and 4 transport motor bracket
(Not Spared)
15. 130E12510 Tray 3 feed sensor (Q08-103) (See
NOTE 1) (REP 8.28)
16. 005E21801 Drive coupling assembly
17. 809E94510 Ground plate (35-55 ppm)
18. 059K58620 Tray 3 and 4 transport roll (35-55 ppm)
(NOTE 2) (REP 8.31, ADJ 4.1)
059K50120 Tray 3 and 4 transport roll (65-90 ppm)
(REP 8.31, ADJ 4.1)
19. 018K01390 Tray 3 stack height sensor actuator
(See NOTE 3)
20. 604K48620 Tray 3 and 4 multifeed roll fix kit (rough
feed rolls) (W/TAG 110)
21. 130E20360 Stack height sensor (REP 7.7)
22. Paper guide (Not Spared)
23. 127K56490 Tray 3 and 4 transport motor and drive
gear kit (Conductive) (65-90 ppm) (REP
8.11)
24. 604K95360 Tray 3 and 4 multifeed rolls spare kit
(rough tread rolls) (W/TAG 110)
25. Feed roll shaft assembly (P/O PL 8.30
Item 20)
26. Paper stack deflector (P/O PL 8.30 Item
20)
NOTE: . 1. For the tray 3 feed sensor actuator, refer to PL 7.15
Item 9.
NOTE: . 2. HFSI. To reset the HFSI count, refer to GP 17.
NOTE: . 3. Also supplied as part of a kit PL 8.30 Item 1.

PL 8.31 Tray 4 Paper Feed Assembly
(W/O TAG 151)
1 604K53950 Tray 3 and 4 paper feed assembly
kit (REP 8.2, REP 8.3)
2 059K43730 Feed roll assembly (NOTE) (W/O
TAG 110)
Feed roll assembly (P/O PL 8.31
3 Mounting bracket (Not Spared)
4 Tray 3 and 4 paper feeder (P/O PL
8.31 Item 1)
7 Idler roll (P/O PL 8.31 Item 11)
9 Tray 4 feed sensor bracket (P/O PL
8.31 Item 12)
10 604K48620 Tray 3 and 4 multifeed roll fix kit
(rough tread rolls) (W/TAG 110)
11 006K29490 Idler shaft assembly
12 130K75380 Tray 4 feed sensor assembly (Q08-
104)
13 130E20360 Stack height sensor
14 604K95360 Tray 3 and 4 multifeed rolls spare
kit (rough tread rolls) (W/TAG 110)
15 Feed roll shaft assembly (P/O PL
8.31 Item 10)
16 Paper stack deflector (P/O PL 8.31
Item 10)

(W/TAG 151)
1 Tray 3 paper feed assembly (P/O PL
31.12 Item 20) (REP 8.40)
2 007K20321 Gear (NOTE 2) (REP 8.47)
4 Tray 3 and 4 transport roll (P/O PL
31.12 Item 19) (See NOTE) (REP
8.47)
5 Sensor mounting (P/O PL 8.32 Item 1)
(REP 8.49, REP 8.50)
6 130E11610 Tray 3 empty sensor (Q07-333)(REP
8.49)/Tray 3 feed sensor (Q08-
103)(REP 8.50)/Tray 3 exit sensor
(Q08-109) (REP 8.45) (NOTE 3)
7 Tray 3 stack height sensor (Q07-383)
(P/O PL 31.13 Item 21) (REP 8.48)
8 110E21540 Tray 3 over elevate switch
9 Tray 3 paper guide (P/O PL 8.32 Item
1) (REP 8.55)
10 Tray 3 feed motor (MOT08-030) (P/O
PL 8.32 Item 1)
11 Feed roll assembly (P/O PL 31.13 Item
14) (See NOTE) (REP 8.54)
12 Nudger roll (P/O PL 8.32 Item 11)
(REP 8.54, ADJ 8.4)
13 Feed frame assembly (P/O PL 8.32
Item 1) (REP 8.40)
14 Earth cable (P/O PL 8.32 Item 1)
15 Support bracket (P/O PL 8.32 Item 1)
(REP 8.40)
16 Tray 3 exit sensor bracket (P/O PL
31.14 Item 17) (REP 8.45)
17 Retard roll (P/O PL 31.13 Item 14) (W/
TAG 151) (REP 8.54, ADJ 8.3)
18 Shim (P/O PL 31.13 Item 21)
19 Nudger roll weight (P/O PL 8.32 Item
11)
20 Gull wing cover (P/O PL 31.14 Item
18)
21 121E27552 Feed clutch
NOTE: 2. Also supplied as part of the transport motor and drives

kit, PL 8.36 Item 16.
NOTE: 3. Also supplied as part of Tray 3 sensor spares kit PL

31.14 Item 17.

(W/TAG 151)
1 Tray 4 paper feed assembly (P/O
PL 31.12 Item 20) (REP 8.41)
2 059K85140 Idler roll assembly (metal shaft)
(REP 8.47)
Idler roll assembly (plastic shaft)
3 130E11610 Tray 4 empty sensor (Q07-
334)(REP 8.52) / Tray 4 feed
sensor (Q08-104)(REP 8.53) / HCF
exit sensor (Q08-108) (NOTE 2)
4 HCF exit sensor bracket (P/O PL
31.12 Item 6)
5 Spring (Not Spared)
6 Tray 4 stack height sensor (Q07-
384) (P/O PL 31.13 Item 21) (REP
8.51)
7 110E21540 Tray 4 over elevate switch
8 Tray 4 feed motor (Q08-040) (P/O
PL 8.33 Item 1)
9 Feed roll assembly (P/O PL 31.13
Item 14) (See NOTE) (REP 8.54)
10 Nudger roll (P/O PL 8.33 Item 9)
(REP 8.54, ADJ 8.4)
Item 1) (REP 8.56)
12 Sensor mounting (P/O PL 8.33 Item
1) (REP 8.53)
13 Earth cable (P/O PL 8.33 Item 1)
14 Feed frame assembly (P/O PL 8.33
Item 1) (REP 8.40)
(REP 8.54, ADJ 8.3)
16 Shim (P/O PL 31.13 Item 21)
17 Nudger roll weight (P/O PL 8.33
Item 9)
18 Gull wing cover (P/O PL 31.14 Item
18)
19 121E27552 Feed clutch
NOTE: 2. The HCF exit sensor is also part of PL 31.12 Item

6.

PL 8.35 Tray 3 Transport Assembly (W/
O TAG 151)
1 848K42530 Jam clearance door
2 059K30402 Takeaway roll assembly (35-55 ppm)
(REP 8.29, ADJ 4.1)
059K50101 Takeaway roll assembly (65-90 ppm)
(REP 8.29, ADJ 4.1)
3 022E26620 Transport roll bearing
4 Flange (P/O PL 8.35 Item 15)
6 023E24440 Drive belt
7 Drive coupling (P/O PL 8.30 Item 16)
8 022E26630 Transport roll (REP 8.30)
10 Spring (P/O PL 8.35 Item 15) (REP
8.30)
11 059K50110 Transport roll assembly (REP 8.30,
ADJ 4.1)
12 022E26640 Idler roll
13 Spring plate (P/O PL 8.35 Item 15)
15 059K43830 Tray 3 transport assembly (REP 8.13)
NOTE: Refer to REP 8.13 for the tray 3 transport assembly.

PL 8.36 Tray 3 Transport Assembly
(W/TAG 151)
1 Jam clearance door (P/O PL 8.36
Item 11)
2 Takeaway roll assembly (P/O PL
31.12 Item 16) (REP 8.46)
3 Takeaway roll bearing (P/O PL
31.12 Item 16) (REP 8.46)
4 Clutch drive (P/O PL 8.36 Item 16)
(REP 8.57)
5 Pulley (P/O PL 8.36 Item 16) (REP
8.57)
(REP 8.57)
7 Drive coupling (P/O PL 31.12 Item
16) (REP 8.46)
8 859K04280 Idler roll assembly (metal shaft)
(REP 8.46)
Idler roll assembly (plastic shaft)
11 038K24380 Tray 3 transport assembly (REP
8.44)
12 Transport gear pulley (P/O PL 8.36
Item 16) (NOTE) (REP 8.43)
13 HCF transport motor (MOT08-045)
(P/O PL 8.36 Item 16) (REP 8.42)
14 Spring (P/O PL 8.36 Item 16) (REP
8.57)
15 Pulley flange (P/O PL 8.36 Item 16)
(REP 8.57)
16 604K97740 Transport motor and drives kit
17 Tray 3 transport brace (Not Spared)
NOTE: Also part of PL 31.14 Item 19.

PL 8.40 Tray 5 Feed Assembly (1 of 3)
1 Upper feeder assembly (REF: PL
8.45 Item 1) (REP 8.38)
2 127K56453 Tray 5 transport motor (MOT08-
046) (REP 8.37)
3 127K61980 Feed motor (MOT08-117) (REP
8.36)
4 Bearing (Not Spared)
6 Not used
7 423W09050 Drive belt (REP 8.33)
8 Upper limit actuator spring (Not
Spared)
9 Upper limit actuator (Not Spared)
10 Belt tensioner (Not Spared)
11 Belt tensioner spring (Not Spared)
12 Not used
13 125E00430 ESD brush
14 Transport motor harness (Not
Spared)
15 Tray 5 upper feeder assembly
harness (Not Spared)
16 962K50475 Elevator motor harness
17 962K63351 IOT to tray 5 harness
18 Not used
19 Feed/elevator motor harness (Not
Spared)
20 Elevator harness shield (Not
Spared)
21 007K14401 Gear 30T bearing

1 059K69991 Upper feed assembly (REP 8.38)
2 Upper feed assembly base (P/O PL
8.45 Item 1)
3 One way gear (P/O PL 8.45 Item
20) (W/TAG P-002)
One way gear (Not Spared) (W/O
TAG P-002)
4 One way coupling (P/O PL 8.45
Item 20)
5 Take away idler roller (P/O PL
31.13 Item 4)
6 130E11610 Tray 5 empty (Q07-401) /feed
sensor (Q08-105) (REP 7.13, REP
8.25)
7 130E20360 Stack height sensor (Q07-402)
(REP 7.14)
10 Nudger roll (P/O PL 8.45 Item 20,
22) (W/TAG P-002)
Nudger roll (Not Spared) (W/O TAG
P-002)
11 Upper feed assembly top cover (P/
O PL 8.45 Item 1)
12 Feed roll (P/O PL 8.45 Item 20, PL
8.45 Item 22) (W/TAG P-002)
Feed roll (Not Spared) (W/O TAG
P-002)
13 Clutch (P/O PL 8.45 Item 20)
14 Gear (38T) (P/O PL 8.45 Item 1)
15 Roller belt (P/O PL 8.45 Item 1)
17 Torsion chute spring (P/O PL 8.45
Item 1)
18 Housing spring (P/O PL 8.45 Item
1)
19 Torsion nudger spring (P/O PL 8.45
Item 1)
20 604K84480 Feed roll retrofit kit (See NOTES 1
& 3) (W/TAG P-002)
21 Not used
22 604K55480 Feed roll kit (Pack of 3) (See
NOTES 2 & 3) (W/TAG P-002)
NOTE: 1. Install kit to improve performance and reduce mis-

feed faults.
NOTE: 2. Replaces the rolls installed with the feed roll retrofit
kit, PL 8.45 Item 20.

1 059K84700 Lower feed assembly (REP 8.38)
(W/TAG P-002)
Retard roll (Not Spared) (W/O TAG
P-002)
3 Actuator pivot shaft (P/O PL 8.47
Item 1)
4 One way pulley clutch (P/O PL 8.47
Item 1)
5 Take away roller (P/O PL 31.13
Item 4) (REP 8.38)
7 Clutch (P/O PL 8.45 Item 20) (W/
TAG P-002)
005E29040 Clutch (W/O TAG P-002)
8 Torsion retard spring (P/O PL 8.47
Item 1)
9 Retard roller shaft (P/O PL 8.47
Item 1)
10 Lower feed assembly base (P/O PL
8.47 Item 1)
11 Clutch coupling (P/O PL 8.45 Item
20) (W/TAG P-002)
Clutch coupling (Not Spared) (W/O
TAG P-002)
12 Actuator pivot shaft bearing (P/O
PL 8.47 Item 1)
13 815E56671 Retard shield (ADJ 7.6)

PL 9.10 Waste Toner Bottle Assembly
1 008R12896 Waste toner bottle
2 130K74702 Waste toner full sensor (Q09-350)
(REP 9.4)
3 802E93283 Waste toner door (REP 9.1)
4 003E77450 Strap (NOTE)
5 803E03180 Hinge block
6 Waste toner door switch (S09-380)
(REF: PL 4.10 Item 8, PL 4.15 Item
8)
7 Sensor cover (Not Spared)
8 848E96690 Toner cover
NOTE: Refer to REP 9.1 for the waste toner bottle assembly.

PL 9.15 Developer Assembly (65-90
ppm)
1. Toner dispense module (P/O PL
9.15 Item 18) (REP 9.5)
2. Developer module (P/O PL 9.15
Item 26) (REP 9.2)
3. Retaining bracket (P/O PL 9.15
Item 1)
4. Toner cartridge (P/O PL 26.11 Item
2) (See NOTE 1)
5. Low toner sensor (Q09-310) (P/O
PL 9.15 Item 13)
6. 962K25641 Registration/Developer bias
harness
7. Toner concentration sensor (Q09-
360) (P/O PL 9.15 Item 2)
8. Toner cartridge latch (P/O PL 9.15
Item 24)
9. Retaining plate (P/O PL 9.15 Item
2)
10. Speed nut (P/O PL 9.15 Item 2)
11. Sleeve (P/O PL 9.15 Item 24)
12. Not used
13. 604K16890 Out of toner sensor kit
14. Push on fastener (P/O PL 9.15 Item
24)
15. Spring (P/O PL 9.15 Item 24)
16. Main drive gear (P/O PL 9.15 Item
23) (See NOTE 2)
17. Not used
18. Toner dispense module kit (REF:
PL 31.12 Item 21)
19. 604K24570 Trickle outlet shutter kit
20. Shutter assembly (P/O PL 9.15
Item 19)
21. Shutter spring (P/O PL 9.15 Item
19)
22. Push on fastener (P/O PL 9.15 Item
19)
23. 604K24930 Developer/Drives interface kit (See
NOTES 2 & 3)
24. 604K18510 Developer latch repair kit
25. Developer material (P/O PL 9.15
Item 26, PL 9.15 Item 27)
26. 604K41371 Developer spares kit (includes
developer)
27. 604K35340 Developer charge kit
NOTE: 1. A waste toner bottle, PL 9.10 Item 1 is supplied
with the toner cartridges.
NOTE: 2. The main drive gear PL 9.15 Item 16 and
developer drive gear/pulley PL 4.12 Item 17, must always be
replaced as a pair.

PL 9.17 Developer Assembly (35-55
ppm)
1 Toner dispense module (P/O PL
9.17 Item 27) (REP 9.5)
2 Developer module (P/O PL 9.17
Item 26) (See NOTE 1) (REP 9.2)
3 Retaining bracket (Not Spared)
4 Toner cartridge (P/O PL 26.11 Item
3) (See NOTE 2)
5 Low toner sensor (Q09-310) (P/O
PL 9.17 Item 13)
6 Registration/Developer bias
harness (Not Spared)
7 Toner concentration sensor (Q09-
360) (P/O PL 9.17 Item 2)
8 Not used
9 Not used
10 Not used
11 Stepped washer (Not Spared)
12 Washer (Not Spared)
13 604K16890 Out of toner sensor kit
14 Push on fastener (P/O PL 9.17 Item
23)
16 Sleeve (P/O PL 9.17 Item 23)
17 Toner cartridge latch (P/O PL 9.17
Item 23)
18 Not used
19 604K24570 Trickle outlet shutter kit
20 Shutter assembly (P/O PL 9.17
Item 19)
21 Shutter spring (P/O PL 9.17 Item
19)
22 Push on fastener (P/O PL 9.17 Item
19)
23 604K30560 Developer latch repair kit
24 Developer material (P/O PL 9.17
25 604K35340 Developer charge kit
26 604K41360 Developer spares kit (includes
developer)
27 604K41610 Toner dispense module kit
NOTE: 1. To remove and replenish the developer material,

refer to the developer charge kit, PL 9.17 Item 25.
NOTE: 2. A waste toner bottle, PL 9.10 Item 1 is supplied

with the toner cartridges.

PL 9.20 Xerographic Module and
Short Paper Path Assembly (40-90
ppm)
1 122K02660 Erase lamp (REP 9.9)
2 Xerographic module (see below for
variants, see also NOTE 1, NOTE 2
and NOTE 3)
113R00672 Metered (USSG/XCL/XE)
113R00673 Sold (XE)
113R00674 Sold (USSG/XCL)
3 Short paper path assembly (REF:
PL 10.25 Item 1) (NOTE 1)
4 130E10510 Relative humidity sensor (Q09-
365)/Ambient temperature sensor
(Q09-375)
5 960K40570 Developer temperature sensor
(Q09-370)
6 055E54960 Erase lamp support
7 Xerographic module latch (P/O PL
9.20 Item 17) (REP 9.6)
8 504K12320 Transfer/Detack corotron (NOTE 1)
(ADJ 9.1)
9 113K03330 Transfer/Detack harness
10 802E87941 Pivot plate
11 Latch spring (P/O PL 9.20 Item 17)
12 Latch pin (P/O PL 9.20 Item 17)
13 Latch plate (Not Spared)
14 031E11102 Developer paddle (REP 9.7)
15 809E69220 Spring
16 Curly clip (Not Spared)
17 604K41120 Developer latch pin kit (REP 9.6)
18 Bracket stabiliser (P/O PL 9.20 Item
19)
19 604K53940 XRU skids kit
20 Stripper finger assembly (P/O PL
9.20 Item 19)
NOTE: 1. A transfer/detack corotron PL 9.20 Item 8 is

supplied with the xerographic module.
NOTE: 2. For the charge scorotron and the charge scorotron

grid harnesses, refer to PL 4.17 or PL 4.12.

PL 9.22 Xerographic Module and
Short Paper Path Assembly (35 ppm)
1 122K02650 Erase Lamp (REP 9.9)
2 Xerographic module (see below for
variants) (NOTE 3)
113R00608 Metered (USSG/XCL/XE)
113R00607 Sold (XE)
113R00610 Sold (USSG/XCL)
3 Short paper path assembly (REF:
PL 10.25 Item 1)
4 130E10510 Relative humidity sensor (Q09-
365)/Ambient temperature sensor
(Q09-375)
5 960K40570 Temperature sensor (Q09-370)
6 055E54960 Erase lamp support
7 Xerographic module latch (P/O PL
9.22 Item 18) (REP 9.6)
8 504K12310 Transfer/Detack corotron (NOTE 1)
(ADJ 9.1)
9 113K03330 Transfer/Detack harness (REP 9.8)
10 Not used
11 Latch spring (P/O PL 9.22 Item 18)
12 Latch pin (P/O PL 9.22 Item 18)
13 Latch plate (Not Spared)
14 031E11102 Developer paddle (REP 9.7)
15 809E69220 Spring
16 802E87941 Pivot plate
17 Curly clip (Not Spared)
18 604K41120 Developer latch pin kit
19 Bracket stabiliser (P/O PL 9.22 Item
21)
20 Stripper finger assembly (P/O PL
9.22 Item 21)
21 604K53940 XRU skids kit
NOTE: 1. A transfer/detack corotron PL 9.22 Item 8 is

supplied with the xerographic module
NOTE: 2. For the charge scorotron and charge scoroton grid
harnesses, refer to PL 4.17.
NOTE: 3. If a new Xerographic module has been installed,

perform ADJ 9.2.

PL 9.25 Ozone Fan and Photoreceptor
Fan
1 127K42790 Ozone fan (REP 9.3)
2 054E33051 Ozone duct
3 053K04960 Ozone filter
4 Magnet (P/O PL 9.25 Item 2)
5 Photoreceptor duct (P/O PL 9.25
Item 6)
6 127K53200 Photoreceptor fan assembly
7 Fan (P/O PL 9.25 Item 6)
8 054E33001 Lower duct

PL 10.8 Fuser Module Assembly (35-
55 ppm)
1 109R00751 Fuser module (XE) (NOTE 1)
109R00752 Fuser module (USSG/XCL) (NOTE
1)
2 Web drive dog (Not Spared)
4 604K48340 Fuser stripper finger kit
5 Fuser latch (P/O PL 10.8 Item 10)
(REP 10.10)
6 Fuser latch pin (P/O PL 10.8 Item
10)
8 Latch stop (P/O PL 10.8 Item 10)
10 604K35371 Fuser latch pin kit
11 110E20190 Fuser exit switch (S10-100) (REP
10.16)
12 Fuser upper exit guide (P/O PL
10.8 Item 1)
13 Fuser top cover (P/O PL 10.8 Item
1)
14 Lower input guide (Not Spared)
15 Lamp (P/O PL 10.8 Item 1)
NOTE: 1. An ozone filter, PL 9.25 Item 3, is supplied with the
fuser module.
NOTE: 2. For the fuser web motor, fuser connector assembly

and fuser CRUM connector, refer to PL 4.15.

PL 10.10 Fuser Module Assembly (65-
90 ppm)
1 109R00772 Fuser module (XE) (NOTE 1)
109R00773 Fuser module (USSG/XCL) (NOTE
1)
2 Web drive dog (Not Spared)
4 604K48340 Fuser stripper finger kit
5 Fuser latch (P/O PL 10.10 Item 10)
(REP 10.10)
6 Fuser latch pin (P/O PL 10.10 Item
10)
8 Latch stop (P/O PL 10.10 Item 10)
10 604K35371 Fuser latch pin kit
11 110K20910 Fuser exit switch (S10-100) (REP
10.16)
12 Fuser upper exit guide (P/O PL
10.10 Item 1)
13 Fuser top cover (P/O PL 10.10 Item
1)
14 Lower input guide (Not Spared)
15 Lamp (P/O PL 10.10 Item 1)
NOTE: 1. An ozone filter, PL 9.25 Item 3 is supplied with the
fuser module.
NOTE: 2. For the fuser web motor, fuser connector assembly

and fuser CRUM connector, refer to PL 4.10.

PL 10.11 Inverter Assembly (1 of 4)
1. 011E25300 Link arm
2. Shaft actuator (P/O PL 10.11 Item
25) (REP 10.9)
3. LH Spring (P/O PL 10.11 Item 25)
4. 006K30320 Nip split shaft assembly (NOTE)
(REP 10.8)
5. RH Spring (P/O PL 10.11 Item 25)
6. 121K44380 Inverter nip solenoid (SOL10-050)
(REP 10.5)
7. 059E05230 Single exit nip roll (REP 10.6)
8. 059K49900 Double exit nip roll (REP 10.6)
9. Not used
10. Nip roll guide (P/O PL 10.11 Item 23)
(REP 10.6)
11. 127K53210 Inverter motor (MOT10-040) (35-55
ppm) (REP 10.3)
127K53540 Inverter motor (MOT10-040) (65-90
ppm) (REP 10.3)
12. Inverter output assembly (P/O PL
10.11 Item 23)
13. 130E12080 IOT Exit sensor (Q10-120) (REP
10.17)
14. 121K44390 Inverter path solenoid (SOL10-045)
(REP 10.4)
15. Not used
16. Not used
17. Inverter nip solenoid bracket (P/O PL
10.11 Item 25)
18. Solenoid link (P/O PL 10.11 Item 23)
19. Bearing (P/O PL 10.11 Item 25)
20. Thermistor assembly (Not Spared)
(65-90 ppm) (W/O TAG 120)
21. Inverter locator (Not Spared) (W/O
TAG 046, TAG 047)
22. 960K32891 Inverter motor driver PWB (65-90
ppm)
960K41881 Inverter motor driver PWB (35-
55ppm)
23. Inverter assembly (See below for
variants)
Inverter assembly (P/O PL 31.11
Item 14) (35-55 ppm) (W/O TAG 046)
(REP 10.2)
Inverter assembly (65-90 ppm) (W/O
TAG 047) (REP 10.2)
Inverter decurler assembly (REF: PL
10.20 Item 5) (35-55 ppm) (W/TAG
046) (REP 10.2)
10.20 Item 5) (65-90 ppm) (W/TAG
047) (REP 10.2)
10.21 Item 5) (W/TAG 148) (REP
10.2)
24. Output guide (P/O PL 10.11 Item 25)
(REP 10.18)
25. Output guide assembly (Not Spared)

1. Inverter output assembly (P/O PL
10.11 Item 23)
2. Post fuser gear (20T) (REF: PL
10.15 Item 7)
3. 013E36980 Bearing
4. 007K19670 Dog drive assembly (REF: PL 10.15
Item 6)
5. Idler gear (20T) (REF: PL 10.15 Item
4)
6. Tri-roll knob (REF: PL 10.15 Item 12)
7. Inverter gate (Not Spared) (REP
10.11)
8. Tri-roll shaft assembly (Not Spared)
(REP 10.12)
9. 006K29971 Post fuser exit roller (See NOTE 2)
(W/O TAG 004)
Post fuser exit roller (P/O PL 10.12
10. Tri-roll guide (P/O PL 10.11 Item 23)
11. Front gravity finger (P/O PL 10.11
Item 23)
12. Gravity gate finger (P/O PL 10.11
Item 23)
13. Rear gravity gate finger (P/O PL
10.11 Item 23) (W/O TAG 005)
Rear gravity gate finger (P/O PL
10.12 Item 25) (W/TAG 005)
14. Upper baffle (P/O PL 10.12 Item 22,
PL 10.12 Item 23)
15. Idler roll (P/O PL 10.12 Item 22, PL
10.12 Item 23)
16. Idler roll shaft (P/O PL 10.12 Item 22,
PL 10.12 Item 23)
17. Spring (P/O PL 10.12 Item 22, PL
10.12 Item 23)
18. Post fuser jam clearance latch (REF:
PL 10.15 Item 11)
19. Inverter sensor (P/O PL 10.12 Item
22) (65-90 ppm) (NOTE)
20. Hinge pin (P/O PL 10.12 Item 22, PL
10.12 Item 23)
21. Torsion spring (P/O PL 10.12 Item
22, PL 10.12 Item 23)
22. 038K17843 Upper baffle assembly (65-90 ppm)
(REP 10.7)
23. Upper baffle assembly (35-55 ppm)
(REF: PL 10.12 Item 22) (See NOTE
1) (REP 10.7)
24. 604K54010 Inverter transparency feed kit (W/
TAG 004)
25. 604K54630 Rear gravity gate finger kit (W/TAG
005)
NOTE: 1. For 35-55 ppm speed machines do not have the
inverter sensor.

1 Inverter assembly duct seal (P/O
PL 10.11 Item 23)
2 Inverter assembly duct (P/O PL
10.11 Item 23)
3 Baffle guide (35-55 ppm) (P/O PL
10.11 Item 23)
4 806E41911 Exit shaft assembly (W/O TAG 046,
TAG 047) (REP 10.14)
Exit shaft assembly (W/TAG 046,
TAG 047) (REP 10.14)
5 013E36980 Bearing
6 Exit gear (REF: PL 10.15 Item 1)
7 Baffle guide (65-90 ppm) (P/O PL
10.11 Item 23)
8 Decurler roll (P/O PL 10.13 Item 9)
(NOTE) (W/TAG 046, TAG 047)
9 604K55120 Decurler soft roll repair kit (NOTE)
(W/TAG 046, TAG 047)
NOTE: The decurler roll is only to be installed on W/TAG 046,
TAG 047 machines.

1 121K44380 Tri roll nip split solenoid (SOL 10-
055) (65-90 ppm)
2 Actuator assembly (Not Spared)
(65-90 ppm)
3 Nip roller (Not Spared)
4 Solenoid ramp (Not Spared) (65-90
ppm)
5 Jam clearance knob (REF: PL
10.15 Item 13)
7 Gear (24T) (REF: PL 10.15 Item 9)
8 Gear assembly (REF: PL 10.15
Item 8)
9 Upper inverter drive shaft (P/O PL
10.14 Item 11) (W/O TAG 051)
10 Lower inverter drive shaft (P/O PL
10.14 Item 11) (W/O TAG 051)

PL 10.15 Inverter Drive Gears and
Jam Clearance Knobs
1 007K13890 Exit gear (20T)
2 807E15800 Idler gear (21T)
3 807E15810 Idler gear (25T)
4 807E15790 Idler gear (20T)
5 807E15780 Idler gear (19T)
6 007K19670 Dog drive assembly
7 807E15770 Post fuser gear (20T)
8 807E15820 Gear assembly
9 807E15850 Gear (24T)
10 807E15840 Gear (21T)
11 003K20990 Post fuser jam clearance latch
12 003E77261 Tri-roll knob
13 003E77271 Jam clearance knob
14 003E77251 Latch cam handle
15 Inverter motor gear (35-55 ppm)
(REF: PL 10.11 Item 11)
Inverter motor gear (65-90 ppm)
(REF: PL 10.11 Item 11)

PL 10.20 Inverter Decurler Assembly
W/TAG 046/047
1 Inverter decurler kit (REF: PL 31.14
Item 1) (65-90 ppm) (W/TAG 047)
(REP 10.2)
604K53914 Inverter decurler kit (35-55 ppm)
(W/TAG 046) (REP 10.2)
2 Retaining ring (P/O PL 10.20 Item
1)
3 Adjuster (P/O PL 10.20 Item 1)
4 Support bracket (P/O PL 10.20 Item
1)
5 604K60872 Inverter decurler assembly (35-
55ppm)
604K60802 Inverter decurler assembly (65-90
ppm)
6 Screw (M4x8) (P/O PL 10.20 Item
1)
7 Shoulder screw (M4x12) (P/O PL
10.20 Item 1)
NOTE: The inverter decurler soft roll repair kit is shown on PL

10.13 Item 9.

PL 10.21 OCT Inverter Decurler
Assembly W/TAG 148
1 604K73492 OCT inverter decurler kit (W/TAG
148) (REP 10.2)
2 Retaining ring (P/O PL 10.21 Item
1)
3 Adjuster (P/O PL 10.21 Item 1)
4 Support bracket (P/O PL 10.21 Item
1)
5 Inverter decurler assembly (P/O PL
10.21 Item 1)
6 Shoulder screw (M4x12) (P/O PL
10.21 Item 1)
7 Rear inverter bush (P/O PL 10.21
Item 1)
8 Tie bar (P/O PL 10.21 Item 1)
9 Right hand cover (P/O item 1)
(WARNING)
Item 1)
11 OCT transport assembly (P/O PL
10.21 Item 1)
12 OCT tray (P/O PL 10.21 Item 1)
13 962K96240 Inverter jumper harness
WARNING
Do not use the W/TAG 148 right hand cover with an
output device other than the OCT Transport assembly.
The right cover will expose moving parts if not used
correctly. Moving parts can cause injury

PL 10.25 Short Paper Path Assembly
1 Short paper path assembly (without
fan) (P/O PL 31.11 Item 4) (W/TAG
114) (REP 10.1)
Short paper path assembly (with
fan) (P/O PL 31.11 Item 4) (W/O
TAG 114) (REP 10.1)
2 Corotron carrier (P/O PL 10.25 Item
1)
3 Gear (P/O PL 10.25 Item 1) (16T)
5 Gear (P/O PL 10.25 Item 1) (32T)
6 Transfer/Detack harness (REF: PL
9.20 Item 9)
7 Intermediate drive assembly (P/O
PL 10.25 Item 1)
8 807E15940 Gear/Pulley (28T/25G)
9 Gear/Pulley (P/O PL 10.25 Item 1)
(16T/30G)
10 Intermediate drive belt (P/O PL
10.25 Item 1) (REP 10.15)
12 Ozone duct (P/O PL 10.25 Item 1)
13 Push rod (P/O PL 10.25 Item 1)
14 Ground harness (P/O PL 10.25
Item 1)
16 Roll assembly (P/O PL 10.25 Item
11)
17 Corotron carrier latch (P/O PL
10.25 Item 20)
19 Spring clip (P/O PL 10.25 Item 20)
20 604K41110 4B latch kit
21 Not Used
22 Carrier seal (P/O PL 31.10 Item 6)
NOTE: 1. For the registration and halo bias contact, refer to

PL 8.15 Item 23.

PL 11.2 2K LCSS Covers
1 802K48330 Exit cover (W/O TAG F-012)
2 848K06190 Top cover (W/O TAG F-012) (REP
11.1-110)
3 Entry guide cover (REF: PL 11.24
Item 5) (REP 11.15-110)
4 Front door cover assembly (P/O PL
11.2 Item 14) (W/O TAG F-012)
(REP 11.1-110)
5 017K03750 Fixed castor
6 017K04520 Adjustable castor
7 Output cover (Not Spared)
8 802K48320 Lower right hand cover
9 050K67380 Bin 0 (W/O TAG F-012)
10 050K68490 Bin 1 (W/O TAG F-012, TAG F-013)
(ADJ 11.1-110)
11 848K06180 Rear cover assembly (W/O TAG F-
012) (REP 11.1-110)
12 Upper right hand cover (Not
Spared)
13 019K13380 Bin 1 alignment clip
14 2K LCSS front door cover assembly
kit (REF: PL 31.12 Item 10) (W/O
TAG F-012)
15 Hole punch assembly cover (Not
Spared)
16 604K48150 Bin 1 tray kit (improved stacking)
(W/TAG F-013)
NOTE: Refer to ADJ 11.2-110 to align the 2K LCSS to the

machine.

PL 11.4 2K LCSS Docking Latch
1 Sensor cover (Not Spared)
2 110K13980 Docking interlock switch (S11-300)
3 003K20401 Link bracket assembly
4 Stopper (Not Spared)
5 Docking latch (P/O PL 11.4 Item 8)
6 Not used
7 120K02590 Docking actuator
8 003K20410 Docking latch assembly (REP
11.16-110)

PL 11.6 2K LCSS Hole Punch Unit
1 130E10360 Punch Head Home Sensor (Q11-
350), Punch Head Present Sensor
(Q11-351) (REP 11.7-110)
2 127K55900 Hole Punch Motor Assembly
(MOT11-042) (REP 11.7-110)
3 Hole punch unit (see below for
variants) (REP 11.7-110, ADJ 11.3-
110)
180K00280 2 Hole (XE)
180K00320 2 Hole Legal
180K00200 3 Hole (USSG/XCL)
180K00310 4 Hole (Sweden)
180K00300 4 Hole (XE)
4 093E03820 Chad Bin
5 Thumb Screw (Not Spared)
7 130E10380 Punch Sensor (Q11-110), Chad Bin
Full Sensor (Q11-348) (REP 11.7-
110)
8 Sensor Bracket (Not Spared)
9 LCSS Hole Punch Repair Kit (REF:
PL 31.14 Item 7) (W/TAG F-006)
(ADJ 11.3-110)
604K53830 LCSS Hole Punch Repair Kit (W/
TAG F-014) (ADJ 11.3-110)
10 Bracket (P/O PL 11.6 Item 9) (W/
TAG F-014)
Bracket (P/O PL 11.6 Item 9) (W/
TAG F-006)
11 Punch Drive Gear (P/O PL 11.6
Item 9) (W/TAG F-006)
Punch Drive Gear (P/O PL 11.6
Item 9) (W/TAG F-014)
12 Punch Cam (P/O PL 11.6 Item 3)
(W/O TAG F-014)
Punch Cam (P/O PL 11.6 Item 9)
(W/TAG F-006)
13 Punch Spacer (P/O PL 11.6 Item 9)
(W/TAG F-006)
14 Punch Sensor Assembly (Not
Spared) (W/O TAG F-008)
Punch Sensor Assembly (Not
Spared) (W/TAG F-008)
15 014K10610 Hole punch assembly cover

PL 11.8 2K LCSS Paddle Wheel/Safety
Gate
1 110K14000 SU1 Safety gate switch (S11-365)
3 Switch actuator (Not Spared)
4 Paddle wheel shaft assembly (Not
Spared) (W/O TAG F-016) (REP
11.12-110)
Paddle wheel shaft assembly (REF:
PL 31.14 Item 20) (W/TAG F-016)
5 013E25790 Bearing
6 Gear (Not Spared)
7 Flag (Not Spared)
8 Cable clamp (Not Spared)
9 Output cover (REF: PL 11.2 Item 7)
10 127K55881 Paddle motor assembly (MOT11-
024)
11 130E10360 Paddle roll position sensor (Q11-
326)
12 Shaft (P/O PL 11.8 Item 4) (W/TAG
F-016)
13 Paddle (P/O PL 11.8 Item 4)
(NOTE) (W/TAG F-016)
NOTE: Paddles are also supplied (4 off) as a kit PL 31.12

Item 11.

PL 11.10 2K LCSS Bin 1 Control
Components (1 of 2)
1 023E24320 Bin 1 drive belt (REP 11.5-110)
2 Rear belt clamp (Not Spared) (ADJ
11.1-110)
3 110E20180 Upper limit switch (S11-334)
110K13990 Upper limit switch (alternate) (S11-
334)
4 Sensor bracket (Not Spared)
5 130E10360 Bin 1 90% full sensor (Q11-331)
6 Pulley (Not Spared)
7 013E25810 Bearing
8 127K55891 Bin 1 elevator motor (MOT11-030)
9 Front belt clamp (Not Spared) (ADJ
11.1-110)
10 Motor bracket (Not Spared)
11 130E20380 Motor encoder sensor (Q11-336)
12 Pulley assembly (Not Spared)
15 Idler (Not Spared)

Components (2 of 2)
1 110K13990 Bin 1 lower limit switch (S11-335)
2 Not used
3 130E10360 Bin 1 Upper level sensor (Q11-
332), Bin 1 Lower level sensor
(Q11-333) (REP 11.11-110)
4 Actuator (Not Spared)
5 Sensor support assembly (Not
Spared)

PL 11.14 2K LCSS Paper Entry
Transport
1 023E24340 Input drive belt (REP 11.2-110)
2 127K55860 Transport motor 1 (MOT11-000)
(REP 11.2-110)
5 013E25790 Nylon bearing
6 006K27980 Feed roll shaft (short)
7 013E25800 Bearing
8 Jam clearance guide (P/O PL 11.24
Item 1)
9 006K31670 Feed roll shaft (long)
10 Thumb wheel (Not Spared)

PL 11.16 2K LCSS Tamper Assembly
1 068K54281 Tamper assembly (REP 11.6-110)
2 Tamper unit (P/O PL 11.16 Item 1)
3 130E10360 Front tamper home sensor (Q11-310),
Rear tamper home sensor (Q11-006),
Rear tamper home away sensor
(Q11-319)
4 Sensor bracket (P/O PL 11.16 Item 1)
5 Static eliminator (stacker) (REF: PL
11.23 Item 7)
6 Sensor retainer (P/O PL 11.16 Item 1)

PL 11.18 2K LCSS Ejector Assembly
1 054K43582 Ejector assembly (REP 11.10-110)
2 Ejector base (P/O PL 11.18 Item 1)
3 130E10360 Ejector home sensor (Q11-320),
Ejector out sensor (Q11-322),
Ejector motor encoder sensor (REP
11.10-110)
5 023E24330 Ejector belt (REP 11.17-110)
6 Clip (P/O PL 11.18 Item 1)
7 019K13390 Support finger set (Qty. 4)
8 020K21490 Pulley drive gear
12 Slide ejector bearing (P/O PL 11.18
Item 15)
13 Wide slide ejector bearing (P/O PL
11.18 Item 15)
14 Cushion washer (P/O PL 11.18
Item 15)
15 604K67690 LCSS bearing assembly kit

PL 11.20 2K LCSS Staple Head Unit/
Traverse Assembly
1 604K41341 Stapler traverse assembly kit (REF:
PL 31.12 Item 9) (REP 11.8-110)
2 Head traverse unit (P/O PL 11.20
Item 1)
3 130E10360 SU1 Home sensor (Q11-370), SU1
Front index sensor (Q11-371)
4 130E10380 SH1 Paper sensor (Q11-361)
5 029K04520 Staple head unit (REP 11.9-110)
6 Stapler cover (P/O PL 11.20 Item 1)
7 Staple cartridge (REF: PL 26.10
Item 11)
8 Not used
9 Sensor cover (P/O PL 11.20 Item 1)
10 Staple head assembly (P/O PL
11.20 Item 1)

PL 11.22 2K LCSS Bin 0 Entry
1 006K27960 Ejector drive shaft
4 023E24330 Intermediate paper drive belt (REP
11.3-110)
(REP 11.4-110)
9 013E25800 Bearing
10 032K04580 Paper guide
11 130E11440 Top exit sensor (Q11-130)
12 121K45010 Diverter solenoid (SOL11-002)
13 Shaft diverter assembly (P/O PL
31.13 Item 6) (W/TAG F-017)
14 023E24340 Paper output drive belt (REP 11.4-
110)
15 006K27970 Drive shaft assembly
16 003K17531 Jam clearance knob

1 032K04610 Left hand paper guide
2 032K04590 Lower right hand paper guide
3 006K27960 Ejector drive shaft (REF: PL 11.22
Item 1)
4 130E11440 2nd to top exit sensor (Q11-140)
7 115E11810 Static eliminator (stacker)
8 Paper output drive belt (REF: PL
11.22 Item 14)
9 Upper right hand paper guide (Not
Spared)
10 013E25800 Bearing
11 Mylar safety cover (P/O PL 11.23
Item 1)

PL 11.24 2K LCSS Entry Guide Cover/
Jam Clearance Guide
1 032K04601 Paper entry guide assembly
2 Jam clearance handle (P/O PL
11.24 Item 1)
3 130E10380 Entry sensor (Q11-100)
5 848K06161 Entry guide cover (REP 11.15-110)
6 Jam clearance guide (P/O PL 11.24
Item 1)
7 809E78390 Latch

PL 11.26 2K LCSS Electrical
1 960K34502 2K LCSS PWB (CAUTION) (REP
11.14-110)
2 105K35842 Power supply module
3 960K34490 Offline staple PWB (S11-373)
4 962K56952 Cord bracket assembly
5 110K13980 Front door interlock switch (S11-
303)
6 110K13970 Top cover interlock switch (S11-
302)
CAUTION
Do not install a new 2K LCSS PWB until the cause of the
damage to the old 2K LCSS PWB has been determined. Go
to the 11G-110 2K LCSS PWB Damage RAP.

PL 11.100 1K LCSS Covers
1 802K48330 Exit cover
2 848K06150 Top cover (REP 11.1-120)
3 Entry guide cover (REF: PL 11.122
Item 5)
4 848K06130 Front door cover assembly (REP
11.1-120)
5 1K LCSS mounting bracket repair
kit (Not Spared)
7 Output cover (Not Spared)
8 Not used
9 050K67380 Bin 0
10 050K68490 Bin 1 (W/O TAG L-013) (ADJ 11.1-
120)
604K48150 Bin 1 tray kit (improved stacking)
(W/TAG L-013)
11 848K06140 Rear cover (REP 11.1-120)
12 Right hand cover (Not Spared)
13 019K13380 Bin 1 alignment clip
14 017E11260 Stability foot (REP 11.3-120)
NOTE: W/TAG L-013 improves stacking on machines

running large stacks of 8.5" x 11" or A4 LEF.

PL 11.102 1K LCSS Docking Latch
1 Sensor cover (P/O PL 11.102 Item
8)
(REP 11.14-120)
3 003K20401 Link bracket assembly (REP 11.14-
120)
4 Not used
5 Docking latch (P/O PL 11.102 Item
8) (REP 11.14-120)
8 003K20391 Docking latch assembly (REP
11.14-120)

PL 11.104 1K LCSS Paddle Wheel/
Safety Gate
1 Shaft (P/O PL 11.104 Item 4) (W/
TAG L-016)
2 Paddle wheel (P/O PL 31.12 Item
11) (NOTE) (W/TAG L-016)
3 Not used
4 Paddle wheel shaft assembly (Not
Spared) (W/O TAG L-016) (REP
11.10-120)
006K34580 Paddle wheel shaft assembly (W/
TAG L-016)
5 013E25790 Bearing
6 Not used
7 Flag/Gear (Not Spared)
8 Not used
9 Output cover (REF: PL 11.100 Item
7)
10 127K55840 Paddle motor assembly (MOT11-
024)
11 130E10360 Paddle roll position sensor (Q11-
326)
NOTE: Paddles are also supplied (4 off) as a kit PL 31.12

Item 11.

Components
1 023E30710 Bin 1 drive belt (REP 11.5-120)
2 Rear belt clamp (Not Spared) (ADJ
11.1-120)
3 110E20180 Bin 1 upper limit switch (S11-334)
5 130E10360 Bin 1 90% full sensor (Q11-331),
Bin 1 upper level sensor (Q11-332)
(REP 11.9-120), Motor encoder
sensor (Q11-336)
7 013E25810 Bearing
8 127K55891 Bin 1 elevator motor (MOT11-030)
9 Front belt clamp (Not Spared) (ADJ
11.1-120)
11 110K13990 Bin 1 lower limit switch (S11-335)
12 Pulley assembly (Not Spared)
13 Sensor support (Not Spared)
14 P-clamp (Not Spared)

PL 11.110 1K LCSS Paper Entry
Transport
1 023E30690 Input drive belt (REP 11.2-120)
(REP 11.2-120)
7 013E25800 Bearing
8 Jam clearance guide (REF: PL
11.122 Item 1)
9 006K31670 Feed roll shaft (long)
10 Thumb wheel (Not Spared)

PL 11.112 1K LCSS Tamper Assembly
1 068K54281 Tamper assembly (REP 11.6-120)
2 Tamper unit (P/O PL 11.112 Item 1)
3 130E20380 Front tamper home sensor (Q11-
310), Rear tamper home sensor
(Q11-006), Rear tamper home
away sensor (Q11-319)
4 Sensor bracket (P/O PL 11.112
Item 1)
5 Static eliminator (stacker) (REF: PL
11.120 Item 7)
6 Sensor retainer (P/O PL 11.112
Item 1)

PL 11.114 1K LCSS Ejector Assembly
1 054K43582 Ejector assembly (REP 11.8-120)
2 Ejector base (P/O PL 11.114 Item
1)
3 130E20380 Ejector home sensor (Q11-320),
Ejector out sensor (Q11-322),
Ejector motor encoder sensor (REP
11.8-120)
5 023E24330 Ejector belt (REP 11.15-120)
6 Clip (P/O PL 11.114 Item 1)
7 020K21490 Pulley drive gear
9 KL-Clip (Not Spared)

PL 11.116 1K LCSS Staple Head
Assembly
1 014K10100 Stapler assembly
Item 1)
3 Stapler harness (P/O PL 11.116
Item 1)
4 130E10380 SH1 Paper sensor (Q11-361) (REP
11.7-120)
5 Staple head unit (P/O PL 11.116
Item 1)
6 Stapler cover (P/O PL 11.116 Item
1)
7 Cable clamp (P/O PL 11.116 Item
1)
8 Staple cartridge (REF: PL 26.10
Item 26)
9 Staple refills (Not Spared)

1 006K27960 Ejector drive shaft
4 023E30700 Intermediate paper drive belt
9 013E25800 Bearing
10 032K04550 Paper guide
11 130E11440 Top exit sensor (Q11-130)
13 Shaft diverter assembly (P/O PL
31.13 Item 6) (W/TAG L-003)
15 006K27970 Drive shaft assembly
16 003K17531 Jam clearance knob

1 032K04570 Left hand paper guide
2 032K04560 Lower right hand paper guide
3 006K27960 Ejector drive shaft (REF: PL 11.118
Item 1)
4 130E11440 2nd to top exit sensor (Q11-140)
7 115E11810 Static eliminator (stacker)
8 023E24340 Paper output drive belt (REP 11.4-
120)
9 Upper right hand paper guide (Not
Spared)
10 013E25800 Bearing
13 127K55830 Transport motor 2 (MOT 11-001)
(REP 11.4-120)
14 Mylar safety cover (P/O PL 11.120
Item 1)

PL 11.122 1K LCSS Entry Guide
Cover/Jam Clearance Guide
1 032K04601 Paper entry guide assembly
2 Jam clearance handle (P/O PL
11.122 Item 1)
3 130E10380 Entry sensor (Q11-100)
5 848K06161 Entry guide cover (REP 11.13-120)
6 Jam clearance guide (P/O PL
11.122 Item 1)
7 809E78390 Latch

PL 11.124 1K LCSS Electrical
1 960K21261 1K LCSS PWB (CAUTION) (W/TAG
L-001) (REP 11.12-120)
2 105K28272 Power supply module
3 Not used
4 962K56942 Cord bracket assembly
5 110K13980 Front door interlock switch (S11-303)
6 110K13970 Top cover interlock switch (S11-302)
7 1K LCSS communication harness (P/
O PL 11.124 Item 4)
8 Power cord (P/O PL 11.124 Item 4)
9 Lower bracket (P/O PL 11.124 Item 4)
10 Upper bracket (P/O PL 11.124 Item 4)
CAUTION
Do not install a new 1K LCSS PWB until the cause of the
damage to the old LCSS PWB has been determined. Go to the
11G-120 LCSS PWB Damage RAP.

PL 11.130 HVF Covers and Docking
1 848K12490 Top cover (REP 11.1-171)
2 848K12501 Front cover (REP 11.1-171)
3 848E17790 Front door (REP 11.1-171)
4 848K12510 Door support (REP 11.1-171)
5 848K12520 Rear cover (REP 11.1-171)
6 848K12530 Vent cover (REP 11.1-171)
7 848E17800 Foot cover (REP 11.1-171)
8 848E17810 Inserter removable cover (REP
11.1-171)
9 848K12540 Top tray (REP 11.3-171)
10 Seal (Not Spared)
11 017K04830 Fixed castor assembly (REP 11.96-
171)
12 Fixed castor bracket (P/O PL
11.130 Item 11)
13 017K04630 Adjustable castor (REP 11.96-171)
14 Adjustable castor washer (P/O PL
11.130 Item 13)
15 017K04641 Mounting bracket assembly

PL 11.135 HVF Stacker
1 848E17820 Upper right side cover (REP 11.5-
171)
2 848E17840 Lower right side cover
3 130E12830 Bin 1 90% full sensor (Q11-311)/Bin
1 encoder sensor (Q11-182)
4 Rear main belt clamp (1 of 2) (Not
Spared)
5 Rear main belt clamp (2 of 2) (Not
Spared)
6 023E31220 Bin 1 main drive belt (REP 11.38-
171)
7 110K20890 Bin 1 upper limit switch (REP
11.75-171) (S11-334)/Bin 1 lower
limit switch (REP 11.75-171) (S11-
335)
8 Main belt pulley (Not Spared)
9 Main belt tensioner (Not Spared)
10 127K56592 Bin 1 elevator motor assembly
(REP 11.12-171)
11 Bin 1 rear lift bar bracket (Not
Spared)
12 Bin 1 front lift bar bracket (Not
Spared)
13 Bin 1 lift bar (Not Spared)
14 Front main belt clamp (2 of 2) (Not
Spared)
15 Front main belt clamp (1 of 2) (Not
Spared)
16 050E23670 Bin 1 (REP 11.4-171)
17 Not used
18 Not used
19 848E17830 Middle right side cover
20 019K13380 Bin 1 retaining clip (REP 11.4-171)
21 Bin 1 lift bar brace (Not Spared)
22 110K20880 Stacker full sensor and lower limit
switch assembly (REP 11.75-171)
23 Sensor/switch bracket (Not Spared)
24 Stacker tray guide (P/O PL 11.135
Item 26)
25 Stacker tray guide pulley (P/O PL
11.135 Item 26)
26 110K21060 Stacker tray guide assembly

PL 11.140 HVF Ejector, Pressing and
Support (1 of 2)
1. Ejector front cover (Not Spared)
2. 059K59494 Ejector assembly (REP 11.6-171)
3. Offset module (Not Spared) (REP 11.9-
171)
4. Front pressing plate finger (P/O PL
11.140 Item 28) (REP 11.7-171)
5. Rear pressing plate finger (P/O PL
11.140 Item 28) (REP 11.7-171)
6. 049K23160 Pressing plate bracket
7. 003K20652 Front support finger (REP 11.8-171)
8. 003K20662 Rear support finger (REP 11.8-171)
9. Support finger motor assembly (P/O PL
11.140 Item 18)
10. Offset rod (Not Spared)
11. 019K13380 Offset rod KL clip
12. Stapler module (P/O PL 11.140 Item 14)
(REP 11.2-171)
13. 032K09651 Rear tamper assembly (REP 11.15-
171)
14. 029K04631 Staple assembly (REP 11.2-171)
15. 130E12830 Pressing and support encoder sensor
(Q11-172), Bin 1 offset sensor (Q11-
337), Offset index sensor (Q11-187),
Offset away sensor (Q11-176)
16. 130K75470 Bin 1 upper level sensor (receiver)
(Q11-332) (REP 11.76-171)
17. 130K75900 Bin 1 rear wall sensor (Q11-196)
18. 127K56551 Motor encoder assembly
19. 127K56580 Bin 1 offset motor (MOT11-034) (REP
11.9-171)
20. 130K75480 Bin 1 upper level sensor (transmitter)
(Q11-332) (REP 11.76-171)
21. 032E35301 Rear tamper arm (W/O TAG V-006)
Rear tamper arm (reinforced) (P/O PL
11.140 Item 13) (W/TAG V-006)
22. 032E35311 Tamper arm set (W/TAG V-006)
23. Stapler harness (P/O PL 11.140 Item
25)
24. P-clip (P/O PL 11.140 Item 25)
25. 962K82410 Stapler harness and p-clip assembly
26. 033K04850 Ejector paddle assembly (W/TAG V-
007) (REP 11.100-171)
27. Rear tamper (P/O PL 11.140 Item 13)
28. 003K21101 Pressing plate kit
29. Ejector assembly safety cover (P/O PL
31.11 Item 15)
30. Pressing and support sensor A (Q11-
192), B (Q11-191), C (Q11-193) (P/O
PL 11.140 Item 13)
31. Rear tamper motor (P/O PL 11.140 Item
13)
32. Rear tamper drive belt (P/O PL 11.140
Item 13)
33. Staple cartridge (REF: PL 26.10 Item
22)
34. 822E18820 Ejector belt cover (REP 11.6-171)
35. Front support finger guide (Not Spared)

PL 11.145 HVF Ejector, Pressing and
Support (2 of 2)
1 Paper pusher (P/O PL 11.145 Item 8)
2 033K04414 Paddle module assembly (REP
11.49-171)
3 Pusher mylar (P/O PL 11.145 Item 8)
4 Timing belt pulley (Not Spared)
5 Timing belt tensioner (Not Spared)
6 Front stacker pulley bracket (Not
Spared)
7 Thrust washer (Not Spared)
8 050K67801 Paper pusher assembly (REP 11.53-
171)
9 Pinion gear E-clip (Not Spared)
10 Compile exit upper guide (Not
Spared)
11 Stacker main drive gear shaft (Not
Spared)
12 Stacker main drive gear (Not Spared)
13 674K03550 Paper pusher motor assembly
(MOT11-083) (REP 11.51-171)
14 Pinion gear (Not Spared)
15 Pinion gear shaft (Not Spared)
16 130E12830 Paper pusher upper sensor (Q11-
171)/Paper pusher lower sensor
(Q11-173) (REP 11.54-171)
17 Stapler gate safety switch (S11-365)
(P/O PL 11.145 Item 22)
18 Sensor screw (P/O PL 11.145 Item
22)
19 Sensor assembly bracket (P/O PL
11.145 Item 22)
20 Lower exit guide (Not Spared)
21 Pusher dampers (P/O PL 11.145 Item
8)
22 674K03541 Sensor assembly (REP 11.54-171)
23 013E37150 Stacker shaft bearing (plastic) (REP
11.37-171)
24 110K13970 Top cover interlock switch (S11-302)
25 Not used
26 Top jam clearance guide assembly
(Not Spared)
27 006K33400 Stacker idler roll (x4) (NOTE 2) (REP
11.10-171)
28 033K04581 Paddle wheel (NOTE 1) (REP
11.101-171)
29 110K13980 Front door interlock switch (S11-303)
NOTE: 2. Supplied as a set of 4 rolls.

PL 11.150 HVF Main Drives
1 127K56570 Buffer feed motor (MOT11-079)
(REP 11.65-171)/Exit feed motor 2
(MOT11-001) (REP 11.66-171)
2 127K56560 Entry feed motor 1 (MOT11-000)
(REP 11.63-171)/Bypass feed
motor (MOT11-080) (REP 11.64-
171)
3 Solenoid bracket (P/O PL 11.150
Item 4)
4 121K45290 BM diverter solenoid (SOL11-074)
(ADJ 11.14-171)/Exit diverter
solenoid (SOL11-002)/Buffer clamp
solenoid (SOL11-082)
5 Solenoid connector (Not Spared)
6 127K56610 Paddle module driving motor
assembly (REP 11.48-171)
7 Entry feed motor 1 belt (Not
Spared)
8 Bypass feed motor belt (Not
Spared)
9 Buffer feed motor belt (Not Spared)
10 Exit feed motor 2 belt (A) (Not
Spared)
11 Exit feed motor 2 belt (B) (Not
Spared)

PL 11.153 HVF Feed Assembly and
Punch (1 of 3)
1 604K54741 HVF hole punch carrier assembly
(XE)
HVF 3 hole punch assembly (Not
Spared) (USSG/XCL)
2 604K83750 HVF chad bin
3 Hole punch thumb screw (P/O PL
11.153 Item 1)
4 059K59551 Hole punch blanking assembly
5 868E05770 Front tamper arm (W/O TAG V-006)
Front tamper arm (reinforced) (P/O
PL 11.140 Item 22) (W/TAG V-006)
6 127K56601 Front tamper motor assembly (REP
11.11-171)
7 038E40870 Diverter exit gate
8 059K59560 Upper exit guide (5c)
9 BM diverter gate (P/O PL 31.14
Item 11) (W/TAG V-008) (REP
11.39-171)
10 059K59531 Buffer pocket jam clearance guide
11 059K59540 Inserter jam clearance guide
assembly (8a)
12 059K59521 Input jam clearance guide (5a)
13 059K59512 Buffer guide assembly (5b) (REP
11.31-171)
14 Nip split motor cover (P/O PL
11.153 Item 13)
15 Nip split motor (MOT11-081) (P/O
PL 11.153 Item 13)
16 121K45300 Magnet
17 130E12810 Paper edge sensor (NOTE)
18 130E12840 Chad bin present sensor (Q11-112)
19 Hole punch unit (see below for
variants)
180K00280 2 Hole (XE)
180K00320 2 Hole Legal
180K00200 3 Hole (USSG/XCL)
180K00300 4 Hole (XE)
180K00310 4 Hole (Sweden)
20 130E10380 Chad bin level sensor (Q11-348)
NOTE: There is no component control code for the paper

edge sensor

Punch (2 of 3)
1 006K32700 Stacker exit feed roll (REP 11.46-
171)
2 Buffer upper roll (REF: PL 11.155
Item 1) (REP 11.45-171)
3 Buffer lower roll (REF: PL 11.155
Item 1) (REP 11.44-171)
4 Inserter guide roll (REF: PL 11.155
Item 1) (REP 11.41-171)
5 Booklet entrance roll (REF: PL
11.155 Item 1) (REP 11.43-171)
6 Buffer pocket roll (REF: PL 11.155
Item 1) (REP 11.42-171)
7 019K13660 Buffer clamp
8 Input roll (REF: PL 11.155 Item 1)
(REP 11.40-171)
10 006K32690 Stacker exit roll
11 Top exit roll (Not Spared)
12 Top exit feed roll (REF: PL 11.155
Item 1) (REP 11.47-171)

Punch (3 of 3)
1 130E12830 Tamper front home sensor (Q11-
310)/Front tamper tray away sensor
(Q11-174)/Nip split sensor (Q11-
170)/Nip home sensor (Q11-159)
2 130E12810 Entry sensor (Q11-100)/2nd to top
exit sensor (Q11-140)/Buffer
position sensor (Q11-157)/Buffer
path sensor (Q11-164)/Inserter
sensor (NOTE)
3 130E12840 Top exit sensor (Q11-130)/Booklet
exit sensor (Q11-158)
NOTE: There is no component code number for the Inserter

sensor

PL 11.157 HVF Power and Control
1 105K30211 HVF power supply unit (REP 11.55-
171)
2 960K41772 HVF control PWB (REP 11.57-171)
3 960K41780 Pause to unload PWB (REP 11.97-
171)
4 105K36840 Power cord
5 Inline fuse (10A slo-blow) (Not
Spared)
6 Harness (Not Spared)
7 952K00411 Power communications cable

PL 11.160 HVF BM Module (Complete)
1 801K27251 BM Module (REP 11.61-171)
2 010K04360 Slide assembly (REP 11.62-171)

PL 11.161 HVF BM Entry and Front
Cover
1 003E69092 Drawer handle
2 809E46511 Crease roll leaf spring
3 802E66650 BM Front cover
4 003E69022 Crease blade knob (6d)
5 003E66010 Crease roll handle (6c)
7 Paper guide (P/O PL 11.161 Item
22) (REP 11.60-171)
8 Jam clearance handle (Not Spared)
(REP 11.60-171)
9 Nip spring (Not Spared) (REP
11.60-171)
10 022E30620 Nip roll (REP 11.60-171)
11 Nip shaft (P/O PL 11.161 Item 22)
(REP 11.60-171)
12 130K74072 Flapper home sensor (Q11-391) (P/
O PL 11.161 Item 30) (REP 11.16-
171)
14 020E39990 BM Entry roll pulley (REP 11.22-
171)
15 006K28660 BM Entry roll (REP 11.22-171)
16 130K74110 BM Entry sensor (Q11-160) (REP
11.23-171)
18 Rear latch (Not Spared)
20 809E46411 Latch spring
21 Front latch (Not Spared)
22 Entrance baffle assembly (Not
Spared) (REP 11.60-171)
23 BM Flapper (P/O PL 11.161 Item
30) (REP 11.16-171)
24 BM flapper bracket (P/O PL 11.161
Item 30)
25 BM Compiler shaft (Not Spared)
26 125K03831 Static eliminator
27 Top baffle (Not Spared)
29 BM flapper drive belt (Not Spared)
30 BM Flapper assembly (Not Spared)

PL 11.162 HVF BM Tamper Assembly
1 107E22600 BM Tamper 1 home sensor (Q11-
384)
2 LH Frame plate (Not Spared)
3 127K47660 BM Tamper 1 motor (MOT 11-066)
(REP 11.30-171)
4 BM Tamper spring (P/O PL 11.162
Item 10)
5 BM Rear tamper arm (P/O PL
11.162 Item 9) (REP 11.30-171)
6 BM Front tamper arm (P/O PL
11.162 Item 10) (REP 11.30-171)
7 BM Rear tamper rack (P/O PL
11.162 Item 9) (REP 11.30-171)
8 BM Front tamper rack (P/O PL
11.162 Item 10) (REP 11.30-171)
9 007K13190 BM Rear tamper assembly (REP
11.30-171)
10 007K13180 BM Front tamper assembly (REP
11.30-171)
11 807E15450 BM Tamper gear (REP 11.30-171)
12 BM Tamper bracket (Not Spared)
(REP 11.30-171)
13 BM Tamper rack guide (Not
Spared) (REP 11.30-171)
14 802E59410 BM Connector cover
15 BM Tamper guide plate (Not
Spared) (REP 11.30-171)
16 BM Rear tamper finger (Not
Spared) (REP 11.30-171)
17 BM Front tamper finger (Not
Spared) (REP 11.30-171)
18 125K03593 BM Static eliminator

PL 11.163 HVF BM Back Stop Motor
1 Ground wire (P/O PL 11.163 Item
20)
3 Motor damper (P/O PL 11.163 Item
20) (REP 11.20-171)
4 BM back stop motor (MOT11-065)
(P/O PL 11.163 Item 20) (REP
11.20-171)
6 BM back stop bearing (Not Spared)
(REP 11.26-171)
7 023E23300 BM back stop drive belt (REP
11.20-171)
8 809E78370 BM back stop tensioner spring
(REP 11.20-171)
9 Allen key (3mm) (Not Spared)
10 802E59180 Sensor cover
11 BM back stop bearing (Not Spared)
(REP 11.26-171)
12 BM back stop idler bracket (Not
Spared) (REP 11.26-171)
13 BM back stop idler shaft (Not
Spared)
14 BM back stop tensioner link (Not
Spared)
15 809E25100 BM back stop link spring (REP
11.26-171)
16 012E20870 BM back stop link (REP 11.26-171)
17 LH frame plate (Not Spared)
18 107E22600 BM back stop guide home sensor
(Q11-383)
19 Not used
20 127K54710 BM back stop motor assembly
(REP 11.20-171)

PL 11.164 HVF BM Back Stop
assembly
1 019E74451 Anti-play shoe
2 BM back stop lock washer (P/O PL
11.164 Item 17)
3 Cable fastener (P/O PL 11.164 Item
17)
4 031E11300 Anti-rattle arm
6 Flanged hex nut (P/O PL 11.164
Item 17)
7 Back stop adjust spring (P/O PL
11.164 Item 17)
8 809E71970 Anti-play spring
9 Solenoid spring (P/O PL 11.164
Item 17)
10 Shaft support (Not Spared)
11 Belt clamp (P/O PL 11.164 Item 17)
12 BM back stop solenoid nut (P/O PL
11.164 Item 17)
13 Pivoting clamp (P/O PL 11.164 Item
17)
14 006K30790 BM back stop drive shaft (REP
11.26-171)
15 023E23140 BM back stop belt (REP 11.26-171)
16 BM back stop shaft (Not Spared)
17 019K13550 BM back stop assembly (REP
11.21-171)

PL 11.165 HVF BM Crease Blade
Motor
1 107E22600 BM Crease blade motor encoder
sensor (Q11-418), BM Crease
blade home sensor (Q11-416) (Not
Spared) (REP 11.18-171)
2 Motor bracket (P/O PL 11.165 Item
3)
3 127K54690 BM Crease blade motor assembly
(MOT11-061) (REP 11.18-171)
4 014E47460 Motor encoder (REP 11.18-171)
5 Drive shaft (Not Spared)
6 007E69830 Drive gear
7 413W30654 Bearing (REP 11.18-171)
8 008E08220 Crank (REP 11.18-171)
9 012E20860 Connecting rod (REP 11.36-171)
11 802E59171 Motor cover
12 809E42861 Crease nip spring (REP 11.58-171)
13 815K11660 Crease blade assembly (REP
11.36-171)
14 032E19330 Crease blade support guide (REP
11.36-171)
15 Crease blade home sensor bracket
(Not Spared)

PL 11.166 HVF BM Crease Rolls Motor
and PWB
1 127K43751 BM Compiler motor (MOT11-060)/
BM flapper motor (MOT11-390)
(REP 11.25-171)
2 Damper bracket (P/O PL 11.166
Item 16) (REP 11.25-171)
4 Ground wire (P/O PL 11.166 Item
16)
5 Not used
6 Not used
7 Not used
8 127K53620 Crease roll gate motor (MOT11-
401) (REP 11.24-171)
9 107E22600 BM Crease roll gate home sensor
(Q11-415), BM Crease roll motor
encoder sensor (Q11-419)
10 960K42390 BM PWB (REP 11.17-171)
11 Motor bracket (P/O PL 11.166 Item
12)
12 127K54680 BM crease roll motor assembly
(MOT11-062) (REP 11.19-171)
13 014E47460 BM Crease roll motor encoder
14 Support bracket (Not Spared)
15 023E25430 Belt
16 127K55520 BM Compiler motor assembly (REP
11.25-171)
17 BM flapper motor pulley (Not
Spared)
18 BM flapper motor drive belt (Not
Spared)
19 Tri-folder interlock cheat (PJ553)
(Not Spared)
20 Tri-folder logic cheat (PJ563) (Not
Spared)

PL 11.167 HVF BM Crease Rolls and
Support Leg
1 Lower crease roll bearing (P/O PL
11.167 Item 23)
2 Shaft keyed clutch plate (P/O PL
11.167 Item 23)
3 413W31054 Crease roll bearing (REP 11.52-
171)
4 Lower crease roll gear (P/O PL
11.167 Item 23)
5 Gear keyed clutch plate (P/O PL
11.167 Item 23) (REP 11.52-171)
6 006K29391 Upper crease roll (REP 11.52-171)
7 Lower crease roll (P/O PL 11.167
Item 25) (REP 11.52-171)
8 007E69081 Crease roll gate rack gear (REP
11.59-171)
9 Not used
10 Not used
11 Not used
13 007E69070 Crease roll gate rack drive gear
(REP 11.59-171)
14 007E68951 Crease roll gate rack (REP 11.59-
171)
15 020E38701 Crease roll gate front guide (REP
11.59-171)
16 020E38081 Crease roll gate rear guide (REP
11.59-171)
17 Crease roll drive shaft (Not Spared)
18 Crease roll gate shaft (Not Spared)
19 050E23160 Crease roll gate (REP 11.59-171)
20 Retainer (P/O PL 11.167 Item 23)
22 807E06040 Upper crease roll gear
23 Lower crease roll and clutch
24 Wavy washer (P/O PL 11.167 Item
25)
25 604K42120 Crease roll repair kit

PL 11.168 HVF BM Stapler Assemblies
1 020E38513 Front follower
2 016E17732 Actuator
3 Rear follower (Not Spared)
4 809E44010 Spring
5 130K74090 BM paper present sensor (Q11-
190)
6 008E06850 Latch slide
7 029K03232 BM Staple head assembly (REP
11.27-171, ADJ 4.1)
8 050K21270 Staple cartridge
9 Staple bracket handle (Not Spared)
(REP 11.28-171)
10 Stapler bracket assembly (Not
Spared) (REP 11.28-171)
11 809E48830 Torsion spring (REP 11.28-171)
12 Bearing (Not Spared) (REP 11.28-
171)
13 Spring (Not Spared) (REP 11.28-
171)
14 802E42770 Staple head cover
15 BM Right hand cover (Not Spared)
(REP 11.56-171)
16 125K03831 Static eliminator
17 130E11640 BM exit sensor (Q11-409) (REP
11.50-171)
18 107E22600 BM Stapler head carrier closed
sensor (Q11-421) (Not Spared)
(REP 11.28-171)
19 Lower shaft (Not Spared) (REP
11.28-171)
20 Upper shaft (Not Spared) (REP
11.28-171)
21 055E51870 Mylar guide

PL 11.169 HVF BM Bin 2
1 023E18612 Conveyor belt (REP 11.29-171)
2 050E21971 HVF BM Bin 2 extension
3 HVF BM Bin 2 upper cover (P/O PL
11.169 Item 8)
4 127K53630 BM Conveyor belt drive motor
(MOT11-402)
5 019E61171 HVF BM Bin 2 90% full sensor
(Q11-389)
6 HVF BM Bin 2 lower cover (P/O PL
11.169 Item 8)
8 HVF BM Bin 2 assembly (Not
Spared)
9 HVF BM Bin 2 connector (Not
Spared)
10 809E47341 HVF Bin 2 actuator spring
11 007E69000 Gear (50T)/pulley (24T)

PL 11.175 Inserter Covers
1 Front cover (Not Spared) (REP
11.83-171)
2 Rear cover (Not Spared) (REP
11.83-171)
3 Sensor tray (P/O PL 11.175 Item
20) (REP 11.89-171)
4 Bottom tray spring (Not Spared)
5 Bottom tray shaft (P/O PL 11.175
Item 19)
6 Bottom tray (P/O PL 11.175 Item
19) (REP 11.90-171)
7 Top left door (P/O PL 11.175 Item
21) (REP 11.92-171)
8 Top cover door (P/O PL 11.179
Item 20)
9 Pivot pin (Not Spared)
10 Acceleration sensor (P/O PL
11.175 Item 21) (REP 11.92-171)
11 Unit empty sensor (Q11-153) (Not
Spared) (REP 11.90-171)
12 Sheet size detector 1 (Q11-150)/
Sheet size detector 2 (Q11-151) (P/
O PL 11.175 Item 20) (REP 11.89-
171)
13 Inserter paper width sensor 1 (Q11-
152) (P/O PL 11.175 Item 19) (REP
11.90-171)
Inserter paper width sensor 2 (P/O
PL 11.175 Item 19) (NOTE) (REP
11.90-171)
14 Bottom tray bracket (P/O PL 11.175
Item 19)
15 Bottom tray rack (P/O PL 11.175
Item 19)
16 Bottom plate sensor (Q11-156) (P/
O PL 11.175 Item 19) (REP 11.94-
171)
17 Top cover (Not Spared)
18 Left hand door interlock switch
(S11-431) (Not Spared) (REP
11.88-171)
19 050K68100 Bottom tray assembly (REP 11.90-
171, REP 11.95-171)
20 848K19170 Sensor tray assembly (REP 11.89-
171)
21 848K19180 Top left door assembly (REP 11.92-
171)
NOTE: Inserter paper width sensor 2 has no component

control code.

PL 11.177 Inserter Main Drives (1 of 3)
2 Idler pin (Not Spared)
3 Gear (Not Spared)
5 Belt (Not Spared)
6 Bracket (Not Spared)
7 Jam drive belt (Not Spared)
8 Top cover interlock switch (S11-
306) (Not Spared) (REP 11.87-171)
9 Loading lever (Not Spared)
10 Loading gear (Not Spared)
12 Torsion spring (Not Spared)
13 Loading shaft (Not Spared)
14 Front loading bracket (Not Spared)

1 050K68080 Pickup assembly (See NOTE)
(REP 11.95-171)
2 Pickup gear (Not Spared)
3 005K12890 Inserter clutch (REP 11.86-171)
4 Reverse roller drive idler (Not
Spared)
5 Pickup assembly bracket (Not
Spared)
7 Reverse roller drive belt (Not
Spared)
8 Reverse roller drive (Not Spared)
9 960K46170 Inserter PWB (REP 11.85-171)
10 IDG pickup sensor (P/O PL 11.179
Item 20) (REP 11.91-171)
11 TE sensor (Q11-155) (REP 11.93-
171)/LE sensor (Q11-154) (REP
11.93-171) (P/O PL 11.179 Item 19)
12 Idle roller assembly (P/O PL 11.179
Item 19) (REP 11.98-171)
13 Idler roller bracket (Not Spared)
14 Idler roller spring (P/O PL 11.179
Item 19)
15 Top inside cover (Not Spared)
16 Idler roller cover (P/O PL 11.179
Item 19)
17 Top cover door (P/O PL 11.179
Item 20) (REP 11.91-171)
18 050K68090 Reverse feed roller (REP 11.95-
171)
19 006K32470 Idler roller assembly (REP 11.93-
171)
20 848K19160 Top cover door assembly (REP
11.91-171)
21 848K37330 Retard cover
22 Drive coupling (Not Spared)
23 Reverse feed roll core (Not Spared)
24 Pin (Not Spared)

1 127K61990 Inserter motor (MOT11-078) (REP
11.84-171)
3 Driver gear (Not Spared)
5 Tray down gear (Not Spared)
6 Gear cover bracket (Not Spared)
8 Bottom shaft drive (Not Spared)
9 Feed roller drive gear (Not Spared)
10 Tray down clutch (Not Spared)
11 Tray down clutch assembly (Not
Spared)

PL 11.190 Tri-Folder Covers
1 Door pin (Not Spared)
2 802K94010 Front door (REP 11.67-171)
3 848K11740 Rear cover (REP 11.67-171)
4 Top cover door assembly (REF: PL
11.195 Item 10) (REP 11.73-171)
5 Top cover door assembly spring (P/
O PL 11.190 Item 8)
6 802E93931 Top cover (REP 11.67-171)
7 848E17430 Right hand side cover (REP 11.67-
171)
8 Tri-Folder (complete) (Not Spared)
9 Top cover door assembly shaft (P/O
PL 11.190 Item 8)
10 107E26490 Top cover interlock sensor (Q11-
394) (REP 11.77-171)
11 Top cover locking stud (Not Spared)
12 802E99581 Front cover
13 017K04190 Castor
NOTE: For detail of bin 2, refer to PL 11.169.

PL 11.193 Tri-Folder Drives module
1 Drive coupling assembly bracket
(P/O PL 11.193 Item 13)
3 Feed/exit roll drive gear (40T) (P/O
PL 11.193 Item 13)
4 Gear (40T) (Black) (P/O PL 11.193
Item 13)
5 Driven pulley (P/O PL 11.193 Item
13)
8 Idler assembly bracket (P/O PL
11.193 Item 13)
9 Clutch drive (P/O PL 11.193 Item
13)
10 023E23290 Crease roll belt
11 023E30780 Coupler drive belt
12 007K14460 Drive assembly
13 005K12690 Drive coupling assembly (REP
11.69-171)
14 675K53640 Tri-Folder install kit (REP 11.68-
171)
15 Thumb screw (P/O PL 11.193 Item
14)
16 960K24000 Tri-folder control PWB (REP 11.80-
171)
17 Drive coupler (P/O PL 11.193 Item
12)
18 Align gauge coupler (P/O PL
11.193 Item 12)
19 962K49592 Bin 2 tray harness (REP 11.81-171)
20 962K49571 Tri-folder harness (REP 11.81-171)
21 Drive belt tensioner pulley (Not
Spared)
22 Feed roller bearing (Not Spared)
23 Feed roll pulley (Not Spared) (REP
11.70-171)
24 Feed roll belt (Not Spared) (REP
11.70-171)
25 023E23370 Feed roll drive belt (REP 11.68-
171)
26 020E39921 Pulley gear 19T/20T BM (REP
11.68-171)
27 020E39930 Pulley gear 38T (REP 11.68-171)
28 Drive assembly bracket (P/O PL
11.193 Item 12)

PL 11.195 Tri-Folder Top Door Cover
Assembly
1 Top access cover (P/O PL 11.195
Item 10)
2 Top cover door assembly spring
(Not Spared)
3 Top cover door assembly shaft (Not
Spared)
4 Latch hook (P/O PL 11.195 Item
10)
5 Top door cover assembly base (P/O
PL 11.195 Item 10)
6 Latch handle (P/O PL 11.195 Item
10)
7 Latch spring (P/O PL 11.195 Item
10)
8 059K58690 Idler assembly (REP 11.73-171)
9 Idler spring (P/O PL 11.195 Item
10)
10 848K11680 Top cover door assembly (REP
11.73-171)
11 Idler assembly (Not Spared)

PL 11.197 Tri-Folder Main Drives
Assembly
1 Roller assembly (Not Spared) (REP
11.74-171)
2 110E19840 Front door interlock switch (S11-
393) (REP 11.77-171)
3 110E19831 Top cover interlock switch (REP
11.77-171)
4 Top access cover docking catch
(Not Spared)
5 Pressing and stacking assembly
(Not Spared)
6 130E11861 Assist gate sensor (Q11-184) (REP
11.78-171)
7 020E38480 Crease roll pulley (REP 11.74-171)
8 121K44660 Assist gate solenoid (SOL11-086)
(REP 11.71-171)
9 011E13832 Centerfold entry gate lever (REP
11.74-171)
10 809E44040 Crease roll spring (REP 11.72-171)
11 130K74920 Entry sensor (Q11-183) (REP
11.78-171)
12 130K74051 Exit sensor (Q11-086) (REP 11.79-
171)
13 Not used
14 Feed roller bearing (Not Spared)
15 Feed roller (Not Spared) (REP
11.70-171)
(REP 11.74-171)
17 050E23180 Diverter gate

PL 12.10 OCT
1 604K41660 OCT (complete)
2 Tray (P/O PL 12.10 Item 1)
3 675K26824 OCT finger kit (REP 12.1)
4 Thumbscrew (P/O PL 12.10 Item 1)
5 130E81311 OCT 90% full sensor (Q12-300)

PL 14.10 Scanner Module, CVT/
Document Glass (W/TAG 150)
1 062K28520 Scanner
2 Not used
3 Top cover (REP 14.14)
4 090E02590 CVT Glass (NOTE) (REP 14.6)
5 090K02451 Document glass assembly (NOTE)
(REP 14.6)
6 Spacer (Not Spared) (REP 14.1)
8 848E57531 Base cover (REP 14.1)
module/UI harness (PJ103 &
PJ104 & PJ130-PJ133 & PJ80)
10 016E18310 Top cover plug
12 032E20580 Rubber stop
13 032K04061 CVT Ramp assembly (REP 14.6)
14 Document glass securing bracket
(P/O PL 14.10 Item 1)
15 Transit screw hole plug (P/O PL
14.10 Item 3)
16 Scanner frame securing bracket
(Not Spared)
NOTE: Refer to ADJ 14.2 for the optics cleaning procedure.

PL 14.15 Electrical Components (W/TAG
150)
1. PWB Cover (Not Spared)
2. 127K68200 Scan motor (REP 14.15)
3. 130E12310 Document size sensor 1 (Q14-315),
Document size sensor 2 (Q14-320)
(REP 14.20)
4. 960K59881 Scanner PWB (REP 14.19)
5. 962K89030 Single board controller PWB/DADH
comms/scanner power harness
(PJ920, PJ921)
6. 130E12300 DADH Closed switch (Q05-300) (REP
14.4)
7. Front end block (Not Spared) (REP
14.9)
8. Rear end block (Not Spared) (REP
14.9)
9. Exposure lamp (P/O PL 14.15 Item 26)
(REP 14.9)
10. 962K88980 Scan carriage ribbon harness (REP
14.18)
11. CCD cover (Not Spared) (USSG)
12. 960K59870 Exposure lamp inverter PWB (REP
14.17)
13. 962K89020 Scanner daughter PWB/scanner PWB
video PWB harness (PJ922)
14. Scanner motor drive belt (P/O PL
31.12 Item 15) (REP 14.16)
15. CCD PWB/Scanner PWB ribbon cable
1 (PJ931) (P/O PL 14.10 Item 1)
16. 130K75130 Scan carriage home sensor (Q14-100)
(REP 14.7)/Input module angle
sensor(Q14-310)(REP 14.8) (Q14-310)
17. 020K12510 Scan idler pulley (REP 14.10)
18. 030K79640 Scan motor bracket (REP 14.15)
19. CCD PWB
20. Actuator spring (Not Spared)
21. 110K14010 Input module angle sensor actuator
(REP 14.8)
22. Actuator support (Not Spared)
23. CCD PWB/Scanner PWB ribbon cable
2 (PJ932) (P/O PL 14.10 Item 1)
24. Scan cable (Not Spared) (REP 14.12)
25. Scan carriage drive belt (P/O PL 31.12
Item 15) (REP 14.16)
26. 604K84690 LED scan carriage assembly (W/TAG
157)
Scan carriage assembly (Not Spared)
(W/O TAG 157)
27. 013E43880 Bearing (REP 14.16)
28. Intermediate pulley (REP 14.16)
29. Intermediate pulley bracket (REP
14.16)
NOTE: . Refer to ADJ 14.2 for the optics cleaning procedure.

PL 14.20 Scanner Module, CVT/
Document Glass (W/O TAG 150)
1 604K73130 Scanner (REP 14.1)
2 Not used
3 802K62500 Top cover (REP 14.14)
4 090E02500 CVT glass (28mm wide) (NOTE)
(REP 14.6)
090E02590 CVT glass (31mm wide) (NOTE)
(REP 14.6)
5 090K02451 Document glass (NOTE) (REP
14.6)
6 Spacer (Not Spared) (REP 14.1)
8 802E93182 Base cover (REP 14.1)
module/UI harness (PJ130-PJ133
& PJ104) (Not Spared)
10 016E18310 Top cover plug
11 Base cover plug (Not Spared)
12 032E20580 Rubber stop
13 032K04061 CVT Ramp assembly (REP 14.6)

PL 14.25 Electrical Components (W/O
TAG 150)
1 PWB Cover (Not Spared)
2 127K55800 Scan motor (REP 14.11)
3 130E12310 Document size sensor 1 (Q14-315),
Document size sensor 2 (Q14-320)
(REP 14.3)
4 960K65810 Scanner PWB (REP 14.5)
5 962K12190 Single board controller module/
CCD PWB PJ125-PJ110 harness
6 130E12300 DADH Closed switch (Q05-300)
(REP 14.4)
7 030K79630 Front end block (REP 14.9)
8 030K79620 Rear end block (REP 14.9)
9 122K02290 Exposure lamp (REP 14.9)
10 962K12210 Lamp ribbon harness
11 960K34340 Fuse (USSG) (REP 14.2)
12 960K34320 Exposure lamp inverter PWB (REP
14.2)
13 152S06184 Single board controller module/
scanner driver PWB/CCD PWB
(PJ455 & PJ450-PJ135) harness
14 023E25140 Scanner drive belt (P/O PL 14.20
Item 1) (REP 14.13)
16 130K75130 Scan carriage home sensor (Q14-
100) (REP 14.7)/Input module
angle sensor (Q14-310) (REP 14.8)
17 020K12510 Scan idler pulley (REP 14.10)
18 030K79640 Scan motor bracket (REP 14.11)
19 CCD PWB (P/O PL 14.20 Item 1)
20 Actuator spring (Not Spared)
21 110K14010 Input module angle sensor actuator
(REP 14.8)
22 Actuator support (Not Spared)
23 CCD PWB/Scanner PWB harness
(P/O PL 14.20 Item 1)
24 Scan cable (Not Spared) (REP
14.12)

PL 17.00 Secure Access Additions
1 101E28760 Secure access controller
2 105E24030 Xerox secure access power supply
3 146E02180 Xerox secure access card reader
(HID)
4 Xerox secure access card reader
(MAGSTRIPE) (Not Spared)
(MIFARE)
(LEGIC)
7 Xerox secure access power cord
(NA) (Not Spared)
(EU) (Not Spared)
(UK) (Not Spared)

PL 20.10 Fax PWBs
1 802E60122 Safety cover
2 Extended fax PWB (see below for
variants)
(R6/R7) (2 Line)(W/O TAG X-001)
(R8) (2 Line) (W/O TAG X-001)
(R8) (2 Line) South Africa only
960K52340 (R9) (2 Line) (W/O TAG X-001)
3 537E67440 Compact flash memory (512Mb)
(W/O TAG X-001)
4 Embedded fax PWB (see below for
variants)
(R7) (1 Line) (W/O TAG X-001)
(REP 3.2)
(R8) (1 Line) (W/O TAG X-001)
(REP 3.2)
960K52330 (R9) (1 Line) (W/O TAG X-001)
(REP 3.2)
(R8) (1 Line) South Africa only ((W/
O TAG X-001) (REP 3.2)
960K58801 Embedded fax PWB (1 Line) (W/
TAG X-001)
5 802E65251 Lower cover
module (REF: PL 3.24 Item 1)
7 Grounding strip (P/O PL 20.10 Item
4)
8 Telephone cable (not shown on
illustration, see below for variants)
(P/O PL 20.10 Item 9, PL 20.10
Item 10)
United Kingdom
(USSG/XCL)
Germany
Italy
Belgium
Austria
France
Finland
Denmark
Netherlands
Norway
Portugal/Spain
Sweden
Switzerland
9 Line 1 fax kit (REF: PL 31.35 Item
1) (W/TAG X-001)
10 Line 2 fax kit (REF: PL 31.40 Item
1) (W/O TAG X-001)

PL 25.10 Convenience Stapler
1 Convenience stapler kit (REF: PL
31.11 Item 2) (NOTE)
2 Power cord (P/O PL 25.10 Item 1)
3 PSU (P/O PL 25.10 Item 1)
4 Staple cartridge (1 cartridge 5000
staples) (REF: PL 26.11 Item 1)
Staple cartridge refill (3 cartridges,
3 x 5000 staples) (REF: PL 26.11
Item 4)
5 Convenience stapler (P/O PL 25.10
Item 1) (XE)
Convenience stapler (USSG/XCL)
(P/O PL 25.10 Item 1)
NOTE: The convenience stapler has no serviceable parts.

PL 26.10 Consumables and Tools (1
of 2)
1 9 Way gender changer/Null modem
adapter (Not Spared)
2 043P00048 Formula A cleaning fluid
(WARNING)
3 600T02133 Line test tool
4 043P00045 Film remover (WARNING)
5 USB Cable (Not Spared)
6 Ethernet crossover cable (Not
Spared)
7 600T02261 Finisher bypass connector
8 043E00550 Plastislip grease
9 043P00081 Lens and mirrors cleaner
10 099P03037 Disposable gloves (general
protection) (Qty. 100) (WARNING)
11 108R00493 Staple cartridge (3 x 5000) (2K
LCSS)
12 Serial cable (Not Spared)
13 035E56460 Wiper
14 082E02000 Test pattern (A3/11x17)
15 082E02010 Test pattern (A4)
16 082E02020 Test pattern (8.5x11)
17 082E08230 Test pattern (solid area density
scale)
18 082P00448 Test pattern (visual scale)
19 008R90273 Antistatic fluid
20 070P00043 Molub grease 777
21 146E02700 USB Reader (HITAG)
22 008R12912 Staple cartridge (HVF) (1 x 5000)
23 600T91952 Mag seal repair tool
24 Not used
25 Compiler carriage support
26 108R00682 1K LCSS staple cartridge
27 1K LCSS staple refill (pack of 40)
WARNING
Wear protective gloves, PL 26.10 Item 10 when using
solvents and cleaning agents

PL 26.11 Consumables and Tools (2 of
2)
1 008R12964 Convenience stapler cartridge (1
cartridge 5000 staples)
2 006R01146 Black toner (Includes waste toner
bottle) (REF: PL 9.15 Item 4) (65-
90 ppm) (Pack of 2)
3 006R01046 Toner cartridge (2) pack (REF: PL
9.17 Item 4) (35-55 ppm)
4 008R12941 Convenience stapler cartridge refill
(staples only - 3 x 5000 staples)
5 Handset tool (Not Spared)
6 600T02329 PFP stack height sensor & retard
shield setting tool
7 600T02331 LVPS test box
8 070P00072 Molykote silicone dry lubricant
9 070E00460 Moovit oil

PL 28.10 Covers
1 DADH covers (REF: PL 5.10)
2 HCF covers (REF: PL 7.25) (W/O
TAG 151)
HCF covers (REF: PL 7.26) (W/
TAG 151)
3 Main covers (REF: PL 8.10)
4 2K LCSS covers (REF: PL 11.2)
5 Not used
6 Not used
7 Scanner covers (W/TAG 150)
(REF: PL 14.10)
8 1K LCSS covers (REF: PL 11.100)
9 Stand covers (REF: PL 7.40)
10 Scanner covers (W/O TAG 150)
(REF: PL 14.20)
11 HVF covers (REF: PL 11.130)
12 Not used
13 Tray 5 covers (REF: PL 7.60)
14 Inserter covers (REF: PL 11.175)
15 Tri-folder covers (REF: PL 11.190)

PL 31.10 Maintenance/Installation/
Removal Kits (1 of 5)
1 097S04292 Copier to MFP conversion kit
2 Foreign interface kit
3 Vend adaptor kit (Not Spared)
4 Fax adapter kit (see below for
variants)
604K67590 UK, Ireland, Spain, Portugal,
Greece
604K67600 France, Netherlands, Belgium
604K67610 Germany, Austria, Italy, Switzerland
604K67620 Sweden, Norway, Finland,
Denmark
5 Hole punch kit (see below for
variants)
498K10260 2 hole punch kit (LCSS)(XE)
498K12090 2 hole punch kit (legal)(LCSS) (XE)
498K10270 3 hole punch kit LCSS (USSG/XCL)
498K10310 4 hole punch kit (Sweden)(LCSS)
(XE)
498K10280 4 hole punch kit (LCSS) (XE)
498K11411 3 hole punch kit (HVF) (XE)
498K17940 4 hole punch kit (HVF) (Sweden)
6 604K67700 Seal replacement kit
7 Finishing devices (see below for
variants)
1K LCSS (no hole punch) (P/O PL
11.100) (32-45 ppm)
2K LCSS (no hole punch) (REF: PL
11.2)
8 Tray 5 (P/O PL 7.60)
9 498K12130 Tray 5 paper feed kit (A3 SEF
option)
10 498K12140 Tray 5 paper feed kit (A4 SEF
option)
11 604K48370 CVT roll kit (grey) (REF: PL 5.25
Item 17)
12 604K54340 Lever arm CRU spares kit (REF: PL
5.17 Item 28) (W/TAG D-001)
NOTE: 497/8K part numbers should not be ordered by the

CSE. 497/8K part numbers are customer install kits and are
for reference only.

1 497K05240 Colour scanning enablement kit
2 498K08260 Convenience stapler kit (XE)
498K08250 Convenience stapler (USSG/XCL)
3 498K16091 Xerox copier assistant (XE)
498K13736 Xerox copier assistant (USSG/XCL)
4 604K73360 Short paper path kit (W/O fan) (W/
TAG 114)
604K73040 Short paper path kit with fan (W/O
TAG 114)
5 604K92120 Rib protector kit
6 497K05760 Server Fax kit
7 497K05720 Network accounting
8 604K67570 Feedhead assembly kit (W/TAG D-
006)
9 Searchable file formats kit
10 497K13850 Paper tray security kit
11 049K00280 Tray 6 install kit
12 607K00010 Ros spares kit (35 ppm) (REF: PL
6.10 Item 4)
604K97840 ROS spares kit (REF: PL 6.10 Item
4) (40-55 ppm)
604K97880 ROS spares kit (REF: PL 6.10 Item
4) (65-90 ppm)
13 Image module spares kit (Not
Spared)
14 604K73160 Inverter spares kit (32-55 ppm)
Inverter spares kit (65-87 ppm)
15 604K73230 HVF ejector assembly safety cover
kit
16 604K48620 Tray 3 and 4 multifeed roll fix kit
(rough tread rolls) (REF: PL 8.30
Item 20, PL 8.31 Item 10) (W/TAG
110)
17 604K48700 Paper tray lip kit (REF: PL 7.10
Item 24)
18 604K48150 Bin 1 tray kit (improved stacking)
(REF: PL 11.2 Item 16, PL 11.100
Item 10) (W/TAG L-013)
19 130K75140 LCSS stapler edge registration kit

for reference only.

1. 604K22250 Tray 4 adjustment kit
2. 604K18510 Developer latch repair kit (65-90 ppm)
(REF: PL 9.15 Item 24)
604K30560 Developer latch repair kit (35-55 ppm)
3. 604K24570 Trickle outlet shutter kit (REF: PL 9.15
4. 604K24620 Tray 4 multi feed kit (REF: PL 7.15
Item 23)
5. 604K24650 Auger damper kit (REF: PL 4.10 Item
11, PL 4.15 Item 13)
6. 607K03190 HCF exit sensor and bracket kit
7. 604K41110 4B latch kit (REF: PL 10.25 Item 20)
8. 604K41120 Developer latch pin kit (REF: PL 9.20
9. 604K41341 Stapler traverse assembly kit (REF: PL
11.20 Item 1)
10. 604K41411 2K LCSS front door cover assembly kit
11. 604K73050 LCSS paddle spares kit (W/TAG F-
016)
12. 604K42020 BM back stop repair kit (REF: PL
11.164 Item 17)
13. 604K67240 Registration clutch kit (REF: PL 8.15
14. 604K42120 Crease roll repair kit (REF: PL 11.167
Item 25)
15. 604K73470 CCDS replacement drive belt kit (REF:
PL 14.15 Item 14)
16. 604K96681 Tray 3 transport shaft kit
17. 604K42680 DADH feed bearing kit (REF: PL 5.15
Item 26)
18. 604K35340 Developer charge kit (REF: PL 9.17
Item 25)
19. 604K83690 Exit shaft kit
20. 604K96691 Feedhead assembly spares kit
21. 604K41610 Toner dispense module kit (35-55 ppm)
604K54040 Toner dispense module kit (65-90 ppm)
developer and developer module)(35-
55 ppm) (REF: PL 9.17 Item 26)
developer and developer module)(65-
90 ppm) (REF: PL 9.15 Item 26)
24. 604K54630 Rear gravity gate mylar kit (REF: PL
10.11 Item 16) (W/TAG 005)
25. 604K54010 Inverter transparency feed kit (REF: PL
10.12 Item 24) (W/TAG 004)
NOTE: . 497/8K part numbers should not be ordered by the
CSE. 497/8K part numbers are customer install kits and are for
reference only.

1. 019K06030 HCF Tray alignment clip kit (REF: PL
7.17 Item 14)
2. 604K35371 Fuser latch pin kit (REF: PL 10.8 Item
10, PL 10.10 Item 10)
3. 604K62080 DADH sensor replacement kit
4. 604K84840 Take away feed /idler roll kit
5. 497K06410 1GB memory kit
6. 604K83560 LCSS Diverter gate assembly spares
kit
7. Work shelf assembly kit (REF: PL
8.10 Item 11)
8. 604K16890 Out of toner sensor kit (REF: PL 9.15
9. 604K18182 Tray 3 & 4 mylar retainer clip kit (REF:
PL 7.17 Item 6)
10. 604K53830 Hole punch field repair kit (REF: PL
11.6 Item 9) (W/TAG F-014)
11. Punch sensor assembly kit (REF: PL
11.6 Item 14)
12. 604K24930 Developer/Drives interface kit (REF:
PL 9.15 Item 23)
13. 801K20310 Separation strip kit (REF: PL 7.15
Item 19)
14. 604K83641 Feed/Nudger/Retard roll spares kit
(W/TAG 151)
15. 604K53950 Tray 3 and 4 paper feed assembly kit
(REF: PL 8.30 Item 1, PL 8.31 Item 1)
16. 1K LCSS mounting bracket repair kit
(REF: PL 11.100 Item 5)
17. 848E17510 Cover infill kit (REF: PL 7.25 Item 10,
PL 7.40 Item 11)
18. 604K54760 Envelope tray feeding kit (REF: PL
7.10)
19. 675K26824 OCT fingers kit (REF: PL 12.10 Item
3)
20. 675K53640 Tri-Folder install kit (REF: PL 11.193
Item 14)
21. 604K84020 Stack height sensor and shim kit
22. 604K48340 Fuser stripper finger kit (REF: PL 10.8
23. 604K84291 Hard disk drive spares kit
24. Feed roll kit (Pack of 3) (REF: PL 8.45
Item 21)
25. 604K53940 XRU skids kit (REF: PL 9.20 Item 19)
26. Replacement HDD kit (Not Spared)
NOTE: . 497/8K part numbers should not be ordered by the
CSE. 497/8K part numbers are customer install kits and are for
reference only.

1 604K53914 Inverter decurler kit (35-55 ppm)
046)
604K55013 Inverter decurler kit (65-90 ppm)
047)
2 498K17550 Foreign device interface kit
3 604K55120 Decurler soft roll repair kit (REF: PL
10.13 Item 9)
4 604K55050 Paper feed module frame repair kit
(REF: PL 7.10) (W/TAG 101)
5 604K55500 Skew bypass tray spares kit (x2
spring) (REF: PL 7.30 Item 29) (W/
TAG 048)
6 Shim kit (REF: PL 5.17 Item 29) (W/
TAG D-003)
7 LCSS Hole Punch Repair Kit (REF:
PL 11.6 Item 9)
8 604K55571 Drive roll repair kit (Pre-reg PL 8.15
Item 26, PL 8.17 Item 27) (Duplex
PL 8.20 Item 17, PL 8.22 Item 16)
(Inverter PL 10.14 Item 11) (SPP
PL 10.25 Item 11) (W/TAG 051)
9 604K60701 DADH mylar guide kit (REF: PL
5.10 Item 17)
10 498K17546 CAC enablement kit (USSG/XCL)
11 604K73370 BM Diverter kit (XE)
12 146E02210 Magstripe USB reader
13 20A adaptor kit (605K17470)
14 Install kit (USSG/XCL) (35-55 ppm)
Install kit (USSG/XCL) (65-90 ppm)
Install kit (XE) (35-55 ppm)
Install kit (XE) (65-90 ppm)
15 604K55100 HCF Heater kit
16 604K84190 FAR HCF bowl curl kit
17 604K96670 Tray 3 sensor spares kit
18 604K94310 Tray 5 adjustable castor kit
19 604K95440 Idle gear shaft spare kit
20 604K73070 Paddle wheel shaft assembly kit
(W/O TAG F-016)

for reference only.

PL 31.35 Line 1 Fax Kits
1 Line 1 Fax Kits (see below for
variants)
497K06330 United Kingdom, Spain, Greece,
Ireland, Portugal
497K06340 Austria, Germany, Switzerland, Italy
497K06350 Netherlands, Belgium, France
Denmark
South Africa (Not Spared)
497K05671 USSG/XCL
497K05661 XE
497K11270 Brazil (USSG/XCL)
for reference only.

PL 31.40 Line 2 Fax Kits
1 Line 2 Fax Kits (see below for
variants)
497K06370 United Kingdom, Spain, Greece,
Ireland, Portugal
497K06380 Austria, Germany, Switzerland, Italy
497K06390 Netherlands, Belgium, France
Denmark
497K07280 South Africa
497K05691 USSG/XCL
497K05681 XE

for reference only.

Common Hardware AX Screw M3x14 Machine
AY Screw M3x18 Self Tapping
AZ Washer M4
A 826E33270 Screw M3x6 Taptite (Zinc finish) BA Screw M4x16 Machine
B Screw M4x8 Taptite BB Screw M4x5 Machine
C 153W42353 Screw M4x12 Self Tapping BC Screw M3x10 Machine
D Screw M3.9.5 Taptite BD Screw M3x6 Machine
E Screw M3x8 Taptite BE Screw M4x7.5 Machine
F Screw M3x7.5 Taptite BF Screw M3x5.5 Machine
G Screw M4x12 Self Tapping BG Washer M3
H Screw M3x4.5 Machine BH Spring Washer M3
I 153W72553 Screw M4x16 Self Tapping BI Screw M3x6 Machine
J Screw M3x14 Self Tapping (Countersunk) BJ Screw M3x22 Self Tapping
K 153W41553 Screw M3x16 Self Tapping BK Retaining Ring (Skiffy) M7
L 153W42253 Screw M4x10 Self Tapping BL 354W00655 Circlip M10
M 354W20852 E-Clip M4 BM Screw M3x8 Machine
N 354W20952 E-Clip M5 BN Screw M4x8 Self Tapping
O 153W62353 Screw M4x12 Self Tapping BO 158W27655 Screw M3x6 Taptite
P 153W72353 Screw M4x12 Taptite BP Screw M3x4 Machine (Countersunk)
Q Screw M4x11 Self Tapping BQ Screw M3x16 Machine
R KL Clip M6 BR Screw M3x9.5 Self Tapping
S Screw M4x30 Taptite BS 251W16355 Washer M4
T Screw M3x10 Self Tapping BT 158W35855 Screw M4x8 Self Tapping
U Screw M3x10 Taptite BU 153W17855 Screw M3x5.5 Self Tapping
V Screw M3x6 Taptite BV Screw M4x7 Taptite
W Screw M3x16 Self Tapping BW 158W27660 Screw M3x6 Self Tapping
X Screw M3x6 Self Tapping BX Screw M3x8 Self Tapping
Y E-Clip M8 BY 158W40459 Screw M4x8 Self Tapping
Z 354W26251 E-Clip M4 BZ Screw M4x16 Taptite
AA 354W29251 E-Clip M7 CA 153W71153 Screw M3x8 Self Tapping
AB Screw M3x25 Self Tapping CB Screw M4x10 Self Tapping
AC 112W25155 Screw M3x4 Taptite CC 158W20459 Screw M4x8 Self Tapping
AD 354W21052 E-Clip M6 CD 153W71253 Screw M3x10 Self Tapping
AE 251W10655 Washer M8 CE Screw M3x12 Self Tapping
AF 265W00650 Spring Washer M6 CF 158W35860 Screw M4x5 Taptite
AG Screw M3.5x10 Self Tapping CG Circlip M6
AH Circlip M5 CH Screw M3x10 Machine
AI Circlip M8 CI 113W35557 Screw M4x5 Machine
AJ 259W30351 Star Washer M4 CJ Screw M3x11 Self Tapping
AK Screw M4x9.5 Machine CK 354W20652 E-clip M2.5
AL Screw M5x18 Self Tapping CL 251W10556 Washer M5
AM Star Washer M3.5 CM Screw M4x9 Self Tapping
AN Screw M3.5x5.5 Machine CN Screw M3x14 Self Tapping
AO Screw M3.5x6 Machine CO Screw M3x8 Self Tapping
AP Screw M5x11 Taptite CP Screw M4x15 Taptite
AQ Screw M3x8 Taptite CQ Spring Washer M8
AR Screw M4x8 Machine CR Screw M3x8 Self Tapping
AS Screw M4x10 Self Tapping CS Screw M4x8 Machine
AT Screw M4x10 Self Tapping CT Screw M3x5.5 Machine
AU Screw M3x5 Machine CU Screw M3x9 Self Tapping
AV E-Clip M3.5 CV Nut M3
AW Screw M3x5.5 Taptite CW Nut M3

Xerox WorkCentre 5790 Family 5-141 Common Hardware
CX Screw M4x6 Machine
CY Screw M4x11.5 Taptite
CZ Screw M3x7.5 Taptite
DA Screw M4x7 Self Tapping
DB Screw M3x6 Self Tapping
DC Screw M3x12 Self Tapping
DD Screw M5x12 Self Tapping
DE Circlip M7
DF Screw M3x6 Machine
DG Screw M3x7.5 Self Tapping
DH Screw M4x7 Self Tapping
DI Screw M4x34 Self Tapping
DJ Screw M4x16 Self Tapping
DK Screw M4x7 Self Tapping
DL Screw M4x6 Taptite
DM M3 Star Washer
DN Screw M4x6 Machine
DO Screw M3x6 Self Tapping
DP M3 Nut (Washer Head)
DQ Screw M4x11 Machine
DR Washer M8 (Nylatron)
DS Screw M3 x 8
DT Screw M3x17 Taptite
DU Screw M2.5x8 Taptite
DV Screw M3.5x10 Torx
DW Screw M3.5x10 Taptite
EA Screw M4x6 Machine
EB Screw M4x10 Machine
EC Screw M4x8 Machine
EF Screw M5x6 machine
EH Pivot pin M4X10 Hex Head
EI 013E25790 Nylon bearing
EJ 013E25800 6mm x 10mm x 13mm bush (bronze)
ET M4 x 5.5 Screw/Machine/Pozi/Wash Hd Brass
EU 658W28660 M3x16 Screw/Machine/Pozi/Pan Hd
EV KL Clip M4
ZZ 354W21251 E-clip M3

Common Hardware 5-142 Xerox WorkCentre 5790 Family
6 General Procedures/Information
GP 1 to GP 9 Diagnostic Codes dC001 to dC131b
GP 1 Diagnostics Entry, Facilities and Exit ..................................................................... 6-3 dC001 Reset Auditron Master PIN .................................................................................. 6-73
GP 2 Fault Codes and History Files ................................................................................ 6-6 dC104 Modal Usage Counters ........................................................................................ 6-73
GP 3 Service Information ................................................................................................ 6-7 dC109 Embedded Fax Protocol Report .......................................................................... 6-74
GP 4 Machine Software .................................................................................................. 6-9 dC111 Tag Matrix............................................................................................................ 6-76
GP 5 Portable Work Station and Tools ........................................................................... 6-21 dC131 NVM Read/Write.................................................................................................. 6-76
GP 6 Screw Usage.......................................................................................................... 6-22 dC131a NVM Tables Chain 1 to 10................................................................................. 6-77
GP 7 Miscellaneous Checks ........................................................................................... 6-23 dC131b NVM Tables Chain 12 to 19............................................................................... 6-102
GP 8 Special Tools and Consumables............................................................................ 6-24
GP 9 Secure Diagnostic .................................................................................................. 6-24 Diagnostic Codes dC132
dC132 NVM Initialization ................................................................................................. 6-105
GP 10 to GP 19
GP 10 How to Check a Motor.......................................................................................... 6-25 Diagnostic Codes dC305 to dC905
GP 11 How to Check a Sensor ....................................................................................... 6-27 dC305 UI Test ................................................................................................................. 6-107
GP 12 How to Check a Solenoid or Clutch ..................................................................... 6-28 dC312 Network Echo Tests............................................................................................. 6-108
GP 13 How to Check a Switch ........................................................................................ 6-29 dC314 Network Connectivity Tests ................................................................................. 6-108
GP 14 How to Switch Off the Machine or Switch On the Machine.................................. 6-29 dC330 Component Control.............................................................................................. 6-109
GP 15 How to Set the Machine Configuration................................................................. 6-31 dC604 Registration Setup Procedure.............................................................................. 6-122
GP 16 How to Safely Lift or Move Heavy Modules ......................................................... 6-31 dC606 Internal Print Test Patterns .................................................................................. 6-124
GP 17 High Frequency Service Items ............................................................................. 6-32 dC640 Video Path Diagnostics........................................................................................ 6-125
GP 18 Machine Lubrication ............................................................................................. 6-32 dC905 TC Sensor Calibration ......................................................................................... 6-125
GP 19 Network Clone Procedure .................................................................................... 6-34 Change Tags
GP 20 to GP 29 Tags ................................................................................................................................ 6-127
GP 20 Paper and Media Size Specifications................................................................... 6-35 Processor Tags ............................................................................................................... 6-128
GP 21 Installation Space Requirements ......................................................................... 6-51 DADH Tags ..................................................................................................................... 6-131
GP 22 Electrical Power Requirements ............................................................................ 6-53 2K LCSS Tags................................................................................................................. 6-132
GP 23 Environmental Data.............................................................................................. 6-55 1K LCSS Tags................................................................................................................. 6-135
GP 24 Customer Administration Tools ............................................................................ 6-55 HVF Tags ........................................................................................................................ 6-136
GP 25 First Copy / Print Out Time and Power On / Off Time.......................................... 6-56 Tray 6 Inserter Tags ........................................................................................................ 6-137
GP 26 Restriction of Hazardous Substances (RoHS) ..................................................... 6-57 Tray 5 Tags ..................................................................................................................... 6-138
GP 27 Fuser/Xerographic Module End of Life Extension................................................ 6-57 Fax Tags ......................................................................................................................... 6-139
GP 28 USB Connection Mode......................................................................................... 6-58
GP 29 Embedded Customer Documentation .................................................................. 6-58
GP 30 to GP 36
GP 30 Copier Only Machine Identification ...................................................................... 6-59
GP 31 How to Set the Date and Time ............................................................................. 6-59
GP 32 How to Enable HTTP ........................................................................................... 6-60
GP 33 How to Configure the PWS to Ping a Device ....................................................... 6-60
GP 34 How to Set the IP Address of the PWS................................................................ 6-61
GP 35 How to Change Ethernet Speed .......................................................................... 6-62
GP 36 How to Disable the Firewall of the PWS .............................................................. 6-63
GP 40
GP 40 Glossary of Terms, Acronyms and Abbreviations ................................................ 6-65
November 2014 General Procedures/Information

General Procedures/Information November 2014
GP 1 Diagnostics Entry, Facilities and Exit Fax routines:
dC109 Protocol Report.
Purpose dC131 NVM Read / Write.
This procedure describes the following items: dC132 NVM Initialization.
How to Enter Diagnostics. dC330 Component Control.
Diagnostic Menu. How to Exit From Diagnostics
How to Exit From Diagnostics. 1. Touch the Exit button to exit from the dC procedures.
How to Enter the Service Copy Mode. 2. Touch the Call Closeout button to exit diagnostics.
NOTE: When the diagnostic mode is entered, all existing copy jobs are cancelled and an 3. When the Call Closeout window is displayed, the following options are available:
Offline screen message is displayed. When exiting the diagnostics mode an Online screen Reset All Counters. The default is No. If the Yes button is touched, the following
message is displayed. counters are reset:
Faults.
To increase diagnostics security, refer to GP 9.
Last 40 faults.
Procedure Total Images made after the last service call.
How to Enter Diagnostics Reboot copier. The default is Yes. The single board controller PWB, IOT, scanner,
GUI, DADH, tray 1 and 2 assembly, HCF and Finisher are rebooted. Touch the No
button if machine reboot is not needed.
2. When the machine in ready, press and hold the # key, then the Log In/Out key.
3. Enter the PIN 1934. Touch the Enter button on the UI. NOTE: If the machine is not rebooted, the exit time from diagnostics is decreased.
NOTE: Press the C Key to clear an incorrect entry. Three incorrect entries cause the entry 4. Touch the Closeout button to complete the exit procedure.
screen to lock for three minutes. How to Enter the Service Copy Mode
The Service Copy Mode allows the engineer to make copies when the Auditron, Foreign Inter-
4. If secure diagnostics is enabled, a second PIN is required to enter Diagnostic Routines.
Refer to GP 9. face or Job Based Accounting are enabled.
5. Select the correct tab from the Diagnostic screen, refer to Table 1.
1. Press and hold the # button, then the Log In/Out key.
Diagnostic Menu
2. Enter the Service Copy Mode, PIN 4391.
The Diagnostic Routines screen gives access to the diagnostic menu, refer to Table 1. The
3. Select the Enter button on the UI.
diagnostic routines available are given below:
4. To exit, press and hold the # button, then the Log In/Out key.
Copier routines:
dC131 NVM Read/Write
dC132 NVM Initialization - Copier.
dC305 UI Test.
dC330 Component Control.
dC604 Registration Setup.
dC640 Video Path Diagnostics.
dC905 TC Sensor Calibration.
Network routines:
dC132 NVM Initialization - Network
dC312 Echo Test.
dC314 Network Connectivity Tests.
Other routines:
dC001 Reset Auditron Master Pin
dC104 Modal Usage Counters.
dC111 Tag Matrix.
dC606 Internal Print Test Patterns.

Xerox WorkCentre 5790 Family 6-3 GP 1
Table 1 Diagnostic screen menu
1st Level 2nd Level 3rd Level 4th Level 5th Level
Service Info GP 3 Software Versions - - NOTE: Only the categories for the installed options are dis-
played.
- Usage Counters Display Current Usage Counters - -
- Machine Serial No.: - - -
- Images Since Last Call: - - -
- Network IP Address: Full Network IP Address value: - -
Fault History GP 2 Fault Log Erase History - -
- Fault Counters Fault Chain 01 Standby Power -
- - - 02 Mode Selection UI -
- - - 03 Machine Run Control -
- - - 04 Start Print Power -
- - - 05 Document Transport -
- - - 06 ROS -
- - - 07 Paper Supply -
- - - 08 Paper Feed and Transports -
- - - 09 Xerographics -
- - - 10 Copy Transports -
- - - 11 Sorter/Mailbox -
- - - 12 Finisher/DFA -
- - - 13 Transition Module -
- - - 14 RIS -
- - - 15 IPS1 -
- - - 16 Network Controller -
- - - 17 Disk Operation -
- - - 18 Connectivity -
- - - 19 Video Image Manipulation -
- - - 20 Fax -
- - - 21 RDT -
- - - 22 Main Controller Module -
Diagnostic Routines Copier Routines dC131 NVM Read/Write 01 Standby Power -
- - - 02 Mode Selection UI -
- - - 03 Machine Run Control -
- - NOTE: Refer to GP 4 Machine Software. 05 Document Transport -
- - - 06 ROS -
- - - 07 Paper Supply -
- - - 08 Paper Feed/Trans -
- - - 09 Xerographics -
- - - 10 Copy Trans/Fusing -
- - - 12 Finisher/DFA -
- - - 14 RIS -
- - - 15 Image Process Sys -
- - - 17 Disk Operation -
- - - 19 Video Image Manip -
- - dC132 NVM Initialization - Copier... All Copier NVM -

GP 1 6-4 Xerox WorkCentre 5790 Family
Table 1 Diagnostic screen menu
1st Level 2nd Level 3rd Level 4th Level 5th Level
- - NOTE: Refer to GP 4 Machine Software. Machine Variable NVM -
- - - SA/KO Dust Off -
- - - System Counters Dust Off -
- - dC305 UI Test... User Interface Button Test -
- - - Audio Tone Test -
- - - LED Indicator Test -
- - - Touch Area Test -
- - - Display Pixel Test -
- - - Video Memory Test -
- - - Communications Self Test -
- - - Reset User Interface -
- - - Application Checksum Verification -
- - dC330 Component Control... - -
- - dC604 Registration Setup... IOT Registration Side 1 -
- - - IOT Registration Side 2 -
- - - Scanner Registration -
- - - Document Handler Registration -
- - dC640 Video Path Diagnostics... Scanner Video Test -
- - - Network Controller/SIP Test -
dC905 TC Sensor Calibration... Start / Stop -
- Network Routines dC132 NVM Initialization - Network All Network NVM -
- - - Variable NVM -
- - - Configuration NVM -
- - dC312 Echo Test TCP/IP Internal. - Tests internal IP stack and hosts file.
- - - - Network. - Tests the Network to find other IP hosts.
- - - Novell Internal. - Tests the internal Novell stack and driver.
- - - - Network. - Tests the Network to find the other IPX devices.
- - - NetBIOS/NetBEUI Network. - Tests the Network to find the other NetBIOS
devices.
- - - AppleTalk Network. - Tests the Network to find the other AppleTalk
devices.
- - - Internal TCP/IP -
- - dC314 Network Connectivity Test... TCP/IP -
- - - Novell or IPX -
- - - NetBIOS/NetBEUI -
- - - AppleTalk -
- - dC001 Reset Auditron Master Pin - -
- Other Routines dC104 Modal Usage - -
- - dC111 Tag Matrix... - -
- - dC606 Print Test Patterns... - -
- Fax Routines dC109 Protocol Report - -
- - dC131 NVM Read/Write - -
- - dC132 NVM Initialization - -
- - dC330 Component Control - -

GP 2 Fault Codes and History Files Table 1 Function and fault code prefixes
Purpose Chain Code Function
To explain the fault code structure and describe fault history contents. 14 Raster input scanner (RIS)
15 Image Processing System (IPS1)
Description 16 Network controller
To access some history files from the UI, refer to Machine Status Button Fault History. 19 Video image manipulation
To view all the machine fault history, clear the last 40 faults, or reset each of the fault 20 Facsimile (FAX)
counters, refer to Diagnostics Fault History. 22 Main controller module
For information on fault codes, refer to Function, Fault, Component and Status Codes.
For information on status codes, refer to OF4 Status Codes and Messages RAP. -
Procedure
Table 2 Fault and control code suffixes
1. Enter diagnostics, GP 1.
2. Select Fault History. Link Code Description
3. Select Fault Log or Fault Counters button as appropriate and follow the on screen 000 to 099 Output
instructions. 100 to 199 Jams
Function, Fault, Component and Status Codes 200 to 299 System timing
Refer to: 300 to 399 Controls
Table 1 Function and fault code prefixes. Also known as the chain code. 400 to 499 Spare or overflow
Table 2 Fault and control code suffixes. Also known as the link code. 500 to 599 Status codes
Table 3 Finisher fault code and status code suffixes. Also known as the extension code. 600 to 699 Xerographic copy/print quality
For example. Displayed code 07-345 - Tray 1 Out of Service: 700 to 799 Non-declared defects
07 - The fault is located in the function chain Paper supply, Table 1. 800 to 899 Optional use
345 - Because this starts with 3, it is a Controls code, Table 2. The 4 and the 5 are 900 to 999 Operator messages
sequence numbers and have no other significance.
NOTE: Where possible, the component related fault codes are the same as the component
control codes.
Table 3 Finisher fault code and status code extensions
Suffix No. Finisher Identifier
Table 1 Function and fault code prefixes 65 OCT

110 2K LCSS
Chain Code Function
120 1K LCSS
01 Standby power
171 HVF
02 User interface mode selection
172 HVF BM
03 Machine run control
173 HVF BM + tri-fold
04 Start print power
174 HVF BM + inserter
05 Document transport
175 HVF BM + tri-fold
06 Raster output scanner (ROS)
176 HVF BM + tri-fold + inserter
07 Paper supply
08 Paper feed and transports
NOTE: The finisher status code extensions are not normally visible. Throughout this manual,
09 Xerographic
the code extension 171 is used for all HVF variants.
10 Fusing
11 Finisher
12 Offsetting catch tray

Machine Status Button Fault History GP 3 Service Information
The most recent fault and status codes can be displayed on the UI by pressing the Machine Purpose
Status button. Touch the Faults tab on the UI, then touch, as appropriate:
To provide machine hardware and software information.
All Faults.
Active Messages - status codes and a status message. Service Information From The Diagnostic Screen
Event Log. Enter Diagnostics, GP 1, select the Service Information tab. This gives the following options:
Diagnostics Fault History
Description Machine Serial Number. See Machine Serial Number
The diagnostics Fault History window contains two options: Images Since Last Call
1. Last 40 faults - Displays the last 40 faults in time or code order. Displays a selected fault Network IP Address
in detail. Permits deletion of the entire history file. HFSI
2. Fault Counters - Displays the title buttons for the faults separated into chains. Selection of Software Versions
a chain will display the fault detail. System Set
NOTE: Categories that do not exist on the machine will not be displayed. Software Upgrade
SIP Application
When a paper jams fault chain is selected and the OK button is touched, the details will be SIP IPS
shown for the selected chain. A Rate button is displayed. Touch the Rate button to show the
SIP IPP
jam rate per million sheets fed (fault counter x 1 000 000 divided by sheets fed).
UBOOT
Operating System
Network Controller
GUI Application
DUI H8
Document Handler Application
Embedded Fax
Embedded Fax Boot Code
Finisher Application
Image Output Terminal Bootstrap
Image Output Terminal Bootloader
Image Output Terminal Application
Scanner Application
Trays 3 and 4
PFM
Booklet Maker Application
Booklet Maker Bootcode
Usage Counters

Xerox WorkCentre 5790 Family 6-7 GP 2, GP 3
Service Information From The UI Machine Information Tab Machine Serial Number
Press the machine status key to the left of the UI to display the machine information tab. This The machine serial number is also on the machine TAG label. The serial number for the US
gives the following options: markets is in the format:
XXX ###### #. Where XXX is the product code (see Product Code). ###### is the serial num-
General Information
ber. # is the model code.
Customer Support
The serial number for the XE markets is in the format: MMM######C. MMM is the manufactur-
Supplies Number
ing location code, ###### is the serial number and C is the check digit, for example
Machine Serial Number. Refer to Machine Serial Number.
2327020103.
System Software Version
Product Code
Fax Line IDs
Primary Build Machines
Total Impressions
Paper Tray Status Primary build machines are supplied as WorkCentres. Configuration changes to faster speeds
and output modules are carried out as secondary build upgrades.
Information Pages
Print Reports (will be greyed out on a copier only machine) Malaysia built machines:
Machine Hardware Options XEE: 35 ppm, DADH, Stand, Mono Scanner, (60Hz).
Paper Supply XEF: 35 ppm, DADH, HCF, Color Scanner, (60Hz).
Finisher XEG: 35 ppm, DADH, HCF, Mono Scanner, (60Hz).
XEH: 55 ppm, DADH, HCF, Color Scanner, (60Hz).
Pre-collation RAM
XEK: 55 ppm, DADH, HCF, Mono Scanner, (60Hz).
Image Disk
XEL: 65 ppm, DADH, HCF, Color Scanner, (60Hz).
Fax
XGB: 35 ppm, Platen, Stand, Mono Scanner, (60Hz).
Fax N V Memory
XGD: 55 ppm, DADH, Stand, Mono Scanner, (60Hz).
Foreign Interface Device XDX: 35 ppm, DADH, Stand, Mono Scanner, (50Hz).
Network Controller (will not be present on a copier only machine) XDY: 35 ppm, DADH, HCF, Mono Scanner, (50Hz).
Network Controller RAM XEA: 35 ppm, DADH, HCF, Color Scanner, (50Hz).
USB Printer Port XEB: 45 ppm, DADH, HCF, Mono Scanner, (50Hz).
Image Processing Card (Not Present) XEC: 45 ppm, DADH, HCF, Color Scanner, (50Hz).
Tray 6 (Inserter) XED: 65 ppm, DADH, HCF, Mono/Color Scanner, (50Hz).
Staple Capacity XGA: 35 ppm, Platen, Stand, Mono Scanner, (50Hz).
XGC: 45 ppm, DADH, Stand, Mono Scanner, (50Hz).
Machine Software Versions
Singapore built machines:
Scanner and Image Processor
XEEN: 35 ppm, DADH, Stand, Mono Scanner, (60Hz).
Image Output Terminal
XEFN: 35 ppm, DADH, HCF, Color Scanner, (60Hz).
User Interface
XEGN: 35 ppm, DADH, HCF, Mono Scanner, (60Hz).
Network Controller
XEHN: 55 ppm, DADH, HCF, Color Scanner, (60Hz).
Document Feeder XEKN: 55 ppm, DADH, HCF, Mono Scanner, (60Hz).
Tray 5 XELN: 65 ppm, DADH, HCF, Mono/Color Scanner, (60Hz).
Fax XGDN: 55 ppm, DADH, Stand, Mono Scanner, (60Hz).
Finisher Secondary Build Upgrades
HLX: 2K LCSS
HLB: 1K LCSS
YFV: HVF
YFW: HVF BM
YFY: Inserter
YGD: Tri-folder
BVU: Tray 5

GP 4 Machine Software Common Upgrade Behavior
A software upgrade is requested if a new hardware module is installed which has an earlier or
Purpose later software version.
To provide machine software information and explain the software loading procedures.
When an upgrade has been initiated the machine will reboot with all modules in upgrade mode.
Description Progress and errors are displayed on the UI touch screen. When the upgrade is complete, the
Software sets are compilations of the various software modules and together with a SCD (soft- machine will reboot.
ware compatibility database) are bundled into a DLM file.
When a machine is switched on, the single board controller PWB module compares its SCD
Refer to the following items for additional information about machine software: with the software in the hardware modules. If necessary, a software upgrade or downgrade is
Modules instigated by the single board controller PWB module.
Software Compatibility Database (SCD)
NOTE: If a component is installed that has a later version of software than the software set on
Common Upgrade Behavior the single board controller PWB module, at machine startup the software on the new compo-
Software Loading Procedures nent is downgraded.
Normal Software Loading Procedure
The SCD is updated on successful completion of the upgrade.
AltBoot Software Loading Procedure
Forced AltBoot Software Loading Procedure Software Loading Procedures
Modules Loading of machine software can be initiated either;
A software module is defined as a programmable piece of software existing as a file in its own
right. Software modules reside on hardware modules. locally from a PWS or USB Flash Drive
remotely via a network connection
The following hardware modules contain firmware and cannot have software upgrades loaded: There are various methods of loading the machine software for the WC5790F machines. Refer
Scanner (W/O TAG 150). to Table 1 to select the appropriate procedure.
Paper feed module.
High capacity feeder. NOTE: The Software Loading From a USB Flash Drive procedure can only be used to upgrade
machine software to a higher version. The procedure will fail if an attempt is made to install
NOTE: The software for the scanner (W/O TAG 150), paper feed module or high capacity machine software of the same version to that currently loaded on a WC5790F machine. If it is
feeder can only be upgraded by installing a newer version of the relevant PWB on each necessary to reload machine software of the same version via a USB Flash Drive the AltBoot
hardware module. Software Loading Procedure must be used.
Software Compatibility Database (SCD)

Table 1 Software loading procedures
The SCD is used to describe the machine system software.
Suitable for
The SCD comprises of the system software version in the format WorkCentre_5735- Suitable for MFD copier only
Software upgrading configured configured Software upgrade
5790_system-sw#(PPP).(MMM).(YYY).(DDD)(RR)#.dlm and a list of software versions for the
procedure type machines machines application
different modules.
Software Loading Via Use on a good working
The description of the system software file name is: the Customers Net- Yes No machine.
PPP - is the platform identifier. work
MMM - is the machine identifier. Software Loading Yes Use on a good working
From the PWS No machine.
YYY - is the year of release.
Software Loading Yes No Use to only upgrade
DDD - is the day, in the year, of release.
From a USB Flash software on a good
RR - is the daily revision number.
Drive working machine. See
NOTE: The system software version is displayed on the UI under Machine Details and on the above Note.
Service Info screen in service mode. PWS Altboot Proce- Yes No Use as directed on a
dure faulty machine.
The primary function of an SCD is to ensure that all software on the machine is compatible.

Table 1 Software loading procedures c. In the General tab, highlight the Internet Protocol (TCP / IP) icon.
Suitable for d. Click on the Properties button.
Suitable for MFD copier only e. Select Use the following IP address.
Software upgrading configured configured Software upgrade
NOTE: Before changing the proxy server settings, record the original IP address and
procedure type machines machines application
Subnet mask. The original settings are reset at the end of this procedure.
USB AltBoot Proce- Yes No Use as directed on a
dure faulty machine. f. Refer to the configuration report for IP address of the machine. Set the IP address of
the PWS one number higher than the machine. For example, if the IP address of the
USB Forced AltBoot Yes Yes Use as directed on a
machine is 192.168.196.112, set the IP address of the PWS to 192.168.196.113.
Procedure faulty machine.
g. Refer to the configuration report for Subnet mask of the machine. Set the Subnet
PWS Forced Altboot Yes Yes Use as directed on a
Procedure faulty machine. mask of the PWS to the same as the Subnet mask of the machine.
NOTE: A default gateway setting is not required.
Normal Software Loading Procedure h. Click on OK to close the properties dialog box.
Use this procedure to load software onto a good, working machine.
i. Click on Close to close the Local Area Connection Properties dialog box.
j. If any settings have been changed, reboot the PWS.
NOTE: Copier only machines can not be upgraded using this procedure. Use the Forced Alt-
Boot Software Loading Procedure to upgrade copier only machines. To identify a copier only 3. Switch on the machine, GP 14.
machine, refer to GP 30 Copier Only Machine Identification. 4. Disconnect the ethernet cable from the machine.
5. Connect the ethernet crossover cable, PL 26.10 Item 6 between the machine and the
Initial Requirements
PWS.
Before software is loaded, ensure that the machine is in a fully operational condition. Any
active faults or jams must be resolved before loading software. NOTE: The machine has a network 802.1x Authentication option. If this option is enabled
the PWS will not connect to the machine. To make a successful connection, press the
NOTE: The procedure will take approximately 15 minutes.
Machine Status button, select Tools / Network Settings / 802.1X / Disable.
If the software loading procedure fails, go to OF5 Boot Up Failure RAP. 6. If the web browser on the PWS is set to use a proxy server, it will not connect to the
Procedure machines web page. Perform the following:
There are three methods to load software, go to the relevant procedure: a. Open the web browser on the PWS.
Software Loading Via the Customers Network. b. Select Tools, then select Internet Options.
Software Loading From the PWS. c. Select the Connections tab.
Software Loading From a USB Flash Drive d. Click on the LAN settings button. The LAN settings dialog box will now be displayed.
Software Loading Via the Customers Network e. The Use a proxy server for your LAN box should not be checked.
The software is loaded via the customers network. As the software loading instructions are 7. Open the web browser. Enter the machines IP address in the web browsers Address field,
subject to change, a read me file is available at the same location as the software. Refer to the then press the enter key. The machines web page will open.
read me file for the software loading procedure.
NOTE: Refer to the configuration report for the machines IP address.
The progress of the software loading procedure is displayed on the UI. For more information,
8. In the machines web page, click on the Properties tab.
refer to Software Loading Progress.
9. Login as the administrator, i.e. Login: Admin. Password: 1111 (default).
If the machine does not go into the software loading procedure, check the following: 10. Open the General Setup folder, then the Machine Software folder.
The relevant cabling to the machine. 11. Select Manual Upgrade.
The functionality of the PC being used to perform the procedure. NOTE: If necessary, enable manual software upgrades.
Software Loading From the PWS
12. Click the browse button in the middle of the screen.
13. Browse to the correct location of the DLM file, then click open.
1. Print a configuration report.
14. Click on the Install Software button.
2. Set the proxy server setting on the PWS. Perform the following:
15. The DLM is displayed in the machines print queue. The upgrade begins in approximately
a. Open Start / Control Panel / Network Connections/Local Area Connections.
10 minutes. The progress of the software loading procedure will be displayed on the UI.
b. Open Local Area Connection. For more information, refer to Software Loading Progress.

16. When the upgrade has completed, the machine will reboot automatically. Software Loading Progress
NOTE: When the machine reboots, the connection to the machines web page is lost. During the software loading procedure, a progress screen is displayed on the UI, Figure 1. The
display has the following features:
17. After the machine has rebooted, a configuration report will be printed. Check the software A progress bar is assigned to each of the hardware modules.
version against the software version in the machine details screen on the user interface. For the upgrade of each hardware module to be successful, the progress bar must reach
18. Compare the configuration reports. Ensure that the configuration report generated after 100% for each module being upgraded. During upgrading, the symbol to the left of the
the upgrade shows the same machine configuration as before the upgrade. progress bar indicates one of the following conditions:
19. If the proxy server setting on the PWS was changed, return the setting to the original Orange circle with white arrows, an upgrade is in progress.
value.
Green tick, an upgrade has completed.
20. Connect the customers network cable to the machine. Switch off the machine, then switch
Red circle with white cross, a module has failed to be upgraded.
on the machine, GP 14.
The upgrade is completed when all the progress bars are 100%.
Software Loading From a USB Flash Drive
NOTE: The Software Loading From a USB Flash Drive procedure can only be used to upgrade
machine software to a higher version. The procedure will fail if an attempt is made to install
machine software of the same version to that currently loaded on a WC5790F machine. If it is
necessary to reload machine software of the same version via a USB Flash Drive the AltBoot
Software Loading Procedure must be used.

1. Create a top level folder on the USB flash drive named upgrade (this is not case sensi-
tive).
2. Copy the WorkCentre_5735-5790_system-sw#ppp.mmm.yyy.dddrr#.dlm file from the
system software CD into the upgrade folder of the USB flash drive.
NOTE: Make sure there is only one file in the upgrade folder.
NOTE: Ensure the Windows safely remove hardware device process is followed, before
removing the USB drive.
3. If possible, complete or delete all pending print jobs. If the prints jobs cannot be deleted,
warn the customer that all pending jobs will be lost.
4. Check the Release Notes and the current software already loaded on the machine.
Ensure that the upgrade can be applied.
5. Connect the USB flash drive into any of the USB ports.
Figure 1 Software upgrade in progress
NOTE: It is not necessary to switch off the machine to perform a software upgrade.
Occasionally the USB flash drive will be incompatible with the machine. Replace the USB
flash drive with a Xerox approved model. Restart the process.
6. The upgrade start screen is displayed, Figure 9.

7. The upgrade will begin and the progress screen will open, Figure 10.
8. The system upgrade process should complete after approximately 5 minutes and the
machine will come to a ready state.
9. If the system upgrade process fails, perform an Altboot. Refer to AltBoot Software Load-
ing Procedure.
10. The machine will reboot several times before returning to a ready state. The machine may
also display the upgrade progress screen, Figure 10. If the power on failure screen is dis-
played, switch off, then switch on the machine, GP 14.
11. After the software has upgraded, a software upgrade report will be printed.

AltBoot Software Loading Procedure 8. The AltBoot process should complete after approximately 5 minutes and the AltBoot com-
plete screen will open, Figure 10. Follow the on screen instructions.
Use this procedure to load software onto a faulty machine. Only use this procedure if directed.
9. If the AltBoot process fails, the AltBoot failed screen will open, Figure 11. Follow the on
screen instructions. Restart the procedure and refer to Troubleshooting as necessary.
10. The UI displays the Data Encryption/Decryption in progress screen, Figure 13.
CAUTION
The AltBoot software loading procedure erases the customer Optional Services (Network NOTE: Do not switch off the machine until directed to on the UI. During the reboot, the
Scanning; E-Mail; Internet Fax; Network Accounting; Server Fax; Hard Disk Overwrite; Xerox hard disk drive is encrypted. Switching off the machine can cause only partial encryption
Standard Accounting (XSA). Check with the customer, that they have the necessary codes to of the hard disks partitions. The AltBoot process may need to be re-run if power is
enable their Optional Services and they can restore any configuration information for the removed at this step.
installed options.
11. The machine will reboot several times before returning to a ready state. If a power on fail-
NOTE: Copier only machines can not be upgraded using this procedure. Use the Forced Alt- ure screen appears, switch off, then switch on the machine, GP 14.
Boot Software Loading Procedure to upgrade copier only machines. To identify a copier only 12. Check that the software set has been installed. Refer to the printed software upgrade
machine, refer to GP 30 Copier Only Machine Identification. report or by pressing the machine status button.
NOTE: To restore the XSA data, use the customers XSA data backup (clone) file on the cus- 13. Perform a NVM restore, refer to GP 5.
tomers PC. Refer to the Customer Administrators Guide CD. 14. Switch off, then switch on the machine, GP 14.
PWS Altboot Procedure
There are two methods of performing an Altboot. Go to the relevant procedure:
Hardware requirements:
USB AltBoot Procedure
Serial cable, PL 26.10 Item 12.
PWS Altboot Procedure
9 way gender changer, PL 26.10 Item 1.
USB AltBoot Procedure
Ethernet crossover cable, PL 26.10 Item 6.
Software requirements:
USB Flash drive.
gawain.uImage - Linux kernal file.
gawain_ramdisk.uboot - Linux root file system file.
The DLM file to be loaded.
The DLM file to be loaded.
1. Create a top level folder on the USB Flash drive named AltBoot.
2. Copy the WorkCentre_5735-5790_system-sw#ppp.mmm.yyy.dddrr#.dlm file from the NOTE: For additional information or if the Altboot fails, refer to the help file supplied with the
system software CD into the AltBoot folder of the USB flash drive. PWS Altboot tool.
NOTE: If there is more than 1 version of a DLM file in the AltBoot folder on the USB flash 1. Print a configuration report.
drive the machine will always access the latest version. 2. If possible, perform a NVM save, refer to GP 5.
3. If possible, perform a NVM save, refer to GP 5. 3. Switch off the machine, GP 14.
4. Switch off the machine GP 14. 4. Disable the wireless network on the PWS.
5. Plug the USB Flash drive into either of the 2 USB ports in the rear of the single board con- 5. Set the proxy server setting on the PWS. Perform the following:
troller PWB module. a. Open Start / Control Panel / Network Connections/Local Area Connections.
6. Switch on the machine GP 14. The Software Upgrade start screen will display on the UI, b. Open Local Area Connection.
Figure 9. c. In the General tab, highlight the Internet Protocol (TCP / IP) icon.
NOTE: If the Upgrade Failed screen, Figure 12 displays at this time, it is an indication of d. Click on the Properties button.
hard disk failure. Refer to the 03C Hard Disk Failure RAP. e. Select Use the following IP address.
7. After approximately 1 minute the upgrade will begin and the progress screen will open, NOTE: Before changing the proxy server settings, record the original IP address and
Figure 10. Subnet mask. The original settings are reset at the end of this procedure.
NOTE: If the upgrade process screen is not displayed after 2 minutes, restart the pro- f. Set the IP address of the PWS to 192.168.0.2.
cess. g. Set the Subnet mask of the PWS to 255.255.255.0.

h. Click on OK to close the properties dialog box. 12. After file transfer, the settings menu is displayed in the terminal window, Figure 3.
i. Click on Close to close the Local Area Connection Properties dialog box.
j. If any settings have been changed, reboot the PWS.
6. Disconnect the ethernet cable from the machine.
7. Connect the crossover ethernet cable from the PWS network port to the machine network
port.
8. Connect the null modem serial cable from the PWS serial port to the machine serial port.
9. Start the PWS AltBoot tool.
10. Browse to and highlight the folder that contains the upgrade files, Figure 2. Select OK.
Figure 3 Settings menu
NOTE: Check that the Received packet line is displayed and that the IP address is set
one digit away from the packet was received from address.
Press y at the prompt and continue. If the valid netmask is not set, press n and change
it to the value shown in Figure 3.
13. From the next menu, Figure 4, select action 5, Install ESS software.
Figure 2 Browse for folder
11. Switch on the machine, GP 14. After approximately 10 seconds, the transfer of the uIm-
age and uboot files will begin.
Figure 4 Action menu

14. At the proceed prompt, Figure 5, select Y. 16. From the next menu, Figure 7, select option 4, Continue.
Figure 5 Install confirmation window Figure 7 Option menu
15. At the second proceed prompt, Figure 6, select Y. 17. From the next menu, Figure 8, select the correct DLM file to download to the machine. A
transfer progress window will then open.
Figure 6 Release image install window

Figure 8 DLM list

18. After the DLM file has been downloaded to the machine, the Software Upgrade start
screen will display on the UI, Figure 9.
NOTE: If the Upgrade Failed screen, Figure 12 displays at this time, it is an indication of
hard disk failure. Refer to the 03C Hard Disk Failure RAP.
19. After approximately 1 minute the upgrade will begin and the progress screen will open,
Figure 10.
NOTE: If the upgrade process screen is not displayed after 2 minutes, restart the process.
20. The AltBoot process should complete after approximately 5 minutes and the AltBoot com-
plete screen will open, Figure 11. Ignore the instruction to remove the USB flash drive,
only press 0 to continue.
21. If the AltBoot process fails, the AltBoot failed screen will open, Figure 12. Follow the on
screen instructions. Restart the procedure and refer to Troubleshooting as necessary.
NOTE: Do not switch off the machine until directed to on the UI. During the reboot, the
hard disk drive is encrypted. Switching off the machine can cause only partial encryption
of the hard disks partitions. The AltBoot process may need to be re-run if power is
removed at this step.
ure screen appears, switch off, then switch on the machine, GP 14. Figure 9 Software upgrade
24. Disconnect the null modem serial cable from the PWS serial port and the machine.
25. Disconnect the special crossover ethernet cable from the PWS network and the machine.
26. Connect the ethernet cable to the machine.
27. Check that the software set has been installed. Refer to the printed software upgrade
report or by pressing the machine status button.
28. If the NVM was saved at the beginning of this procedure, perform a NVM restore, refer to
GP 5.
Figure 10 Start of upgrade

Figure 11 Altboot complete Figure 13 Encryption progress
Troubleshooting
Listed below are possible problems that may stop AltBoot software loading:
Possible causes and solutions are:
Incompatible USB flash drive. Use a Xerox approved model of USB flash drive.
Corrupt .dlm file. Replace the .dlm file.
Incorrect spelling of the AltBoot directory on USB flash drive.
Bad data connection to a HDD. Re-seat the HDD data cable, PL 3.22 Item 11.
Hard disk drive corruption or failure.
USB port damage. Use a different USB port.
UI failure. Refer to OF2 Touch Screen Failure RAP.
Single board controller PWB failure, PL 3.24 Item 3.
Check the +5V supply to the USB ports at PJ106 pin 6 on the single board controller
PWB. Refer to WD 3.
Software Loading Progress
During the software loading procedure, a progress screen is displayed on the UI, Figure 1. The
display has the following features:
A progress bar is assigned to each of the hardware modules.
For the upgrade of each hardware module to be successful, the progress bar must reach
100% for each module being upgraded. During upgrading, the symbol to the left of the
Figure 12 Upgrade failed progress bar indicates one of the following conditions:
Orange circle with white arrows, an upgrade is in progress.
Green tick, an upgrade has completed.
Red circle with white cross, a module has failed to be upgraded.
The upgrade is completed when all the progress bars are 100%.

Forced AltBoot Software Loading Procedure Perform the following:
Use this procedure to load software onto a faulty machine. Only use this procedure if directed. NOTE: For additional information or if the Forced Altboot fails, refer to the help file supplied
with the PWS Altboot tool.
CAUTION 1. Print a configuration report.

The Forced AltBoot software loading procedure erases the customer Optional Services (Net- 2. If possible, perform a NVM save, refer to GP 5.
work Scanning; E-Mail; Internet Fax; Network Accounting; Server Fax; Hard Disk Overwrite; 3. Switch off the machine, GP 14.
Xerox Standard Accounting (XSA). Check with the customer, that they have the necessary 4. Disable the wireless network on the PWS.
codes to enable their Optional Services and they can restore any configuration information for 5. Set the proxy server setting on the PWS. Perform the following:
the installed options. a. Open Start / Control Panel / Network Connections/Local Area Connections.
NOTE: To restore the XSA data, use the customers XSA data backup (clone) file on the cus- b. Open Local Area Connection.
tomers PC. Refer to the Customer Administrators Guide CD. c. In the General tab, highlight the Internet Protocol (TCP / IP) icon.
There are two methods of performing a Forced Altboot. Go to the relevant procedure: d. Click on the Properties button.
USB Forced AltBoot Procedure e. Select Use the following IP address.
PWS Forced Altboot Procedure NOTE: . Before changing the proxy server settings, record the original IP address
USB Forced AltBoot Procedure and Subnet mask. The original settings are reset at the end of this procedure.
Hardware requirements: f. Set the IP address of the PWS to 192.168.0.2.
USB Flash drive. g. Set the Subnet mask of the PWS to 255.255.255.0.
NOTE: . A default gateway setting is not required.
The FORCED_UPGRADE file.
The DLM file to be loaded. h. Click on OK to close the properties dialog box.
Perform the following: i. Click on Close to close the Local Area Connection Properties dialog box.
1. Create a folder named AltBoot on a USB Flash drive (not case sensitive). j. If any settings have been changed, reboot the PWS.
2. Locate the FORCED_UPGRADE file (file size = 0 KB) in GSN library 11297. 6. Disconnect the ethernet cable from the machine.
3. Unzip then copy the FORCED_UPGRADE file into the AltBoot folder on the USB Flash drive. 7. Connect the crossover ethernet cable from the PWS network port to the machine network port.
4. Copy the DLM file into the AltBoot folder on the USB Flash drive. 8. Connect the null modem serial cable from the PWS serial port to the machine serial port.
5. If possible, perform a NVM save, refer to GP 5. 9. Start the PWS AltBoot tool.
6. Switch off the machine, GP 14. 10. Browse to and highlight the folder that contains the upgrade files, Figure 14. Select OK.
7. Plug the USB Flash drive into either of the 2 USB ports in the rear of the single board con-
troller PWB module.
9. Follow the instructions on user interface touch screen until the software loading is complete.
11. If the NVM was saved at the beginning of this procedure, perform a NVM restore, refer to GP 5.
12. If the Forced AltBoot process fails, restart the procedure and refer to Troubleshooting if
necessary.
PWS Forced Altboot Procedure
Serial cable, PL 26.10 Item 12.
9 way gender changer, PL 26.10 Item 1.
Ethernet crossover cable, PL 26.10 Item 6.
gawain.uImage - Linux kernal file.
gawain_ramdisk.uboot - Linux root file system file.
The DLM file to be loaded. Figure 14 Browse for folder

11. Switch on the machine, GP 14. After approximately 10 seconds, the transfer of the uIm- 14. At the proceed prompt, Figure 17, select Y.
age and uboot files will begin.
12. After file transfer, the settings menu is displayed in the terminal window, Figure 15.
Figure 17 Install confirmation window

Figure 15 Settings menu
NOTE: Check that the Received packet line is displayed and that the IP address is set 15. At the second proceed prompt, Figure 18, select Y.
one digit away from the packet was received from address.
Press y at the prompt and continue. If the valid netmask is not set, press n and change
it to the value shown in Figure 15.
13. From the next menu, Figure 16, select action 11, Forced Install ESS software.
Figure 18 Release image install window
Figure 16 Action menu

16. From the next menu, Figure 19, select option 4, Continue. 18. After the DLM file has been downloaded to the machine, the Software Upgrade start
screen will display on the UI, Figure 21.
NOTE: If the Upgrade Failed screen, Figure 24 displays at this time, it is an indication of
hard disk failure. Refer to the 03C Hard Disk Failure RAP.
19. After approximately 1 minute the upgrade will begin and the progress screen will open,
Figure 22.
NOTE: If the upgrade process screen is not displayed after 2 minutes, restart the process.
20. The Forced AltBoot process should complete after approximately 25 minutes and the Alt-
Boot complete screen will open, Figure 23. Ignore the instruction to remove the USB flash
drive, only press 0 to continue.
21. If the Forced AltBoot process fails, the AltBoot failed screen will open, Figure 24. Follow
the on screen instructions. Restart the procedure and refer to Troubleshooting as neces-
sary.
NOTE: Do not switch off the machine until directed to on the UI. During the reboot, the
hard disk drive is encrypted. Switching off the machine can cause only partial encryption
of the hard disks partitions. The Forced AltBoot process may need to be re-run if power is
removed at this step.
Figure 19 Option menu ure screen appears, switch off, then switch on the machine, GP 14.
24. Disconnect the null modem serial cable from the PWS serial port and the machine.
17. From the next menu, Figure 20, select the correct DLM file to download to the machine. A
transfer progress window will then open. 25. Disconnect the special crossover ethernet cable from the PWS network and the machine.
26. Connect the ethernet cable to the machine.
28. If the NVM was saved at the beginning of this procedure, perform a NVM restore, refer to GP 5.
Figure 20 DLM list
Figure 21 Software upgrade

Figure 22 Start of upgrade Figure 24 Upgrade failed
Figure 23 Altboot complete Figure 25 Encryption progress

GP 5 Portable Work Station and Tools Enable/Disable Log Files
The network controller process/state log files are permanently enabled. The following logs can
Purpose be enabled or disabled, as a group, using the PWS:
To describe the PWS diagnostic tools for machines.
Description CAUTION
Enabling these logs will degrade machine performance.
NOTE: Before using these diagnostic tools ensure that the USB printing option is set to Xerox
NC Debug Logs.
Copier Assistant/PWS Service Tool. Refer to GP 28 USB Connection Mode.
Event Log.
The PWS Diagnostic Tools are: Shutdown Log.
SBC Altboot Tool Error / Warning Log.
Counter Retrieval Completed Job Log.
Network Configuration
NOTE: It is not necessary to keep the PWS connected if selectable logging is enabled.
Network Controller Logging
NVM Save and Restore NVM Save and Restore
SBC Altboot Tool NVM Save and Restore is used to save NVM settings to the PWS, then restore them to the
Use this tool to perform a Altboot software load when the USB flash drive method can not be machine. Previous NVM values can be restored after loading a software set using AltBoot, or if
used. the machines NVM settings are changed.
NOTE: If the machines NVM has become corrupt, the most recent Golden NVB Restore file
Counter Retrieval
will be required. The file is available from Office Black & White and ColorQube GSN library,
Use this tool to save the billing counters information to file. The file includes details of regis- number 10231.
tered fault codes, plus a list of the last 40 fault codes.
NOTE: From PWS Tools version 130.00.0006 onwards. The NVM Save and Restore tool has
Network Configuration the option to perform the dC132 NVM Initialization, All Copier NVM routine.
Network Configuration is used to manage network systems. This tool displays the state of the
network settings
CAUTION
Network Controller Logging When the machine software is upgraded using AltBoot, customer NVM settings are not auto-
matically saved. The customer NVM settings must be saved, then restored using NVM Save
Network Controller Logging is used to enable or disable network controller logging and also and Restore.
retrieve log files for off-line viewing. The following logging files are stored on the network con-
Procedure
troller and can be accessed, and with one exception displayed on the PWS:
1. Important - Connect the USB cable between the PWS and the machine before opening
Network controller Process / State Logs - a record of state changes.
the NVM tool.
Network controller Debug Logs / Core Files - a compressed file containing all the log files,
2. Ensure that the PWS is connected to a mains AC power supply.
cannot be displayed on PWS. It is saved on the PWS as a *.log file for analysis.
3. Open the NVM Save and Restore application on the PWS. Follow the instructions.
Event Log - a record of unscheduled events.
If the PWS suffers a power failure or crash during the procedure, the machine should recover.
Shutdown Log - a record of faults serious enough for the network controller to stop work-
ing (if the fault allows the fault to be logged). If the machine has not recovered after 5 minutes, perform the following:
Error / Warning Log - a record of anomalies that are not serious enough to cause the sys- 1. Switch on the PWS. Open the NVM Save and Restore application on the PWS.
tem to reset. 2. Select the Exit button in the NVM Save and Restore window.
Completed Job Log - a record of the completed jobs. 3. Restart the NVM Save and Restore procedure.
There is a Status and Results window, and log files can be saved to a *.log text file on the 4. Set the USB connection mode to Walk Up USB Printing, refer to GP 28.
PWS.

GP 6 Screw Usage
Purpose CAUTION
To prevent damage to parts that may be damaged by screws not being installed correctly. Use the following procedure to avoid broken screws and damaged holes:
1. Ensure that the screw is a thread forming screw, refer to Figure 1.
Procedure
Replacing Existing Screws
Always use the correct driver for the type of screw head. Use a nut driver if possible; this gives Majority of thread is parallel
a better grip than a slotted or cross-head driver.
Take care not to install self-tapping screws into machine-screw holes, or machine-screws into
self-tapper holes.
Tapered end to thread
When replacing self-tapping screws into plastic components, turn the screw counterclockwise
to engage the original thread, then turn the screw clockwise. Do not overtighten. If a new
thread is cut, the plastic component will lose the ability to hold the screw as firmly, and eventu-
ally not at all. This also applies, to a lesser degree, to metal components. Three or four lobes on the end
of the thread
NOTE: Reverse the direction of turn for left-hand threads.
Use the same method for machine thread screws and nuts to avoid cross threading.
Inserting a Screw into an Un-threaded Hole

Some new components are supplied with fastening holes that do not have the screw thread
pre-cut. It is the insertion of the first screw into the hole that forms the thread.
Figure 1 Thread forming screw
If the screw that is used to fasten the component does not appear to be a thread forming
screw, temporarily use a thread forming screw from another location on the machine.
2. Do not assemble the new part into the machine yet, form the screw threads first.
3. Use the correct screw driver or nut driver to ensure a good grip on the head of the screw.
4. Using a moderate axial force, insert the screw to form the thread in the hole, then remove
the screw.
5. Repeat step 4 as necessary until all fastening holes in the new component are threaded
6. Assemble the component on the machine.

GP 7 Miscellaneous Checks Shafts
Contamination.
Purpose
Misalignment.
To indicate which types of problems to look for when checking or inspecting parts of the
machine. Rotates without binding.
Procedure
1. Assess the fault. Is the part broken, too loose, too tight. Check if it needs cleaning or lubri-
cating.
2. Check the following items as appropriate:
Actuators
Free movement.
Damage
Contamination.
Bearings
Wear.
Damage.
Contamination.
Drive Belts
Wear.
Damaged teeth.
Correct tension.
Contamination of tension rollers and support shafts.
Gears
Contamination.
Chips or cracks.
Wear.
Misalignment.
Gravity Fingers and Stripper Fingers
Free movement.
Missing fingers.
Damage.
Contamination on the fingers, rollers or on the pivot shaft.
Harnesses and Wiring
Continuity.
Short-circuits caused by physical damage or contamination of conductors, terminals or
connectors.
Overheated insulation.
Damaged insulation near moving parts and sharp edges.
Pin and receptacle damage on connectors.
Rollers
Flats.
Tears.
Contamination.
Secure E-clips and other retainers.

GP 8 Special Tools and Consumables GP 9 Secure Diagnostic
Description Purpose
Refer to the following: The purpose is to provide increased security to Diagnostics pathways.
Use this procedure when the diagnostics entry code 1934 has been compromised or added
WARNING security has been requested by the customer.
Wear protective gloves when using solvents and cleaning agents, PL 26.10 Item 10. How to Enable Secure Diagnostics
Antistatic fluid, PL 26.10 Item 19. 1. Enter diagnostics, GP 1.
Cleaning agent. 2. Select Diagnostics Routines.
Disposable gloves, PL 26.10 Item 10. 3. Select Copier Routines.
General protection. 4. Select 131 NVM Read / Write.
Ethernet crossover cable, PL 26.10 Item 6. 5. Select 03 Machine Run Control.
PWS to machine. 6. Select Location 03-900 Restrict Diag Pin.
Film remover, PL 26.10 Item 4.
NOTE: The default PIN is 1962. The PIN must be between 1000 and 99999999.
Cleaning agent.
Finisher bypass harness, PL 26.10 Item 7. To change the secure diagnostics PIN:
Electrical cheat for PJ151. a. Select Read / Write.
Formula A cleaning fluid, PL 26.10 Item 2. b. Enter a new PIN using the key pad.
General cleaning. NOTE: The secure diagnostic PIN has to be a number that has been agreed by the
Lens and mirror cleaner, PL 26.10 Item 9. team or district (e.g. team telephone number or the last 5 digits of the machine serial
Optics cleaning. number).
Micro fiber wiper, PL 26.10 Item 13. c. Press Save.
General cleaning. d. In the options window, press OK.
9 way gender changer/null modem adapter PL 26.10 Item 1. e. Check that the new secure diagnostics PIN is displayed in the 03-900 Value volume.
PWS to machine. f. To return the secure diagnostics entry PIN to default, press the Reset and Save.
Plastislip grease, PL 26.10 Item 8. 7. Select 131 NVM Read / Write.
Lubrication for plastic gears and components. 8. Select 08 Paper feed / Transport.
Serial cable, PL 26.10 Item 12. 9. Select Location 08-900 Enable Diag Access.
PWS to machine. a. Select Read / Write.
Staple cartridge, PL 26.10 Item 11. b. Use the key pad to change value from 0 to 1 to enable then press Save.
Test pattern, A3/11X17, PL 26.10 Item 14. c. To reset the value to 0, press Reset and Save.
IQS 1 Solid Area Density and IQS 2 Background. 10. Exit diagnostic and complete the Call Closeout procedure.
Test pattern, A4, PL 26.10 Item 15.
NOTE: If the PIN has been forgotten, contact your technical specialist.
IQS 1 Solid Area Density and IQS 2 Background.
Test pattern, 8.5 X 11, PL 26.10 Item 16.
IQS 1 Solid Area Density and IQS 2 Background.
Test pattern, solid area density scale, PL 26.10 Item 17.
IQS 1 Solid Area density.
Test pattern, visual scale, PL 26.10 Item 18.
IQS 2 Background.
USB cable, PL 26.10 Item 5.
PWS (portable work station) to single board controller PWB.
Xerox approved USB pen drive.

GP 8, GP 9 6-24 Xerox WorkCentre 5790 Family
GP 10 How to Check a Motor Four Wire Stepper Motor
This procedure describes how to check the following motors: NOTE: A stepper motor with an internal open circuit may appear to be fully functional under
Two Wire DC Motors. dC330 component control. However, under normal operation it will run with intermittent failure.
Four Wire Stepper Motor Use the standard digital meter to check that the resistance of the stepper motor coils are simi-
lar.
Six Wire Stepper Motor.
Initial Actions NOTE: In some service manuals, the phase winding wires, A, /A, B and /B may be marked: A+,
A-, B+ and B-, or as: phase A+, phase A-, phase B+ and phase B-.
Go to Flag 6. Disconnect PJH. Check the motor on pulses on the harness when the com-
WARNING ponent control code for the motor is entered.
Ensure that the electricity to the machine is switched off while performing tasks that do Go to Flag 6. Disconnect PJJ. Check the motor on pulses on the harness when the com-
not need electricity. Refer to GP 14. Disconnect the power cord. Electricity can cause ponent control code for the motor is entered.
death or injury. Moving parts can cause injury. Check the wiring and the connectors for the motor circuit.
1. Check that the motor is free to rotate. References:
2. Check that all the motors mechanisms are clean, free to move and lubricated correctly. 01G +24V Distribution RAP.
3. Enter the component control code for the motor, refer to dC330. Run the motor for 30 sec- 01B 0V Distribution RAP.
onds, if the motor shows signs of or can be heard to slow down, then the motor is defec-
REP 1.2 Wiring Harness Repairs.
tive. Replace the motor.
Six Wire Stepper Motor
4. Perform the appropriate procedure:
Two Wire DC Motors. NOTE: A stepper motor with an internal open circuit may appear to be fully functional under
Four Wire Stepper Motor. dC330 component control. However, under normal operation it will run with intermittent failure.
Use the standard digital meter to check that the resistance of the stepper motor coils are simi-
Six Wire Stepper Motor.
lar.
NOTE: The voltages, PJ numbers, pin numbers and PWB names shown are an example
NOTE: In some service manuals, the phase winding wires, A, /A, B and /B may be marked: A+,
only. Go to the circuit diagram in the RAP for the correct information.
A-, B+ and B-, or as: phase A+, phase A-, phase B+ and phase B-.
NOTE: For the motors supplied through the IOT PWB, refer to the OF7 IOT Diagnostics
Go to Flag 5. Disconnect PJF. Check the +24V supply and the motor on pulses when the
RAP.
component control code for the motor is entered.
Two Wire DC Motors Go to Flag 4. Disconnect PJD. Check the +24V, +5V and 0V supplies.
NOTE: In cases where the motor may be driven forward or backward, the same two feed wires Go to Flag 4. Check the clock pulses.
are used, but the voltages on them are reversed, to reverse the motor direction. Such motors Go to Flag 4. Check that the signal on PJD pin 13 changes when the component control
may have two component control codes, for forward and reverse. A typical application is a tray code for the motor is entered.
lift motor with a tray-up and a tray-down direction. Check the wiring and the connectors for the motor circuit.
Go to Flag 2. Disconnect PJB. Check that +24V is measured when the component control References:
code for the motor is entered. 01G +24V Distribution RAP.
Go to Flag 1. Disconnect PJA. Check for +24V on the LVPS. 01E +5V distribution RAP.
Go to Flag 3. Disconnect PJC. Check that the signal changes on the IOT PWB when the 01B 0V Distribution RAP.
component control code for the motor is entered. REP 1.2 Wiring Harness Repairs.
Check the wiring and the connectors for the motor circuit.
References:


GP 11 How to Check a Sensor Procedure
Description For the upper sensor in Figure 1:
Go to Flag 1. Disconnect PJA. Check for +3.3V and 0V at PJA on the harness.
Use this procedure to check the operation of all types of sensor.
Go to Flag 2. Disconnect PJC. Check the wiring and the connectors for the sensor circuit.
NOTE: The upper circuit diagram, in Figure 1 shows a flag sensor. Some sensors have a resis- Go to Flag 2. Check for +3.3V and 0V at PJC on the IOT PWB.
tor within the sensor, other sensors require a resistor on the PWB, such as R1 in Figure 1. The If necessary, install new components or repair the wiring.
resistor limits the current through the LED. This decreases the voltage on the sensor LED to
References:
1.2V, typically.
NOTE: The voltages, PJ numbers, pin numbers and PWB names shown are an example only. 01D +3.3V Distribution RAP.
Go to the circuit diagram in the RAP for the correct information.
Initial Actions
WARNING
1. Make sure that the sensor is installed correctly.
2. Clean the sensor and the area around the sensor.
3. If a flag actuator is installed, check that it has free movement.
4. Check that the paper path is clear.
5. If the sensor activates by a surface that reflects, check that the surface is clean. Also
make sure that there is not an obstruction between the sensor and the surface.
6. If the sensor actuates by an encoder disc, ensure the holes or gaps in the disc are aligned
correctly with the sensor.
Sensor Action
In the upper sensor, in Figure 1, when light from the LED is allowed to fall on the photo-sensi-
tive transistor, the sensing line, PJA, pin2, is low. When light from the LED is blocked by the
flag, the sensing line is high.
In the lower sensor in Figure 1, when light from the LED is reflected by the paper onto the
photo-sensitive transistor, the sensing line, PJE, pin 2 is low. When no paper is present, no
light falls on the transistor and the sensing line is high.
Quick Sensor Check

Enter the component control code for the sensor, refer to dC330. Activate the sensor. If the dis-
play changes, the sensor operates correctly. If the display does not change, perform the proce- Figure 1 Circuit diagram
dure.

GP 12 How to Check a Solenoid or Clutch
Description
Use this procedure to check a clutch or solenoid.
Initial Actions
WARNING
1. For a clutch, check that the mechanical components are clean, free to move and lubri-
cated correctly
2. For a solenoid, check that the armature and associated mechanical components are free
to move.
Procedure
NOTE: The voltages, PJ numbers, pin numbers and PWB names shown are an example only.
NOTE: When a solenoid is energized in diagnostics, armature movement is seen. When a
clutch is energized in diagnostics, the sound of the clutch action is heard. If possible, energize
the motor connected to the clutch to confirm when the clutch is energized.
Go to Flag 1. Check that the signal changes on the IOT PWB when the component con-
trol code for the clutch or solenoid is entered.
Go to Flag 2. Disconnect PJC. Check that +24V is measured when the component control
code for the clutch or solenoid is entered.
Go to Flag 3. Disconnect PJD. Check for +24V on the LVPS.
Check the wiring and the connectors for the clutch or solenoid circuit.
References:

GP 13 How to Check a Switch GP 14 How to Switch Off the Machine or Switch On the
Description Machine
Use this procedure to check the operation of a switch. Purpose
To show how to switch off or switch on the machine, without the loss of customer data or dam-
NOTE: The circuit in Figure 1 shows an interlock switch activated by the closing of a door. age to the system hardware.
Initial Actions
WARNING
WARNING
Do not use the on/off switch as a safety disconnect device. The on/off switch is not a
disconnect device. Disconnect the power cord from the supply to isolate the equipment.
Refer to:
Switch Off Procedure
Manually check that the switch operates. Ensure that the magnet or other actuator has enough
mechanical movement to operate the switch. Switch Off Failure Procedure
Quick Restart
NOTE: The voltages, PJ numbers, pin numbers and PWB names shown are an example only. Switch On Procedure
Power Saver Mode
Procedure Switch Off Procedure
Go to Flag 1. Disconnect PJA. Check the electrical operation of the switch.
Go to Flag 1. Disconnect PJB. Check for +5V and 0V on the IOT PWB. CAUTION
Go to Flag 1. Check the wiring and the connectors for the switch circuit. Do not disconnect the power lead or interrupt the electricity supply before the power down is
References: complete unless advised. The data and software can become damaged.
01B 0V Distribution RAP. 1. Press the on/off switch. The Power Down Options window will display.
NOTE: The Power Down Confirmation window replaces the Power Down Options window
REP 1.2 Wiring Harness Repairs. when the following operations are performed:
a. The machine is in the diagnostics mode.
b. During CRU replacement.
c. The machine is in the Install Wizard or Setup Modes.
d. A module is not communicating.
e. The Power Saver mode is disabled.
f. A software upgrade is performed.
g. The network controller initializes.
2. Touch the Power Down button on the UI.

3. When the Power Off Confirmation window is displayed, touch the Confirm button.
NOTE: If a controlled power off is confirmed, the on / off switch is disabled until the
sequence is completed.
If there is a fault that prevents power down, the UI requests that the power lead is
removed and replaced after one minute.
4. When the machine has switched off, remove the power lead from the outlet.
5. If the machine does not switch off, go to Switch Off Failure Procedure.

General If the machine switches on, but the UI is blank, go to the OF2 UI Touch Screen Fail-
1. When power down is selected and confirmed, power down starts after a maximum of 45 ure RAP.
seconds with the following exceptions: If the machine does not respond, go to the OF5 Dead Machine RAP.
a. If the system and the UI cannot communicate, then power down begins after 3 sec- If the machine switches on, but does not respond, go to the OF5 Boot Up Failure
onds. RAP.
b. If possible, the system finishes all jobs. General
c. The delays occur if the machine cancels: 1. When the power lead is connected, the LVPS +3.3VSB supply is energized. The LVPS
i. A print job or copy job. +3.3VSB supply provides +3.3VSB to the on/off switch and the IOT PWB.
ii. An exposure lamp calibration. 2. When the on/off switch is pressed, the LVPS is energized. The +3.3V, +5V, +12V, +24V
and AC voltage for the auxiliary output sockets and fuser module is distributed.
iii. An image quality adjustment.
3. Each module manages its power-on self-test (POST) and power-up sequence.
iv. Diagnostic mode communications.
d. If a module does not respond and the power down is possible, the power down com- NOTE: Refer to GP 22 Electrical Power requirements for further information.
pletes after a maximum of 2 minutes.
2. The machine stops processing all jobs that remain in the queue.
Power Saver Mode
The Power Saver mode is selected from the Power Down window. The Power Saver mode is
3. A warning message displays on the UI.
delayed until the machine is not active for 30 seconds.
Switch Off Failure Procedure
1. If the machine fails to power down, disconnect the power lead. NOTE: If the power saver feature is disabled, the option is not displayed. Refer to GP 22 Elec-
2. If necessary, reconnect the power lead after two minutes. trical Power Requirements for further information.
3. If the machine does not power down again, perform the 03-374 Power Off Failure RAP.
Quick Restart
The quick restart causes the system to reset the software of the single board controller PWB,
the IOT PWB and the GUI.
1. Press the on/off switch. The Power Down Options window is displayed.
NOTE: The Power Down Confirmation window replaces the Power Down Options window
when the following operations are performed:
a. The machine is in the diagnostics mode.
b. During CRU replacement.
c. The machine is in the Install Wizard or Setup Modes.
d. A module is not communicating.
e. The Power Saver mode is disabled.
f. A software upgrade is performed.
g. The network controller initializes.
2. Touch the Quick Restart button on the UI.

3. When the Quick Restart Confirmation window is displayed, touch the Confirm button.
4. The Quick Restart window is displayed with the following message: Quick Restart is
underway and will take approximately 1 minute.
Switch On Procedure
1. After a machine has been switched off, wait a minimum of two minutes before the
machine is switched on.
2. After a service call, ensure that all service tools are removed from the machine.
3. Connect the power lead from the power supply outlet to the machine.
4. Press the on/off switch.
5. If the machine does not initialize, go to the appropriate RAP as follows:

GP 15 How to Set the Machine Configuration GP 16 How to Safely Lift or Move Heavy Modules
Description Purpose
Use this procedure when a new IOT PWB has been installed or the message Machine Speed Use this procedure when lifting or moving heavy modules.
Configuration Error occurs.
Procedure
Procedure When removing heavy modules from the machine, the following instructions must be observed:
Perform the following: 1. Ensure that a suitable stable surface to support the module after removal is located in
close proximity to the machine.
1. Enter dC131 NVM location 03-005 System Install Phase. Set the value to 2.
2. Exit diagnostics, then reboot the machine. NOTE: Other parts of the machine are not a suitable stable surface.
3. Re-run the install wizard. When requested, input the relevant activation code. 2. Ensure that the height of the support surface is between 750mm and 1000mm (30 inches
NOTE: The activation code can be found on a label on the rear of the machine. A copier and 39 inches).
only machine will have DC 57XX in the top right corner of the label, a multi-function 3. Ensure that there are no hazards or obstacles between the machine and the support sur-
machine will have MF 57XX. face.
4. Complete the final actions, SCP 6. 4. If instructed to remove the module toward the rear of the machine and only one person is
available, the module must be removed while standing at the rear of the machine. If two
people are available, the module may be removed while standing at the front of the
machine.
5. Two people are required if the module is to be lifted on to the floor or lifted from the floor.

GP 17 High Frequency Service Items GP 18 Machine Lubrication
Purpose Purpose
To provide the service engineer with a method to view the service history of the high frequency To give information on the use of lubricants.
service items (HFSI). The service engineer can reset the counters and change the setting of
the maximum life and threshold value of each HFSI item. Procedure
Procedure
Enter diagnostics GP 1. Select the Service Info window and touch the HFSI feature to select WARNING
the HFSI table. Ensure that the electricity to the machine is switched off while performing tasks that do
The five columns in the HFSI table on the display are: death or injury. Moving parts can cause injury.
The Item column, shows the HFSI item to be tracked.
The Status column, indicates the status of an item relative to its threshold setting. Values
CAUTION
are Off (not tracked), OK or Check.
Only use lubricants as directed. Incorrect use of lubricants could seriously affect the perfor-
The Unit column, shows the events that are being used to track the item.
mance of the machine.
The Actual column, shows the actual count value against the HFSI item.
Take the following precautions when performing machine lubrication:
The Max. Life column, shows the maximum life count value of the HFSI item.
Wear disposable gloves, PL 26.10 Item 10.
The Actual and Maximum Life count value have a numeric range of 0 to 9999999 for all HFSI
Only use lubricants that are specified in the Parts List.
items.
Only lubricate parts of the machine as directed in the relevant RAPs, Repairs and Adjust-
The first item in the HFSI table will be the item that requires attention (if needed) then the item ments etc.
will be displayed as Check. If the item has not yet reached threshold the OK is displayed. Apply only the smallest amount of lubricant, sufficient to lubricate the parts. To prevent
contamination, remove any surplus lubricant before the machine is run.
To change the maximum life or threshold value of each HFSI item, perform the following: Take great care not to contaminate other parts of the machine with the lubricant.
1. Select and highlight the HFSI item to change.
2. Touch the Edit button.
3. Enter the new value using the numeric keypad. The new value will overwrite the existing
value in the table. Touch the Save button to enter the new maximum life or threshold
value into the file. If the entered value is incorrect, press the Undo button. This stops the
process and the old value is retained.
A threshold value of zero indicates that there is no threshold value assigned to the item and the
status will be Off (not tracked).
The maximum life setting and the threshold settings are independent of each other. The
threshold value can exceed the maximum life value.
To reset the HFSI item Actual count value to zero, perform the following:
1. Select and highlight the HFSI item to reset.
2. Touch the Reset button,
3. Touch the OK button to reset the count value to zero.
For details of high frequency service items, refer to SCP 5 Subsystem Maintenance.

Specific Lubrication for the Registration Transport Nip Assembly
1. Remove the registration transport assembly, REP 8.4. CAUTION
2. Figure 1, remove the nip assembly. Only use plastislip grease. The use of any other type of grease may dissolve the plastic.
4. Use plastislip grease, PL 26.10 Item 8 to lubricate the nip roll shaft contact areas of the
housing, Figure 3.
2
Slide the nip assembly to
1 the left and remove
Remove screw 1
Apply small amounts of grease to
Figure 1 Nip assembly removal the contact areas only, see Caution
3. Turn over the nip assembly and remove two screws to release the transparent nip roll Figure 3 Lubricant application
housing, Figure 2.
5. Reassemble the parts and install the registration transport assembly, REP 8.4.
Figure 2 Transparent nip roll housing

GP 19 Network Clone Procedure 8. On the Cloning DLM, right click, select Save Target As.
9. Select File Name - Enter.DLM
Purpose
10. Save to the PWS.
To save and restore the customers unique network controller configuration setting.
How to Install a Clone File
The clone file must be taken at the first service call and whenever the system software is 1. Open the web browser. Enter the machine IP address in the web browser address field.
changed. Then press the Enter key. The machine web page will open.
NOTE: Refer to the configuration report for the machine IP address.

Procedure
Setting Up the PWS 2. Select: Index.
Perform the following: 3. Select Cloning.
1. Print a copy of the latest configuration report. 4. At install clone file, scroll down and select the Browse and select the floppy drive.
2. Set the proxy server setting on the PWS. Perform the following: 5. Select the clone file, open the file and press install.
a. Open Start / Control Panel / Network Connections / Network Connections / Local NOTE: There is no indication or message to say that the install has been completed.
Area Connections.
b. Double click the Internet Protocol (TCP / IP) icon, or open Properties when selected
c. Select Use the following IP address.
NOTE: Before changing the proxy server settings, record the original IP address and
Subnet mask. The original settings are reset at the end of this procedure.
d. Refer to the configuration report for IP address of the machine. Set the IP address of
the PWS one number higher than that of the machine. For example, if the IP address
of the machine is 192.168.196.112, set the IP address of the PWS to
192.168.196.113.
e. Refer to the configuration report for Subnet mask of the machine. Set the Subnet
mask of the PWS to the same as the Subnet mask of the machine.
f. Click on OK to close the properties dialog box.

g. Click on OK to close the Local Area Connection Properties dialog box.
h. If any settings have been changed, it will be necessary to reboot the PWS.
4. Disconnect the ethernet cable from the machine.
5. Connect the ethernet crossover cable, PL 26.10 Item 6 between the machine and the
PWS.
How to Save a Clone File
1. Open the web browser. Enter the machines IP address in the web browser Address field,
then press the enter key. The machine web page will open.
NOTE: Refer to the configuration report for the machines IP address.
2. Select Index
3. Select Cloning
4. Ensure that all the boxes are ticked
5. Select Clone
6. Enter User name and Password
7. Press OK and follow the on screen cloning instructions.

GP 20 Paper and Media Size Specifications Table 7 2K LCSS output paper sizes. The table defines the paper sizes that can be deliv-
ered to the output trays of a 2K LCSS.
Purpose Table 8 HVF output paper sizes. The table defines the paper sizes that can be delivered
To list the paper and media size specifications. to the output bins of the HVF.
Table 9 Output stock performance. The table shows the media (stock) performance con-
Specifications straints for the output. Performance will not be guaranteed for media not listed in the
The baseline papers used in this specification, are defined as: table. Media that is smaller than 139 mm (5.5 inches) in either the process or cross pro-
cess direction cannot be duplexed.
Xerox 4200 (20lb / 75 gsm) 8.5 x 11 inch paper. Table 10 Input document material definitions.
Xerox Premier TCF 80 gsm A4 paper. Table 11 Input document quality definitions.
The machine design and performance is optimized for these papers. Envelope Specifications
NOTE: Check that the paper tray settings match the paper size in the tray. Table 1 Performance indication
Refer to the following: Code Description
Table 1 Performance indication. Use this table to determine the meaning of the alpha 3 Excellent performance
numeric codes in Table 2 and Table 3.
2 Good performance (Good image quality, some jams and poor stacking)
Table 2 European papers.
1 Degraded performance (Image quality defects, increased jams or bad stacking)
Table 3 American papers.
X Not recommended (outside specification)
Table 4 U.S. paper weight conversion. Use this table to determine approximate equivalent
N Size unrecognized and not acceptable
points in weight specifications other than for U.S. bond weight.
U Size unrecognized but acceptable
Table 5 Input / output paper sizes. The table defines the paper sizes that are recognized
Y Size recognized and accepted
by the DADH, document glass and the paper trays when using an OCT output device.
Table 6 1K LCSS output paper sizes. The table defines the paper sizes that can be deliv-
ered to the output trays of a 1K LCSS.
Table 2 European papers

Paper Size Paper Weight gsm Feed Direction Paper Type Tray 1/2 Tray 3/4 Bypass Duplex Tray 5 Defects
A4 60 LEF Plain paper 2 2 2 2 2 Duplex show through
A4 60 SEF Plain paper 2 X 2 2 X Duplex show through
A4 61 - 120 LEF Plain paper 3 3 3 3 3 None
A4 61 - 120 SEF Plain paper 3 X 3 3 X None
A4 121 - 200 LEF Plain paper 2 2 2 2 2 None
A4 201 - 216 LEF / SEF Plain paper X X 2 X X None

A4 - LEF / SEF Labels (see NOTE 2) X X 2 X X None
A4 - LEF / SEF Plain transparency X X 2 X X None
A4 - LEF White strip transparency X X 2 X X None
A4 - SEF White strip transparency X X X X X Out of specification
A4 - LEF Paper backed transparency X X 2 X X None
A4 - SEF Paper backed transparency X X X X X Out of specification
Oversize A4 - LEF Tabs 2 X 2 X X Productivity reduction
Oversize A4 - LEF Covers 2 X 2 X X Productivity reduction
A3 60 SEF Plain paper 2 X 2 1 X Curl

Table 2 European papers
Paper Size Paper Weight gsm Feed Direction Paper Type Tray 1/2 Tray 3/4 Bypass Duplex Tray 5 Defects
A3 161 - 200 SEF Plain paper 2 X 2 1 X Mis-registration and skew
A5 60 LEF Plain paper 2 X 2 1 X Curl
A5 60 SEF Plain paper X X 2 1 X Curl
A5 61 - 120 LEF Plain paper 3 X 3 3 X None
A5 61 - 120 SEF Plain paper X X 3 3 X None
A5 121 - 200 LEF Plain paper 2 X 2 2 X None
A5 121 - 200 SEF Plain paper X X 2 1 X Mis-registration and skew
A6 60 LEF Plain paper X X X X X Out of specification.
A6 60 SEF Plain paper X X 2 X X Out of specification.
A6 61 - 120 LEF Plain paper X X X X X Out of specification.
A6 61 - 120 SEF Plain paper X X 3 X X Out of specification.
A6 121 - 200 LEF Plain paper X X X X X Out of specification.
A6 121 - 200 SEF Plain paper X X 1 X X Out of specification.
A4 60 LEF / SEF Nekosa 1 1 1 1 1 Jams
8.5 x 12.4 All SEF Spanish Folio 2 X 2 2 X Not tested
inch
A4 200 LEF / SEF Premier TCF 2 2 2 2 2 Poor fusing on 35-65 ppm machines.
All All LEF / SEF Envelopes (see NOTE 1) 2 X 2 X X Wrinkle
All 100 LEF / SEF Conqueror finely ridged laid 2 2 2 2 2 Poor fusing on 35-65 ppm machines.
All 80 LEF / SEF Recycled 1 1 1 1 1 Excessive curl
Any Any LEF / SEF Jobs with covers 1 X 1 1 X Rear cover of stapled sets of more than 35 sheets plus 2 cov-
ers, may be mis-registered in the 1K LCSS and 2K LCSS.
All 200 LEF / SEF Colortech (coated paper) 2 2 2 2 2 Stapling more than 10 sheets not recommended
A4 200 LEF / SEF Beaverboard 2 2 2 2 2 Poor fusing on 35-65 ppm machines.
NOTE: 1. Optional envelope tray kit is required to feed envelopes from tray 2.
NOTE: 2. Enablement code required to feed labels from tray 1 or 2.
Table 3 American papers

Paper Size Paper Weight US
inches bond lb. Feed Direction Paper Type Tray 1/2 Tray 3/4 Bypass Duplex Tray 5 Defects
8.5 x 11 16 LEF Plain paper 2 2 2 2 2 Duplex show through
8.5 x 11 16 SEF Plain paper 2 X 2 2 X Duplex show through
8.5 x 11 20 - 32 LEF Plain paper 3 3 3 3 3 None
8.5 x 11 20 - 32 SEF Plain paper 3 X 3 3 X None
8.5 x 11 34 - 53 LEF Plain paper 2 2 2 2 2 None
8.5 x 11 57 LEF / SEF Plain paper X X 2 X X None
8.5 x 11 - LEF / SEF Labels (see NOTE 2) 2 X 2 X X None
8.5 x 11 - LEF / SEF Plain transparency X X 2 X X None

Table 3 American papers
Paper Size Paper Weight US
inches bond lb. Feed Direction Paper Type Tray 1/2 Tray 3/4 Bypass Duplex Tray 5 Defects
8.5 x 11 - LEF White strip transparency X X 2 X X None
8.5 x 11 - SEF White strip transparency X X X X X Out of specification
8.5 x 11 - LEF Paper backed transparency X X 2 X X None
8.5 x 11 - SEF Paper backed transparency X X X X X Out of specification
Oversize 8.5 - LEF Tabs 2 X 2 X X Productivity reduction
x 11
Oversize 8.5 - LEF Covers 2 X 2 X X Productivity reduction
x 11
11 x 17 16 SEF Plain paper 2 X 2 1 X Curl
11 x 17 20 - 32 SEF Plain paper 3 X 3 3 X None
11 x 17 34 - 53 SEF Plain paper 2 X 2 1 X Mis-registration and skew
8.5 x 14 16 SEF Plain paper 2 X 2 1 X Curl
8.5 x 14 34 - 53 SEF Plain paper 2 X 2 1 X Mis-registration and skew
8.5 x 5.5 16 LEF Plain paper 2 X 2 1 X Not tested
8.5 x 5.5 16 SEF Plain paper X X 2 1 X Not tested
8.5 x 5.5 20 - 32 LEF Plain paper 3 X 3 3 X Not tested
8.5 x 5.5 20 - 32 SEF Plain paper X X 3 3 X Not tested
8.5 x 5.5 34 - 53 LEF Plain paper 2 X 2 2 X Not tested
8.5 x 5.5 34 - 53 SEF Plain paper X X 2 1 X Not tested
5.5 x 4.25 16 LEF Plain paper X X X X X Out of specification.
5.5 x 4.25 16 SEF Plain paper X X 2 X X Out of specification.
5.5 x 4.25 20 - 32 LEF Plain paper X X X X X Out of specification.
5.5 x 4.25 20 - 32 SEF Plain paper X X 3 X X Out of specification.
5.5 x 4.25 34 - 53 LEF Plain paper X X X X X Out of specification.
5.5 x 4.25 34 - 53 SEF Plain paper X X 1 X X Out of specification.
All All LEF / SEF Envelopes (see NOTE 1) 2 X 2 X X Wrinkle
11 x 17 32 SEF Domtar (10% recycled) 1 X 1 1 X Bad stacking due to curl
8.5 x 11 110 LEF / SEF Bristol Vellum 2 2 2 2 2 Poor fusing on 35-65 ppm machines.
Any Any LEF / SEF Jobs with covers 1 1 1 1 1 Rear cover of stapled sets of more than 35 sheets plus 2 cov-
ers, may be mis-registered in the LCSS
NOTE: 1. Optional envelope tray kit is required to feed envelopes from tray 2.
NOTE: 2. Enablement code required to feed labels from tray 1 or 2.
Table 4 U.S. paper weight conversion

US post card thickness US bond weight US text / book weight US cover weight US Bristol weight US index weight US tag weight Metric weight
(mm) (see NOTE) (lb.) (lb.) (lb.) (lb.) (lb.) (lb.) (gsm)
- 16 41 22 27 33 37 60
- 17 43 24 29 35 39 64

Table 4 U.S. paper weight conversion
US post card thickness US bond weight US text / book weight US cover weight US Bristol weight US index weight US tag weight Metric weight
(mm) (see NOTE) (lb.) (lb.) (lb.) (lb.) (lb.) (lb.) (gsm)
- 20 50 28 34 42 46 75
- 21 54 30 36 44 49 80
- 22 56 31 38 46 51 83
- 24 60 33 41 50 55 90
- 27 68 37 45 55 61 100
- 28 70 39 49 58 65 105
- 32 80 44 55 67 74 120
- 34 86 47 58 71 79 128
- 36 90 50 62 75 83 135
0.18 39 100 55 67 82 91 148
0.19 42 107 58 72 87 97 158
0.20 43 110 60 74 90 100 163
0.23 47 119 65 80 97 108 176
0.25 51 128 70 86 105 117 190
0.26 53 134 74 90 110 122 199
0.27 54 137 75 93 113 125 203
0.29 58 146 80 98 120 133 216
0.32 65 165 90 111 135 150 244
0.33 66 169 92 114 138 154 250
0.34 67 171 94 115 140 155 253
0.35 70 178 98 120 146 162 264
0.36 72 183 100 123 150 166 271
NOTE: U.S. Post Card measurements are approximate. Use for reference only.
Table 5 Input / output Paper sizes

Document glass size Output
Paper size Orientation Paper tray size sensing DADH size sensing sensing device Notes
Common Inch (W x L) mm (W x L) Tray 1 Bypass Tray 3 Eur / Eur /
Name +/-1/32 inch +/-1 mm LEF / SEF and 2 tray and 4 Tray 5 NASG Asia Latin NASG Asia Latin OCT -
Letter 8.5 x 11 216 x 279 SEF Y Y N Y* Y Y Y Y Y Y Y *Fixed size dependant on pur-
chased option
Letter 8.5 x 11 216 x 279 LEF Y Y Y* Y* Y Y Y Y Y Y Y *Fixed size dependant on pur-
chased option
Ledger 11 x 17 279 x 432 SEF Y Y N Y* Y Y Y Y Y Y Y *Fixed size dependant on pur-
chased option
Invoice 8.5 x 5.5 216 x 138 SEF N Y N N Y* Y* Y* Y Y Y Y *ISO A5 or 8.5 x 5.5 depends on
(statement) NVM 2 setting

Invoice 8.5 x 5.5 216 x 138 LEF Y Y N N Y* Y* Y* Y Y Y Y *ISO A5 or 8.5 x 5.5 depends on
(statement) NVM 2 setting
Postcard 4.25 x 5.5 108 x 139 SEF N Y N N N N N Y U U Y -
Postcard 4.25 x 5.5 108 x 139 LEF N N N N N N N U U U N Cannot be fed in IOT
Legal 8.5 x 14 216 x 356 SEF Y Y N Y* Y Y Y Y U U Y *Fixed size dependant on pur-
chased option
ISO A4 8.26 x 11.69 210 x 297 SEF Y Y N Y** Y* Y* Y* Y Y Y Y *ISO A4 or 8.5 x 13 depends on
NVM 1 setting
** Fixed size dependant on pur-
chased option
ISO A4 8.26 x 11.69 210 x 297 LEF Y Y Y Y* Y Y Y Y Y Y Y *Fixed size dependant on pur-
chased option
ISO A3 11.69 x 16.54 297 x 420 SEF Y Y N Y* Y Y Y Y Y Y Y *Fixed size dependant on pur-
chased option
ISO A5 5.83 x 8.27 148 x 210 SEF N Y N N Y* Y* Y* U Y U Y *ISO A5 or 8.5 x 5.5 depends on
NVM 2 setting
ISO A5 5.83 x 8.27 148 x 210 LEF Y Y N N Y* Y* Y* U Y U Y *ISO A5 or 8.5 x 5.5 depends on
NVM 2 setting
ISO A6 4.13 x 5.83 105 x 148 SEF N Y N N N N N U Y Y Y -
ISO A6 4.13 x 5.83 105 x 148 LEF N N N N N N N U U U N -
Foolscap or 8.5 x 13 216 x 330 SEF Y Y N N Y* Y* Y* U Y Y Y *ISO A4 or 8.5 x 13 depends on
Euroletter NVM 1 setting
JIS B5 7.17 x 10.12 182 x 257 SEF U Y N N Y Y Y Y Y Y Y -
JIS B5 7.17 x 10.12 182 x 257 LEF U Y N N Y Y Y Y Y Y Y -
JIS B4 10.12 x 14.33 257 x 364 SEF U Y N N U* U* U* Y Y Y Y * Detected as ISO B4
JIS B6 5.08 x 7.17 128 x 182 SEF N Y N N N N N Y Y Y Y -
JIS B6 5.08 x 7.17 128 x 182 LEF N N N N U* U* U* U U U Y * Detected as ISO B5
ISO B5 6.93 x 9.84 176 x 250 SEF N U N N Y Y Y U U U Y -
ISO B5 6.93 x 9.84 176 x 250 LEF U U N N Y Y Y U U U Y -
ISO B4 9.84 x 13.9 250 x 353 SEF U U N N Y Y Y Y Y Y Y -
SB4 9.9 x 14.09 252 x 358 SEF U U N N U* U* U* U U U Y *Detected as ISO B4
Postcard- 4.5 x 6 114 x 152 SEF N U N N N N N U U U Y -
Lakes
Postcard- 4.5 x 6 114 x 152 LEF N N N N U* U* U* U U U N * Detected as ISO A5 or 8.5 x 5.5
Lakes depending on NVM 2 setting
Postcard 5x7 127 x 178 SEF N U N N N N N U U U Y -
Postcard 5x7 127 x 178 LEF N N N N U* U* U* U U U N * Detected as ISO A5 or 8.5 x 5.5
depending on NVM 2 setting

Oufuku- 5.83 x 7.87 148 x 200 SEF N U N N U* U* U* U U U Y * Detected as ISO A5 or 8.5 x 5.5
Hagaki depending on NVM 2 setting
Postcard
Oufuku- 5.83 x 7.87 148 x 200 LEF U U N N U* U* U* U U U Y *Detected as ISO A5 or 8.5 x 5.5
Hagaki depending on NVM 2 setting
Postcard
6 x 9 inch 6x9 152 x 229 SEF N U N N U* U* U* U U U U *Detected as ISO A5 or 8.5 x 5.5
6 x 9 inch 6x9 152 x 229 LEF U U N N U* U* U* U U U Y *Detected as ISO A5 or 8.5 x 5.5
Royal 6 x 9.5 152 x 241 SEF N U N N U* U* U* U U U Y *Detected as ISO A5 or 8.5 x 5.5
Octavo depends on NVM 2 setting
Royal 6 x 9.5 152 x 241 LEF U U N N U* U* U* U U U Y *Detected as ISO B5
Octavo
Foolscap 6.5 x 8.25 165 x 206 SEF N U N N U* U* U* U U U Y *Detected as ISO B5
Quarto
Foolscap 6.5 x 8.25 165 x 206 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
Quarto
Crown 7.25 x 9.5 184 x 241 SEF U U N N U* U* U* U U U Y *Detected as ISO B5
Quarto
Crown 7.25 x 9.5 184 x 241 LEF U U N N U* U* U* U U U Y *Detected as ISO B5
Quarto
Executive 7.25 x 10.5 184 x 267 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
Executive 7.25 x 10.5 184 x 267 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
16K Taiwan 7.64 x 10.51 194 x 267 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
16K Taiwan 7.64 x 10.51 194 x 267 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
Quarto 8 x 10 203 x 254 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
Quarto 8 x 10 203 x 254 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8 x 10.5 203 x 267 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8 x 10.5 203 x 267 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
8 x 13 inch 8 x 13 203 x 330 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
foolscap
- 8.26 x 10 210 x 254 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8.26 x 10 210 x 254 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8.26 x 10.63 210 x 270 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8.26 x 10.63 210 x 270 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8.26 x 13 210 x 330 SEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
depends on NVM 1 setting
Foolscap 8.25 x 13.06 209 x 333 SEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
Folio depends on NVM 1 setting

Demi Quarto 8.46 x 10.7 215 x 273 SEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
Demi Quarto 8.46 x 10.7 215 x 273 LEF U U N N U* U* U* U U U Y *Detected as 8.5 x 11
- 8.46 x 10.83 215 x 275 SEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
- 8.46 x 10.83 215 x 275 LEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
Folio (Spain) 8.46 x 12.4 215 x 315 SEF Y# U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
depends on NVM 1 setting.
#Detected as 8.5 x 13
- 8.66 x 13 220 x 330 SEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
- 8.75 x 11.69 223 x 297 SEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
- 8.75 x 11.69 223 x 297 LEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
Arch A 9 x 12 229 x 305 SEF U U N N U* U* U* U U U Y *Detected as ISO A4 or 8.5 x 13
SB4 9.92 x 14.09 252 x 258 SEF U U N N U* U* U* U U U Y *Detected as ISO B4
SB4 9.92 x 14.09 252 x 258 LEF U U N N U* U* U* U U U Y *Detected as ISO B4
Accounting 10 x 14 254 x 356 SEF U U N N U* U* U* U U U Y *Detected as ISO B4
- 10 x 15 254 x 381 SEF U U N N U* U* U* U U U Y *Detected as ISO B4
8K Taiwan 10.51 x 15.28 267 x 388 SEF U U N N U* U* U* U U U Y *Detected as ISO B4
Table 6 1K LCSS output paper sizes

Paper Size Orientation Output Staple position Output
Common Name Inch (W x L) mm (W x L) LEF / SEF Stack Corner Top Tray

Letter 8.5 x 11 216 x 279 SEF Y Y Y
Letter 8.5 x 11 216 x 279 LEF Y Y Y
Ledger 11 x 17 279 x 432 SEF Y Y Y
Invoice (statement) 8.5 x 5.5 216 x 140 SEF Y Y Y
Invoice (statement) 8.5 x 5.5 216 x 140 LEF Y Y Y
Postcard 4.25 x 5.5 108 x 140 SEF N N Y
Postcard 4.25 x 5.5 108 x 140 LEF N N N
Legal 8.5 x 14 216 x 356 SEF Y Y Y
ISO A4 8.26 x 11.69 210 x 297 SEF Y Y Y
ISO A4 8.26 x 11.69 210 x 297 LEF Y Y Y
ISO A3 11.69 x 16.54 297 x 420 SEF Y Y Y


ISO A5 5.83 x 8.27 148 x 210 SEF Y Y Y
ISO A5 5.83 x 8.27 148 x 210 LEF Y Y Y
ISO A6 4.13 x 5.83 105 x 148 SEF N N Y
ISO A6 4.13 x 5.83 105 x 148 LEF N N N
Foolscap or Euroletter 8.5 x 13 216 x 330 SEF Y Y Y
JIS B5 7.17 x 10.12 182 x 257 SEF Y Y Y
JIS B5 7.17 x 10.12 182 x 257 LEF Y Y Y
JIS B4 10.12 x 14.33 257 x 364 SEF Y Y Y
JIS B6 5.08 x 7.17 128 x 182 SEF N N Y
JIS B6 5.08 x 7.17 128 x 182 LEF N N N
ISO B5 6.93 x 9.84 176 x 250 SEF Y Y Y
ISO B5 6.93 x 9.84 176 x 250 LEF Y Y Y
ISO B4 9.84 x 13.9 250 x 353 SEF Y Y Y
SB4 9.92 x 14.09 252 x 358 SEF Y Y Y
ISO A4 Cover or Tab 8.78 x 11.69 297 x 223 SEF Y Y Y
ISO A4 Cover or Tab 8.78 x 11.69 297 x 223 LEF Y Y Y
Letter Cover or Tab 9 x 11 229 x 279 SEF Y Y Y
Letter Cover or Tab 9 x 11 229 x 279 LEF Y Y Y
Postcard-Lakes 4.5 x 6 114 x 152 SEF N N Y
Postcard-Lakes 4.5 x 6 114 x 152 LEF N N N
Postcard 5x7 127 x 178 SEF N N Y
Postcard 5x7 127 x 178 LEF N N N
Oufuku-Hagaki Postcard 5.83 x 7.87 148 x 200 SEF Y Y Y
Oufuku-Hagaki Postcard 5.83 x 7.87 148 x 200 LEF Y Y Y
6 x 9 inch 6x9 152 x 229 SEF Y Y Y
6 x 9 inch 6x9 152 x 229 LEF Y Y Y
Royal Octavo 6 x 9.5 152 x 241 SEF Y Y Y
Royal Octavo 6 x 9.5 152 x 241 LEF Y Y Y
Foolscap Quarto 6.5 x 8.25 165 x 206 SEF Y Y Y
Foolscap Quarto 6.5 x 8.25 165 x 206 LEF Y Y Y
Crown Quarto 7.25 x 9.5 184 x 241 SEF Y Y Y
Crown Quarto 7.25 x 9.5 184 x 241 LEF Y Y Y
Executive 7.25 x 10.5 184 x 267 SEF Y Y Y
Executive 7.25 x 10.5 184 x 267 LEF Y Y Y
16K Taiwan 7.64 x 10.51 194 x 267 SEF Y Y Y
16K Taiwan 7.64 x 10.51 194 x 267 LEF Y Y Y
Quarto 8 x 10 203 x 254 SEF Y Y Y
Quarto 8 x 10 203 x 254 LEF Y Y Y
- 8 x 10.5 203 x 267 SEF Y Y Y


- 8 x 10.5 203 x 267 LEF Y Y Y
- 8 x 13 203 x 330 SEF Y Y Y
- 8.26 x 10 210 x 254 SEF Y Y Y
- 8.26 x 10 210 x 254 LEF Y Y Y
- 8.26 x 10.63 210 x 270 SEF Y Y Y
- 8.26 x 10.63 210 x 270 LEF Y Y Y
Foolscap Folio 8.25 x 13.06 209 x 333 SEF Y Y Y
8.26 x 13 210 x 330 SEF Y Y Y
Demi Quarto 8.46 x 10.7 215 x 273 SEF Y Y Y
Demi Quarto 8.46 x 10.7 215 x 273 LEF Y Y Y
- 8.46 x 10.83 215 x 275 SEF Y Y Y
- 8.46 x 10.83 215 x 275 LEF Y Y Y
Folio (Spain) 8.46 x 12.4 215 x 315 SEF Y Y Y
- 8.66 x 13 220 x 330 SEF Y Y Y
- 8.75 x 11.69 223 x 297 SEF Y Y Y
- 8.75 x 11.69 223 x 297 LEF Y Y Y
Arch A 9 x 12 229 x 305 SEF Y Y Y
SB4 9.92 x 14.09 252 x 358 SEF Y Y Y
Accounting 10 x 14 254 x 356 SEF Y Y Y
- 10 x 15 254 x 381 SEF Y Y Y
8K Taiwan 10.51 x 15.28 267 x 388 SEF Y Y Y

Paper Size Orientation Output Staple position Option Output
Common Name Inch (W x L) mm (W x L) LEF / SEF Stack Front Rear Dual Hole punch (all types) Top Tray
Letter 8.5 x 11 216 x 279 SEF Y Y Y N Y Y
Letter 8.5 x 11 216 x 279 LEF Y Y N Y Y Y
Ledger 11 x 17 279 x 432 SEF Y Y N Y Y Y
Invoice (statement) 8.5 x 5.5 216 x 140 SEF Y Y N N N Y
Invoice (statement) 8.5 x 5.5 216 x 140 LEF Y Y Y N Y Y
Postcard 4.25 x 5.5 108 x 140 SEF N N N N N Y
Postcard 4.25 x 5.5 108 x 140 LEF N N N N N N
Legal 8.5 x 14 216 x 356 SEF Y Y Y N Y Y
ISO A4 8.26 x 11.69 210 x 297 SEF Y Y Y N N Y
ISO A4 8.26 x 11.69 210 x 297 LEF Y Y N Y Y Y
ISO A3 11.69 x 16.54 297 x 420 SEF Y Y N Y Y Y
ISO A5 5.83 x 8.27 148 x 210 SEF Y Y N N N Y

ISO A5 5.83 x 8.27 148 x 210 LEF Y Y N N N Y
ISO A6 4.13 x 5.83 105 x 148 SEF N N N N N Y
ISO A6 4.13 x 5.83 105 x 148 LEF N N N N N N
Foolscap or Euroletter 8.5 x 13 216 x 330 SEF Y Y Y N Y Y
JIS B5 7.17 x 10.12 182 x 257 SEF Y Y N N N Y
JIS B5 7.17 x 10.12 182 x 257 LEF Y Y N N N Y
JIS B4 10.12 x 14.33 257 x 364 SEF Y Y N N N Y
JIS B6 5.08 x 7.17 128 x 182 SEF N N N N N Y
JIS B6 5.08 x 7.17 128 x 182 LEF N N N N N N
ISO B5 6.93 x 9.84 176 x 250 SEF Y Y N N N Y
ISO B5 6.93 x 9.84 176 x 250 LEF Y Y N N N Y
ISO B4 9.84 x 13.9 250 x 353 SEF Y Y N N N Y
SB4 9.92 x 14.09 252 x 358 SEF Y Y N N N Y
ISO A4 Cover or Tab 8.78 x 11.69 297 x 223 SEF Y Y N N N Y
ISO A4 Cover or Tab 8.78 x 11.69 297 x 223 LEF Y Y N N N Y
Letter Cover or Tab 9 x 11 229 x 279 SEF Y Y N N N Y
Letter Cover or Tab 9 x 11 229 x 279 LEF Y Y N N N Y
Postcard-Lakes 4.5 x 6 114 x 152 SEF N N N N N Y
Postcard-Lakes 4.5 x 6 114 x 152 LEF N N N N N N
Postcard 5x7 127 x 178 SEF N N N N N Y
Postcard 5x7 127 x 178 LEF N N N N N N
Oufuku-Hagaki Postcard 5.83 x 7.87 148 x 200 SEF Y Y N N N Y
Oufuku-Hagaki Postcard 5.83 x 7.87 148 x 200 LEF Y Y Y N N Y
6 x 9 inch 6x9 152 x 229 SEF Y Y N N N Y
6 x 9 inch 6x9 152 x 229 LEF Y Y N N N Y
Royal Octavo 6 x 9.5 152 x 241 SEF Y Y N N N Y
Royal Octavo 6 x 9.5 152 x 241 LEF Y Y N N N Y
Foolscap Quarto 6.5 x 8.25 165 x 206 SEF Y Y N N N Y
Foolscap Quarto 6.5 x 8.25 165 x 206 LEF Y Y Y N N Y
Crown Quarto 7.25 x 9.5 184 x 241 SEF Y Y N N N Y
Crown Quarto 7.25 x 9.5 184 x 241 LEF Y Y N N N Y
Executive 7.25 x 10.5 184 x 267 SEF Y Y N N N Y
Executive 7.25 x 10.5 184 x 267 LEF Y Y N N N Y
16K Taiwan 7.64 x 10.51 194 x 267 SEF Y Y N N N Y
16K Taiwan 7.64 x 10.51 194 x 267 LEF Y Y N N N Y
Quarto 8 x 10 203 x 254 SEF Y Y Y N N Y
Quarto 8 x 10 203 x 254 LEF Y Y N N N Y
- 8 x 10.5 203 x 267 SEF Y Y Y N N Y
- 8 x 10.5 203 x 267 LEF Y Y N N N Y

- 8 x 13 203 x 330 SEF Y Y Y N N Y
- 8.26 x 10 210 x 254 SEF Y Y Y N N Y
- 8.26 x 10 210 x 254 LEF Y Y N N N Y
- 8.26 x 10.63 210 x 270 SEF Y Y Y N N Y
- 8.26 x 10.63 210 x 270 LEF Y Y N N N Y
Foolscap Folio 8.25 x 13.06 209 x 333 SEF Y Y Y N N Y
8.26 x 13 210 x 330 SEF Y Y Y N N Y
Demi Quarto 8.46 x 10.7 215 x 273 SEF Y Y Y N N Y
Demi Quarto 8.46 x 10.7 215 x 273 LEF Y Y N N N Y
- 8.46 x 10.83 215 x 275 SEF Y Y Y N N Y
- 8.46 x 10.83 215 x 275 LEF Y Y N N N Y
Folio (Spain) 8.46 x 12.4 215 x 315 SEF Y Y Y N N Y
- 8.66 x 13 220 x 330 SEF Y Y Y N N Y
- 8.75 x 11.69 223 x 297 SEF Y Y N N N Y
- 8.75 x 11.69 223 x 297 LEF Y Y N Y Y Y
Arch A 9 x 12 229 x 305 SEF Y Y N N N Y
SB4 9.92 x 14.09 252 x 358 SEF Y Y N N N Y
Accounting 10 x 14 254 x 356 SEF Y Y N N N Y
- 10 x 15 254 x 381 SEF Y Y N N N Y
8K Taiwan 10.51 x 15.28 267 x 388 SEF Y Y N N N Y
Table 8 HVF output paper sizes

Hole punch Booklet

Common Name Inch (W x L) mm (W x L) LEF / SEF Stack Front Rear Dual Multiple (all types) Top Tray maker
Letter 8.5 x 11 216 x 279 SEF Y Y Y Y Y Y Y Y
Letter 8.5 x 11 216 x 279 LEF Y Y Y Y Y Y Y N
Ledger 11 x 17 279 x 432 SEF Y Y Y Y Y Y Y Y
Invoice (statement) 8.5 x 5.5 216 x 140 SEF Y N N N N N Y N
Invoice (statement) 8.5 x 5.5 216 x 140 LEF Y Y Y Y Y Y Y N
Postcard 4.25 x 5.5 108 x 140 SEF N N N N N N Y N
Postcard 4.25 x 5.5 108 x 140 LEF N N N N N N N N
Legal 8.5 x 14 216 x 356 SEF Y Y Y Y Y Y Y Y
ISO A4 8.26 x 11.69 210 x 297 SEF Y Y Y Y Y N Y Y
ISO A4 8.26 x 11.69 210 x 297 LEF Y Y Y Y Y Y Y N
ISO A3 11.69 x 16.54 297 x 420 SEF Y Y Y Y Y Y Y Y
ISO A5 5.83 x 8.27 148 x 210 SEF Y N N N N N Y N

Hole punch Booklet

ISO A5 5.83 x 8.27 148 x 210 LEF Y Y Y Y Y N Y N
ISO A6 4.13 x 5.83 105 x 148 SEF N N N N N N Y N
ISO A6 4.13 x 5.83 105 x 148 LEF N N N N N N N N
Foolscap or Euroletter 8.5 x 13 216 x 330 SEF Y Y Y Y Y Y Y Y
JIS B5 7.17 x 10.12 182 x 257 SEF Y Y Y Y Y N Y N
JIS B5 7.17 x 10.12 182 x 257 LEF Y Y Y Y Y N Y N
JIS B4 10.12 x 14.33 257 x 364 SEF Y Y Y Y Y N Y N
JIS B6 5.08 x 7.17 128 x 182 SEF N N N N N N Y N
JIS B6 5.08 x 7.17 128 x 182 LEF N N N N N N N N
ISO B5 6.93 x 9.84 176 x 250 SEF Y Y N N N N Y N
ISO B5 6.93 x 9.84 176 x 250 LEF Y Y Y Y Y N Y N
ISO B4 9.84 x 13.9 250 x 353 SEF Y Y Y Y Y N Y N
ISO A4 Cover 8.78 x 11.69 297 x 223 SEF Y Y Y Y Y N Y N
ISO A4 Cover 8.78 x 11.69 297 x 223 LEF Y Y Y Y Y N Y N
ISO A4 Tab Stock - - LEF Y Y Y Y Y Y Y N
Letter Cover 9 x 11 229 x 279 SEF Y Y Y Y Y N Y N
Letter Cover 9 x 11 229 x 279 LEF Y Y Y Y Y N Y N
8.5 x 11 inch Tab Stock - - LEF Y Y Y Y Y Y Y N
Postcard-Lakes 4.5 x 6 114 x 152 SEF Y N N N N N Y N
Postcard-Lakes 4.5 x 6 114 x 152 LEF N N N N N N N N
Postcard 5x7 127 x 178 SEF Y N N N N N Y N
Postcard 5x7 127 x 178 LEF N N N N N N N N
Oufuku-Hagaki Postcard 5.83 x 7.87 148 x 200 SEF Y N N N N N Y N
Oufuku-Hagaki Postcard 5.83 x 7.87 148 x 200 LEF Y Y Y Y Y N Y N
6 x 9 inch 6x9 152 x 229 SEF Y N N N N N Y N
6 x 9 inch 6x9 152 x 229 LEF Y Y Y Y Y N Y N
Royal Octavo 6 x 9.5 152 x 241 SEF Y N N N N N Y N
Royal Octavo 6 x 9.5 152 x 241 LEF Y Y Y Y Y N Y N
Foolscap Quarto 6.5 x 8.25 165 x 206 SEF Y N N N N N Y N
Foolscap Quarto 6.5 x 8.25 165 x 206 LEF Y Y Y Y Y N Y N
Crown Quarto 7.25 x 9.5 184 x 241 SEF Y Y Y Y Y N Y N
Crown Quarto 7.25 x 9.5 184 x 241 LEF Y Y Y Y Y N Y N
Executive 7.25 x 10.5 184 x 267 SEF Y Y Y Y Y N Y N
Executive 7.25 x 10.5 184 x 267 LEF Y Y Y Y Y N Y N
16K Taiwan 7.64 x 10.51 194 x 267 SEF Y Y Y Y Y N Y N
16K Taiwan 7.64 x 10.51 194 x 267 LEF Y Y Y Y Y N Y N
Quarto 8 x 10 203 x 254 SEF Y Y Y Y Y N Y N
Quarto 8 x 10 203 x 254 LEF Y Y Y Y Y N Y N

Hole punch Booklet

- 8 x 10.5 203 x 267 SEF Y Y Y Y Y N Y N
- 8 x 10.5 203 x 267 LEF Y Y Y Y Y N Y N
- 8 x 13 203 x 330 SEF Y Y Y Y N N Y N
- 8.26 x 10 210 x 254 SEF Y Y Y Y Y N Y N
- 8.26 x 10 210 x 254 LEF Y Y Y Y Y N Y N
- 8.26 x 10.63 210 x 270 SEF Y Y Y Y Y N Y N
- 8.26 x 10.63 210 x 270 LEF Y Y Y Y Y N Y N
Foolscap Folio 8.25 x 13.06 209 x 333 SEF Y Y Y Y Y N Y N
- 8.26 x 13 210 x 330 SEF Y Y Y Y Y N Y N
Demi Quarto 8.46 x 10.7 215 x 273 SEF Y Y Y Y N N Y N
Demi Quarto 8.46 x 10.7 215 x 273 LEF Y Y Y Y Y N Y N
- 8.46 x 10.83 215 x 275 SEF Y Y Y Y Y N Y N
- 8.46 x 10.83 215 x 275 LEF Y Y Y Y Y N Y N
- 8.66 x 13 220 x 330 SEF Y Y Y Y Y N Y N
Arch A 9 x 12 229 x 305 SEF Y Y Y Y Y N Y N
SB4 9.92 x 14.09 252 x 358 SEF Y Y Y Y Y N Y N
SB4 9.92 x 14.09 252 x 358 LEF N N N N N N N N
Accounting 10 x 14 254 x 356 SEF Y Y Y Y Y N Y N
- 10 x 15 254 x 381 SEF Y Y Y Y Y N Y N
8K Taiwan 10.51 x 15.28 267 x 388 SEF Y Y Y Y Y N Y N
Custom size, cross process 4.13 105 - N N N N N N Y N
direction (minimum)
Custom size, process direction 5.5 138 - N N N N N N Y N
(minimum)
Custom size, cross process 11.69 297 - N N N N N N Y N
direction (maximum)
Custom size, process direction 17.01 432 - N N N N N N Y N
(maximum)
Table 9 Output stock performance

Trays 1 Trays 3 Duple Hole Booklet Tri-
Stock Type and 2 Bypass and 4 Tray 5 x Offset Stack Staple punch Maker folder Inserter Notes
Bond/standard 70 gsm to 90 gsm Y Y Y Y Y Y Y(1) Y(2) Y Y Y Y (1) Possible performance degradation if
(16lbs to 24lbs) small documents and stacked on large.
Index Y Y Y Y Y Y Y(1) Y(2) Y Y Y Y (2) For stapled sets, staple build up may
Recycled Y Y Y Y Y Y Y(1) Y(2) Y Y Y Y affect stack quality.

Table 9 Output stock performance
Trays 1 Trays 3 Duple Hole Booklet Tri-
Stock Type and 2 Bypass and 4 Tray 5 x Offset Stack Staple punch Maker folder Inserter Notes
Transparency (non paper backed) N Y N N N Y(1)(2) Y(1) N N N N N (1) An increase in set scatter or set to set
registration may occur with greater than 20
sheets.
(2) LCSS only.
Transparency (paper backed) (3) N Y N N N Y(1)(2) Y(1) N N N N N Must be fed with sealed edge leading. Must
not be inverted.
(1) An increase in set scatter or set to set
registration may occur with greater than 20
sheets.
(2) LCSS only.
(3) Must be fed into the output device
sealed edge first.
Labels (1) N (3) Y N N N N N Y(2) N N N N (1) Must not be inverted.
(2) LCSS = Top tray only.
(3) Except for hospital labels.
Card stock, 120 gsm to 200 gsm Y Y Y Y Y Y Y Y Y Y(2) N Y (1) Pro-rata reduction in capacity with
Card stock, 216 gsm N Y N N Y N Y Y Y Y(2) N Y weight of stock.
(2) One cover may be included within the
quoted sheet capacity consistent with paper
weight of the body of the booklet.
Tabs (1) Y Y N N N N Y Y Y N N N (1) Tabs must be on trail edge when fed
from trays and bypass, but lead edge when
arriving at the output. Therefore tab stock
will be inverted before output. Hole punch
registration performance may be degraded.
Punched Y Y Y Y N Y Y Y Y N N Y -
Envelopes (1) Y(2) Y N N N N N Y(3) N N N N (1) Must not be inverted.
(2) ID #10 envelopes can be fed from tray 2
if the optional envelope kit is installed.
(3) LCSS = Top tray only.
Carbonless paper N N N N N N N N N N N N
Table 10 Input document material definitions

Category Material Image Type
Group I. Common usage input. 80 gsm (20lb.) to 120gsm (32lb.) or equivalent weight range (rag bond Impact typewriter, offset image, Xerographic image, gravure image, Letter-
offset and ledger paper). This group includes 4040 paper. press image, pencil 2H or harder, ballpoint pen, ink pen.
Group II. Heavy weight common usage 121gsm (32.1lb.) to 200gsm (110lb.) index or equivalent weight range Impact typewriter, offset image, Xerographic image, gravure image, Letter-
input. (rag bond and ledger paper). press image, pencil 2H or harder, ballpoint pen, ink pen.
Group III. Light weight common usage 60gsm (16lb) to 79gsm (19.9lb.) bond or equivalent weight range (rag Impact typewriter, offset image, Xerographic image, gravure image, Letter-
input. bond, offset, mimo/duplicator, and NCR paper). press image, pencil 2H or harder, ballpoint pen, ink pen.
Group IV. Common surface finished paper. 60gsm (16lb) to 200gsm (110lb.) index or equivalent (Bristol text, maga- Impact typewriter, offset image, Xerographic image, gravure image, Letter-
zine, cover, vellum, safety paper) press image, pencil 2H or harder, ballpoint pen, ink pen.

Table 10 Input document material definitions
Category Material Image Type
Group V. Uncommon and other input. 80 gsm (20lb.) to 200gsm (110lb.) or equivalent weight: plastic laminated Impact typewriter, offset image, Xerographic image, gravure image, Letter-
paper: metallic cover stock: tag stock: plastic transparencies: Telecopier press image, pencil 2H or harder, ballpoint pen, ink pen. Liquid developed
paper: label stock: silver photographic paper: Electrofax paper (ZnO) electrostatic image.
race-erase: paste ups with loose edges type 1, 2 and 3: XE approved
punched or perforated stock: Continuous computer forms.
Group VI. Light weight input. 49gsm (13lb.) to 59gsm 15.9lb.) bond or equivalent weight range (rag Impact typewriter, offset image, Xerographic image, gravure image, Letter-
bond, ledger mimeo or GSE papers). press image, pencil 2H or harder, ballpoint pen, ink pen.
34gsm (9lb) to 48gsm (12.9lb) bond or equivalent weight range (rag Impact typewriter, offset image, Xerographic image, gravure image, Letter-
Group VII. bond, ledger mimeo or GSE papers). press image, pencil 2H or harder, ballpoint pen, ink pen.
Table 11 Input document quality definitions

Defect Acceptable Marginal Unacceptable Notes
Holes. Maximum of three cleanly punched Four to nine cleanly punched holes. Rough or torn holes. -
holes up to 6mm. (0.25 inch) diameter.
Staples. Cleanly removed staples. Poorly removed staples resulting in dog- Staples not removed.
ears*.
Edge defects. None. Any cut or tear near a corner less than 3mm. Any cut or tear not at a corner or greater than 3 -
(0.125 inch) in length. mm. (0.125 inch) in length,
Folds* (in the Two letter folds less than 1.5 mm. Two letter folds less than 3mm. (0.125 inch) Any fold greater than 3mm. (0.125 inch) high. * Folds must be flattened to within
feed direction). (0.062 inch) high. high. 6mm (0.25 inch) height before plac-
ing in the input device.
Folds* (across None. One fold not to exceed 3mm. (0.125 inch) Any fold greater than 3mm. (0.125 inch) high. * Folds must be flattened to within
the feed direc- high. 6mm (0.25 inch) height before plac-
tion) ing in the input device.
Curl (measured None. In-ream or inherent curl up to 13mm. (0.5 Curl greater than 13mm.
from a flat sur- inch) maximum.
face).
Wrinkle. None. Multiple moderate wrinkles, up to 38mm. (1.5 Severe wrinkles greater than 38mm. (1.5 inch) -
inch) long in any direction, 3mm. (0.125 inch) long in any direction, greater than 3mm. (0.125
in height. inch) in height
Foreign material None. Hole reinforcement, correction fluid or dry Correction tape major paste-up or correction -
on the surface. glue no greater than 13 square millimeters. fluid greater than 13 square millimeters. (0.02
(0.02 square inch) per correction. square inch) per correction.
Bent corners No bent corners One bent corner up to 75mm. (3 inch) diago- One or more bent corner exceeding 75mm. (3 * Dog ears must be flattened to within
(dog-ears)* nal length inch) diagonal length. 6mm (0.25 inch) height before plac-
ing in the input device.
Computer fan - Perforated tractor feed edges cleanly Perforated tractor feed edges not removed. -
fold sheets removed.

Envelope Specifications
Tray 2 (With Optional Kit)
Refer to Table 12 and Table 13 for the envelope sizes that can be fed from tray 2 if the optional
envelope kit is installed.
Table 12 European envelope sizes

ID Size Flap minimum length Flap maximum length Feed orientation
DL 110 x 220mm (4.33 x 8.66 inch) 25mm (1.0 inch) 55mm (2.1 inch) LEF, open trailing flap
C5 162 x 229mm (6.38 x 9.02 inch) - 55mm (2.1 inch) LEF, open non-leading flap
Table 13 American envelope sizes

7 3/4 (Monarch) 98 x 190mm (3.87 x 7.5 inch) 36mm (1.4 inch) 55mm (2.1 inch) LEF, open trailing flap
10 105 x 241mm (4.12 x 9.5 inch) 29mm (1.1 inch) 55mm (2.1 inch) LEF, open trailing flap
Bypass Tray
Refer to Table 14 and Table 15 for the envelope sizes that can be fed from the bypass tray.
Table 14 European envelope sizes

DL 110 x 220mm (4.33 x 8.66 inch) 25mm (1.0 inch) 55mm (2.1 inch) LEF, open trailing flap
C5 162 x 229mm (6.38 x 9.02 inch) - 55mm (2.1 inch) LEF, open non-leading flap
Table 15 American envelope sizes

7 3/4 (Monarch) 98 x 190mm (3.87 x 7.5 inch) 36mm (1.4 inch) 55mm (2.1 inch) LEF, open trailing flap
NOTE: All sizes quoted are with the flap closed. Except for C5 envelopes, only envelopes with Exclusions:
flaps on the long edge are acceptable. Envelopes must not be inverted. Some wrinkle is No windows
expected on the back of envelopes.
No board backed
Acceptable flap types: No gusset type
Diamond/Banker No padded
Pocket No peel and seal
Wallet
Weight:
Lightweight
Medium weight
Acceptable sealing:
Gummed
Press and seal

GP 21 Installation Space Requirements NOTE: Machine weight does not include the weight of the finisher or tray 5.
Purpose 65-90 ppm

To outline the general space requirements to enable safe use and adequate access for service. Basic machine weight = 123.15kg (271.5lbs.) (W/O TAG 151).
Basic machine weight = 124.45kg (274.4lbs.) (W/TAG 151).
Fully configured machine weight = 125.5 kg (276.7lbs.) excluding media shelf. (W/O TAG
151).
WARNING
Fully configured machine weight = 126.8 kg (279.5lbs.) excluding media shelf. (W/TAG
Do not work in a confined space. 1 m (39 inches) space is needed for safe working. 151).
NOTE: Machine weight does not include the weight of the finisher or tray 5.
WARNING Optional Tray
USA and Canada. Do not install this machine in a hallway or exit route that does not Tray 5 = 30 kg (66lbs.)
have 1.12 m (44 inches) of space additional to the normal space requirements in front of
Finishers
the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space
is needed in front of the machine in hallway and exit routes. OCT = 2 kg (4.5lbs.)
Machine Height 1K LCSS = 25 kg (55lbs.)
2K LCSS = 30 kg (66.5lbs.)
35-55 ppm
HVF = 82 kg (181lbs.)
Machine height with the platen lowered = 1010mm (40 inches)
HVF BM = 109 kg (240lbs.)
Machine height with the platen raised = 1400mm (55 inches)
HVF BM with PPI = 116.2 kg (256lbs.)
Machine height with the DADH lowered = 1140mm (44.7 inches)
HVF BM with PPI and Tri-folder = 136.5 kg (301lbs.)
Machine height with the DADH raised = 1450mm (57 inches)
65-90 ppm Machine Dimensions and Installation Space Requirements
Machine height with the DADH lowered = 1147mm (45.2 inches) Table 1 shows the dimensions of the WC5790F machines and the installation space required
for safe operation.
Machine height with the DADH raised = 1457mm (57.3 inches)
Machine Weight NOTE: The installation dimensions in Table 1 allow for a 1 metre (39.4 inches) minimum safety
35-55 ppm work space around the machine. To acquire this minimum safety work space it may be neces-
Basic machine weight = 98.75kg (217.7lbs.) (W/O TAG 151). sary to move the machine within the area specified.
Basic machine weight = 100.05kg (220.6.) (W/TAG 151). A gap of 100 mm is required at the rear of the IOT for airflow to the fans. This is also be suffi-
cient for the DADH when raised.
Basic machine with DADH weight = 118kg (260.1lbs.) (W/O TAG 151).
Basic machine with DADH weight = 119.3kg (263lbs.) (W/TAG 151). Figure 1 represents a plan view of a machine installation and is to be read in conjunction with
Fully configured machine weight = 122kg (269lbs.) excluding media shelf (W/O TAG 151). Table 1. The dimensions A and B outline a footprint of the machine within the boundary of safe
operation, dimensions C and D. The dimension E indicates the area required for airflow / work
Fully configured machine weight = 123.3kg (271.8lbs.) excluding media shelf. (W/TAG
space at the rear of the machine.
151).
Table 1 Dimensions and space requirements

Install width required Install depth required Install airflow / service work space
Machine width Machine depth
(C) mm / inches (D) mm / inches (E) mm / inches
(A) mm / (B) mm /
Configuration inches inches Moveable Fixed Moveable Fixed Moveable Fixed
WC5735-WC5755 with OCT and media shelf 1240 / 48.8 675 / 26.6 2240 / 88.2 3240 / 127.6 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with OCT and tray 5 1344 / 53 675 / 26.6 2344 / 92.3 3244 / 131.7 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with 1K LCSS and media shelf 1499 / 59 675 / 26.6 2499 / 98.4 3499 / 137.8 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with 1K LCSS and tray 5 1603 / 63 675 / 26.6 2603 / 102.5 3603 / 142 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4

Table 1 Dimensions and space requirements
Install width required Install depth required Install airflow / service work space
Machine width Machine depth
(C) mm / inches (D) mm / inches (E) mm / inches
(A) mm / (B) mm /
Configuration inches inches Moveable Fixed Moveable Fixed Moveable Fixed
WC5735-WC5755 with 2K LCSS and media shelf 1499 / 59 675 / 26.6 2499 / 98.4 3499 / 137.8 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with HVF and media shelf 1935 / 76.2 675 / 26.6 2935 / 115.6 3935 / 154.9 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with HVF and tray 5 2039 / 76.2 675 / 26.6 3039 /119.6 4039 / 150 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with HVF BM and media shelf 1955 / 77 675 / 26.6 2955 / 116.3 3955 / 155.7 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with HVF BM and tray 5 2059 / 81.1 675 / 26.6 3059 120.4 4059 / 159.8 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with HVF BM and tri-fold 2315 / 91.1 675 / 26.6 3315 / 130.5 4315 / 169.9 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5735-WC5755 with HVF BM, tri-fold and tray 5 2419 / 95.2 675 / 26.6 3419 / 134.6 4419 / 174 1675 / 66 2675 / 105.3 100 / 4 1000 / 39.4
WC5765 with OCT and media shelf 1297 / 51 725 / 28.5 2297 / 90.4 3297 / 129.8 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765 with OCT and tray 5 1344 / 53 725 / 28.5 2344 / 92.3 3344 / 131.7 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with 1K LCSS and media shelf 1556 / 61.3 725 / 28.5 2556 / 100.6 3556 / 140 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with 2K LCSS and media shelf 1556 / 61.3 725 / 28.5 2556 / 100.6 3556 / 140 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with HVF and media shelf 1992 / 78.4 725 / 28.5 2992 / 117.8 3992 / 157.2 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with HVF and tray 5 2039 / 80.3 725 / 28.5 3039 / 119.6 4039 / 159 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with HVF BM and media shelf 2012 / 79.2 725 / 28.5 3012 / 118.6 4012 / 158 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with HVF BM and tray 5 2059 / 81.1 725 / 28.5 3059 / 120.4 4059 / 159.8 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with HVF BM, tri-fold and media shelf 2372 / 93.4 725 / 28.5 3372 / 132.8 4372 / 172.1 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
WC5765-WC5790 with HVF and tray 5 2419 / 95.2 725 / 28.5 3419 / 134.6 4419 / 174 1725 / 68 2725 / 107.3 100 / 4 1000 / 39.4
Figure 1 Installation plan
Front

GP 22 Electrical Power Requirements Low Power Mode
Low power mode is automatically entered after a period of inactivity (determined by timer set-
Power Requirements ting) whilst in standby/ready mode. Timer setting range is from 1 to 120 minutes, refer to Table
Refer to Table 1 and Table 3. 2 for the default settings. Single board controller disk off, IOT +24V disabled, ROS motor off,
fuser to low power. The mode of power is returned to standby following a user request, a key
Table 1 Electrical power requirements pressed on the user interface, offline staple button, power switch, document in the DADH,
Average current DADH opened, incoming FAX or print job. Entry into low power mode is controlled by
Nominal Voltage 35-55 ppm 65-90 ppm Comments Sleep Mode

110VAC (60Hz) Less than or equal Less than or equal Specific XLA markets only. Sleep mode is automatically entered after a period of inactivity (determined by timer setting)
Plus 6% minus 10% to 13.2A RMS. to 17.6A RMS. whilst in Low Power Mode. Timer setting range is from 10 to 120 minutes, refer to Table 2 for
127VAC (60Hz) Less than or equal Less than or equal Mandatory for Saudi Arabia the default settings. The mode of power is returned to standby following a user request, a key
Plus 6% minus 10% to 13.2A RMS. to 17.6A RMS. only. press on the user interface, power switch, incoming FAX or print job.
127VAC (60Hz) Less than or equal Less than or equal To operate at 127VAC +10%
Plus 6% minus 10% to 13.2A RMS. to 17.6A RMS. for long periods. Mandatory Table 2 Default settings
for Mexico only. Standby to low Low power mode to
120VAC (60Hz) Less than or equal Less than or equal Run mode, USA and Can- Speed power mode (mins.) sleep mode (mins.)
Plus 6% minus 10% to 13.2A RMS. to 17.6A RMS. ada. 35 ppm 1 5
120VAC (60Hz) Less than or equal Less than or equal Warm up, All 60Hz markets 40 ppm 2 45
Plus 6% minus 10% to 13.2A RMS. to 17.6A RMS. including USA and Canada.
45 ppm 5 45
220VAC (50Hz) Less than or equal Less than or equal Europe and other 50Hz
55 ppm 8 45
Plus 6% minus 10% to 10A RMS. to 10A RMS. markets.
65 ppm 8 45
75 ppm 15 45
Plus 6% minus 10% to 10A RMS to 10A RMS. markets.
90 ppm 15 45
Plus 6% minus 10% to 10A RMS. to 10A RMS. markets.
Power consumption
Power Save Modes Refer to Table 3 for power the consumption of all modes:
There are two power save modes which are entered after pre-set timers have expired, low
power mode and sleep mode. Both of these power modes are initially set to factory default time
values but are customer adjustable. Entry to both modes can set by the customer to be either
job activated or intelligent ready. The machine will automatically enter low power, then sleep
mode after a period of inactivity exceeds a timer value, refer to Table 2. If intelligent ready is
set, the default value for the timer is preset but is adjusted by the machine based on customer
usage.
Table 3 Power consumption in all modes

Run mode Standby EPA Typical Energy
Configuration (Watt) (Watt) Low power (Watt) Sleep (Watt) Plug-in/off mode (Watt) Consumption Value (Kwh/week)
35 ppm 1050 290 Less than 125 Less than 15 Less than or equal to 0.9 7.0
Additional power for 1K LCSS 70 10 0 0 0 N/A

Table 3 Power consumption in all modes
Run mode Standby EPA Typical Energy
Configuration (Watt) (Watt) Low power (Watt) Sleep (Watt) Plug-in/off mode (Watt) Consumption Value (Kwh/week)
Additional power for 2K LCSS (35-55 ppm) 80 10 0 0 0 N/A
Additional power for 2K LCSS (65-90 ppm) 90 10 0 0 0 N/A
Additional power for HVF (55 ppm) 160 30 0 0 0 N/A
Additional power for HVF (65-90 ppm) 190 30 0 0 0 N/A
Additional power for HVF BM (55 ppm) 160 30 0 0 0 N/A
Additional power for HVF BM (65-90 ppm) 190 30 0 0 0 N/A

GP 23 Environmental Data GP 24 Customer Administration Tools
Operating Purpose
Temperature range: 10 to 32 degrees C (50 to 90 degrees F) To gain access to customer administration tools.
Humidity: 15% to 85% RH.
Noise: How to Enter Customer Administrator Tools
NOTE: Blue Angel criteria measured in accordance with ISO 7779
Table 1 contains the maximum value in decibels of noise that can be generated by 2. When the machine is ready, press the Log in/out (key symbol) button on the key pad or
the basic machine. select Guest on the UI.
Table 2 contains the maximum value in decibels of noise that can be generated by 3. Enter User Name admin (case sensitive). Select Next.
the machine in other configurations.
4. Enter the Password 1111 (default setting). Select Next. If the password is not 1111, per-
form dC001 Reset Auditron Master PIN to reset the password to default. Inform the cus-
Table 1 Maximum noise limits, basic machine tomer that the password has been changed.
PPM Standby (dBA) Run continuous (dBA) Run impulse (dBA) 5. Select Tools Pathway.
35 35 54 57
NOTE: After entering customer administration tools, all existing copy jobs are cancelled. The
40 35 55 58 network controller will stop accepting jobs and a Offline screen message is displayed. When
45 35 56 59 exiting Customer Administration Tools, an Online screen message is displayed.
55 35 56 61
The customer administration Tools contains the Device Setting, Network Setting and the Trou-
65 35 57 62 ble Shooting features. The features are listed below.
75 35 57 62
90 35 58 63 System Settings
Feature Defaults
Table 2 Maximum noise limits, all configurations Consumables Management
PPM Standby (dBA) Run continuous (dBA) Run impulse (dBA) Screen Defaults
Connectivity and Network Setup
35 35 58 61
Customer Support and Supplies Numbers
40 35 58 62
Access and Accounting
45 35 59 63
Online/Offline
55 35 59 63
Optional Services
65 35 59 63
Machine Tests
75 35 60 63
Customer Software Upgrade
90 35 61 64
Power Saver Administration
Copy Activity Report
Altitude: 0 to 1829 metres (0 to 6000 feet)
Software Reset
Storage
Temperature and humidity range:
Call Closeout
55 degrees C (131 degrees F) 85% RH max.
1. Select admin on the UI button to exit Customer Administration Tools.
-25 degrees C (-13 degrees F) 15% RH max.
2. Select Logout.
Altitude: 0 to 3048 metres (0 to 10000 feet).

GP 25 First Copy / Print Out Time and Power On / Off Time
The first copy out time (FCOT) is the duration from the start copy request to the delivery of the
first copy in the OCT. Values in Table 1 are based on a standard job where the original is cop-
ied at 100% from the document glass or DADH onto A4 LEF paper fed from the bypass tray.
The first print out time (FPOT) is the duration from the print job request to the delivery of the
print in the OCT. FPOT values in Table 1 are based on a 1 byte ASCII text file sent using TCP/
IP and LPR, from a Pentium II 128Mb NT 4.0 PC with 100Mb Ethernet.
Table 1 Machine timing

Response time
Description 35 ppm 40 ppm 45 ppm 55 ppm 65 ppm 75 ppm 90 ppm Notes

FCOT from the document glass 4.6 seconds 4.6 seconds 3.4 seconds 3.4 seconds 2.7 seconds 2.7 seconds 2.7 seconds A4 sheet, bypass tray to
OCT no invert.
FCOT from the DADH 9.3 seconds 9.3 seconds 7.3 seconds 7.3 seconds 5.9 seconds 5.9 seconds 5.9 seconds A4 sheet, bypass tray to
OCT no invert.
FPOT 9.2 seconds 9.2 seconds 7.0 seconds 7.0 seconds 5.5 seconds 5.5 seconds 5.5 seconds A4 sheet, bypass tray to
OCT no invert.
Recovery from low power mode. Less than or Less than or Less than or Less than or Less than or Less than or Less than or From low power mode to
equal to 9 sec- equal to 9 sec- equal to 9 sec- equal to 9 sec- equal to 9 sec- equal to 9 sec- equal to 9 sec- ready to copy, print or fax.
onds. onds. onds. onds. onds. onds. onds.
Recovery from sleep mode. Less than or Less than or Less than or Less than or Less than or Less than or Less than or From sleep mode to ready
equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- to print or copy.
Power on time to ready to copy. Less than or Less than or Less than or Less than or Less than or Less than or Less than or Ready to copy is indicated
equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- by the message Ready to
onds. onds. onds. onds. onds. onds. onds. Scan being displayed on
the user interface.
Power on time to ready to print. Less than or Less than or Less than or Less than or Less than or Less than or Less than or Print is indicated by the
equal to 2 min- equal to 2 min- equal to 2 min- equal to 2 min- equal to 2 min- equal to 2 min- equal to 2 min- message Machine On Line
utes and 10 sec- utes and 10 sec- utes and 10 sec- utes and 10 sec- utes and 10 sec- utes and 10 sec- utes and 10 sec- being displayed on the user
onds. onds. onds. onds. onds. onds. onds. interface.
Power on time to ready to fax. Less than 28 Less than 28 Less than 28 Less than 28 Less than 28 Less than 28 Less than 28 sec- Fax ready is indicated by
seconds. seconds. seconds. seconds. seconds. seconds. onds. the presence of the Fax icon
being displayed on the user
interface.
Power off time, multi functional Less than or Less than or Less than or Less than or Less than or Less than or Less than or -
machine. equal to 35 sec- equal to 35 sec- equal to 35 sec- equal to 35 sec- equal to 35 sec- equal to 35 sec- equal to 35 sec-
Quick restart time. Less than or Less than or Less than or Less than or Less than or Less than or Less than or From re-start option con-
equal to 40 sec- equal to 40 sec- equal to 40 sec- equal to 40 sec- equal to 40 sec- equal to 40 sec- equal to 40 sec- firmed, to ready to print or
onds. onds. onds. onds. onds. onds. onds. copy.
Fax recovery from sleep mode Less than or Less than or Less than or Less than or Less than or Less than or Less than or From activity detected on
time. equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- equal to 28 sec- the Fax line to start of paper
onds. onds. onds. onds. onds. onds. onds. feed.

GP 26 Restriction of Hazardous Substances (RoHS) GP 27 Fuser/Xerographic Module End of Life Extension
Purpose Purpose
To give information on the RoHS Directive. To allow the customer a further 5000 prints while a new module is ordered and delivered.
NOTE: Ensure that the customer has ordered a replacement module. This is a one-time only
The RoHS Directive restricts the use of certain hazardous substances in electrical and elec-
tronic equipment. It applies to equipment placed in the European Union (EU) market. The procedure and at the next Replace now screen, the CRU must be replaced.
directive takes effect from 1st July 2006. NOTE: This procedure works only when the CRU is at the End Of Life stage. It will not work if
the CRU is exchanged for another CRU. It is not possible to extend the life of a CRU from a dif-
NOTE: Currently these restrictions are only for the European Union (EU) market and some ferent machine.
associated countries. For more information go to www.Xerox.com. However Xerox has man-
dated that all WC5790F machines must be maintained as RoHS compliant. Procedure
The hazardous substances are: Perform the following procedure when one of the following two messages is displayed:
Lead (Pb) Replace the fuser module now, no prints can be made until module replacement.
Mercury (Hg) Replace the xerographic module now, no prints can be made until module replacement.
Cadmium (Cd) 1. Press the Machine Status button.
Hexavalent Chromium (Cr 6+, Cr [VI]) 2. Select the Tools tab. The Device Settings screen will display.
Polybrominated Diphenyl Ethers (PBDEs) 3. Select the Option Enablement.
Polybrominated Biphenyls (PBBs) 4. For the fuser module, use the numerical keypad to enter the following code:
*33886724691.
The asterisk must be entered before the number. Press Enter.
Identification of a RoHS Compliant Machine 5. For the xerographic module, use the numerical keypad to enter the following code:
Xerox will maintain a central list of RoHS compliant machines. *33886714351
The asterisk must be entered before the number. Press Enter.
All WC5790F machines are RoHS compliant at time of manufacture.
6. Switch off, then switch on the machine, GP 14.
Procedure
CAUTION
Failure to comply with RoHS guidelines can result in
Product recalls
Fines or penalties
Imprisonment
Use only spares that are listed in the WC5790F Spare Parts List. Do not use spare parts from
other similar machines, even if the parts look identical. All WC5790F machines are RoHS com-
pliant at time of manufacture and must be maintained as RoHS compliant.

GP 28 USB Connection Mode GP 29 Embedded Customer Documentation
Purpose Purpose
To set the USB connection mode. To explain how to print the embedded customer documentation.
NOTE: In order to use the CAT/PWS tools the USB print option must be set to Xerox Copier Procedure
Assistant/PWS Service Tool. Perform the following:
Procedure 1. Press the Machine Status button.
Perform the following: 2. Select Information Pages.
1. Enter Customer Administration Tools, GP 24. 3. Select the relevant information page, then select Print.
3. Select Tools.
4. Select Network Settings.
5. Select USB Printer Port.
6. Select Xerox Copier Assistant/PWS Service Tool.
7. Select Save.
8. Exit Customer Administration Tools, GP 24.

GP 30 Copier Only Machine Identification GP 31 How to Set the Date and Time
Purpose Purpose
To explain how to identify a copier only configured machine. To set the machines date and time.
Procedure Procedure
Enter dC131 NVM location 03-016 SIP Machine Type and 08-004 Machine Type. If the values Perform the following:
are set to 2, the machine is configured as a copier only. 1. Enter Customer Administration Tools, GP 24.
NOTE: These values are protected, they can only be reset by running the install wizard. Refer
3. Select the Tools tab.
to GP 15 How to Set the Machine Configuration.
4. Select Device Settings.
NOTE: Copier only machines are only purchasable within the United States of America. Dis- 5. Select the General folder.
abling of the network features is applied when the activation code is entered during the installa-
6. Select Date & Time.
tion of the machine.
7. Set the correct date and time, then select Save.
Observe the activation code label on the rear of the machine. A copier only machine will have 8. Log out of Customer Administration Tools.
DC 57XX in the top right corner of the label. A multi-function machine will have MF 57XX.
There are no hardware differences between a copier and multi function device.
Be aware of the following:

Other than checking the above NVM values and activation code label, there are no other
methods for identifying a copier only machine.
Copier only machines:
Will display the network controller booting up message when the machine is
switched on.
Will display a status message if a network controller fault is detected.
Have some network controller maintenance features still present, for example, on
demand image overwrite.
Can not have software upgraded via DLM from either the network or USB flash
drive.
Can only have software upgrades made via the Forced AltBoot Software Loading
Procedure. Refer to GP 4 Machine Software.
NOTE: Copier only configured machines loaded with pre SMP 1 software do not per-
form a power on software upgrade.
Must have the Forced Altboot Software loading Procedure performed every time a
PWB is changed, unless software level SMP 1 or higher is loaded onto the copier.

GP 32 How to Enable HTTP GP 33 How to Configure the PWS to Ping a Device
Purpose Purpose
To enable the hyper text transfer protocol (HTTP) networking protcol. To configure the PWS to ping a device on a network.
Procedure Procedure
Perform the following: Perform the following:
1. Enter Customer Administration Tools, GP 24. 1. Set the IP address of the PWS one digit higher or lower than the device to be pinged. For
2. Press the Machine Status button. example, if the IP address of the device is 192.168.10.15, set the PWS to 192.168.10.14
3. Select the Tools tab. or 192.168.10.16. To set the IP address of the PWS, refer to GP 34.
4. Select Network Settings. 2. Set the subnet mask of the PWS the same as the devise to be pinged.
5. Select Network Setup. 3. On the PWS, Select Start, then Run.
6. Select TCP/IP. 4. In the Run dialog box, type cmd.
7. Select HTTP/IPP Enablement. 5. Select OK. A command window will open.
8. Select Enabled. 6. In the command window, type ping and the address of the device. Refer to number 1 in
Figure 1.
9. Select Save.
7. If the ping command is successful, a reply from the devise will be received. Refer to num-
10. Select Close.
ber 2 in Figure 1.
11. Log out of Customer Administration Tools.
Figure 1 Successful ping command

8. If the ping command is unsuccessful, a timed out message will be received, Figure 2. GP 34 How to Set the IP Address of the PWS
Purpose
To set the IP address of the PWS.
Procedure
NOTE: This procedure applies to the Windows XP operating system.

1. On the PWS, right click on the My Network Places desktop icon or select Start, then My
Network Places. Select Properties from the menu. The Network and Dial-up Connections
window will open.
2. Right click on Local Area Connection icon, then select Properties. The Local Area Con-
nection Properties window will open.
3. Highlight Internet Protocol (TCP/IP), then select Properties, refer to Figure 1. The Internet
Protocol (TCP/IP) Properties window will open.
Figure 2 Unsuccessful ping command
Figure 1 Properties window

4. Select Use the following IP address. Enter the IP address and Subnet mask, Figure 2. GP 35 How to Change Ethernet Speed
Purpose
To change the machines ethernet speed.
Procedure
1. Enter Customer Administration Tools, GP 24.
3. Select the Tools tab.
4. Select Network Settings.
5. Select Ethernet Physical Media.
6. Select the speed, then Save.
7. Log out of Customer Administration Tools.
5. Select OK to close the Internet Protocol (TCP/IP) Properties window.

6. Select OK to close the Local Area Connection Properties window.

GP 36 How to Disable the Firewall of the PWS 3. Right click on Local Area Connection icon, then select Properties. The Local Area Con-
nection Properties window will open, Figure 2.
Purpose
To disable the firewall of the PWS.
Procedure
NOTE: This procedure applies to the Windows XP operating system.

1. On the PWS, right click on the My Network Places desktop icon or select Start, then My
Network Places. Select Properties from the menu. The Network and Dial-up Connections
window will open.
2. Check if the firewall is enabled or disabled. If the Local Area Connection icon has a pad-
lock symbol, the firewall is enabled, Figure 1. If the firewall is enabled, continue with this
procedure.
4. Select the Advanced tab, then the Settings button, Figure 3. If available, uncheck Protect
my computer and network by limiting or preventing access to the computer from the Inter-
net. Select OK. The Windows Firewall window will open.
Figure 1 Padlock symbol
Figure 3 Settings button

5. Select the Off (not recommended) radio button to disable the windows firewall, Figure 4.
Figure 4 Settings button
6. Close all open windows.

7. Disable any other Firewall software or utilities that may be running.

GP 40 Glossary of Terms, Acronyms and Abbreviations Table 1 Abbreviations
Where possible unit designations as appear in ISO 1000 (International Organization for Stan- Term Description
dardization) and Xerox Standard MN2-905 have been used. All measurement appear in ISO BT Busy Tone
units followed by any conversion in brackets e.g.; 22.5mm (0.885 inches) C Celsius
CAT Customer Admin Tool
Refer to Table 1.
CB Certification Bodies
Table 1 Abbreviations CC Copy Centre
Term Description CCA Cenelec Certification Agreement
CCA Customer Call Assistance
AAA Authentication, Authorisation and Accounting
CCD Charged Coupled Device
ABS Automatic Background Suppression.
CCITT Comite Consultatif International Telegraphique et Telephonique
ACK Acknowledge
CCR Change Control Request
ADF Automatic Document Feeder
CD Copy Darker. A copy density setting
ADU Automatic Duplexing Unit
CD-ROM Compact Disk - Read Only Memory
AGC Automatic Gain Control
CDDU Controller and Drivers Delivery Unit
AHA Advanced Hardware Architecture
CDDUW Controller and Drivers Delivery Unit - West Coast
AMCV Average Monthly Copy Volume
CDS Charge - deficient spot. A photo conductor defect that as a very small
AMF Advanced Multi Function device
black spot (image quality parameter).
AMPV Average Monthly Print Volume
CED Called Station Identification
AMR Automatic Meter Read
CEH&S Corporate Environmental Heath and Safety
AMS Automatic Magnification Selection
CentreWare CentreWare internet services is the embedded HTTP server application
ANSI American National Standards Institute
that is available on network enabled machines. It enables access to print-
API Application Programming Interface ing, faxing and scanning over the internet.
APS Auto Paper Selection CFR Confirmation To Receive
ARP Address Resolution Protocol. Converts an IP address to a MAC address. CISPR Comite International Special des Perturbations
See RARP. CID Command Identification
ASIC Application Specific Integrated Circuit CIG Calling Subscriber Identification
ASP Authorized Service Provider CIS Contact Image Sensor
ASTM American Standard Test Method CL Copy Lighter. A copy density setting
ATPD Across The Process Direction Click Charge Charge by copy/print rate
AZAP Any Zone Any Paper COD Customer Operating Division
B Bels (applies to sound power level units) CPHI Calls Per Hundred Installs
B (A) Bels (A weighted) (applies to sound power level units) CPM Copies per minute
B (A) I Bels (A weighted) Impulse response (applies to sound power level units) CPSR Capture / Print, Save and Reprint
BABT British Approvals Board for Tele-Communication CQ Copy Quality
BAM Bundes Anstalt fur Materialprufung CR Change Request
BEUI BIOS Extended User Interface CRU Customer Replaceable Unit
Bluetooth Wireless local area network CRUM Customer Replaceable Unit Monitor
BM Booklet Maker CSE Customer Service Engineer
BMF Basic Multi Function device CSF Call Service Fault
BootP Boot Protocol. AN IP protocol for automatically assigning IP addresses. CSMS Customer Satisfaction Management System
BPS Bits Per Second
BS Behavior Specification

Table 1 Abbreviations Table 1 Abbreviations
Term Description Term Description
Customer Drivers Customer drivers are specially developed generally made with a driver DOF Direction Of Feed, paper width sensors
toolkit. These drivers can provide a full set of features for Xerox printers. DPI Dots per inch
In the past, customers drivers have been provided for all major operating DRAM Dynamic Random Access Memory
systems. A customer print driver is costly to develop, and does not used
DRS Drum to Roll Spacing
standard operating system components. For this reason, PPD / GPD
solutions will be used in future whenever possible. DSR Data Set Ready
CTC Continue To Correct DST Daylight Saving Time
CTF Contrast Transfer Function DT Dial Tone
CTR Response For Continue To Correct DTC Digital Transmit Command
CTS Clear To Send DTMF Dual Tone Multiple Frequency
CVT Constant Velocity Transport DU Density Units
CW CentreWare DUI Display User Interface
CWW CentreWare Web Dust Off Routine to return machine to pre-install state
DADF Duplex Automatic Document Feeder (feeds documents to a different EAA Electron Auditron Administrator
stack) EBS Electronic Billing Service
DADH Duplex Automatic Document Handler (feeds documents to bottom of EC European Community
existing feed stack) ECE External Customer Engagement
DB Database ECM Error Correction Mode. Electronic Counter Measure
dB Decibel (applies to sound pressure level units) EEC European Economic Community
dB(A) Decibels (A weighted) (applies to sound pressure level units) EET Edge Enhancement Technology
dB(A)I Decibels (A weighted) Impulse response (applies to sound pressure level EHS Environmental Health and Safety
units) ELOG Electronic Log
dC Diagnostic code EMC Electromagnetic Compatibility
DC Digital Copier Embedded Fax A fax system included in a system device
DC Device Controller, generic term for any module that acts as a image han- EME Electromagnetic Emission
dling device e.g., SIP. Digital Copier
EN European Norm
DC Direct Current
EOL End Of Line
DC + Fax Digital Copier with embedded Fax card
EOM End Of Message
DCN Disconnect
EOP End Of Procedure
DCS Digital Command Signal
EOR End Of Retransmission
DDF Device Description File
EPA Environmental Protection Agency
DHCP Dynamic Host Config Protocol (similar to BootP)
EPC Electronic Page Collation (memory dedicated to temporary retention of
DIMM Dual In Line Memory Module
images captured from the scanner and network controller)
DIN Deutches Institute fur Normung
EPROM Erasable / Programmable Read Only Memory
DLM Dynamically Loadable Module
EP-SV Electronic Partnership Supervisor (kit)
DMO-E Developing Markets Operations East (was part of RX)
ERR End Retransmission Response
DMO-W Developing Markets Operations West (was part of ACO)
ERU Engineer Replaceable Unit
DOS Disk Operating Systems
ESD Electrostatic Discharge
DPHM Defects Per Hundred Machines
ESG European Solutions Group
DIS Digital Identification Signal
ESS Electronic Sub-System. For this machine use NC
DMA Direct Memory Access
ETP Electronic Test Pattern
DMO Developing Markets Operations
EU European Union

EUR Europe GUI Graphics User Interface
FAX Facsimile GWA Green World Alliance
FAR Fully Active Retard feeder HC High Capacity
FCC Federal Communications Commission HCF High Capacity Feeder
FCD Facsimile Coded Data HDD Hard Disk Drive
FCS Facsimile Checking Sequence HDLC High Level Data Link Control
FCOT First Copy Out Time HFLEN High - Frequency (random) Line - Edge Noise. image quality metric.
FD Functional Description HFSI High Frequency Service Intervals
FER Feature Enhancement Request HLD High Level Design. A document that defines the software high level
FID Foreign Interface Device design.
FIF Facsimile Information Field HTTP Hyper Text Transfer Protocol
FIFO First In First Out HUI Hybrid User Interface
FireWire IEEE 1349. High speed serial communications system, comprising hard- HVF High Volume Finisher
ware plus protocol. Operates at 100, 200 or 400Mbits/s, with 800Mbits/s HVF / BM High Volume Finisher Booklet Maker
under development. See USB and RS-232 HVPS High Voltage Power Supply
firmware Software in a ROM Hz Hertz
FLASH On board erasable and re-programmable non volatile memory IB or I/B InBoard
FOIP FAX Over Internet Protocol I2C-bus Inter Integrated Circuit bus. This provides a simple bidirectional 2-wire
FPGA Field Programmable Gate Array bus for efficient inter-IC control. All I2C-bus compatible devices incorpo-
FPOT First Print Out Time rate an interface which allows them to communicate directly with each
other via the I2C-bus.
FRU Fuser Replacement Unit
ICAT Internal Customer Acceptance Test
FSK Frequency Shift Keying
ICE Internal Customer Engagement
FSMA Field Service Maintenance Agreement
ID Identification
FTP File Transfer Protocol
IEC International Electrotechnical Commission
FTT Failure To Train
IDG Inter document gap
FX Fuji Xerox
IEE Institute of Electrical Engineers
G3 Group 3
IEEE 1284 Parallel port communication
GC Group Command
IETF Internal Engineering Task Force
GDI Graphical Display Interface
IFAX Internet Fax
GI Group Identification
IIT Image Input Terminal
GLCD Graphic Liquid Crystal Display
IM Interim Maintenance
GND Ground
Intlk Interlock
GPD Minidrivers A Generic Printer Description file has a function similar to PPD files. This
format was developed by Microsoft to provide a simple method to IOT Image Output Terminal
develop drivers for non-postScript printers. Standard GPD minidrivers IOTC Image Output Terminal Controller (IOT PWB, LVPS and HVPS). Some-
share the same lamentations as the PPD minidrivers, but they too can be times referred to as the Power and Control Assembly.
enhanced using plug-ins. GPD Minidrivers are a new technology intro- IP Internet Protocol
duced for Windows 2000 and they will also be supported Windows NT 4.
IPA Image Processing Accelerator. Used by the machine scanning services
In Windows 95/98, a similar, but less powerful unidriver format was to convert scanned images to a standard format e.g. for scan to file /
used.
scan to E-mail for network transmission.
GS German safety
IPM Incremental Preventative Maintenance
GSM Grams per square metre
IPM Images per minute

IPP Internet Printing Protocol LUI Local user Interface
IPS Image Processing Service m metre
IPS1 Image Processing System MAC Address Media Access Code. This is the basic, unique identifier of a networked
IPX Internetwork Protocol eXchange device. An incoming message is analysed and an address in another
IQ Image Quality form, such as an IP address, is resolved by a lookup table to a MAC
address. The message is then directed to, and accepted by the equip-
IR Infrared
ment thus identified. It is the burnt-in, hardware address of a NIC.
ISDN Integrated Services Digital Network / International Standard Data Net-
MB Megabyte (one MB = 1,048,576 bytes = 1024 kilobytes). Mail Box
work
Mb Mega bit (one million bits)
ISIL Inter and Side Image Lamp
MCF Message Confirmation
ISO International Standards Organization
Mem-Mem Memory to Memory
ITP Internal Test Pattern
MF Multifunction
ITTCC International Telegraph and Telephone Consultative Committee
MFLEN Mid - Frequency (random) Lines - Edge Noise
ITU -T International Telecommunications Union - Telecommunication
MH Modified Huffman
JBA Job Based Accounting (Network Accounting)
MIB Machine Information Block. SNMP database element
JBIG Joint Bi-Level Image Experts Group file interchange format
MJ Modular Jack
jitter A line of missing or corrupted information in the fast scan direction.
mm millimetre
JPEG Joint Photographic Experts Group file interchange format
MMC Microsoft Management Console
kg kilogram
MMR Modified Modified Read compression
kHz kilohertz
MN Multi - National
Kill All Routine to return all NVM, including protected NVM, to a virgin state.
Modem MOdulator/DEModulator. Hardware unit that converts the one and zero
Factory use only
binary values from the computer to two frequencies for transmission over
KO Key Operator the public telephone network (modulation). It also converts the two fre-
LAA Local Area Addressing quencies received from the telephone network to the binary values for
LAN Local Area Network the computer (demodulation).
LCD Liquid Crystal Display Moire Image quality defect caused by interference between patterned originals
LCDM Liquid Crystal Display Module and the digital imaging process. Moire patterns are repetitive and visible
as bands, plaids or other texture.
LCS Line Conditioning Signal
MPS Multi-Page Signal
LCSS Low Capacity Stapler Stacker
MR Modified Read compression
LDAP Lightweight Directory Access Protocol (allows sharing of corporate
phone book information) MRC Modified Read Compression
LE Lead edge MSG Management Steering Group
LED Light Emitting Diode ms millisecond
LEF Long Edge Feed MSI Multi-Sheet Inserter
LEISUS Low End Interface Unsolicited Status-B MSO Mixed Size Originals
LG Legal MX Modi Xerox
LOA Load Object Attributes N Newton
lpi Lines per inch NA North America
LSI Large Scale Integration NASG-N North American Solutions Group (equivalent to XCI)
LT Letter NASG-S North American Solutions Group (equivalent to USCO)
LVPS Low Voltage Power Supply nC nano Coulomb
Lwr Lower NC Network Controller (equivalent to ESS).

NC Normal Contrast. Copy contrast setting PCL Printer Control Language
NCP Network Core Protocol PCMCIA Personal Computer Memory Card International Association
NCR No Copying Required PD Process Direction
NCU Network Control Unit PDF Adobe Acrobat Portable Document Format
NDS NetWare Domain Services or Novell Directory Services PDL Page Description Language
NDS Context NetWare Domain Services Context PDT Product Delivery Team
NDS Tree NetWare Domain Services Tree Pels Picture Data (Pixel)
NetBEUI NetBIOS Extended User Interface. A network device driver or transport PFM Paper Feed Module
protocol that is the transport driver supplied with LAN Manager. It can PFP Paper Feed Platform
bind with as many as eight media access control drivers. PHI per Hundred Installs
NetBIOS Network Basic Input / Output System. Software developed by IBM that PIN Procedural Interrupt Negative
provides the interface between the PC operating system, the I?O bus,
PIN Personal Identification Number
and the network. Since its design, NetBIOS has become a de facto stan-
dard. ping Packet InterNet Groper. Tool to test connections between nodes by send-
ing and returning test data.
NGI Next Generation Infrastructure (new files and mail servers)
PIP Procedural Interrupt Positive
NIC Network Interface Card. Converts the data to a form suitable for trans-
mission and reception. Uses ARP and RARP. PJL Printed Job Language. Hewlett Packard page description language.
Nm Newton metre PMC Programme Management Committee
NOHAD Noise, Ozone, Heat, Airflow and Dust POPO Power Off Power On
NP Printer configuration POO or P of O Principles of Operation
NS Normal Sharpness. Copy sharpness setting POST Power On Self Test
NSC Non-Standard Facilities Command PPC Power PC. A EPROM manufacturer
NSF Non-Standard Facilities PPD Postscript Printer Description. A PPD file is a simple formatted text file
NSS Non-Standard Set-Up that contains a description of the printers features and the corresponding
PostScript code needed to activate each feature. Apple LaserWrite driv-
NSSD Network. The SESS and CentreWare development team based in Roch-
ers and application programs such as Adobe PageMaker can use PPD
ester NY. This group is now named CDDU.
files. With a OOD file, many of the printing features of a network printer
NVM Non-Volatile Memory can be made available to users. However advanced features such as
OA Open Architecture LAN Fax, Accounting and Exception Page Programming cannot be pro-
OB or O/B Out Board vided.
OCT Offsetting Catch Tray PPD Minidrivers PPD minidrivers are available in Windows operating systems (from Win-
dows 95 onwards). With these, a Xerox - supplied PPD file is used in
OEM Original Equipment Manufacturer
conjunction with an operating system supplied driver ton create a Post-
OGM On Going Maintenance
Script driver tailored for a specific device. In windows 95/98, a driver pro-
OOP Out Of Paper vided by this method has lamentations and not all devices features can
OpCo Operating Company be made available to the user. With Windows NT 4 and Windows 2000, it
OSA Online support Assistant is possible to make more features available by using a user interface ren-
dering plug - in. In this document, if the driver is to be provided with If no
OSCG Office Systems Component Group
plug-ins are provided, then it is called a standard minidriver.
P/R Photoreceptor
PPHI Problems Per Hundred Installs
PABX Private Automatic Branch Exchange
PPI Post Process Inserter
PC Personal Computer
PPM Prints per minute / Parts Per Million
PC Fax Personal Computer Fax
PPR Partial page Request
PCI Peripheral Component Interface
pps Partial Page Signal / pulses per second
PCI Personal Computer Interface

PPS Product Performance Specification RS-232, RS-423, Series of standards for serial communication of data by wire. RS-232
PR Photo-Receptor RS-422, RS-485 operates at 20kbits/s, RS-423 operates at 100kbits/s, RS-422 and RS-
PRI-EOM Procedure Interrupt-EOM 485 operate at 10Mbits/s. See FireWire and USB.
PRI-EOP Procedure Interrupt-EOP RTN Retrain Negative
PRI-MPS Procedure Interrupt-MPS RTP Retrain Positive
PSM1 Power Save Mode 1 (low power mode) RTS Request To Send
PSM 3 Power Save Mode 3 (sleep mode) Rx Receive
PS Post Script S2E Scan-to-E-mail
PSTN Private Switched Telephone Network S2F Scan-to-File
PSW Portable Service Workstation S2X Scan-to-Export
PTT Post, Telephone, Telegraph (national public utilities) SA Systems Administration
PVC Poly Vinyl Chloride SAD Solid Area Density
PVT Product Verification Test SAKO Systems Administration Key Operator
PWB Printed Wiring Board SAP Service Advertising Protocol. a network device will broadcast its capabili-
ties onto the network at a defined intervals.
PWB A Printed Wiring Board Assembly
SAF Safety
PWS Portable Work Station
SAP Service Advertising Protocol
QIT Quality Improvement Team
SAR Semi-Active Retard feeder
RAM Random Access Memory
SBC Single board controller
RARP Reverse Address Resolution. Reverse of ARP. Converts a MAC address
SCD Software Compatibility Database
to an IP address. The document centre resolves its address using RARP.
See also MAC, NIC and ARP. SCM Software Configuration Management
RBT Ring Back Tone SCN Specification Change Notice
RCA Remote Customer Assistance SCR Software Change Request
RDT Remote Data Transfer SCSI Small computer Systems Interface
R/E Reduction / Enlargement SCT Simple Catch Tray
REN Ringer Equivalence Number S/D Shut Down
RFC Request for comment. An IETF standard reference. SDK Software Development Kit
RPC Remote Procedure Call SDP Software Development Plan
RH Relative humidity SDR Shut Down Rate
RIC Remote Interactive Communications SDRAM Static Dynamic Remote Access Memory
RIS Raster Input Scanner Server Fax A fax system that uses a remote Fax server. Faxes transmit as a Scan to
File job sent to the server. Fax receive as print jobs submitted to the Con-
Riser PWB A card that increases the number of PCI slots.
nection Device.
RJ 45 Phone type network connector
SEF Short Edge Feed
RM Requirements Management
SESS Strategic Electronic Sub-System
RMS Root Mean Square (AC effective voltage)
SIM Scanner Input Module
RNR Receive Not Ready
Single board con- Copy, print and UI controllers all on one PWBA within the image process-
RO Regional Operations troller PWB ing module.
ROM Read Only Memory SIP Scanning and Image Processing
ROS Raster Output Scanner SIR Standard Image Reduction
RR Receive Ready Sixth Sense A single device and group management tool
RRB Requirements Review Board SLP Service Location Protocol (finds servers)

SM Scheduled Maintenance TP Test Point
SMART Systematic Material Acquisition Release Technique TOS Teflon over Silicon
SMB Server Message Block. Microsoft Server / Client Communications proto- TPM Technical Programme Manager
col Transmissive LCD Liquid Crystal Display lit from the back
SMP1 Service Maintenance Pack 1 (contains a software package) TRC Toner Reproduction Curve
SPAR Software Problem Action Request Tri-Folder Output device that creates C and Z folds
SNMP Simple Network Management Protocol TRN Train
Snr Sensor TSH Technical Service Hours
SOD System Operating Description TSI Transmit Subscriber Identification
SPL Sound Pressure Level TTY Teletype Terminal
SPP Short Paper Path TUI Textual User Interface
spi Spots per inch Tx Transmit
SPID Service Profile Identification UGD An upgrade file, i.e. filename.ugd
SQA Software Quality Assurance UART Universal Asynchronous Receiver Transmitter
SR Service Representative UDP User Datagram Protocol
SRAM Static Random Access Memory UI User Interface (display screen)
SRC Software Requirements UK United Kingdom
SS or S/S Sub System UM Unscheduled Maintenance
ST System Terminal Device. Multi-functional device as defined by Energy UMR Unscheduled Maintenance Rate
Star (includes DC / NC and DC / NC / Fax) URL Universal Resource Locator
STP Standard Test Pattern USB Universal Serial Bus.
STS Side To Side, paper width sensors High speed successor to parallel port for local device communications.
SW Switch Operates at 12Mbits/s. See FireWire and RS-232.
SW or S/W Software USCO United States Customer Operations
SWL Sound Power Level UTP Un-shielded Twisted Pair
system kernel Minimal operating system V.17 / V.29 / V.34 Modem standards
T&M Time and Materials VALO Value Added Logistic Organization
TAR Take away Roll VAR Value Added Reseller
TBC To Be Confirmed VDE Verband Deutscher Elektrotechniker
TBD To Be Defined VGA Video Graphics Array
TCP / IP Transmission Control Protocol / Internet Protocol VOIP Voice Over Internet Protocol
TE Trail Edge WC WorkCentre
Template A collection of Scan to File attributes that can be conveniently re-used. WC + PS WorkCentre + PostScript print drivers
TC Toner Concentration WCP WorkCentre Pro
TCF Training Check Field WEB UI CentreWare Internet Services
TDT Transfer Detack WINS Window Internet Name Service
TEC Typical Electricity Consumption XAP Xerox Asia Pacific
TEI Terminal Endpoint Identifier XCL Xerox Canada Limited
TIFF Tagged Image File Format XCMI Xerox Common Management Interface
TIFF FX TIFF Fax eXtended XCRU Xerographic CRU (also known as XRU)
TIFFX Tagged Image File Format - for internet FAX XE Xerox Europe

Table 1 Abbreviations
Term Description
XI Xerox Initiated
XL Xerox Limited
XLA Xerox Latin America
XOG Xerox Office Group
XRU Xerographic Replacement Unit
XSA Xerox Standard Accounting
XUL Xerox Unique Login enables use of the xerox corporate directory

dC001 Reset Auditron Master PIN dC104 Modal Usage Counters
Purpose Purpose
To reset the customer administration password to the default, (1111). To list counters that provide information about features of the machine that have been used by
the customer.
Procedure
1. Enter diagnostics, GP 1. Procedure
2. Select Diagnostic Routines, select Other Routines, select 001 Reset Auditron Master PIN. 1. Enter diagnostics, GP 1.
3. Select Reset Auditron Master PIN. 2. Select Diagnostic Routines, select Other Routines, select 104 Modal Usage Counters.
4. Select confirm or cancel. The modal usage counters screen displays, showing the list of counters and the amount
of use.

Xerox WorkCentre 5790 Family 6-73 dC001, dC104
dC109 Embedded Fax Protocol Report If the Protocol Report gives errors that show that the Fax is not able send a Fax, go to
RAP 20B Unable To Send A Fax.
Purpose If the Protocol Report gives errors that show that it is unable to receive a Fax, go to RAP
This procedure allows the CSE to print out the Protocol reports for both line 1 and line 2 if con- 20D Unable To Receive A Fax.
figured. The protocol report contains the protocol information about the last fax transmission If the EQM column in the Job details, gives a code of greater than 5xxx, go to RAP 20D
whether it was a send or receive job. The protocol report contains the following: Unable To Receive A Fax.
Date and time

The last local ID and name of the transaction for line 1 or line 2.
A firmware version listing for FPGA, application, boot code and hardware.
The Job details with the job, line, Fax number, start time and duration. The results column
will show the speed of the communications to the remote machine and the connection
status. The EQM column will show the EQM value to determine the line quality.
The communication summary with the time and a local and remote column. The local and
remote columns will display abbreviations refer to Table 1.
Procedure
2. Select Diagnostic Routines.
3. Select Fax dC Routines, select 109 Protocol Report.
4. Select Protocol Report Line 1 or Protocol Report Line 2 if configured for 2 lines, then
select, Print Report.
5. The Print Report button greys out until the job has been submitted. The Fax card builds
the protocol report job and places the job in the Fax NVM. This is the equivalent of an
active Fax job in the Fax card queue. The job does not print, it remains in the queue until
the Fax card exits diagnostics.
6. Exit Diagnostics, GP 1.
7. The protocol report prints out.
Analyse the Protocol Report.
For an example of a send and a receive Fax protocol report, refer to Figure 1 or Figure 2.
In Job Details:
The results column also shows the line speed (i.e. 1440 bps).
The EQM column indicates the line quality (i.e. if the value is greater than 5xxx, then the
line quality is poor). Figure 1 Send Fax protocol report
In Communications summary:
The time column records the time at which each event occurs, from the start of the com-
munication.
The local and remote column shows the G3 protocol command or response with a direc-
tion arrow. Refer to Table 1 for the description of the abbreviations.
The FCF column providing a Hex value of the data information contained in the G3 fac-
simile checking field.
the FIF column providing a Hex value of the data information contained in the G3 facsim-
ile information field.
Identify the fault and refer to the appropriate RAP:
If the Protocol Report is blank, go to RAP 20A Fax Entry.

dC109 6-74 Xerox WorkCentre 5790 Family
Table 1 Local and remote abbreviations
Term Description
DCS Digital command signal
DIS Digital identification signal
DTC Digital transmit command
EOM End of message
EOP End of procedure
EOR End of retransmission
EQM Eye quality monitor (measures the quality of the line)
ERR Response for end of transmission
FCD Facsimile coded data
FCF Fax Code Field
FIF Fax Information Field
FTT Failure to train
JM Joint menu
MCF Message confirmation
MPS Multi page signal
NSC Non to standard facilities command
NSF Non to standard facilities
NSS Non to standard setup
PID Procedure interrupt
PIN Procedure interrupt negative
PIP Procedure interrupt positive
PPS Partial page signal
PPR Partial page request
Figure 2 Receive Fax protocol report PRI-EOM Procedure interrupt to EOM
PRI-EOP Procedure interrupt to EOP
Table 1 Local and remote abbreviations PRI-MPS Procedure interrupt to MPS
Term Description PWD Password for (polling)
ANSam Modulated answer tone PWD Password for (transmission)
CED Called terminal identification RCP Return to control for partial page
CFR Confirmation to receive RNR Receive not ready
CI Call indicator RR Receive ready
CIG Calling subscriber indentation RTN Retrain negative
CJ CM terminator RTP Retrain positive
CM Call menu SEP Selective polling
CNG Calling tone SUB Subaddress
CRP Command repeat TCF Training check
CSI Called subscriber identified TSI Transmitting subscriber identification
CTC Continue to correct
CTR Response for continue to correct
DCN Disconnect

Xerox WorkCentre 5790 Family 6-75 dC109
dC111 Tag Matrix dC131 NVM Read/Write
Purpose Purpose
This NVM store provides the CSE with a means to enter, store, delete and retrieve Tag Num- To review and modify values within the machine configuration and control parameters stored in
bers that show which hardware and software upgrades are incorporated in the machine. NVM.
Description NOTE: This does not include customer administration or accounting data, these are accessible
from the billing and auditron facilities, refer to the User Guide.
NOTE: This store is not deleted during a dustoff procedure, dC132 NVM initialisation.
Description
Tags are issued with a module identifying prefix and number as follows:
Each NVM item is identified using a chain and location code in the form XX-XXX, where XX- is
Processor module to 001 to 250.
the chain prefix, and -XXX is an identifier in the range 001 to 999. For example 09-245. Refer
DADH module to D001 to D050. to GP 2 Fault Codes and History Files.
Finisher module to F001 to F050.
The tag numbers are stored in areas defined by module and are entered into the Tag Matrix dC Procedure
111 without the prefix. 1. Save the NVM, GP 5.
Refer to the procedure Tags. This contains a list of Tag numbers together with an description of
each of the modifications.
4. Select required dC routine category:
Procedure Copier Routines.
1. Enter diagnostics, GP 1. Fax Routines.
2. Select Diagnostic Routines, select Other Routines, select dC111 Tag Matrix. 5. For copier routines, select the appropriate button for the NVM chain to be viewed.
3. Select the appropriate module button, and follow the on screen instructions. 6. Use the scroll buttons to view the other NVM locations of the chain.
Use the keyboard to type the three digit identifier code into the Find: field and then
touch the Find: button. This puts the found NVM value at the top of the list.
NOTE: Press the keypad C button to reset the Find: button to 000.
7. Touch the selected NVM in the list, and touch the Read/Write button.
The Read/Write window will open for editable NVM, and the Read Only window will
open for Read Only (protected) NVM.
8. Refer to the tables that follow for NVM chain locations and parameters:
NVM Tables Chains 1 to 10 dC131a.
NVM Tables Chains 12 to 19 dC131b.
NOTE: Refer to the Fax NVM Document for the fax (chain 20) NVM values.
9. When the values of an editable NVM have been changed, switch off the machine, then
switch on the machine, GP 14, to check and evaluate the changes made to the NVM.
NOTE: If the NVM default characters exceed 10 characters only the first eight characters are
displayed in the list. The full string is displayed in the Read/Write window.
NOTE: Selecting Reset will cause the selected NVM location to be reset to its default value.
Selecting Cancel closes the window and cancels any changes made in the now closed win-
dow.
NOTE: The CSE cannot read or modify any NVM that contains customer administrative or
accounting data.
NOTE: The Read Only (protected) NVM can only be changed using a password obtained from
Xerox. Protected NVM cannot be reset from dC132 NVM initialisation.

dC111, dC131 6-76 Xerox WorkCentre 5790 Family
dC131a NVM Tables Chain 1 to 10 Table 3 NVM chain 3
Location NVM Name NVM Description Value Default
General
03-007 Value Added Defines installation's value 0 to 255 255
1. Refer to the following for NVM parameters chain 1 to 10:
Reseller added reseller. Password
NVM chain 1 Table 1 protected.
NVM chain 2 Table 2 03-008 Product Identifier Sets the product identifier. 151 = 35 ppm 73
NVM chain 3 Table 3 This is used to identify the 152 = 40 ppm
NVM chain 5 Table 4 printer type over the net- 153 = 45 ppm
NVM chain 6 Table 5 work (through the sysOb- 154 = 55 ppm
jectID Object). 155 = 65 ppm
NVM chain 7 Table 6
Password protected. 156 = 75 ppm
NVM chain 8 Table 7 157 = 90 ppm
NVM chain 9 Table 8 NOTE: For machine identi-
fication, refer to SCP 7
NVM chain 10 Table 9
Machine Features.
03-009 Install Client Defines current client of 0 to 255 0
Table 1 NVM chain 1
system installation.
03-010 SVC Copy Mode Service copy mode entry 1000 to 999999999 4391
01-001 Power Save Defines whether power save is 0=disabled 1 PIN code. Normally the reverse
Enable enabled. 1=enabled of the diagnostic entry
code.
Table 2 NVM chain 2 03-011 Auto Hold Hold job queue if 0=disable 1=enable 1
Enable resources unavailable.
03-012 Prod config Defines product configura- 35=35ppm 33
02-001 Printer Language - 0 0
(speed) tion (processing speed). 40=40ppm
08-001 must be set to the 45=45ppm
Table 3 NVM chain 3 same speed. 55=55ppm
Location NVM Name NVM Description Value Default 65=65ppm
75=75ppm
03-001 Foreign Interface Determines whether for- 0=disabled 1=enabled 0 85=90ppm
eign interface is config-
03-013 Doc Handler Defines if the DADH or 0=DADH 1=Document 1
ured.
Config document cover is present, cover
03-003 Market Region Defines market region. 0=USCO, 1=XCL, 0
Auto select.
Password protected. 2=FX, 3=FXAPO,
4=ACO, 5=XE 03-014 Inverter Switch Determines if sheets deliv- 0=face up 1=face 1
ered face up (non inverted) down
03-004 System Config Defines type of system. 0=Digital Copier, 0
or face down (inverted).
1=Multi-Functional
03-015 SIP Machine Machine Configuration Range 0 to 8 0
Device, 2=Printer,
3=Scan Server, Model Setting. (WC5790F = 7)
Password protected.
4=OEM Scanner,
5=OEMPrinter, 03-016 SIP Machine Machine Type Setting. 0=Unknown 0
6=OEM MultiFunction, Type Password protected. 1=Universal
7=Atlanta Only 2=DC
3=MF
03-005 System Install Defines system's current 0=manfg, 1=FIC, 0
4=Spare
Phase installation phase. 2=Customer Install,
3=Customer Setup, 03-017 SIP CommsPort- Image Processing serial 0=Disabled 1
4=Install Complete Accs communication port 1=Enabled
access - either disabled or
03-006 Auto Configura- Determines if the system 0=disabled 1=enabled 1
enabled.
tion runs through auto configu-
ration, detect at power on.

Xerox WorkCentre 5790 Family 6-77 dC131a
Table 3 NVM chain 3 Table 3 NVM chain 3
Location NVM Name NVM Description Value Default Location NVM Name NVM Description Value Default
03-018 DC Install Phase Define platform current 0=Incomplete 0 03-405 IQA K4 Constant Image quality adjustment. Range 0 to 5000 35-55
phase. 1=Incomplete K4 constant. ppm = 0,
2=Incomplete 65-90
3=Install Wizard ppm =
4=Complete 3000
03-019 SIP Serial Port SIP serial port mode. 0=Debug mode 0 03-406 IQA K5 Constant Image quality adjustment. Range 0 to 500000 35-55
Mode 1=Modem Mode K5 constant. ppm =
03-020 ADV Threshold Determines the threshold 1 to 100 1 135000,
for when the daily count is 65-90
added to the Average daily ppm =
volume. 91000
03-021 SIP USBPort SIP USB communication 0 = Disable 1 03-407 IQA K6 Constant Image quality adjustment. Range 0 to 3000 0
Access port access disabled or 1 = Enabled K6 constant.
enabled. 03-408 IQA White Max Image quality adjustment Range 0 to 25 15
03-022 Full Odio Time- Defines system manager Range 0 to 255 60 mins SD maximum standard devia-
out full ODIO timeout. tion limit for white back-
ground.
03-023 Stndrd Odio Tim- Defines system manager Range 0 to 255 20 mins
eout standard ODIO timeout. 03-409 IQA Max Av Image quality adjustment Range 0 to 255 0
03-024 SIP Machine Machine configuration set- Range 0 to 255 49 Grey Lvl maximum average grey (Grey scale units 0 =
level. Black, 255 = White)
Quay ting machine key. (Set in manufacturing)
03-410 IQA Min Av Grey Image quality adjustment 0 to 255 230
03-025 PowerManage- Power management mode 0= intelligent ready 0
Lvl minimum average grey
mentMode 1= job activated
2= scheduled level.
03-029 FastResStatus Fast Resume status 0=Disabled 0 03-411 IQA Highlight C IQA HighLight Reference Range 0 to 255 138
Ref (Grey scale units 0 =
1=Enabled
Black, 255 = White)
03-400 IQA Highlight Image quality adjustment Range 0 to 255 136
03-412 IQA Shadow C IQA Shadow Reference 16
Ref highlight reference. (Grey scale units 0 =
Black, 255 = White) Ref Range 0 to 255
(Grey scale units 0 =
03-401 IQA Shadow Ref Image quality adjustment Range 0 to 255 13
Black, 255 = White)
shadow reference. (Grey scale units 0 =
03-413 ABSMinBinLimit Maximum background 0 to 255 64
Black, 255 = White)
suppression value
03-402 IQA K1 Constant Image quality adjustment. Range 0 to 3000 35-55
K1 constant. ppm 03-414 ABSMaxStdDev Minimum background sup- 0 to 6550 10
pression value
=2500,
65-90 03-415 ABSMinBinSum Background suppression 0 to 65535 16384
ppm value sum
=500 03-420 AutoModeTRC- TRC Slope in auto mode 10 to 80 20
03-403 IQA K2 Constant Image quality adjustment. Range 0 to 6000 35-55 Slope (Toner reproduction curve)
K2 constant. ppm 03-421 AutoModeTR- TRC offset in auto mode 0 to 500 400
=1500, COffset
65-90 03-422 SpecialMode- TRC slope in special mode 10 to 80 20
ppm TRCSlope
=5500
03-423 SpecialModeTR- TRC offset in special mode 0 to 500 400
03-404 IQA K3 Constant Image quality adjustment. Range 0 to 200 0 COffset
K3 constant.
03-424 PhotoModeTRC- TRC slope in photo mode 10 to 80 20
Slope

dC131a 6-78 Xerox WorkCentre 5790 Family
03-425 PhotoModeTR- TRC offset in photo mode 0 to 500 400 06-005 Extended Rng Ros Indicates which type of ROS 0 = 3 to 6 Erg/ 1
COffset Enable is fitted (35 ppm only). cm2 range
03-426 CustomMedi- Custom display names for 0 = Disable 0 ROS
aEnable custom media types - fea- 1 = Enabled 1 = 1.5 to 6
ture enablement Erg/cm2
03-427 CustomMediaL- Custom display names - 0 = Disable 0 Extended
range ROS
istInit Custom media type List 1 = Enabled
Initialized flag
Table 6 NVM chain 7
03-900 Restrict Diag. Retains the restricted diag- 1000 to 99999999 1962
Pin nostics pin. Use with 08- Location NVM Name NVM Description Value Default
900
07-001 Feeder Module Type Defines feeder module type 67 to 180 67
67=2 internal trays + bypass
Table 4 NVM chain 5 68=2 internal trays + bypass
Location NVM Name NVM Description Value Default + HCF
177=2 internal trays + bypass
05-001 DADH Feed Head Number of feeds. 0 to 300000 0
+ tray 5180=2 internal trays +
Count
bypass + HCF + tray 5
05-002 CRU Days Number of days. 0 to 65535 0
07-002 LE Late T5 Feed Steps allowed before a sheet 0 to 800 500
05-007 Detect Paper Size 1 DADH sensor to detect sizes 0=A4, 2 Snr is declared a misfed. LE late
for market regions. 1=8.5x13, to tray 5 feed sensor.
2=Auto market
07-003 LE Late Wait Point Number of transport motor 0 to 2000 35-55 ppm
region set
T5 steps allowed between the =1052,
05-008 Detect Paper Size 2 DADH sensor to detect sizes 0=A5; 2 LE at TAR nips to hand over 65-90 ppm
for market regions. 1=8.5x5.5, before a jam is declared. =724
2=auto market
07-004 Wait Point Steps T5 Number of transport motor 0 to 500 35-55
region set
steps from the time the LE is ppm=115,
05-009 DADH Mag (copy Half speed adj for >100% 0 to 200 35-55 ppm at pre hand over to hand over 65-90 ppm
mode) copy. minus 10% to =100, point. =223
plus 10% 65-90 ppm
07-005 T1 Stock Level Number of steps tray 1 has 0 to 700 0
=94
been lifted since it was last
05-012 DADH Duplex Motor Adjustment of duplex motor 0=normal 0 closed.
Speed speed. 1=quiet mode 07-006 T2 Stock Level Number of steps tray 2 has 0 to 700 0
(reduced
been lifted since it was last
speed)
closed.
07-007 T1 Stack Height Number of steps tray 1 has to 0 to 40 7
Table 5 NVM chain 6 Adjust be lifted above the stack
Location NVM Name NVM Description Value Default height sensor for optimum
06-001 Laser Light Level ROS light level 600 dpi and 1500 to 6000 35ppm feed position.
1200 dpi. =3471, 07-008 T2 Stack Height Number of steps tray 2 has to 0 to 40 7
09-319 must be set to the 40-55 ppm Adjust be lifted above the stack
same value as 06-001. =2250, height sensor for optimum
65-90 ppm feed position.
=2400 07-009 LE Late T1 Feed Maximum number of steps 0 to 500 200
06-003 Ros Motor Time-out Time after which ROS motor 100 to 5000 Snr from tray 1 feed motor to LE
fault will be called. 20000ms at tray 1 feed sensor.

07-010 LE Late T2 Feed Maximum number of steps 0 to 500 200 07-025 Release Steps T3- Number of steps the HCF 0 to 15 5
Snr from tray 2 feed motor to LE T4 transport motor should run
at tray 2 feed sensor. after the release sheet com-
07-011 T1 Buckle Size Number of steps from LE at 0 to 200 13 mand.
tray 1 feed sensor to start of 07-026 LE Late T4 From T3 Maximum number of steps 0 to 2000 1000
transport motor. from tray 3 TAR nips to LE at
07-012 T2 Buckle Size Number of steps from LE at 0 to 200 13 tray 4 feed sensor.
tray 2 feed sensor to start of 07-027 Wait Point Steps T3- Number of steps from tray 4 30 to 100 35-55 ppm =4
tray 1 and 2 transport motor. T4 feed sensor to stop position. 0,
07-013 LE Late T1 From T2 Maximum number of steps 0 to 1200 940 65-90 ppm =
from tray 2 TAR nips to LE at 53
tray 1 feed sensor. 07-028 PreRelease Dis- Number of steps for pre- 100 to 150 130
07-014 LE Late Wait Point Maximum number of steps 0 to 1400 1000 tance T1 sheet separation.
T1-T2 from tray 1 TAR nips to LE at 07-029 Tray Media Combi Tray media size sensing 0=Old 1
wait sensor. Switch switch to alternate between combination1
07-015 Wait Point Steps T1- Number of steps from LE at 0 to 600 35-55 ppm old and new switch combina- =New combi-
T4 wait sensor to tray 1 and 2 =240, tions. nation
transport motor stop. 65-90 ppm 07-032 FeedCL4AcqDelayT HCF (W/TAG 151) Delay 0 to 6000ms 35 ppm =
=434 ime before feed clutch is enabled 400, 40-45
07-016 Release Steps T1- Number of steps the tray 1 0 to 2000 440 to acquire a sheet ppm =250, 55
T4 and 2 transport motor should ppm = 50, 65
run after the release sheet ppm = 100,
command. 75 ppm = 60,
90 ppm = 0
07-017 LE Late T2 From Time for the LE of an HCF 0 to 2000 35-55 ppm =
T3-T4 sheet to reach the tray 2 feed 1400, 65-90 07-033 HCFWaitPoint4Step HCF (W/TAG 151) Number of 0 to 2000 35 ppm =
sensor. ppm = 1950 s HCF tray 4 motor steps from 180, 40-55
07-018 Release Steps T5 Distance from wait point to 0 to 1000 116 HCF exit sensor to the HCF ppm =140,
wait point 65-75 ppm =
transport motor releasing
200, 90 ppm
sheet.
= 230
07-019 T3 Stack Height Number of steps tray 3 has to 0 to 100 50
Adjust be lifted above the stack 07-034 T4ExSenClutchOffS HCF (W/TAG 151) Number of 0 to 1000 342
tps steps of the tray 4 feed motor
height sensor for optimum
from the LE at HCF exit sen-
feed position.
sor to tray 4 feed clutch de-
07-020 T4 Stack Height Number of steps tray 4 has to 0 to 100 50 energised
Adjust be lifted above the stack
07-035 T4RampSteps HCF (W/TAG 151) Number of 0 to 500 54
height sensor for optimum
steps in the tray 4 feed motor
feed position.
ramp from/to 525mm/sec.
07-021 LE Late T3 Feed Maximum number of steps 0 to 700 350 Used to correct clutch de-
Snr from tray 3 feed motor to LE
energise time.
at tray 3 feed sensor.
07-036 T4WaitPtRelDelTim HCF (W/TAG 151) Minimum 0 to 500ms 35-45 ppm =
07-022 LE Late T4 Feed Maximum number of steps 0 to 800 400
e delay time from PFM release 250, 55 ppm
Snr from tray 4 feed motor to LE sheet (sheet ahead) to sheet =150, 65-75
at tray 4 feed sensor.
being released from HCF ppm = 110,
07-023 T3 Buckle Size Size of de-skew buckle. 0 to 15 3 wait point. 90 ppm = 80
07-024 T4 Buckle Size Size of de-skew buckle. 0 to 15 10

07-037 T3FeSenClutchOffS HCF (W/TAG 151) Number of 0 to 2000 35-55 ppm = 07-058 HCFMotorNom- HCF (W/TAG 151) Nominal 100 to 525
tps steps from the LE at feed 260, 65-75 Speed HCF transport motor velocity 1000mm/s
sensor to the clutch de-ener- ppm = 215, 07-059 HCFMatchPFM- HCF (W/TAG 151) Speed that 100 to 35 ppm =
gise - TE at nudger A4 LEF. 90 ppm = 192 Speed HCF transport motor will use 1000mm/s 185, 40-55
07-038 HCFNVM7 Reserved for future use - - to match the required PFM ppm =265,
07-039 HCFNVM8 Reserved for future use - - process speed 65-90 ppm =
07-040 HCFWaitPoint3Step HCF (W/TAG 151) Number of 0 to 2000 35-75 ppm = 373
s steps from HCF exit sensor to 180, 90 ppm 07-060 HCFMatchPFMHiS- HCF (W/TAG 151) Speed that 100 to 35 ppm =
the HCF wait point. = 220 peed HCF transport motor will use 1000mm/s 185, 40-55
to match the required PFM Hi ppm =265,
07-041 T3WaitPtRelDelTim HCF (W/TAG 151) Minimum 0 to 500ms 35 ppm =
e delay time from PFM sheet 250, 40-55 speed 65-90 ppm =
685
release (sheet ahead) to ppm =150,
sheet being released from 65-90 ppm = 07-061 HCFHiSpeed HCF (W/TAG 151) HCF 200 to 35-55 ppm
HCF wait point 80 motor high speed to enable 1000mm/s =525, 65-75
07-042 FeedMotorOffsteps HCF (W/TAG 151) Number of 0 to 1000 100 catch up and productivity. ppm =700, 90
ppm = 844
steps after the last feed
request between clutch de- 07-062 HCFNVM31 Reserved for future use. - -
energise and feed motor 07-063 HCFNVM32 Reserved for future use. - -
stop. 07-064 HCFNVM33 Reserved for future use. - -
07-043 Sens2HiSpeedCom HCF (W/TAG 151) Number of 0 to 200 0 07-065 HCFNVM34 Reserved for future use. - -
pStps steps that the HCF transport 07-066 HCFNVM35 Reserved for future use. - -
motor stays at delivery speed
07-067 T3FeedWPSteps HCF (W/TAG 151) Number of 0 to 1000 0
after the LE has arrived the
steps past the tray 3 exit sen-
T2 feed sensor.
sor to start ramping down the
07-044 DelayTAR4SnsrClrS HCF (W/TAG 151) Step delay 0 to 500 23 feed motor.
tps from TE at HCF exit sensor to
07-068 Feed3AcqDelTime HCF (W/TAG 151) Tray 3 0 to 2000ms 35 ppm =600,
allow the TE to clear tray 4
delay to start sheet acquire 40-45 ppm
nip before the feed motor can
change speeds. from the tray. =350, 55 ppm
= 250, 65
07-045 HCFNVM14 Reserved for future use. - -
ppm = 100,
07-046 HCFNVM15 Reserved for future use. - - 90 ppm = 0
07-047 HCFNVM16 Reserved for future use. - - 07-069 T3SheetReadyTime HCF (W/TAG 151) Delay 0 to 2000ms 140
07-048 HCFNVM17 Reserved for future use. - - before sheet is ready to be
07-049 HCFNVM18 Reserved for future use. - - sent from tray 3.
07-050 HCFNVM19 Reserved for future use. - - 07-070 T3DelayToHiSpeed HCF (W/TAG 151) Number of 0 to 2000 260
07-051 HCFNVM20 Reserved for future use. - - Step feed steps from tray 3 TAR to
the feed motor going to high
speed.
07-071 LElateToFeed3Time HCF (W/TAG 151) Maximum 0 to 3000ms 500
07-054 HCFNVM23 Reserved for future use. - - time the tray 3 clutch is ener-
07-055 HCFNVM24 Reserved for future use. - - gised to LE at tray 3 feed
07-056 HCFNVM25 Reserved for future use. - - sensor.
07-057 FeedMotorVelocity HCF (W/TAG 151) Nominal 200 to 525 07-072 LElateToTAR3Time HCF (W/TAG 151) Maximum 0 to 6000ms 1000
feed motor velocity 1000mm/s time the tray 3 clutch is ener-
gised to LE at tray 3 exit sen-
sor.

07-073 T3LElateToTAR4Ti HCF (W/TAG 151) Maximum 0 to 6000ms 35 ppm =600, 08-001 Print Rate Number of prints per minute 0 = 35 ppm 7
me time from tray 3 feed motor 40-55 ppm (Controls the IOT print rate). 9 = 40 ppm
start, when the sheet is at the =550, 65-90 03-012 must be set to the 1 = 45 ppm
horizontal wait point to the LE ppm = 500 same speed. 2 = 55 ppm
at the HCF exit sensor. 3 = 65 ppm
07-074 LElateToFeed4Time HCF (W/TAG 151) Maximum 0 to 3000ms 500 4 = 75 ppm
time the tray 4 feed clutch is 6 = 90 ppm
energised to LE at tray 4 feed 08-002 Process speed Speed at which sheets move 160 to 500 35 ppm=179,
sensor. through machine. 40-55 ppm
07-075 LElateToTAR4Time HCF (W/TAG 151) Maximum 0 to 6000ms 600 =257,
time the tray 4 feed clutch is 65-90
energised to LE at HCF exit ppm=362
sensor, 08-003 Machine Model Machine configuration set- 0 to 8 0
07-076 HCFNVM45 Reserved for future use. - - ting.
07-077 Tray4SheetReadyD HCF (W/TAG 151) Delay 0 to 5000ms 20 08-004 Machine Type Machine type setting. 0=Unknown 0
elay before sheet ready is sent 1=Universal
tray 4 only. 2=DC
07-078 T4PreAcquireTime HCF (W/TAG 151) Pre- 0 to 5000 35-75 ppm = 3=MF
4=Spare
acquire time for tray 4 (90 0, 90 ppm =
ppm only). Timed from LE at 100 08-005 Machine Quay Machine configuration setting 0 to 255 49
tray 2 feed sensor to start the Machine Key.
acquisition of the next sheet 08-045 Short Cycle Out IOT inactivity shutdown timer 0 to 15 seconds 0
07-079 HCF(FAR) Pur- HCF(W/TAG 151) Purge 0 = Disable 1 Time (except ROS motor).
geEnable enable - move sheets to the 1 = Enabled 08-046 Long Cycle Out Inactivity cycle out timer. 0 to 180 sec- 35-45 ppm=0
left hand door for easier Time onds 55-90 ppm =60
clearance. 08-047 Abnormal Cycle Abnormal cycle out time. 0 to 15 seconds 35-45 ppm=0
07-080 HCF(FAR) Feed HCF (W/TAG 151) Number of 0 to 10 5 Out Time 55-90 ppm =10
Retry feed retry attempts. 08-048 Top Edge Reg Tray Tray 1 top edge registration 7300 to 7700 7510
07-081 FeedMotorOnDelay HCF (W/TAG 151) Time from 0 to 10 1 Simp simplex.
clutch energise to starting the 100000ms 08-049 Top Edge Reg Tray Tray 2 top edge registration 7300 to 7700 7510
feed motor. 2 Simp simplex.
07-082 FeedMotorSlow- HCF (W/TAG 151) Speed that 0 to 100 08-050 Top Edge Reg Tray Tray 3 top edge registration 7300 to 7700 7522
Speed the feed motor runs when the 100000mm/s 3 Simp simplex.
clutch is disabled (retard roll
08-051 Top Edge Reg Tray Tray 4 top edge registration 7300 to 7700 7504
geared to run half this
4 Simp simplex.
speed).
08-052 Top Edge Reg MSI Bypass tray top edge regis- 7300 to 7700 7522
07-083 HCFNVM52 Reserved for future use. - - Simp tration simplex.
07-084 HCFNVM53 Reserved for future use. - - 08-059 Top Edge Reg Tray Tray 1 top edge registration 7300 to 7700 7510
07-085 HCFNVM54 Reserved for future use. - - 1 Dup duplex.
4 Dup duplex.

08-063 Top Edge Reg MSI Bypass tray top edge regis- 7300 to 7700 7522 08-152 Le Reg Snr To Simplex buckle. 100 to 900 35 ppm =630,
Dup tration duplex. Clutch On 40-55 ppm
08-074 IOT LE Reg Simp IOT lead edge registration 0 to 255 141 =440,
simplex. 65-90 ppm
=290
08-075 IOT LE Reg Dup IOT Lead Edge Reg Dup. 0 to 255 129
08-153 Sync To Reg Clut Simplex registration. 100 to 360 35 ppm =314,
08-107 Inv Mot Fwd To IOT paper path timing, restart 0 to 2500 35 ppm=1353,
Rev D1 sheet into duplex for mode 1. 40-55 ppm On Simp 40-55 ppm
=219,
=927,
65-90 ppm
65-75 ppm
=669, =154
90 ppm=697 08-154 Te Reg Snr To Ensures sheet clear of reg 100 to 1200 35 ppm =860,
Clutch Off nips before turning clutch off. 40-55 ppm
08-108 Inv Mot Fwd To IOT paper path timing, restart 100 to 4000 35 ppm=3055,
(See 08-619 for 90 ppm) =610,
Rev D2 sheet into duplex for mode 2. 40-55 ppm
=2130, 65-75 ppm
=288
65-75ppm
=1579, 08-155 Te Reg Snr To Ensures sheet clear of reg 100 to 1500 35 ppm =1194,
90 ppm=1185 Cltch Of Evl nips before turning clutch off, 40-55 ppm
08-109 Inv Mot Fwd To IOT paper path timing, restart 100 to 5000 35 ppm=3771, when media type is enve- =843,
lopes. 65-90 ppm
Rev D3 sheet into duplex for mode 3. 40-55 ppm
=475
=2631,
65-75ppm 08-159 Te Dup Snr To Time after paper reaches 100 to 1100 35 ppm =860,
=2062, Clutch Off sensor to switch clutch off. 40-55 ppm
90 ppm=1725 =610,
65-90 ppm
08-127 Res Sht To Le Dup Restart sheet to duplex jam 200 to 2556 35 ppm =2400,
Lt Jam 3 window to indicate LE of 40-55 ppm =600
sheet is late in mode 3. =1670, 08-160 Pitch Sync To Dup Time to switch duplex motor 10 to 60 30
65-90 ppm Mot On on.
=900 08-162 Rel Sht Msi To Le Release sheet to reg to MSI 200 to 1200 35 ppm =630,
08-128 Res Sht To Le Dup Restart sheet to duplex jam 200 to 3000 35 ppm =2010, Reg Jam jam window to indicate LE of 40-55 ppm
Lt Jam 4 window to indicate LE of 40-55 ppm sheet is late. =440,
sheet is late in mode 4. =1340, 65-90 ppm
65-90 ppm =350
=900 08-169 Simp Buckle Simplex buckle for transpar- 100 to 900 35 ppm =630,
08-148 Le Dup Snr To Clh Duplex buckle timer mode 1. 0 to 700 35 ppm =496, Transp'y ency stock. 40-55 ppm
On Act 40-55 ppm =440,
=343, 65-90 ppm
65-75 ppm =290
=244, 08-170 Simp Buckle Simplex buckle for enve- 100 to 900 35 ppm =630,
90 ppm = 256 Enlopes lopes. 40-55 ppm
08-149 PSync To Reg Clut Duplex registration mode 1. 100 to 380 35 ppm =314, =440,
On Dup 40-55 ppm 65-90 ppm
=219, =290
65-90 ppm 08-171 Simp Buckle Simplex buckle for labels. 100 to 900 35 ppm =600,
=154 Labels 40-55 ppm
=420,
65-90 ppm
=290

08-172 Simp Buckle Card- Simplex buckle for card 100 to 900 35 ppm =630, 08-200 Pitch Tick Simp IOT paper path timing pitch 400 to 3500 35 ppm =1460
stock stock. 40-55 ppm Mode 1 tick setting - Simplex mode 1. 40 ppm =1330
=440, 45 ppm =1220
65-90 ppm 55 ppm =1090
=290 65 ppm =920
08-177 Le Reg Snr To LE at reg sensor to clutch off. 0 to 1000 35 ppm =530, 75 ppm =800
Clutch Off (See 08-618 for 90 ppm) 40-55 ppm 90 ppm =690
=350, 08-201 Pitch Tick Simp IOT paper path timing pitch 1000 to 3500 35 ppm =2390,
65-75 ppm Mode 2 tick setting - Simplex mode 2. 40-55 ppm
=235 =1670,
08-178 Le Dup Snr To LE at dup sensor to clutch 0 to 1000 35 ppm =380, 65-75 ppm
Clutch Off off. 40-55 ppm =1220,
=240, 90 ppm =110
65-90 ppm 08-202 Pitch Tick Simp IOT paper path timing pitch 1000 to 3500 35 ppm =2760,
=205 Mode 3 tick setting - Simplex mode 3. 40-55 ppm
08-179 Le Dup Snr To Cl LE at dup sensor to clutch 0 to 1000 35 ppm =496, =1930,
On Nom on. 40-55 ppm 65-75 ppm
=343, =1430,
65-75 ppm 90 ppm =1290
=244, 08-203 Pitch Tick Simp IOT paper path timing pitch 1000 to 4000 35 ppm =3540,
90 ppm =256 Mode 4 tick setting - Simplex mode 4. 40-55 ppm
08-180 Simp Buckle Simplex buckle for rough 100 to 900 35 ppm =630, =2500,
Rough Stock stock. 40-55 ppm 65-75 ppm
=440, =1880,
65-90 ppm 90 ppm =1640
=290 08-204 Pitch Tick Simp IOT paper path timing pitch 600 to 3500 35 ppm =2600,
08-183 Tab Length Tab time. 0 to 1000 35 ppm =70, Mode 5 tick setting - Simplex mode 5. 40-55 ppm
40-55 ppm =1800,
=50, 65-75 ppm
65-90 ppm =40 =1300,
08-190 Inv Mot Fwd To IOT paper path timing. 100 to 4000 35 ppm =3055, 90 ppm =1280
Rev D4 Restart sheet into duplex for 40-55 ppm 08-205 Pitch Tick Simp IOT paper path timing pitch 1000 to 3500 35 ppm =2760,
mode 4. =2130, Mode 6 tick setting - Simplex mode 6. 40-55 ppm
65-75 ppm =1700,
=1478, 65-90 ppm
90 ppm =1185 =1210
08-191 Simp Buckle MSI Simplex buckle for MSI spe- 100 to 800ms 35 ppm =630, 08-206 Pitch Tick Dup IOT paper path timing pitch 600 to 3500 35 ppm =1560,
std cific standard stock. 40-55 ppm Mode 1 tick setting - Duplex mode 1. 40-55 ppm
=440, =1090,
65-90 ppm 65-75 ppm
=290 =800,
90 ppm =690

08-207 Pitch Tick Dup IOT paper path timing pitch 1000 to 3500 35 ppm =2390, 08-215 Nip Open Inv Mot Time for nip to open after 10 to 1600ms 35 ppm =1300,
Mode 2 tick setting - Duplex mode 2. 40-55 ppm Rev M2 inverter motor starts to 40-55 ppm
=1670, reverse (duplex for mode 2). =900,
65-75 ppm 65-90 ppm
=1220, =240
90 ppm =1110 08-216 Nip Open Inv Mot Time for nip to open after 10 to 2000ms 35 ppm =1300,
08-208 Pitch Tick Dup IOT paper path timing pitch 1000 to 3500 35 ppm =2760, Rev M3 inverter motor starts to 40-55 ppm
Mode 3 tick setting - Duplex mode 3. 40-55 ppm reverse (duplex for mode 3). =900,
=1930, 65-90 ppm
65-75 ppm =640
=1430, 08-217 Nip Open Inv Mot Time for nip to open after 10 to 1600ms 35 ppm =1300,
90 ppm =1290 Rev M4 inverter motor starts to 40-55 ppm
08-209 Pitch Tick Dup IOT paper path timing pitch 1000 to 3500 35 ppm =2390, reverse (duplex for mode 4). =900,
Mode 4 tick setting - Duplex mode 4. 40-55 ppm SEF Heavyweight invert only 65-90 ppm
=1670, pitch. =640
65-75 ppm 08-218 Nip Open Inv Mot Time for nip to open after 10 to 1000ms 35 ppm =570,
=1220, Rev M5 inverter motor starts to 40-55 ppm
90 ppm =1110 reverse (duplex for mode 5) =400,
08-210 Pitch Tick Dup IOT paper path timing pitch 600 to 3500 35 ppm =1560, transparencies. Transpar- 65-90 ppm
Mode 5 tick setting - Duplex mode 5. 40-55 ppm ency pitch mode 1 simplex. =240
Transparency pitch mode 1 =1090, 08-219 Nip Open Inv Mot Time for nip to open after 10 to 1000ms 35 ppm =570,
simplex. 65-75 ppm Rev M6 inverter motor starts to 40-55 ppm
=800, reverse (duplex for mode 6). =400,
90 ppm =690 Envelopes pitch simplex only. 65-90 ppm
08-211 Pitch Tick Dup IOT paper path timing pitch 1000 to 3500 35 ppm =1560, =240
Mode 6 tick setting - Duplex mode 6. 40-90 ppm 08-220 Inv Mot Rev Dup NVM inverter motor reverse 0 to 200ms 35 ppm =0,
=1090 Mot M1 to duplex motor speed up for 40-55 ppm =0,
08-212 Restart Dup M5 IOT transparency timing 0 to 2500ms 35 ppm =1331, mode 1. 65-90 ppm =0
Txpar restart sheets into duplex for 40-55 ppm 08-221 Inv Mot Rev Dup NVM inverter motor reverse 0 to 2000ms 35 ppm =1180,
mode 5. Transparency pitch =927, Mot M2 to duplex motor speed up for 40-55 ppm
mode 1 simplex. 65-75 ppm mode 2. =820,
=985, 65-90 ppm
90 ppm =697 =550
08-213 Restart Dup M6 IOT envelopes timing restart 0 to 2500ms 35 ppm =1331, 08-222 Inv Mot Rev Dup NVM inverter motor reverse 0 to 2000ms 35 ppm =1760,
Envelope sheets into duplex for mode 40-55 ppm Mot M3 to duplex motor speed up for 40-55 ppm
6. =927, mode 3. =1230,
Envelope pitch mode 1. 65-75 ppm 65-90 ppm
=985, =550
90 ppm =697 08-223 Inv Mot Rev Dup NVM inverter motor reverse 0 to 2000ms 35 ppm =1180,
08-214 Nip Open Inv Mot Time for nip to open after 10 to 1000ms 35 ppm =570, Mot M4 to duplex motor speed up for 40-55 ppm
Rev M1 inverter motor starts to 40-55 ppm mode 4. SEF Heavyweight =820,
reverse (duplex for mode 1). =400, invert only pitch mode 2. 65-90 ppm
65-90 ppm =550
=240
08-224 Inv Mot Rev Dup NVM inverter motor reverse 0 to 200ms 35 ppm =0,
Mot M5 to duplex motor speed up for 40-55 ppm =0,
mode 5 transparencies pitch 65-90 ppm =0
mode 1 simplex.

08-225 Inv Mot Rev Dup NVM inverter motor reverse 0 to 200ms 35 ppm =0, 08-234 Inv Mot Slow Down Inverter motor slow down for 0 to 1000ms 35 ppm =100,
Mot M6 to duplex motor speed up for 40-55 ppm =0, M5 mode 5. Transparencies 40-55 ppm
mode 6. Envelope pitch sim- 65-90 ppm =0 pitch mode 1 simplex. =100,
plex. 65-90 ppm
08-226 Rst Dup Jam Win- Restart sheet to duplex jam 200 to 1500ms 35 ppm =1050, =100
dow M1 window to indicate LE of the 40-55 ppm 08-235 Inv Mot Slow Down Inverter motor slow down for 0 to 1000ms 35 ppm =100,
sheet is late in mode 1. =690, M6 envelopes mode 6 - enve- 40-55 ppm
65-90 ppm lopes pitch simplex. =100,
=500 65-90 ppm
dow M2 window to indicate LE of the 40-55 ppm 08=236 Lead Edge Thresh- NVM Lead edge threshold. 1 35 ppm =1,
sheet is late in mode 2. =1340, old 40-55 ppm =1,
65-90 ppm 65-90 ppm =1
=900 08-237 Trail Edge Thresh- NVM Trail edge threshold. 0 to 4 35-55 ppm =4,
08-228 Rst Dup Jam Win- Restart sheet to duplex jam 200 to 3000ms 35 ppm =1050, hold 65-90 ppm =1
dow M5 window to indicate LE of the 40-55 ppm 08-238 Inv Mot on Fwd Inverter motor on forward. 0 to 1000ms 35 ppm =860,
sheet is late in mode 5. =690, Use on 65-90 ppm only for 40-55 ppm
Transparencies pitch mode 1 65-90 ppm A6 media. =600,
simplex. =500 65-90 ppm
dow M6 window to indicate LE of the 40-55 ppm 08-239 Eng Nip To Mov Engages nips to move sheet 0 to 400ms 35 ppm =230,
sheet is late - Envelope pitch =690, Sheet into inverter path. 40-55 ppm
simplex only. 65-90 ppm =130,
=500 65-90 ppm =10
08-230 Inv Mot Slow Down Inverter motor slow down for 0 to 1000ms 35 ppm =100, 08-240 Inv Mot On Rev Inverter motor on reverse 100 to 340ms 35 ppm =230,
M1 mode 1. Delay from invert 40-55 ppm Open until open. 40-55 ppm
motor start ramp down from =100, =180,
high speed to restart in oppo- 65-90 ppm 65-90 ppm
site direction. =100 =140
08-231 Inv Mot Slow Down Inverter motor slow down for 0 to 1000ms 35 ppm =100, 08-241 Inv Mot FwdStop Time for inverter motor to go 36 to 80ms 35-55 ppm
M2 mode 2. Delay from invert 40-55 ppm Rev forward, then stop, then to =50,
motor start ramp down from =100, reverse. 65-90 ppm =66
high speed to restart in oppo- 65-90 ppm 08-242 Le Fsri Inv Mot On Time to turn on inverter 0 to 1000ms 35 ppm =860,
site direction. =100
dup motor after LE leaves fuser 40-55 ppm
08-232 Inv Mot Slow Down Inverter motor slow down for 0 to 1000ms 35 ppm =100, (duplex). =600,
M3 mode 3. Delay from invert 40-55 ppm 65-90 ppm =0
motor start ramp down from =100, 08-243 Le Nip Closed Dup Time between trail edge and 0 to 400ms 35 ppm =230,
high speed to restart in oppo- 65-90 ppm
nip closed (duplex). 40-55 ppm
site direction. =100
=130,
08-233 Inv Mot Slow Down Inverter motor slow down for 0 to 1000ms 35 ppm =100, 65-90 ppm =0
M4 mode 4. SEF heavyweight 40-55 ppm 08-244 Exit Sen To Ofset Time from exit sensor to off- 0 to 3000ms 35 ppm =0,
invert only pitch mode 2. =100,
Mot On set tray motor on. 40-55 ppm =0,
65-90 ppm
65-90 ppm =0
=100

08-245 Post Fsr To Top Timing from post fuser to top 100 to 2000ms 35 ppm =1520, 08-254 Le Top Exit TE Top Lead edge top exit to trail 90 to 350ms 35 ppm =220,
Tray Mot tray motor (forward). 40-55 ppm Exit Win edge top exit jam window to 40-55 ppm
=1060, indicate lead edge / trail edge =170,
65-90 ppm late. 65-90 ppm
=750 =130
08-246 Top Tray Mot To Timing from top tray motor to 100 to 3000ms 35 ppm =1880, 08-255 LE late To Reg Lead edge late to registration 0 to 1000ms 35 ppm =350,
Post Fsr post fuser. 40-55 ppm Cltch On after registration clutch on. 40-55 ppm
=1360, =250,
65-90 ppm 65-90 ppm
=750 =150
08-247 PFM Jam Window Release sheet registration 100 to 800ms 35 ppm =400, 08-256 Reg Clutch On To Registration clutch on to trail 0 to 1000ms 35 ppm =350,
PFM jam window to indicate 40-55 ppm TE Late edge late to duplex sensor. 40-55 ppm
LE of sheet is late. =280, =190,
65-90 ppm 65-90 ppm
=250 =350
08-248 Clutch On Post Fsr Clutch on to post fuser jam 600 to 1850ms 35 ppm =1410, 08-258 Tim After Sen Nominal time after hitting 0 to 200ms 35-55 ppm
Jam window to indicate LE of 40-55 ppm Ramp Dwn M1 sensor that speed ramps =20,
sheet is late. =980, down for mode 1. 65-90 ppm
65-90 ppm =130
=700 08-259 Slow Down Correct Temperature value to correct 0 to 1000ms 35 ppm =36,
08-249 LE Post Fsr Exit Lead edge post fuser to exit 360 to 1100ms 35 ppm =920, slowdown. Ramp down time 40-55 ppm
Jam Win jam window to indicate lead 40-55 ppm from high to process speed, =17,
edge of sheet is late. =680, used in error correction algo- 65-90 ppm =27
65-90 ppm rithm mode 1
=490 08-260 Main Mot Run Up Main motor run up time. 0 to 4000ms 35 ppm =450,
08-250 TE Post Fsr Exit Trail edge post fuser to exit 500 to 1700ms 35 ppm =1490, 40-90 ppm
Jam Win jam window to indicate trail 40-55 ppm =400
edge of sheet is late. =1060, 08-261 PR Mot Run Up Photoreceptor motor run up 0 to 4000ms 35 ppm =400,
65-90 ppm time. 40-90 ppm
=760 =500
08-251 LE Post Fsr Exit Lead edge post fuser to top 1000 to 35 ppm =3000, 08-262 LE Sen To MSI Rel Time from release to lead 0 to 2000ms 35 ppm =505,
Late Win exit jam windows to indicate 3300ms 40-55 ppm edge at registration sensor 40-55 ppm
lead edge of sheet is late. =2000, =364,
65-90 ppm 65-90 ppm
=1420 =260
08-252 LE Post Fsr TE Lead edge post fuser to trail 0 to 500ms 35 ppm =270, 08-263 LE Sen To PFM Time from PFM release to 0 to 2000ms 35 ppm =177,
Late Win edge post fuser jam window 40-55 ppm Rel lead edge at registration sen- 40-55 ppm
to indicate trail edge of sheet =170, sor. =122,
is late. 65-90 ppm 65-90 ppm =61
=130 08-264 TE Reg Fsr Exit Trail edge detection at regis- 0 to 1000ms 35 ppm =60,
08-253 Le Iot Exit Iot Exit Lead edge IOT exit to trail 90 to 350ms 35 ppm =220, tration, fuser + exit sensor = 40-55 ppm
Late edge IOT exit jam window to 40-55 ppm paper size - NVM from LE. =40,
indicate lead / trail late. =170, 65-90 ppm =70
65-90 ppm
=130

08-265 TE Duplex Trail edge detection duplex 0 to 1000ms 35 ppm =270, 08-275 Inv Mot Rev To Inverter motor reverse to 0 to 1000ms 35 ppm=628,
sensor = paper size - NVM 40-55 ppm Stop Dup 5 inverter motor stop duplex 5 40-55 ppm
from LE duplex sensor. =200, (transparencies). =343,
65-90 ppm 65-90 ppm
=100 =500
08-266 Pitch Win Rel Del Pitch window release delay. 0 to 1000ms 35 ppm =440, 08-276 Inv Mot Rev To Inverter motor reverse to 0 to 1000ms 35 ppm=628,
40-55 ppm Stop Dup 6 inverter motor stop duplex 6 40-55 ppm
=320, (envelopes). =343,
65-90 ppm 65-90 ppm
=227 =500
08-267 Fin Finish Tim Finisher finish time. 0 to 0 35 ppm =0, 08-277 Add To MSUI Pitch Addition to normal bypass 0 to 1000ms 35-55 ppm=0
40-55 ppm =0, Period (MSI) pitch period. 65 ppm=170
65-90 ppm =0 75 ppm=290
08-268 Fin Prep Tim Finisher preparation time. 0 to 0ms 35 ppm =0, 90 ppm=400
40-55 ppm =0, 08-278 Split Nip Control S1 Split nip control for 1st sheet. 0 to 350ms 210
65-90 ppm =0 08-279 Tim To Del Simp IOT time to deliver simplex. 0 to 5000ms 35 ppm=2814,
08-269 MSI Stray Sheet Jam timer for stray sheets 0 to 1000ms 35 ppm =0, 40-55 ppm
from the bypass tray (MSI). 40-55 ppm =0, =1961,
65-90 ppm =0 65-90 ppm
08-270 MSI Feed To PFM Delay from the bypass tray 0 to 1000ms 35 ppm =370, =1429
Feed (MSI) feed to paper feed 40-55 ppm 08-280 Tim To Del Invet IOT time to deliver: inter 0 to 5000ms 35 ppm=3218,
module (PFM) feed to avoid =250, (simplex + paper length). 40-55 ppm
jam. 65-90 ppm =2247,
=172 65-90 ppm
08-271 Inv Mot Rev To Inverter motor reverse to 0 to 1000ms 35 ppm =628, =1710
Stop Dup1 inverter motor stop duplex 1. 40-55 ppm 08-281 Tim To Del Simp3 IOT time to deliver duplex 0 to 5000ms 35 ppm=2814
=343, (simplex + 3 pitches). 40-55 ppm
65-90 ppm =1961,
=500 65-75 ppm
08-272 Inv Mot Rev To Inverter motor reverse to 0 to 1000ms 35-55 ppm =1429,
Stop Dup 2 inverter motor stop duplex 2. =188, 90 ppm=1432
65-75 ppm 08-282 Fsr 3min Warning Temperature threshold level. 10 to 50 deg. C 40
=219, Temp
65-90 ppm 08-283 Fsr 2min Warning Temperature threshold level. 40 to 100 deg. 60
=179 Temp C
08-273 Inv Mot Rev To Inverter motor reverse to 0 to 1000ms 35 ppm =410, 08-284 Fsr 1min Warning Temperature threshold level. 60 to 120 deg. 90
Stop Dup 3 inverter motor stop duplex 3. 40-55 ppm Temp C
=414, 08-286 Fsr Delta Temperature difference 0 to 0 deg. C 45
65-90 ppm
between the 2 thermistors.
=365
08-287 Fsr TolrunA Temperature tolerance either 0 to 0 deg. C 20
08-274 Inv Mot Rev To Inverter motor reverse to 10 to 2000ms 35-55 ppm
side of run target tempera-
Stop Dup 4 inverter motor stop duplex 4. =188, ture. Thermistor A.
65-75 ppm
08-288 Fsr Tolsave Temperature tolerance either 0 to 0 deg. C 35-45 ppm=0
=219,
side of power save target 55-90 ppm=15
90 ppm =179
temperature.

08-289 Fsr Step Temperature difference 0 to 0 deg. C 3 08-302 TE Inv Snr To Inv Disables inverter path sole- 0 to 100 steps 35-45 ppm=0
between 2 consecutive read- Sol Off noid to divert sheet into invert 55-90 ppm=40
ings. path after TE at inverter sen-
08-290 Fsr TolrunB Temperature tolerance either 0 to 0 deg. C 35-45 ppm=0 sor.
side of run target tempera- 55-90 ppm=40 08-303 TE Inv Snr To Mot Inverter motor off stop posi- 0 to 400 steps 35-55 ppm=40
ture. Thermistor B. Of Smp S2 tion (simplex). 65-90 ppm =58
08-291 Fsr Max1 Temperature at which soft- 0 to 0 deg. C 230 08-304 TE Inv Snr To Mot Time to turn off inverter motor 0 to 400ms 35-55 ppm=97
ware calls an over tempera- Of Dup S2 after TE leaves inverter sen- 65-90 ppm =90
ture fault. sor (duplex).
08-292 Fsr Max2 Temperature at which the 0 to 0 deg. C 245 08-305 TE Pst Fsr Exit Number of steps from TE 400 to 1700 35-55 ppm
electronics shutdown the Jam Win S2 post fuser to exit jam window. =640,
fuser. 65-75 ppm
08-293 Fsr Tolstandby Temperature tolerance either 0 to 0 deg. C 35 ppm=26 =760
side of standby target tem- 40-55 ppm=20 08-306 LE Lt Inv Frm LE Number of steps from LE at 0 to 300 35-55 ppm
perature. 65-90 ppm =15 Pst Fsr post fuser to LE at inverter =130,
08-294 Fsr Apply Power Fuser apply power time. 100 to 200 sensor. 65-90 ppm
Time 20000ms =170
08-295 Fsr Bias To Run Fuser bias to marking mode 0 to 0 deg. C 0 08-307 Tri Rol Open Frm Number of steps before the 0 to 200 0
Time time. Fsr Snr tri roll split nip opens after TE
08-296 Trange Cooling Temperature offset above T 0 to 0 deg. C 10 at fuser exit switch.
save at which control and 08-308 Tri Rol Close Frm Number of steps before the 0 to 200 35-55 ppm =0
fault detection is enabled. Inv Off tri roll split nip closes after 65-90 ppm =30
inverter motor off (forward).
08-297 Inv Mot On Fwd Time from LE at inverter sen- 200 to 35 ppm=860
sor to inverter motor on for- 20000ms 40-55 ppm 08-309 Tim To Del Invert IOT time to deliver. 800 to 2000 35-55 ppm
ward. =600, steps =1678,
65-90 ppm 65-90 ppm
=330 =1553
08-298 LE Inv Snr Mot On Time to turn on inverter 300 to 1000ms 35 ppm=860 08-310 TE Late Frm Inv Jam window for TE late from 0 to 300 steps 35 ppm=168
Frwd Dup motor on after LE leaves 40-55 ppm Sensor inverter sensor. 40-55 ppm
fuser (duplex). =600, =117,
65-90 ppm 65-90 ppm =83
=330 08-311 Top Edge Reg T5 Tray 5 top edge registration 7300 to 7700 7510
08-299 TEF sr Exit Jam TE post fuser to exit jam win- 400 to 1700ms 35 ppm=1490 Dup duplex.
Win Siz2 dow. 40-55 ppm 08-312 T5 Feed Head Tray 5 nudger roll, feed roll 0 to 1500000 0
=1060, Count and retard roll feed count.
65-75 ppm 08-313 Tray 5 Configura- 0 = Tray 5 Standard: A4 LEF, 0 to 2 0
=640 tion 8.5x11 LEF
08-300 TE Inv Snr To Inv Actuates inverter path sole- 0 to 100 steps 35-55 ppm=30 1 = Tray 5 Kit A: A3 SEF,
Path Sol noid to divert duplex sheet to 65-90 ppm =40 11x17 SEF
output from TE of previous 2 = Tray 5 Kit B: A4 SEF,
sheet at inverter sensor. 8.5x11 SEF, 8.5x14 SEF
08-301 TE Snr To Inv Sol Actuates inverter path sole- 500 to 800 35-55 ppm 08-314 PFP Top Edge Reg Tray 5 top edge registration 7300 to 7700 7510
On Exit noid to divert duplex sheet to steps =628, Simp simplex.
output from TE of previous 65-90 ppm 08-315 PFM Wait Point Adj Paper feed module wait point 0 to 20ms 35-55 ppm=8
sheet when registration =620 adjustment. 65-90 ppm =9
clutch turns on.

08-316 PFM Release Adj Paper feed module release 0 to 20 35-55 ppm=8 08-327 Pitch Simp Mode 6 IOT paper path timing pitch 1000 to 35 ppm=2760
adjustment. 65-90 ppm =15 Alt tick setting -simplex mode 6 - 3500ms 40-55 ppm
08-317 LCSS Fin Ready LCSS finisher ready delay. 0 to 5000ms 200 transparency - pitch mode 1 =1700,
Delay simplex. 65-90 ppm
=1210
08-319 HVF Fin Ready HVF finisher ready delay. 0 to 5000ms 0
Delay 08-328 Pitch Simp Mode 7 IOT paper path timing pitch 700 to 3500 35 ppm=1560,
08-320 Pitch Tick Simp IOT paper path timing pitch 700 to 3500ms 35 ppm=1630 Alt tick setting -simplex mode 7. 40-55 ppm
=2180,
Mode 7 tick setting - simplex mode 7. 40-55 ppm
65-90 ppm
=2180,
65 ppm=920, =800
75-90 ppm 08-582 Fsr 3 min. Warning Temperature threshold level. 10 to 50 deg C 40
=800 T(2)
08-321 Pitch Tick Dup IOT paper path timing pitch 600 to 3500ms 35 ppm=1560 08-583 Fsr 2 min. Warning Temperature threshold level. 40 to 100 deg C 60
Mode 7 tick setting - duplex mode 7. 40-55 ppm T(2)
=2180, 08-584 Fsr 1 min. Warning Temperature threshold level. 60 to 120 deg C 90
65 ppm=920, T(2)
75-90 ppm 08-586 Fsr Delta(2) Temperature difference 0 to 0 deg C 45
=800 between the 2 thermistors.
08-322 Pitch Simp Mode 1 IOT paper path timing pitch 400 to 3500ms 35 ppm=1560 08-587 Fsr Tol run A(2) Temperature tolerance either 0 to 0 deg C 35 ppm=40
Alt tick setting - simplex mode 1. 40 ppm=1450 side of run target on ther- 40-90 ppm =20
45 ppm=1220 mistor A.
55 ppm=1090
08-588 Fsr Tol save(2) Temperature tolerance either 0 to 0 deg C 35-45 ppm=0
65 ppm=920 side of power save target. 55-90 ppm=15
75 ppm=800
08-589 Fsr Step(2) Temperature difference 0 to 0 deg C 3
90 ppm=690
between 2 consecutive read-
08-323 Pitch Simp Mode 2 IOT paper path timing pitch 1000 to 35 ppm=2390
ings.
Alt tick setting -simplex mode 2. 3500ms 40-55 ppm
=1670, 08-590 Fsr Tol run B(2) Temperature tolerance either 0 to 0 deg C 35-45 ppm=0
side of run target on ther- 55-90 ppm=40
65-90 ppm
mistor B.
=1190
08-591 Fsr Max 1(2) Temperature at which the 0 to 0 deg C 230
08-324 Pitch Simp Mode 3 IOT paper path timing pitch 1000 to 35 ppm=2760
Alt tick setting -simplex mode 3. 3500ms 40-55 ppm machine calls an over tem-
perature fault.
=1930,
65-90 ppm 08-592 Fsr Max 2(2) Temperature at which the 0 to 0 deg C 245
=1380 machine shutdowns the
08-325 Pitch Simp Mode 4 IOT paper path timing pitch 1000 to 35 ppm=3540 fuser.
Alt tick setting -simplex mode 4 - 4000ms 40-55 ppm 08-593 Fsr Tol Standby (2) Temperature tolerance either 0 to 0 deg C 35 ppm=26
SEF heavyweight invert =2500, side of standby target tem- 40-55 ppm =20
pitch. 65-90 ppm perature. 65-90 ppm =15
=1640 08-594 Fsr Apply Power Fuser apply power time. 100 to 200
08-326 Pitch Simp Mode 5 IOT paper path timing pitch 600 to 3500ms 35 ppm=2600 Time (2) 20000ms
Alt tick setting -simplex mode 5 - 40-55 ppm 08-596 T Range Cool- Temperature offset above 0 to 0 deg C 10
transparency - pitch mode 1 =1800, ing(2) Tsave at which control and
simplex. 65-75 ppm fault detection is enabled.
=1040
90 ppm=1280

08-597 TE Reg Clutch Off Time to ensure the sheet is 100 to 1200ms 35 ppm=860 08-607 LE Dup Snr To Duplex buckle timer mode 1. 0 to 700ms 35 ppm=496
Transp clear of the registration nips 40-55 ppm Clutch On M6 40-55 ppm
before switching clutch off. =610, =343,
65-90 ppm 65-75 ppm
=700 =244,
08-600 VT Fan On In Enable/disable vacuum 0=Disabled 0 90 ppm=256
Duplex transport fan continuously on 1=Enabled 08-608 LE Dup Snr To Duplex buckle timer mode 1. 0 to 700ms 35 ppm=496
during duplex printing. Clutch On M7 40-55 ppm
08-601 Inv Mt Fwd To Inv Restart sheet into duplex 0 to 2500ms 35 ppm=1353 =343,
Mt Rev M7 (mode 7), sheets >185mm 40-55 ppm 65-75 ppm
size 2. =927, =244,
65-75 ppm 90 ppm=256
=985, 08-609 LE Dup Snr To Clt LE at duplex sensor to clutch 0 to 1000ms 35 ppm=496
90 ppm=697 On Nom M2 on. 40-55 ppm
08-602 Inv Mt Fwd To Inv Restart sheet into duplex 0 to 2500ms 35 ppm=478 =343,
Mt Rev S1 (mode 1), sheets <185mm 40-55 ppm 65-75 ppm
size 1. =927, =425,
65-75 ppm 90 ppm=431
08-603 LE Dup Snr To Duplex buckle timer mode 1. 0 to 700ms 35 ppm=496 =343,
Clutch On M2 40-55 ppm 65-75 ppm
=343, =425,
65-75 ppm 90 ppm=431
=343, =425,
65-75 ppm 90 ppm=431
=343, =244,
65-75 ppm 90 ppm=256
90 ppm=431 On Nom M6 on 40-55 ppm
=343, =244,
65-75 ppm 90 ppm=256
=244,
90 ppm=256

08-614 LE Dup Snr To Clt LE at duplex sensor to clutch 0 to 1000ms 35 ppm=496 09-005 Chute Bias Mid Chute bias inter document 0 to 1400 V 35 ppm=650
On Nom M7 on 40-55 ppm level. Refer to 09-004. 40-55 ppm
=343, =735,
65-75 ppm 65-90 ppm
=244, =890
90 ppm=256 09-006 Chute Bias TE Chute bias trail edge level. 0 to 1400 V 35 ppm=650
08-615 HVF RFNS Time removes a variable time in O to 40ms 35-45 ppm= 0 Refer to 09-004. 40-55 ppm
delay ms from HVF RFNS 55-90 ppm= 40 =735,
08-616 FsrTolrunC Temp tolerance either side of 35-45 ppm=0 65-90 ppm
run target temp-Thermistor 55 ppm=30 =890
C. 65-90 ppm=0 09-007 Transfer LE Side 1 Side 1 transfer corotron LE. 150 to 1000 35 ppm=210
08-617 FsrTolrunC(2) Temp tolerance either side of 35-45 ppm=0 microampere 40-55 ppm
run target temp-Thermistor 55 ppm=30 =300,
C. 65-90 ppm=0 65-90 ppm
=350
08-618 LeRegSnrTo- This NVM is for 90ppm only. 0 to 50 90 ppm=10
ClutchOffH LE Reg Snr To Clutch Off 09-008 Transfer Mid Side Side 1 transfer corotron 150 to 1000 35 ppm=210
1 intra-document. microampere 40-55 ppm
08-619 TeRegSnrTo- This NVM is for 90ppm only. 0 to 200 90 ppm=112
ClutchOffH TE Reg Snr To Clutch Off =300,
65-90 ppm
08-900 Enable Diag. Use to enable or disable 0 = disabled 0
=350
Access restricted diagnostics 1 = enable
09-009 Transfer TE Side 1 Side 1 transfer corotron TE. 150 to 1000 35 ppm=210
access. Use with 03-900
microampere 40-55 ppm
=300,
Table 8 NVM chain 9
65-90 ppm
Location NVM Name NVM Description Value Default =350
09-001 TC Lockout Low CSF NVM lockout for TC 0=clear 1=lock- 0 09-010 Transfer LE Side 2 Side 2 transfer corotron LE. 150 to 1000 35 ppm=210
process control failure out microampere 40-55 ppm
(low). =300,
09-002 Charge Scorotron Charge scorotron (wire). 500 to 3000 35 ppm=800 65-90 ppm
=350
Absolute value in NVM, real microampere 40-90 ppm
value is negative. =2050 09-011 Transfer Mid Side Side 2 transfer corotron 150 to 1000 35 ppm=210
2 intra-document. microampere 40-55 ppm
09-003 Charge Grid Charge scorotron (grid). 150 to 700 V 35 ppm=420
Absolute value in NVM, real 40-55 ppm =300,
65-90 ppm
value is negative. =430,
=350
65-90 ppm
=420 09-012 Transfer TE Side 2 Side 2 transfer corotron TE. 150 to 1000 35 ppm=210
09-004 Chute Bias LE Chute bias print level. 0 to 1400 V 35 ppm=650 microampere 40-55 ppm
=300,
Unsigned no. in NVM table 40-55 ppm
65-90 ppm
(displayed on GUI) to be =735,
converted to signed no. 65-90 ppm =350
over range of -500 to +900 =890 09-013 Detack AC Side 1 Side 1 detack corotron volt- 3000 to 5000 V 4200
(Volts) by subtraction of 500 age.
from table value. 09-014 Detack AC Side 2 Side 2 detack corotron volt- 3000 to 5000 V 4200
age.

09-015 Detack LE Side 1 Side 1 detack corotron LE. 0 to 220 micro- 35 ppm=150 09-021 Dev Bias Print Developer bias print level. 100 to 600 V 35 ppm=350
Unsigned no. in NVM table ampere 40-90 ppm Level Absolute value in NVM real 40-90 ppm
(and displayed on GUI) to =130 value is negative. =345
be converted to signed no. 09-022 Dev Age Table Developer age table. 0 or 1 0
over range of +20 to -200
09-023 T MMONCI Main motor on cycle In. 0 to 1000 ms 35 ppm=770
microampere by subtrac- 40-55 ppm
tion of 200 from value in
=540,
table.
65-90 ppm
09-016 Detack Mid Side 1 Side 1 detack corotron 0 to 220 micro- 35 ppm=165 =380
intradocument. Unsigned ampere 40-90 ppm 09-024 T CSONCI Charge scorotron on cycle 0 to 1000 ms 35 ppm=430
no. in NVM table (and dis- =160
In. 40-55 ppm
played on GUI) to be con-
=300,
verted to signed no. over 65-90 ppm
range of +20 to -200 micro-
=210
ampere by subtraction of
09-026 T PCELONCI Pre clean erase lamp on 0 to 1000 ms 35 ppm=430
200 from value in table.
cycle In. 40-55 ppm
09-017 Detack TE Side 1 Side 1 detack corotron TE. 0 to 220 micro- 199 =300,
Unsigned no. in NVM table ampere
65-90 ppm
(and displayed on GUI) to
=210
be converted to signed no.
over range of +20 to -200 09-027 T DBONCI Developer bias on cycle In. 0 to 1000 ms 35 ppm=270
40-55 ppm
microampere by subtrac-
=170,
tion of 200 from value in
table. 65-90 ppm
=100
09-018 Detack LE Side 2 Side 2 Detack Corotron LE. 0 to 220 micro- 35 ppm=150
09-029 T PCELONCI_alt Pre clean erase lamp on 0 to 1000 ms 0
Unsigned no. in NVM table ampere 40-90 ppm
cycle in alternative.
(and displayed on GUI) to =130
be converted to signed no. 09-031 T TCONRUN Transfer corotron on run. 0 to 1000 ms 35 ppm=500
over range of +20 to -200 40-55 ppm
microampere by subtrac- =360,
tion of 200 from value in 65-90 ppm
table. =220
09-019 Detack Mid Side 2 Side 2 detack corotron 0 to 220 micro- 35 ppm=165 09-032 T DCONRUN Detack corotron on run. 0 to 1000 ms 35 ppm=530
intradocument. Unsigned ampere 40-90 ppm 40-55 ppm
no. in NVM table (and dis- =160 =360,
played on GUI) to be con- 65-90 ppm
verted to signed no. over =260
range of +20 to -200 micro- 09-033 T CBONRUN Chute bias on run. 0 to 1000 ms 35 ppm=540
ampere by subtraction of 40-55 ppm
200 from value in table. =380,
09-020 Detack TE Side 2 Side 2 detack corotron TE. 0 to 220 micro- 199 65-90 ppm
Unsigned no. in NVM table ampere =270
(and displayed on GUI) to 09-036 T CBOFFRUN Chute bias off run. 0 to 100 ms 35 ppm=60
be converted to signed no. 40-55 ppm =40
over microampere range of 65-90 ppm =30
+20 to -200 microampere
by subtraction of 200 from
value in table.

09-037 T TCOFFRUN Detack corotron off run. 0 to 100 ms 35 ppm=60 09-051 T PRMOFCO Photoreceptor motor off 0 to 1500 ms 35 ppm=1130
40-55 ppm =40 cycle out. 40-55 ppm
65-90 ppm =50 =790,
09-039 T DCOFFRUN Detack corotron off run. 0 to 500 ms 35 ppm=150 65-90 ppm
40-55 ppm =560
=110, 09-052 T MMOFCO-alt Main motor off cycle out 0 to 1500 ms 35 ppm=1120
65-90 ppm =80 alternative. 40-55 ppm
09-040 T TCLERUN Transfer corotron lead edge 0 to 500 ms 35 ppm=140 =780,
switch. 40-55 ppm 65-90 ppm
=100, =550
65-90 ppm =70 09-053 T DBOFCO-alt Developer bias off cycle out 0 to 1500 ms 35 ppm=1130
09-041 T TCT ERUN Transfer corotron trail edge 0 to 500 ms 35 ppm=90 alternative. 40-55 ppm
switch. 40-55 ppm =60 =790,
65-90 ppm =40 65-90 ppm
=560
09-042 T DCLERUN Detack corotron lead edge 0 to 500 ms 35 ppm=140
switch. 40-55 ppm 09-054 XeroCycleInMode Xerographic cycle in mode. 0=normal 0
=100, 1=alternative
65-90 ppm =70 09-056 XeroTransCoro- Xerographic transfer 0=normal 35-45 ppm=0
09-043 T DCTERUN Detack corotron trail edge 0 to 500 ms 35 ppm=130 RunMode corotron run mode. 1=alternative 55 ppm=1
switch. 40-55 ppm =90 65-90 ppm =0
65-90 ppm =60 09-057 XeroDetackCoro- Xerographic detack 0=normal 1
09-044 T CBLERUN Chute bias lead edge 0 to 500 ms 35 ppm=140 Run corotron run mode. 1=alternative
switch. 40-55 ppm 09-058 XeroChuteBias- Xerographic chute bias run 0=normal 1
=100, RunMode mode. 1=alternative
65-90 ppm =70 09-059 T DBOFCOFS Developer bias off cycle out 0 to 1000 ms 35 ppm=420
09-045 T CBTERUN Chute bias trail edge switch. 0 to 500 ms 35 ppm=140 fast shutdown. 40-55 ppm
40-55 ppm =310,
=100, 65-90 ppm
65-90 ppm =70 =220
09-048 T DBOFCO Developer bias off cycle 0 to 500 ms 35 ppm=350 09-060 XeroCycleOut- Xerographic cycle out 0=normal 0
out. 40-55 ppm Mode mode. 1=alternative
=240, 09-061 Detack ID Side 1 Detack corotron inter docu- 0 to 220 micro- 200
65-90 ppm ment level, side 1. ampere
=160
09-062 Detack ID Side 2 Detack corotron inter docu- 0 to 220 micro- 200
09-049 T MMOFCO Main motor off cycle out. 0 to 500 ms 35 ppm=390 ment level, side 1. ampere
40-55 ppm 09-063 XRU Total Count Backup of CRU data: XRU 0 Read only 0
=270,
total count.
65-90 ppm
09-064 FRU Total Count Backup of CRU data: FRU 0 Read only 0
=190
total count.
09-050 T PCELOFCO PR erase lamp off cycle out. 0 to 1500 ms 35 ppm=1100
40-55 ppm 09-065 XRU PR Cycle Backup of CRU data: XRU 0 Read only 0
Count P/R cycle count.
=770,
65-90 ppm 09-066 FRU Web Usage Backup of CRU data: FRU 0 Read only 0
=550 Count xeb usage count.
09-068 TC Setpoint Sets target TC for devel- 0 0
oper process controls.

09-069 TCSensorCtrtVolt- Sets TC sensor control volt- 400 to 1200 800 09-112 Cumulative Disp Total dispense time. 0 to 0
age age to adjust sensitivity. (mVx10) Time 78000000ms
09-070 TCSetupCom- TC setup completed. 0 or 1 0 09-114 Rep Lev Snr Fault Flag to indicate replenisher 0 0
pleted sensor failure.
09-073 Last Pixel Count Cumulative Pixel Count 0 Read only 0 09-115 TC Sensor Fault TC sensor fault. 0 0
over the last TC control 09-116 Paper path fans Paper path cooling mode. 0=disabled 35-55 ppm=0
block (20 prints). mode 1=enabled 65-90 ppm =1
09-083 ReplenCart- Maximum continuous run 15 to 40 ms 30 09-117 Scorotron On Charge scorotron ON cycle 0 to 1000ms 100
MotRun period. Ramp Up in ramp up.
09-087 Rep Cartridge Toner (replenisher) car- 0 or 1 0 09-118 Dev bias On Ramp Developer bias ON cycle in 0 to 1000ms 160
Empty tridge empty status. Up ramp up.
09-090 Waste Full Thresh- Waste Full Print Count at 1 to 1000 prints 35-45 ppm=0 09-119 GridV Off Ramp Charge scorotron grid volt- 0 to 1000ms 35 ppm=80
old which Bottle Full status is 55-90 ppm Dwn age OFF cycle out ramp 40-90 ppm
confirmed. =100 down. =120
09-093 Waste Shutdown Maximum number of prints 0 to 10000 35-45 ppm=0 09-120 Ozone max life Stores the maximum prints 0 to 350k
Limit allowed post waste full prints 55-90 ppm to make with the current 4294967295
before shutdown. =1000 ozone filter.
09-096 Developer Temp Actual developer temp as Degrees C. 0 09-121 Man Cleaning Charge Scorotron Manual 2 to 50 25k
measured by sensor. Interval Cleaning Interval. Fre-
09-097 Humidity% RH Actual machine humidity as %RH 0 quency in K sheets for
measured by sensor. when a manual scorotron
09-098 Altitude Altitude adjustment in 0 = zero to 0 cleaning request is dis-
metres. 749m played.
1 = 750 to 09-122 Auto Cleaning Charge Scorotron Auto 2 to 50 20k
1499m Interval Cleaning Interval. Fre-
2 = 1500 to quency in K sheets for
2249m when a manual scorotron
3 = 2250 to cleaning request is dis-
2999m played.
4 = 3000+m 09-123 Num Images Number of images deliv- 0 to 0
09-100 Main Motor Delay Enables or disables a delay 0=disabled 0 Delivered ered. 4294967295
Flag to the main motor and pho- 1=enabled 09-124 InactivityLimit The set limit of machine 120 to 4320 300
toreceptor motor run up inactivity in minutes
times by adding 1150 to 09-125 Dev Bias Off Developer bias OFF cycle 0 to 1000ms 160
both of the read NVM val-
Ramp Dwn out ramp down.
ues for IOT NVM.
09-126 Dev Bias Off Developer bias OFF cycle 0 to 1000ms 35-55 ppm=0
09-101 Ambient Temp Actual ambient temp as Degrees C 0
Ramp Dwn Alt out ramp down alternative. 65-90 ppm
measured by sensor. =100
09-110 Replenisher Replenisher capacity. 1050 to 1787 35-55 ppm 09-127 Dev Bias Off FS Developer bias OFF fast 0 to 1000ms 35-55 ppm=0
capacity grams =1353,
Ramp Dwn Alt shutdown cycle out ramp 65-90 ppm
65-90 ppm
down. =100
=1750
09-128 PC From Flash Or For development only. 0 to 1 0
09-111 Repl. Delivery Replenisher delivery rate. 15 to 60 35-55 ppm Ram Alters process control fac-
Rate decigrams/min =460,
tors source from either flash
65-90 ppm
or NVM.
=550

09-129 Disp Mot Min Run Dispense motor minimum 100 to 1000ms 200 09-279 Charg Clean Cout Charge cleaner count 0=disabled 0
run time for toner dispense. Enable enable. 1=enabled
09-130 Disp Mot Ramp Up Dispense motor ramp up 10 to 20000ms 30 09-280 Inactivity Limit IOT Machine inactivity limit held 120 to 4320 300
time. on the IOT PWB. minutes
09-131 Disp Mot Run On Dispense motor run on 10 to 20000ms 320 09-281 TDT AutoClean Transfer/Detack auto clean 0=disabled 1
time. Enable enable flag. 1=enabled
09-132 Nh Vac Fan Off To Nohad vacuum fan on time. 0 to 100ms 35 ppm=61 09-282 Dev Age Time Developer age - time 0 to 0
Off Tme 40-90 ppm =43 Based based. 2147483647
09-133 Nh Vac Fan Off To Nohad vacuum fan off time. 0 to 100ms 35 ppm=42 seconds
On Tme 40-90 ppm =29 09-312 Grid Voltage Offset Used to display the grid 0 to 50 = 0 to 0
09-134 Rep Del Rate Adj Replenisher delivery rate 95 to 115% 100 voltage offset value held in +50V
Factor adjustment factor. the XRU CRUM. 129 to 178 = -1
09-135 TggAdaptiveEn- Enables and disables the 0=disabled 1 to -50V
able replenisher delivery rate 1=enabled 09-313 Grid Volt Adj Nom Used to display the grid 110 to 740 35 ppm=420
adjustment feature voltage adjusted nominal. 40-55 ppm
=430
09-267 Humidity Sensor Humidity sensor fault. 0 0
Fault 65-90 ppm
=420
09-268 Dev Temp Sensor Developer temperature sen- 0 0
09-314 Grid Volt Adj Used to enable grid voltage 0=disabled 1
Fault sor fault.
Enable nominal adjustment. 1=enabled
09-269 AmbTempSensor- Ambient temperature sen- 0 0
09-315 Grid Curr Scaler Used to display the grid cur- 0 0
Fault sor fault.
rent scaler value held in the
09-271 Developer age Developer material age. 0 to 0 XRU CRUM.
2147483647
09-316 Grid Curr Adj Nom Used to display the grid cur- 250 to 4500mA 35 ppm=800
pages
rent adjusted nominal. 40-95 ppm
09-273 OCT Full Filter OCT 90% full filter. 0 to 50 pages 30
=2050
Page Count
09-317 Grid Curr Adj Used to enable grid current 0=disabled 1
09-274 Chute Bias inter Chute bias inter document 0 to 1400V 0 Enable nominal adjustment. 1=enabled
doc level. Unsigned no. in NVM
09-318 ROS Laser Scaler Used to display the ROS 0 0
table (displayed on GUI) to
laser light level scaler value
be converted to signed no.
over range of -500 to +900 held in the XRU CRUM.
(Volts) by subtraction of 500 09-319 ROS Laser Adj Used to display the ROS 750 to 9000 35 ppm=3471
from table value. Nom laser light level adjusted 40-55 ppm
nominal. =2250,
09-275 TC Setup Target Toner concentration setup 0 to 500 35-45 ppm=0
Voltage target voltage. (mVx10) 55-90 ppm 06-001 must be set to the 65-75 ppm
same value as 09-319. =2400
=185
09-320 ROS Laser Adj Used to enable ROS laser 0=disabled 1
09-276 TC lockout high CSF NVM lockout for TC 0 0
Enable light level nominal adjust- 1=enabled
process control. Failure =
high. ment.
09-277 Int Man Clean Interim manual charge 0=disabled 35 ppm=0 09-321 IQA Grid V Offset IQA Grid V Offset level. 0 to 80 40
Unsigned no. in NVM table
Enable scorotron cleaning ennoble- 1=enabled 40-90 ppm =1
(displayed on GUI) to be
ment flag.
converted to signed no.
09-278 Auto Clean Enable Auto charge scorotron 0=disabled 35 ppm=0 over range of -40 to +40
cleaning ennoblement flag. 1=enabled 40-90 ppm =1
(Volts) by subtraction of 40
from table value.

09-322 IQA ROS Level IQA ROS Level Offset level. 0 to 3000 1500 10-028 Standby Temp Target temperature during 10 to 218 35 ppm=190
Offset Unsigned no. in NVM table standby mode. degrees C 40-55 ppm
(displayed on GUI) to be =195,
converted to signed no. 65-90 ppm
over range of -1500 to =208
+1500 (mErg/cm2) by sub- 10-029 Run Temp Target temperature during 100 to 213 35 ppm=185
traction of 1500 from table run mode. degrees C 40-55 ppm
value. =195,
09-331 Upper Relaxation Upper relaxation capping 100 to 600% 400 65-90 ppm
limit when aggressive dis- =203
pense mode active. 10-030 Low Power Temp Target temp during Power 50 to 150 35 ppm=85
09-332 Prop B Factor Additional factor applied to 100 to 1000% 100 save mode. The low power degrees C 40-55 ppm
the proportional term when simmer temperature is deter- =95,
aggressive dispense mode mined by the Power Save 65-90 ppm
active. mode set in Tools. =135
09-400 XRU Blade A Coefficient A. 0 to 10000ug/s 35 ppm=200 10-042 101-120 mm offset Offset temperature required 0 to 20 10
40-55 ppm on thermistor B for paper
=350, width. Unsigned number in
65-90 ppm NVM table (displayed on
=500 GUI) to be converted to
09-401 XRU Blade B Coefficient B. 0 to 1000ug per 16 signed number. by subtrac-
10^5 pixels tion of 10 from table value.
i.e. 8 displayed in NVM is
09-402 XRU Blade Mco Blade maintenance level at 0 to 3000mg 0
cycle out. equivalent to -2 degrees Cel-
sius
09-403 XRU Blade CICO Prediction of blade mainte- 0 to 100mg 35 ppm=8
10-043 121-140 mm offset Offset temperature required 0 to 20 10
bands nance provided by cycle in 40-55 ppm =9
on thermistor B for paper
and cycle out bands. 65-90 ppm =11
width. Unsigned number in
09-404 XRU Blade XRU Blade maintenance 2 to 3000mg 10 NVM table (displayed on
Level(1) threshold level 1.
GUI) to be converted to
09-405 XRU Blade XRU Blade maintenance 1 to 3000mg 30 signed number. by subtrac-
Level(2) threshold level 2. tion of 10 from table value.
09-406 XRU Blade XRU Blade maintenance 0 to 3000 0 i.e. 8 displayed in NVM is
Count(1) event type 1 counter. equivalent to -2 degrees Cel-
09-407 XRU Blade XRU Blade maintenance 0 to 3000 0 sius
Count(2) event type 2 counter. 10-044 141-160 mm offset Offset temperature required 0 to 20 10
09-408 XRU Blade C Coefficient C. 0 to 10000ug 805 on thermistor B for paper
per 10^5 pixels width. Unsigned number in
NVM table (displayed on
09-409 XRU Blade Enable XRU Blade maintenance 0=disable (XT) 0 for XT,
GUI) to be converted to
enable/disable. 1=enable (EA) 1 for EA
signed number. by subtrac-
09-410 XRU Blade XRU Blade maintenance 0 to 300ug 42 tion of 10 from table value.
ML(max) level maximum level.
equivalent to -2 degrees Cel-
sius

10-045 161-180 mm offset Offset temperature required 0 to 20 10 10-049 241-260 mm offset Offset temperature required 0 to 20 10
on thermistor B for paper on thermistor B for paper
width. Unsigned number in width. Unsigned number in
NVM table (displayed on NVM table (displayed on
GUI) to be converted to GUI) to be converted to
signed number. by subtrac- signed number. by subtrac-
tion of 10 from table value. tion of 10 from table value.
i.e. 8 displayed in NVM is i.e. 8 displayed in NVM is
equivalent to -2 degrees Cel- equivalent to -2 degrees Cel-
sius sius
sius sius
sius sius
10-048 221-240 mm offset Offset temperature required 0 to 20 10 10-053 80 gms Offset Media type offset for fuser roll 0 to 30 10
on thermistor B for paper temperature. Unsigned num-
width. Unsigned number in ber in NVM table (displayed
NVM table (displayed on on GUI) to be converted to
GUI) to be converted to signed number. by subtrac-
signed number. by subtraction of 10 from table value.
tion of 10 from table value. i.e. 8 displayed in NVM is
i.e. 8 displayed in NVM is equivalent to -2 degrees Cel-
equivalent to -2 degrees Cel- sius
sius 10-058 Transparency Off- Media type offset for fuser roll 0 to 30 35-55 ppm
set temperature. Unsigned num- =10,
ber in NVM table (displayed 65-90 ppm=0
on GUI) to be converted to
tion of 10 from table value.
sius

10-059 Card stock offset Media type offset for fuser roll 0 to 25 15 10-071 Rough Stock Off- Media type offset for fuser roll 0 to 25 15
temperature. Unsigned num- set temperature. Unsigned num-
ber in NVM table (displayed ber in NVM table (displayed
on GUI) to be converted to on GUI) to be converted to
sius sius.
10-060 Envelopes Offset Media type offset for fuser roll 0 to 30 15 10-072 Rough Stock Media type time delay for 0 to 8 seconds 4
temperature. Unsigned num- Delay fuser roll temperature.
ber in NVM table (displayed 10-074 Rough Stk FRU Rough Stock Fuser (TOS) Disable = 0 0
on GUI) to be converted to Enable Enable = 1
10-075 Type 256 FRU Type 256 Fuser Disable = 0 1
Enable Enable = 1
equivalent to -2 degrees Cel- 10-102 Te PFs Toinv Mot Inverter motor off stop posi- 0 to 800 ms 35 ppm=530
Off Dup tion (simplex). 40-55 ppm
sius
=360,
10-061 Labels Offset Media type offset for fuser roll 0 to 30 15
65-90 ppm =0
temperature. Unsigned num-
ber in NVM table (displayed 10-122 Te PFs To Inv Mot Time to turn off inverter motor 0 to 1200ms 35 ppm=740
Off Dup after TE leaves fuser 40-55 ppm
(duplex). =510,
tion of 10 from table value. 65-90 ppm =0
i.e. 8 displayed in NVM is 10-123 Fsr Range Temperature range below 10 to 30 deg C 35 ppm=30
equivalent to -2 degrees Cel- standby in which start print 40-55 ppm
sius can begin. =10
10-063 Total Fsr Web Total fuser web count. Cycles 0 65-90 ppm
=28
Count
10-124 Te Inv Snr To Mot Inverter motor off stop posi- 0 to 800 ms 35 ppm=530
10-064 Transparency Media type time delay for 0 to 8 seconds 0
Of SmpS1 tion (simplex). 40-55 ppm
delay fuser roll temperature.
=360,
10-065 Cardstock delay Media type time delay for 0 to 8 seconds 4 65-90 ppm
fuser roll temperature.
=200
10-066 Envelopes delay Media type time delay for 0 to 8 seconds 4
10-125 Te Inv Snr Inv Of Time to turn off inverter motor 200 to 1200ms 35 ppm=740
Dup Siz 1 after TE leaves inverter sen- 40-55 ppm
10-067 Labels delay Media type time delay for 0 to 8 seconds 4 sor for sheets <185mm and =510,
fuser roll temperature. >216mm. 65-90 ppm
10-068 Tab stock delay Media type time delay for 0 to 8 seconds 4 =295
fuser roll temperature. 10-126 Web Advance Web advance group banding 1 = group 1 2
10-069 Cold Start Offset Fuser cold start offset profile. 0 to 3 35-55 ppm=0 Group select. 2 = group 2
65-90 ppm =2 3 = group 3
10-070 Cold Roll Offset Fuser cold roll offset profile. 0 to 11 35 ppm=1 10-328 Standby Temp (2) Target temperature during 10 to 230 deg 35 ppm=190
40-55 ppm =6 standby mode. C 40-55 ppm
65-90 ppm =8 =195,
65-90 ppm
=208

10-329 Run Temp (2) Target temperature during 100 to 230 deg 35 ppm=185 10-345 161-180mm Offset Offset temperature required 0 to 20 10
run mode. C 40-55 ppm (2) on thermistor B for paper
=195, width. Unsigned number in
65-90 ppm NVM table (displayed on
=203 GUI) to be converted to
10-330 Low Power Temp Target temperature during 50 to 150 deg 35 ppm=85 signed number. by subtrac-
(2) power save mode. The low C 40-55 ppm tion of 10 from table value.
power simmer temperature is =95, i.e. 8 displayed in NVM is
determined by the Power 65-90 ppm equivalent to -2 degrees Cel-
Save mode set in Tools. =135 sius
10-342 101-120mm Ofsfet Offset temperature required 0 to 20 10 10-346 181-200mm Offset Offset temperature required 0 to 20 10
(2) on thermistor B for paper (2) on thermistor B for paper
sius sius
10-343 121-140mm Offset Offset temperature required 0 to 20 10 10-347 201-220mm Offset Offset temperature required 0 to 20 10
sius sius
10-344 141-160mm Offset Offset temperature required 0 to 20 10 10-348 221-240mm Offset Offset temperature required 0 to 20 10
sius sius

10-349 241-260mm Offset Offset temperature required 0 to 20 10 10-359 Card Stock Offset Media type offset for fuser roll 0 to 25 15
(2) on thermistor B for paper (2) temperature. Unsigned num-
width. Unsigned number in ber in NVM table (displayed
NVM table (displayed on on GUI) to be converted to
GUI) to be converted to signed number. by subtrac-
signed number. by subtraction of 10 from table value.
tion of 10 from table value. i.e. 8 displayed in NVM is
i.e. 8 displayed in NVM is equivalent to -2 degrees Cel-
equivalent to -2 degrees Cel- sius.
sius 10-360 Envelopes Offset Media type offset for fuser roll 0 to 30 15
10-350 261-280mm Offset Offset temperature required 0 to 20 10 (2) temperature. Unsigned num-
(2) on thermistor B for paper ber in NVM table (displayed
width. Unsigned number in on GUI) to be converted to
NVM table (displayed on signed number. by subtrac-
GUI) to be converted to tion of 10 from table value.
signed number. by subtrac- i.e. 8 displayed in NVM is
tion of 10 from table value. equivalent to -2 degrees Cel-
i.e. 8 displayed in NVM is sius.
equivalent to -2 degrees Cel- 10-361 Labels Offset (2) Media type offset for fuser roll 0 to 30 35-55 ppm
sius temperature. Unsigned num- =15,
10-351 281-300mm Offset Offset temperature required 0 to 20 10 ber in NVM table (displayed 65-90 ppm
(2) on thermistor B for paper on GUI) to be converted to =10
width. Unsigned number in signed number. by subtrac-
NVM table (displayed on tion of 10 from table value.
GUI) to be converted to i.e. 8 displayed in NVM is
signed number. by subtrac- equivalent to -2 degrees Cel-
tion of 10 from table value. sius.
i.e. 8 displayed in NVM is 10-364 Transp_cy Delay Media type time delay for 0 to 8 seconds 0
equivalent to -2 degrees Cel- (2) fuser roll temperature.
sius
10-365 CardStock Delay Media type time delay for 0 to 8 seconds 4
10-353 80gms Offset (2) Media type offset for fuser roll 0 to 20 10 (2) fuser roll temperature.
temperature. Unsigned num-
10-366 Envelopes Delay Media type time delay for 0 to 8 seconds 4
ber in NVM table (displayed (2) fuser roll temperature.
10-367 Labels Delay (2) Media type time delay for 0 to 8 seconds 4
i.e. 8 displayed in NVM is 10-368 Tab Stock Delay Media type time delay for 0 to 8 seconds 4
equivalent to -2 degrees Cel- (2) fuser roll temperature.
sius. 10-370 Cold Roll offset (2) Fuser cold roll offset profile. 0 to 11 35 ppm=1
10-358 Transp_cy Offset Media type offset for fuser roll 0 to 30 35-55 ppm 40-55 ppm =6
(2) temperature. Unsigned num- =10, 65-90 ppm =8
ber in NVM table (displayed 65-90 ppm = 0
sius.

Table 9 NVM chain 10 dC131b NVM Tables Chain 12 to 19
General
10-371 Rough Stock Off- Media type offset for fuser roll 0 to 30 15
1. Refer to the tables that follow for NVM parameters chain 12 to 28:
set (2) temperature. Unsigned num-
ber in NVM table (displayed NVM chain 12 Table 1
on GUI) to be converted to NVM chain 14 Table 2
signed number. by subtrac- NVM chain 15 Table 3
tion of 10 from table value. NVM chain 17 Table 4
NVM chain 19 Table 5
sius.
Table 1 NVM chain 12
10-372 Rough Stock Media type time delay for 0 to 8 seconds 4
Delay (2) fuser roll temperature. Location NVM Name NVM Description Value Default
10-423 Fsr Range (2) Temperature range below 10 to 30 deg C 35 ppm = 30 12-001 Finisher Module Defines finisher module 65=OCT 100
standby in which start print 40-55 ppm = Type types 110=LCSS2K
can begin. 10 120=LCSS1K
65-90 ppm = 176=HVFBM
28 100=No Fin-
10-426 Web Advance Web advance group banding 1=group 1 2 isher
Group (2) select. 2=group 2 12-002 OCTFullFilter OCT 90% full filter 0 to 5000 ms 35 ppm=4000
3=group 3 40-90 ppm
=2500
12-003 BookMkrCompile- Used to adjust the compiler 0 to 200 100
Offset position of the booklet 0.1137mm/step
maker back stop.
12-004 BookMkrStapleOff- Used to align the staple to 0 to 200 100
set the fold. 0.1137mm/step
12-005 BookMkrFold Off- Used to centre the fold and 0 to 200 100
set the staple relative to the 0.1137mm/step
lead edge.
12-006 BookMkrTampRdy- Used to adjust the booklet 0 to 200 100
Offset maker tamping ready posi- 0.265mm/step
tion.
12-009 BookMkrTriFoldC- Used to position upper tri- 60 to 140 100
Fold fold. Moves fold relative to 0.1137mm/step
lead edge on C Fold.
12-010 BookMkrTriFoldZ- Used to position lower tri- 60 to 140 100
Fold fold. Moves fold relative to 0.1137mm/step
lead edge on Z Fold.
12-011 BookMkrTriFold- Used to adjust the amount 90 to 110 100
Deskew of de-skew for the 2nd fold
in a tri-fold by varying the
amount of buckle length in
registration for the paper
entering TF.

dC131a, dC131b 6-102 Xerox WorkCentre 5790 Family
12-012 BookMkrStapleOff- Used to control the staple 0 to 200 100 14-027 Scanner Mag Adj Adjust platen scan speed in 50 to 150 100
setM offset position for 8.5x11 0.1137mm/step slow scan direction to com-
and 8.5x14 paper. HVF BM pensate for magnification
only. errors
12-013 BookMkrStapleOff- Used to control the staple 0 to 200 100 14-028 Green Gain Set Green scan calibration set- 150 to255 200
setL offset position for 11x17 and 0.1137mm/step point Nvm ting.
A3 paper. HVF BM only. 14-029 Red Gain Set point Red scan calibration setting. 150 to255 195
12-050 FinisherSoftCyc- Time out for soft cycling of 0 to 60 sec- 35 ppm=40 Nvm
Time finisher to time seconds onds 45=35, 14-030 Blue Gain Set point Blue scan calibration set- 150 to255 203
55-90 ppm=30 Nvm ting.
14-031 Red Sako Adjust Red color balance adjust- 0 to 200 100
Table 2 NVM chain 14 Nvm ment setting.
Location NVM Name NVM Description Value Default 14-032 Green Sako Adjust Green color balance adjust- 0 to 200 100
14-001 DADH Centre Reg DADH CVT centre registra- 3513 to 3770 35-55 ppm Nvm ment setting.
tion pixels =3563, 14-033 Blue Sako Adjust Blue color balance adjust- 0 to 200 100
65-90 ppm Nvm ment setting.
=3720 14-034 Light Sako Adjust Lighten/Darken balance 0 to 200 100
14-002 DADH LE Reg DADH lead edge registra- 0 to 150 scan 70 Nvm adjustment setting.
tion lines 14-129 Scanner type Used to set the type of scan- 1= FWA; 2= 1
14-003 Platen Top Edge Platen top edge registration 7056 to 7313 35-55 ppm ner. CCDS, 3=Low
Reg pixels =7106, Speed North-
65-90 ppm wood PF2,
=7263 4=High Speed
Northwood
14-004 Platen Lead Edge Platen lead edge registra- 0 to 150 scan 70
PF2,
Reg tion lines
5=CCDS2
14-012 Scanner CVT posi- Adjusts position of scan car- 4868 to 4898 35-55 ppm
tion riage at the CVT position 0.1mm incre- =4988, 14-169 DADH Mag Adjusts the DADH magnifi- 2 to 200 (0.1% 100
cation. increments)
ments 65-90 ppm
=4878
14-013 Scanner Doc Size Adjusts position of scan car- 0 to 5000 35-55 ppm
Pos riage at the document size 0.1mm incre- =700, Location NVM Name NVM Description Value Default
position ments 65-90 ppm
15-005 ScannerFSResolu- To provide configuration sup- 400 or 600 600
=500 tion port for scanners with Fast
14-014 Scanner LE Hotline Scanner lead edge active 200 to 500 35-55 ppm Scan resolutions of 400 dpi and
hot line 0.1mm incre- =350, 600 dpi.
ments 65-90 ppm
15-006 Scanner Direction To provide configuration sup- 0=reverse 1
=230 port for scanners with different 1=forward
14-025 Scan CCD Gain To adjust pixel gain set point 150 to 255 35-55 ppm Fast Scan direction.
Setpt during scanner CCD calibra- increments of =212,
15-007 CVT scanning Percentage increase with 0 to 20% 10
tion 1 bit 65-90 ppm
image gain adjust- respect to document glass
=214 ment scanning gain.
14-026 Scan CCD Offset To adjust offset point during 0 to 20 Incre- 0
Pnt scanner CCD calibration ments of 1 bit

Xerox WorkCentre 5790 Family 6-103 dC131b
Table 4 NVM chain 17 (image disk drive not used) Table 5 NVM chain 19
17-001 Disk Mode Disk present. 1=enabled 0 19-012 Comp EPC Dup Number of images inputted Range 1 to 50 4
0=disabled Img No before a compiled duplex print
17-002 Disk spin up Time before image disk 0 to 30 seconds 10 job is released for marking
delay receives power

19-001 Megs of Mem- Amount of memory installed 0 to 65535M 16
ory
19-002 Resource% Resource percentage reported 0 to 99% 10
Reported
19-003 Use Partial Used partial blocks 0 or 1 1
Blocks
19-004 Mark mode Marking mode when EPC full 0 or 3 0
EPC full
19-005 Memory on Tar- Memory on target 0 to 65535 32
get
19-006 Image Alloc Nominal compression ratio 1 to 50% 30
Ratio
19-007 Print Img Limit Maximum number of network 35 to 5000 3501
controller images that can be in
EPC at any given time
19-008 EPC Setting Governs the setting of the EPC 1 = Optimized for 1
low and intermediate thresh- smaller sheets,
olds. A4/8.5x11inch.
EPC less than
256Mb.
2 = Intermediate
setting, optimized
for medium size
sheet
3 = Optimized for
large sheet, A3/
11x17 inch. EPC
greater than
256Mb
19-009 Ncomp EPC Number of images inputted Range 1 to 50 2
Simp Img No before a non-compiled simplex
print job is released for marking
19-010 Ncomp EPC Number of images inputted Range 1 to 50 4
Dup Img No before a non-compiled duplex
19-011 Comp EPC Number of images inputted Range 1 to 50 2
Simp Img No before a compiled simplex

dC131b 6-104 Xerox WorkCentre 5790 Family
dC132 NVM Initialization 7. Enter dC131 location 09-069 TCSensorCtrlVoltage. Set the value to the value recorded
on the NVM sheet stored in the wallet on the rear cover.
There are 4 items under this heading: Network Controller NVM initialization
Copier NVM Initialization
Purpose
Network Controller NVM initialization
To return to default network settings, configuration and flags.
Embedded Fax NVM initialization
NVM to Install Condition Description
There are three routines:
NOTE: Certain NVM settings are password protected.
All Network NVM - This initialization will default all network and configuration settings to a
Copier NVM Initialization pre-installation state.
Purpose Variable NVM - The items that will be initialized are related to crash recovery, software
The NVM initialization routine provides the means for the CSE to reset specific machine vari- upgrade settings, alternate boot and any other items needing to be set to default values
able NVM or all machine variable NVM non-volatile memory (with the exception of Protected that are not included in the network controller configuration initialization routine.
NVM for which a password is required) to their default values. Configuration NVM - This initialization will clear all fault and system usage counters, net-
work controller variable, configuration NVM and reset the network controller error log.
Description Procedure
If the machine configuration changes through the addition of an input or output device, an ini- 1. Save the NVM, GP 5.
tialization of the NVM for that device must be performed to make sure that all configuration val-
ues are correct for that device.
NOTE: initialization does not affect the billing counter, accounting, fault counter, diagnostic 4. Select Network Routines, 132 NVM initialization-Network.
data, or auditron services. These, with the exception of billing counters, can be reset if the 5. Touch the appropriate button to select the NVM to be initialized and follow the on screen
machine is restored to the install state using the NVM to Install Condition procedure. instructions.
NOTE: The auditron (billing counters) is initialized using the auditron setup routine, refer to the
User Guide. Embedded Fax NVM initialization
NOTE: From PWS Tools version 130.00.0006 onwards. The NVM Save and Restore tool has Purpose
the option to perform the dC132 NVM Initialization, All Copier NVM routine. To return to default the fax NVM settings. Refer to the Fax NVM Document, tables 1, 2, 3 and
4.
The market region configuration attribute must have been preset at the factory or at first install
to ensure that the NVM default values are regionally correct. Some post install configuration Procedure
can be performed using the configuration tool, refer to dC131 NVM Read / Write.
1. Save the NVM, GP 5.
Procedure 2. Enter diagnostics, GP 1.
1. Save the NVM, GP 5. 3. Select Diagnostic Routines.
2. Enter diagnostics, GP 1. 4. Select Fax dC Routines, 132 NVM initialization
3. Select Diagnostic Routines. 5. Touch the appropriate button to select the NVM to be initialized and follow the screen
instructions. Refer to Table 2, for the functions that are reset to default.
4. Select Copier Routines, 132 NVM initialization-Copier.
Reformat
5. Touch the appropriate button to select the NVM to be initialized and follow the on screen
All Fax Directories
instructions. Refer to Table 1, for the functions that are reset to default.
Fax Job NVM
All Copier NVM.
Fax Configuration NVM
Machine Variable NVM, (i.e. paper path, platen and DADH registration).
Fax SA / KO Settings NVM
SA / KO Dust Off.
System Counters Dust Off
NVM to Install Condition
NOTE: The NVM window will gray out while the initialization is in progress.
The Dust Off routines are available to return the machine to a pre-installed state, refer to Table
6. Switch off the machine, then switch on the machine, GP 14. 1.

Dust Off Table 1 Copier NVM
The NVM Dust Off routine will: Machine System
Clear all non-billing counters. All Copier Variable SA / KO counters
Default all SA / KO NVM including default PINs. Initialization Function NVM NVM Dust Off Dust Off
Clear fault history. Completed Job Log Y
Set the install NVM (install Byte) to default to enable an install procedure at the next Controller Access N
power-on, while retaining all existing configuration NVM e.g. paper path registration, xero- Machine Speed, Market Region
graphic parameters and market configuration values. JBA Database Y Y
NOTE: The auditron is initialized using the auditron setup routine, refer to User Guide. JBA Configuration Y Y
HFSI Counter N N N N
Not alter any protected NVM.
The routine is accessed and performed as follows:
1. Save the NVM, GP 5.
2. Enter diagnostics, GP 1. Table 2 Embedded Fax NVM
3. Select Diagnostic Routines, then Copier Routines, then 132 NVM initialization-Copier, Reformat Reset Reset Reset Reset
then System Counters Dust Off. Fax file type Category Reset All Directories Jobs Configuration Variables
4. Follow the on-screen instructions.
Dial Directories Y Y
Group Directories Y Y
Junk Directories Y Y
Table 1 Copier NVM Logo Directories Y Y

Mailbox Directories Y Y
Machine System
All Copier Variable SA / KO counters Poll Directories Y Y
Initialization Function NVM NVM Dust Off Dust Off Jobs Sets Y Y
NVM ALL Jobs Y Y
IOT (with Flag type: = Reset All Image Y Y
Billing Counter N Bitmaps Y Y
System Usage Counter Y Y Job ID Y Y
Fault Counter Y Y Mailboxes Y Y
Diagnostic Counter Y Y Alarm Y Y
SA / KO Setting Y Y Fax Protocol Trace Y Y
Fault Log Y Protocol Records Y Y
Configuration Y Container Versions Y N
Diagnostic Y Fax NVM Category = Y Y Y
NVM Configuration
Debug Y
Fax NVM Category = Y Y Y
NVM Machine Variable Y Y
NVM SA / KO Settings
IOT with Flag type: = Reset Nominal
Machine Variable Zero Y Y
Machine Variable Registration Y Y
Machine Variable Paper Path Y Y
Machine Variable DADH Y Y
Machine Variable Platen Y Y
Auditron Y Y
Crash Recovery Y

dC305 UI Test NOTE: The calibration mode window will be displayed together with a dynamic text string,
after the Calibration Mode button is touched, Figure 1. Follow the dynamic text instruc-
Purpose tions, then touch each numbered grid intersection point as directed. After the 9th grid
To initiate component testing of the local UI. This function also provides a means to test the UI intersection point has been touched the machine will automatically reboot.
memory and to restart the local UI.
Description
The tests that can be performed are:
1. User Interface Button Test - tests the keys on the user interface.
2. Audio Tone Test - produces audible tones at the user interface.
3. LED Indicator Test - energizes all LEDs on the user interface.
4. Touch Area Test - enables the tester to test all areas on the touch panel.
5. Display Pixel Test - tests the individual pixels on the user interface.
6. Video Memory Test - tests that the SRAM used by the video controller on the local user
interface is functioning properly.
7. Communications Self Test - tests communications with the single board controller PWB.
8. Reset User Interface - used to restart/reboot the UI, will cause the POST to start.
9. Application Checksum Verification - permits access to a procedure that displays and veri-
fies the checksum and can display any errors found.
10. Calibration Mode - enables the user to calibrate the user interface touch screen.
Procedure
2. Select, Diagnostics Routines, Copier Routines, dC305 UI Tests.
3. Touch the appropriate test button. Figure 1 Calibration mode window
4. Touch Start Test and follow the on-screen instructions.

dC312 Network Echo Tests dC314 Network Connectivity Tests
Purpose Purpose
To enable verification of the machines connectivity to an attached network. Performing a test To assist the SA and CSE to isolate the cause of printing, feature network scanning, or network
will give the result, pass or fail, eliminating the possibility of the machines hardware being at fax problems. The test will interrogate each device on the network so that they respond with
fault during a diagnostic session. In addition it will test the machines network drivers. their identity and other information. The data files will be stored on the machine (files deleted at
next boot) and can be retrieved. Refer to GP 5 Portable Workstation and Tools.
Description
The dC312 Echo Test is available through two pathways: Description
1. Diagnostics pathway, dC312 (available to the CSE). The network interface tests that can be performed are:
2. Tools pathway (for use by the System Administrator and the Key Operator). 1. TCP/IP
Network controller interface where host discovered (Enet).
NOTE: The Tools window does not have a test for Internal TCP / IP.
Device name.
The tests that can be performed are: Device subnet mask.
TCP/IP. Device IP address.
Novell or IPX. Device media access control (MAC) address.
NetBIOS / NetBEUI. Gateway IP address.
AppleTalk. 2. Novell or IPX
Internal TCP / IP - Will initiate a ping to the IP device name local host. This test is per- Frame type (local network devices only).
formed to make sure that the IP stack is up and the hosts file is intact.
Server name.
Procedure Print queue name.
1. Enter diagnostics, GP 1. Server internal network number.
2. Select, Network Routines, dC312 Echo Test. Server node (media access control) address.
3. Touch the appropriate test button. Server NOS version number.
NOTE: The feature button is grayed out and disabled for unavailable protocols. Hop count to device (local net), extended test.
Is the printer attached to file server status.
4. Touch Start Test and follow the on-screen instructions.
Is the printer attached to print queue status.
NDPS enabled
3. NetBIOS/NetBEUI
No data need be collected as the network controller has a dynamic internal name
table stored in RAM.
4. AppleTalk
ESS port id.
Device type (router, print server, file server, workstation etc.).
NBP registered device name, such as:
Appleshare file server name or;
Novell PAP server name or;
PAP printer registered name.
Device NBP protocol address.
Device media access control (MAC) address.
Network number.
Zone name.
Sub zone names.
Device OS version number.

Hop count to device. dC330 Component Control
Procedure
Purpose
To show the status of input components e.g. sensors, and to energies and exercise output
2. Select, Network Routines, dC314 Network Connectivity Test.
components e.g. motors, solenoids.
3. Touch the appropriate test button.
NOTE: The feature button is grayed out and disabled for unavailable protocols. Description
4. Touch Start Test and follow the on-screen instructions. Output and input component codes are entered into the Component Control Table on the UI,
and then energized individually or in permitted groups. The codes in the tables are grouped in
function chain (GP 2) order.
Go to the appropriate procedure:

Input Components
Output Components
Input Components
When the appropriate code is entered the status of the component will be shown on the UI.
NOTE: The logic level shown on the circuit diagrams 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 UI, especially where the output is inverted. When testing components using
these control codes, look for a change in state, not for a high or low.
The displayed status of the input component can be changed by causing the component status
to change, e.g. operating a sensor with a sheet of paper. When a sensor is operated a beep
will sound.
Go to the appropriate table:

Table 1 Input codes 01
Table 2 Input Codes 05

Output Components NOTE: The Find Component button is not available if components are energized.
When the appropriate code is entered, the component will energize for a set time and then stop i. Enter the chain number into the Chain: button. Touch the Chain button to dis-
to protect the components. The default time-out for most components is set at 90 s, but can be
play the control codes for that chain.
as short as 5 s. Some components require that other components are energized at the same
ii. Use the scroll buttons to locate the required code, touch the Component Name
time and it is possible to enter and energize up to six component control codes (not fax), but
only in permitted groups. If illegal combination of codes are entered the illegal codes will not button to highlight it and touch Select.
energize. iii. Repeat as required to add components to the Component Name table.
iv. Touch Save to save the selections to the Component Name table list and return
Go to the appropriate table: to the Component Control window.
Table 11 Output Codes 04 5. To energize a component or group of components:
Table 12 Output Codes 05 a. Touch the control code to highlight it.
Table 13 Output Codes 06 b. Touch Start.
Table 14 Output Codes 07 c. The status of the component is shown in the Status column i.e.:
Table 15 Output Codes 08 i. On
Table 16 Output Codes 09 ii. Off
Table 17 Output Codes 10 iii. High
Table 18 Output Codes 11 iv. Low
Table 19 Output Codes 12 v. A numeric value with up to four digits e.g. 0020.
Table 20 Output Codes 14 6. Touching a component in the component table and then touching Stop, stops that compo-
Table 21 Output Codes 20 nent. To stop all components touch Stop All.
Procedure 7. Touching Exit closes the Component Control window.
8. To exit diagnostics mode, GP 1, select the Call Close Out button.
CAUTION
Do not press Exit before stopping any energized components. The UI may lock up and grey
out. If this occurs, switch off the machine, GP 14 and remove the power cord. Reconnect the
power cord and switch on the machine GP 14.
1. Enter Diagnostics, GP 1.
2. Select Diagnostics Routines.
3. Select required dC routine category:
Copier Routines, 330 Component Control.
Fax dC Routines, 330 Component Control.
4. Select and input the required codes as follows:
NOTE: After a fault condition it may be necessary to switch off the machine and switch on
the machine (GP 14) for the codes to operate.
NOTE: To clear an incorrectly entered code and reset the Add Component button to
00.000, press the hard key C.
a. From the component control Input Components tables and the Output Components
tables, select and enter the appropriate code into the Add Component button, and
touch the button. This will add the component to the top of the Component Name
table list, and when the list is full; the addition of more components will cause com-
ponents to be deleted from the bottom of the list.
NOTE: Fax component control codes can only be energized one at a time.
b. If a control code is not known, it can be selected from the list displayed when the
Find Component button is touched, as follows:

Input Codes Table 4 Input codes 07
Code Displayed Name Description General
07-301 T1 Home Switch Tray 1 home switch (S07-301) High = tray home, low =
Code Displayed Name Description General tray not home
01-300 Front Door Inter- Front door interlock switch (S01- High = door closed, low = 07-302 T2 Home Switch Tray 2 home switch (S07-302) High = tray home, low =
lock 300) door open tray not home
01-305 Left Door Interlock Left hand door interlock (S01-305) High = door closed, low = 07-303 T3 Home Switch Tray 3 home switch (S07-303) (W/ High = tray home. low =
door open O TAG 151) tray not home
07-303 T3 Home Sensor Tray 3 home sensor (Q07-303) (W/ High = tray home. low =
Table 2 Input codes 05 TAG 151) tray not home
Code Displayed Name Description General 07-304 T4 Home Switch Tray 4 home switch (S07-304) (W/ High = tray home, low =
O TAG 151) tray not home
05-300 Document handler DADH closed switch (S05-300) High = DADH lowered, low
closed switch = DADH raised 07-304 T4 Home Sensor Tray 4 home sensor (Q07-304) (W/ High = tray home, low =
TAG 151) tray not home
05-305 Document handler Top cover interlock switch (S05- High = cover closed, low =
07-306 T5 Door Switch Tray 5 Door switch (S07-306) High = door closed, low
cover interlock 305). cover open
= door open
05-310 Document handler Document present sensor (Q05- High = document present,
07-311 T1 Size Switch 1 Size switch 1 (S07-311) High = made
doc present sensor 310). low = no document
07-312 T1 Size Switch 2 Size switch 2 (S07-312) High = made
05-315 Document handler DADH length sensor 1 (Q05-315). High = document present,
length sensor 1 low = no document 07-313 T1 Size Switch 3 Size switch 3 (S07-313) High = made
05-320 Document handler DADH length sensor 2 (Q05-320). High = document present, 07-314 T1 Size Switch 4 Size switch 4 (S07-314) High = made
length sensor 2 low = no document 07-321 T2 Size Switch 1 Size switch 1 (S07-321) High = made
05-325 Document handler Document width sensor (Q05-325). Analogue output. 07-322 T2 Size Switch 2 Size switch 2 (S07-322) High = made
width sensor 07-323 T2 Size Switch 3 auto size sensing (optional). High = made
05-330 Document handler Feed sensor (Q05-330). High = document present, 07-324 T2 Size Switch 4 auto size sensing (optional). High = made
feed sensor low = no document
07-331 T1 Empty Sensor Tray 1 empty sensor (Q07-331) High = tray empty, low =
05-335 Document handler Takeaway sensor (Q05-335). High = document present, paper in tray
takeaway sensor low = no document
05-340 Document handler Registration sensor (Q05-340). High = document present, paper in tray
reg sensor low = no document 07-333 T3 Empty Sensor Tray 3 empty sensor (Q07-333) High = tray empty, low =
05-345 Document handler Exit sensor Q05-345). High = document present, paper in tray
exit sensor low = no document
05-350 Document handler CVT sensor (Q05-350). High = document present, paper in tray
CVT sensor low = no document
07-335 Bypass Empty Sensor Bypass empty sensor (Q07-335) High = tray empty, low =
paper in tray
Table 3 Input codes 06 07-336 T1 stack height Sensor Tray 1 stack height sensor (Q07- High = top of stack
Code Displayed Name Description General 336) sensed, low = top of
06-320 ROS Motor Ready Detects when ROS motor is at High = motor ready. Toggle stack not sensed
Snr required speed. ROS motor (06-020) on 07-337 T2 stack height Sensor Tray 2 stack height sensor (Q07- High = top of stack
and off to check sensor. 337) sensed, low = top of
stack not sensed
06-340 ROS Ready Indicates that the ROS laser has High = ready. Toggle ROS
reached its operating level and the motor (06-020) on and off 07-338 T3 Level Encoder Detects tray 3 paper level encoder High = top of stack
ROS motor is up to required speed. to check sensor. The ROS status (Q07-338) sensed, low = top of
laser level will only be set stack not sensed
once the ROS motor has 07-339 T4 Level Encoder Detects tray 4 paper level encoder High = top of stack
reached the required status (Q07-339) sensed, low = top of
speed. stack not sensed

Table 4 Input codes 07 Table 5 Input codes 08
Code Displayed Name Description General Code Displayed Name Description General
07-341 T1 paper low switch Detects if the stack height of tray 1 High = more than 25% 08-101 T1 Feed Sensor Detects when lead edge of paper is High = paper present,
is more than 25% (S07-341) full, Low = less than at tray 1 feed sensor, (Q08-101) low = no paper
25% full 08-102 T2 Feed Sensor Detects when lead edge of paper is High = paper present,
07-342 T2 paper low switch Detects if the stack height of tray 2 High = more than 25% at tray 2 feed sensor, (Q08-102) low= no paper
is more than 25% (S07-342) full, Low = less than 08-103 T3 Feed Sensor Detects when lead edge of paper is High = paper present,
25% full at tray 3 feed sensor, (Q08-103) low = no paper
07-350 Bypass Width Sensor Bypass width sensor (Q07-335) Display indicates width 08-104 T4 Feed Sensor Detects when lead edge of paper is High = paper present,
setting 100 to 300 mm at tray 4 feed sensor, (Q08-104) low = no paper
(3.93 to 11.81 inch)
08-105 T5 Feed Sensor Detects when the lead edge of the High = paper present,
07-372 T5 Docking Switch Detects that tray 5 is in the docked High = Tray 5 docked paper is at tray 5 feed sensor (Q08- Low = no paper
position (S07-372) 105)
07-383 T3 Stack Height Sen- Tray 3 stack height sensor (Q07- High = top of stack 08-108 HCF Exit Sensor Detects a sheet being fed from the High = paper present,
sor 383) sensed, low = top of HCF Low = no paper
stack not sensed
08-109 Tray 3 Exit Sensor Detects a sheet being fed through High = paper present,
07-384 T4 Stack Height Sen- Tray 4 stack height sensor (Q07- High = top of stack the tray 3 horizontal transport Low = no paper
sor 384) sensed, low = top of
08-110 T5 wait Point Sensor Wait sensor (Q08-110), detects High = paper present,
stack not sensed when lead edge of paper at wait low = no paper
07-385 T3 hall Sensor Tray 3 hall sensor (Q07-385) High = Made. Only run point. (same sensor as for 08-100)
The sensor is located on a small when T3 door is open
08-111 T5 Release Sheet Hot- Displays the state of the release High = hotline active,
PCB and detects magnetic field
line sheet hotline low = not active
changes as the feed motor rotates.
08-150 Registration Sensor Detects when paper is at the regis- High = paper present,
07-386 T4 hall Sensor Tray 4 hall sensor (Q07-386) High = Made. Only run tration sensor (Q08-150) low = no paper
The sensor is located on a small when T4 door is open
08-160 Duplex Sensor Detects when paper is at the duplex High = paper present,
PCB and detects magnetic field
sensor (Q08-160) low = no paper
changes as the feed motor rotates.
07-387 HCF 24V Monitor Indicates the state of 24V input High = 24V present
monitor Table 6 Input codes 09
07-401 T5 Tray Empty Sensor Detects the presents of paper on High = paper present, Code Displayed Name Description General
tray 5 (Q07-401) Low = no paper 09-060 HVPS Fault Detects a fault in the HVPS High = fault, low = good
07-402 T5 Stack Height Sen- Tray 5 stack height sensor (Q07- High = top of stack 09-070 Scorotron cleaner Detects the scorotron cleaning High = head not home,
sor 402) sensed, Low = top of head home sensor head in the home position low = head in home
stack not sensed position
07-403 T5 24V Monitor Indicates the state of 24V input High = 24V present 09-073 Transfer / Detack Transfer / detack cleaner head High = head not home,
monitor Home Sensor home sensor. Low = head in home
07-405 T5 Stack Down Sensor Tray 5 stack down sensor (Q07- High = tray is fully down position
405), detects when the tray is in the Stack with transfer /
fully lowered position detack corotron cleaner
07-406 T5 El Motor Encoder Encoder sensor (Q07-406), detects High = detected, low = motor stall sensor,
Sensor state of motor encoder sensor bit not detected motor forward and
motor reverse
08-100 Wait Sensor Wait sensor (Q08-100), detects High = paper present,
when lead edge of paper at wait low = no paper
point.

09-074 Transfer / Detack Stall Transfer / detack cleaner head stall High = actuated, Low = 11-100 Entry Sensor LCSS and HVF entry sensor (Q11- High = paper present,
Sensor sensor. not actuated 100) low = no paper
The stall sensor is a electrical Stack with transfer / 11-110 Punch Sensor LCSS and HVF punch position sen- High = paper present,
device within the motor control on detack corotron cleaner sor (Q11-110) low = no paper
the IOT PWB. motor stall sensor,
11-112 Chad Bin Set Sensor HVF chad bin set sensor (Q11-112) High = chad bin
motor forward and detects when the chad bin installed installed
motor reverse
11-130 Top Exit Sensor LCSS and HVF top exit sensor High = paper present,
09-310 Low Toner Sensor Low toner sensor (Q09-310) High = toner in sump,
(Q11-130) low = no paper
low = toner depleted
11-140 2nd to Top Exit Snr LCSS and HVF 2nd to top exit sen- High = paper present
09-350 Waste Toner Full Sen- Waste toner full sensor(Q09-350) High = container full,
sor (Q11-140) detects paper exiting low = no paper
sor detects when waste toner reaches low = container not full to the bin (bin 1)
a certain level in the container.
11-150 Inserter Sheet Size HVF inserter sheet size detector 1 High = sheet size
09-360 Toner Concentration Toner concentration sensor (Q09- Displays toner concen-
Detector 1 (Q11-150) detects the DOF (Direc- detected
Sensor 360) tration level in%
tion Of Feed) sheet size in inserter
09-365 Humidity Sensor Relative humidity sensor (Q09-365) Displays RH% tray
09-370 Dev. Temp. Sensor Developer temperature sensor Displays temperature in 11-151 Inserter Sheet Size HVF inserter sheet size detector 2 High = sheet size
(Q09-370) degrees C Detector 2 (Q11-151) detects the DOF (Direc- detected
09-375 Ambient Temp. Sensor Ambient temperature sensor (Q09- Displays temperature in tion Of Feed) sheet size in inserter
375) degrees C tray
09-380 Waste Toner Door Sw Waste toner door switch (S09-380) High = bottle present/ 11-152 Inserter STS Sheet HVF inserter STS (Side To Side) High = sheet size
detects if the waste bottle is miss- door closed, low = bottle Size Detector sheet size detector (Q11-152) detected
ing or the door is open during run missing/door open detects STS (Side To Side) sheet
size in inserter tray
Table 7 Input codes 10 11-153 Inserter Unit Empty HVF inserter unit empty sensor High = paper present,
Sensor (Q11-153) detects paper present low = no paper
inserter tray
10-100 Fuser Exit Switch Fuser exit switch (S10-100), High = paper present,
11-154 Inserter LE Sensor HVF inserter LE sensor (Q11-154) High = LE detected, low
detects when paper exits the fuser low = no paper detects the LE of the paper = LE not detected
10-105 Invert Sensor Inverter sensor (Q10-105), detects High = paper present, 11-155 Inserter TE Sensor HVF inserter TE sensor (Q11-155) High = TE detected, low
when paper enters the inverter low = no paper
detects the TE of the paper = TE not detected
10-120 IOT Exit Sensor IOT exit sensor (Q10-120), detects High = paper present,
11-156 Inserter Bottom Plate HVF inserter bottom plate sensor High = home position,
when paper exits the IOT low = no paper
Sensor (Q11-156) detects the bottom plate low = not home
10-300 Fuser Module Temp Displays current thermistor values. 0-255 degrees C. in home position
Sensor A Converts input resistance of ther- 11-157 Buffer Position Sen- HVF Buffer position sensor (Q11- High = paper present,
mistors and shows A-D conversion.
sor 157) detects paper low = no paper
10-310 Fuser Module Temp Displays current thermistor values. 0-255 degrees C.
11-158 HVF Booklet Exit HVF booklet exit sensor (Q11-158) High = paper present,
Sensor B Converts input resistance of ther-
Sensor detects paper exiting the finisher to low = no paper
mistors and shows A-D conversion. enter into booklet maker
10-315 Fuser Module Temp Detects fault in fuser thermistor. High = fault low = good 11-159 Nip Home Sensor HVF nip home sensor (Q11-159) High = Nip home
Fault Snr
detects the position of the buffer
movement tray in descending
11-160 BM Entry Sensor HVF BM entry sensor (Q11-160) High = paper present,
Code Displayed Name Description General detects paper entry to the booklet low = no paper
maker
11-044 Punch Unit Home HVF punch unit home sensor (Q11- High = home, low = unit
Sensor 044) not home

11-164 Buffer Path Sensor HVF buffer path sensor (Q11-164) High = paper present, 11-185 Tri Folder Exit Sensor HVF tri folder exit sensor (Q11-185) High = made, low = not
detects paper low = no paper detects booklet and tri folder exit to detected
11-170 Nip Split Sensor HVF nip split sensor (Q11-170) High = Nip split home tray
detects the position of the buffer 11-187 Offset Unit Index Sen- HVF offset unit index sensor (Q11- High = made, low = not
movement tray in ascending sor 187) detects if offset unit is in index detected
11-171 Paper Pusher Upper HVF paper pusher upper sensor High = upper position position
Sensor (Q11-171) detects if the pusher is in 11-190 BM Paper Present HVF BM paper present sensor High = paper present,
the upper position Sensor (Q11-190) detects when paper is low = no paper
11-172 Pressing and Sup- HVF pressing and support encoder High = made, low = not present in the booklet maker com-
port Encoder Sensor sensor (Q11-172) detects the tim- detected piling area
ing for pressing and support motor 11-191 Pressing and Sup- HVF pressing and support initial High = made, low = not
11-173 Paper Pusher Lower HVF paper pusher lower sensor High = made, low = not port Init Snr sensor (Q11-191) detects the initial detected
Sensor (Q11-173) detects if paper pusher detected position sensor
is in lower position 11-192 Pressing and Sup- HVF pressing and support home High = made, low = not
11-174 Front Tamper Tray HVF front tamper tray away sensor High = made, low = not port Home Snr sensor (Q11-192) detects the home detected
Away Sensor (Q11-174) detects the front tamper detected position sensor
is in away position 11-193 Pressing and Sup- HVF pressing and support out sen- High = made, low = not
11-175 Stapler Unit Mid HVF stapler unit mid home sensor High = made, low = not port Out Snr sor (Q11-193) detects the out posi- detected
Home Sensor (Q11-175) detects if stapler unit is detected tion sensor
in mid home position 11-194 Paddle Unit Upper HVF paddle unit upper sensor High = made, low = not
11-176 Offset Unit Away Sen- HVF offset unit away sensor (Q11- High = made, low = not Sensor (Q11-194) detects the paddle unit detected
sor 176) detects if offset unit is in away detected position
position 11-195 Paddle Unit Lower HVF paddle unit lower sensor High = made, low = not
11-177 Ejector Module Motor HVF ejector module motor encoder High = made, low = not Sensor (Q11-195) detects paddle unit lower detected
Encoder Sensor sensor (Q11-177) detects the tim- detected position
ing for ejector module motor 11-196 Bin 1 Rear Wall Sen- HVF Bin1 paper stack sensor, Q11- Low = paper stack
11-178 Ejector Plate Motor HVF ejector plate motor encoder High = made, low = not sor 196 operates together with Q11- detected, High = not
Encoder Sensor sensor (Q11-178) detects the tim- detected 322. detected
ing for ejector plate motor 11-300 Docking Interlock LCSS and HVF docking interlock High = docked, low =
11-179 Ejector Plate Home HVF ejector plate home sensor High = made, low = not switch (S11-300) un-docked
Sensor (Q11-179) detects if ejector plate is detected 11-302 Top Cover Intlk LCSS and HVF top cover interlock High = closed, low =
in home position switch (S11-302), detects if top open
11-180 Ejector Unit Lower HVF ejector unit lower paddle High = made, low = not cover is open.
Paddle Home Sensor home sensor (Q11-180) detects if detected 11-303 Front Door Intlk LCSS and HVF front door interlock High = closed, low =
eject unit lower paddle is in home switch (S11-303), detects if front open
position door is open.
11-182 Stacker Unit Encoder HVF stacker unit encoder sensor High = made, low = not 11-306 Inserter Top Cover HVF inserter top cover interlock High = made, low = not
Sensor (Q11-182) detects the timing for detected Intlk sensor (Q11-306) detects if inserter detected
stacker unit motor tray top cover is closed
11-183 Tri Folder Entry Sen- HVF tri folder entry sensor (Q11- High = made, low = not 11-310 Tamp Front Home Snr LCSS and HVF front tamper home High = home, low = not
sor 183) detects the booklet and tri detected sensor (Q11-310) Detect if front home
folder entry. Trigger point for CL80 tamper is home
11-184 Tri Folder Assist Sen- HVF tri folder assist sensor (Q11- High = made, low = not 11-311 Tamp Rear Home Snr LCSS and HVF rear tamper home high = home, low - not
sor 184) detects trigger point for L81 detected sensor (Q11-311), detects if rear home
tamper is home

11-319 Tamp Rear Away Snr LCSS and HVF rear tamper away High = away home, low 11-351 Punch Hd Present LCSS punch head present sensor High = punch installed,
home sensor (Q11-319), detects if = not away home Snr (Q11-351) detects if a hole punch is low = punch not
the rear tamper is at the away installed installed
home position 11-360 SH 1 Home Sensor LCSS and HVF staple head 1 High = home, low = not
11-320 Ejector Home Sensor HVF ejector home sensor (Q11- High = home, low = not home sensor (Q11-360) detects home
320) detects the home (closed) home when the staple head is fully open
position of the ejector housing. (home position)
LCSS ejector home sensor (Q11- 11-361 SH 1 Paper Sensor LCSS and HVF staple head 1 High = paper present,
320) detects the home position of paper present sensor (Q11-361) low = no paper
the ejector assembly detects when paper is within the
11-322 Ejector Out Sensor LCSS and HVF Ejector out sensor High = out, low= not out jaws of the stapler
(Q11-322) detects the out position 11-362 SH 1 Low Staples Snr LCSS staple head 1 low staples High = almost empty,
of the ejector assembly sensor (Q11-362) detects when low = plentiful staples
11-326 Paddle Roll Home LCSS paddle roll position sensor, High = home, low = not staple cartridge is almost empty
Snr HVF BM paddle roll home sensor home 11-363 SH 1 Cartridge Sen- LCSS staple head 1 cartridge High = cartridge
(Q11-326) detects the home posi- sor present sensor (Q11-363) detects installed, low = cartridge
tion of the paddle roll when a staple cartridge is installed not installed
11-331 Bin 1 90% Full Sen- LCSS and HVF bin 1 90% full sen- High = 90% or more full, 11-364 SH 1 Priming Sensor LCSS staple head 1 priming sensor High = primed, low = not
sor sor (Q11-331) detects when bin 1 is low = less than 90% full (Q11-364) detects when the front primed
90% or more full two staples have been pre-formed
11-332 Bin 1 Upper Level Snr LCSS bin 1 upper level sensor and High = stack sensed, (primed)
HVF bin 1 upper level sensor (Q11- low = stack not sensed 11-365 SU 1 Safety Gate LCSS stapling unit 1 safety gate High = safety gate
332) detects the top of the paper Switch switch (S11-365) closed
stack in bin 1
11-367 SU 1 Edge Reg Sen- LCSS staple unit 1 edge registra- High = paper present,
11-333 Bin 1 Lower Level Snr LCSS bin 1 lower level sensor High = stack sensed, sor tion sensor (Q11-367) detects the low = no paper
(Q11-333) detects the top of the low = stack not sensed edge of the paper is correctly regis-
paper stack in bin 1 tered
11-334 Bin 1 Upper Limit SW LCSS and HVF bin 1 upper limit High = bin detected, low 11-370 SU 1 Home Sensor LCSS staple unit 1 home sensor High = stapler home,
switch (S11-334) detects the upper = bin not detected (Q11-370) detects when the staple low = stapler not home
limit of bin 1 movement head is at the corner staple position
11-335 Bin 1 Lower Limit SW LCSS and HVF bin 1 upper limit High = bin detected, low 11-371 SU 1 Front Index Snr LCSS staple unit 1 front index sen- High = at stapling posi-
switch (S11-335) detects the lower = bin not detected sor (Q11-371) detects the index tion, low = not at sta-
limit of bin 1 movement position of the stapling head pling position
11-336 Bin 1 Mot Encoder LCSS bin 1 motor encoder sensor High = bar in encoder 11-373 Offline Staple SW LCSS offline staple switch (S11- High = switch pressed,
Snr (Q11-336) generates motor speed wheel, low = gap in 373) detects the operator com- low = switch not
pulses encoder wheel mand for offline stapling pressed
11-337 Bin1 Offset Sensor HVF bin 1 offset sensor (Q11-337) High = tray moving from 11-374 Offline Staple LED LCSS offline staple LED, detects High = paper present,
detects the offset and home posi- home to offset, low = paper to be stapled low = not detected
tion of bin 1 tray moving from offset
11-383 BM Guide Home Snr HVF backstop guide home sensor High = home, low = not
to home (Q11-383) detects when the back- home
11-348 Chad Bin Lvl Sensor LCSS and HVF chad bin full sensor High = bin full, low = bin stop is in the home position
(Q11-348) detects when the weight not full
11-384 BM Tamper1 Home HVF tamper 1 home sensor (Q11- High = home, low = not
of the chad reaches a pre-set value
Snr 384) detects when the BM tampers home
11-350 Punch Head Home LCSS and HVF punch head home High = punch home, low are in the home position
Snr sensor (Q11-350) detects the home = punch not home
position of the punch head

11-389 BM Bin2 90% Full Snr HVF bin 2 90% full sensor (Q11- High = 90% or more full, 11-431 Inserter Left Hand HVF Insert left hand door interlock High = closed, low =
389) detects when bin 2 is 90% or low = less than 90% full Door Interlock (Q11-431) detects the state of the open
more full inserter door interlock
11-391 BM Flapper Sector HVF booklet maker flapper sector High = home
Roll Home Sensor roll home sensor (Q11-391)
11-392 PTU Switch HVF PTU switch (S11-392) detects High = made, low = not
if pause to unload button is pressed detected Table 9 Input codes 12
11-393 TriFold Front Dr Inter- HVF tri fold door interlock (S11- High = closed, low = Code Displayed Name Description General
lock 393) detects if the tri fold door is door open 12-300 OCT Level Sensor OCT 90% full sensor (Q12-300) High = 90% or more full,
closed
detects when tray is 90% or more low = less than 90% full
11-394 TriFold Top Cover HVF tri fold top cover interlock High = closed, low = full.
Interlock (S11-394) detects if the tri fold top cover open
12-301 OCT Index Sensor OCT index sensor (Q12-301) High = tray moving from
cover is closed detects the offset and home posi- home to offset, low =
11-409 BM Exit Sensor HVF BM exit sensor (Q11-409) High = detected, low = tion of bin 1 tray moving from offset
detects booklets exiting the booklet not detected to home
maker
11-411 BM SH1 Home Snr HVF BM staple head 1 home sen- High = home, low = not Table 10 Input codes 14
sor (Q11-411) detects when the sta- home
ple head is fully open (home Code Displayed Name Description General
position) 14-100 Carriage Home Sensor Scan carriage home sensor (Q14- High - Home, low = not
11-412 BM SH1 Staples Low HVF BM staple head 1 staples low High = almost empty, 100) detects the home position of home
sensor (Q11-412) detects when low = plentiful staples the scan carriage
staple cartridge is almost empty 14-310 DADH Angle Sensor Input module angle sensor (Q14- High = input module
11-413 BM SH2 Home Snr HVF BM staple head 2 home sen- High = home, low = not 310) detects the input module at lowered, low input mod-
sor (Q11-413) detects when the home 30% angle for size sensing. ule raised
staple head is fully open (home 14-315 Doc Size Sensor 1 Document size sensor 1 (Q14-310) High = document not
position) sensed, low = document
11--414 BMSH2 Staples Low HVF BM staple head 2 staples low High = almost empty, sensed
sensor (Q11-412) detects when low = plentiful staples 14-320 Doc Size Sensor 2 Document size sensor 2 (Q14-314) High = document not
staple cartridge is almost empty sensed, low = document
11-415 BM Crease Gate HVF BM crease roll gate home High = gate raised, low sensed
Home sensor (Q11-415) detects when the = gate not raised
gate is fully raised Output Codes
11-416 BM Crease Blade HVF BM crease blade home sensor High = home, low = not
Home (Q11-416) detects when the crease home Table 11 Output codes 04
blade is fully retracted
11-418 BM Blade Mot HVF BM crease blade motor High = bar in encoder
04-010 Main motor Drives the pre-registration, registra- On/Off. 60 seconds timeout
Encoder encoder sensor (Q11-418) gener- wheel, low = gap in
tion, developer, fuser and paper
ates motor speed pulses encoder wheel
output modules.
11-419 BM Crease Mot HVF BM crease roll motor encoder High = bar in encoder
Encode sensor (Q11-419) generates motor wheel, low = gap in
Table 12 Output codes 05
speed pulses encoder wheel
11-421 BM SH Carrier HVF BM staple head carrier closed High = closed, low = not Code Displayed Name Description General
Closed sensor (Q11-421) detects when the closed 05-010 Document handler DADH feed solenoid (SOL05-010) On/off. 30 seconds timeout
carrier is in the closed position feed solenoid

Table 12 Output codes 05 Table 15 Output codes 08
05-020 Document handler DADH feed motor (MOT05-020) On/off. 90 seconds time out 08-010 T1 Feed Motor Energizes the tray 1 feed motor On/off. Linked to tray 1
feed motor (MOT 08-010). home sensor. Paper tray
05-025 DADH feed clutch DADH feed clutch (CL05-025) On/off. Normally linked with must be open when motor
feed motor. 30 seconds time- energized. 90 seconds time-
out out
05-030 Document handler DADH CVT motor (MOT05-030) On/off. 90 seconds timeout 08-020 T2 Feed Motor Energizes the tray 2 feed motor. On/off. Linked to tray 2
CVT motor (MOT08-020) home sensor. Paper tray
must be open when motor
05-050 Document handler DADH duplex solenoid (SOL05- On/off. 30 seconds timeout
energized. 90 seconds time-
duplex solenoid 050)
out
Table 13 Output codes 06 08-025 T1+2 Transport Energizes the tray 1 and 2 trans- On/off. 90 seconds timeout
Motor port motor (MOT08-025)
Code Displayed Name Description General 08-030 T3 Feed Motor Energizes the tray 3 feed motor On/off. Linked to tray 3
06-020 ROS Motor Run Drives ROS motor at run mode On/off. 90 seconds timeout (MOT08-030) home sensor. Paper tray
speed. must be open when motor
06-025 ROS Motor Drive ROS motor at standby mode On/off. 90 seconds timeout energized. 90 seconds time-
Standby speed. out
08-033 T3 Feed Clutch Energizes/de-energizes the tray 3 On/off. Linked to tray 3
Table 14 Output codes 07 feed clutch (W/TAG 151) home sensor. Paper tray 3
must be open when the sole-
noid isenergized
07-010 T1 Elevate Motor Energizes the tray 1 elevator motor On/off. Linked to tray 1 08-040 T4 Feed Motor Energizes the tray 4 feed motor On/off. Linked to tray 4
(MOT07-010) up. home sensor. Only ener- (MOT08-040) home sensor. Paper tray
gize with tray out. 5 seconds must be open when motor
timeout energized. 90 seconds time-
07-020 T2 Elevate Motor Energizes the tray 2 elevator motor On/off. Linked to tray 2 out
(MOT07-020) up. home sensor. Only ener- 08-043 T4 Feed Clutch Energizes/de-energizes the tray 4 On/off. Linked to tray 4
gize with tray out. 5 seconds feed clutch (W/TAG 151) home sensor. Paper tray 4
timeout must be open when the sole-
07-030 T3 Elevate Motor Energizes the tray 3 elevator motor On/off. Linked to tray 3 noid isenergized
(MOT07-030) up. home sensor. Only ener- 08-045 T3+4 Transport Energizes the tray 3 and 4 trans- On/off. 90 seconds timeout
gize with tray out. 10 sec- Motor port motor (MOT08-045)
onds timeout 08-045 HCF Transport Energizes the HCF transport On/off. 90 seconds timeout
07-040 T4 Elevate Motor Energizes the tray 4 elevate motor On/off. Linked to tray 4 Motor motor (MOT08-045) (W/TAG 151)
(MOT07-040) up. home sensor. Only ener-
08-046 T5 Transport Motor Energizes the tray 5 transport On/off. 60 seconds timeout
gies with tray out. 10 sec-
motor (MOT08-046)
onds timeout
08-050 Bypass Feed Sole- Energizes the bypass feed sole- On/off. 5 seconds timeout
07-373 Raise T5 Elevate Energizes the tray 5 elevate motor On/off. Only runs while tray noid noid (SOL08-050)
Motor (MOT07-373) to move the tray up. transport limits are not
08-060 Duplex Motor Slow Energizes the duplex motor at sim- On/off. 90 seconds timeout
reached. 10 seconds time-
plex speed.
out
08-062 Duplex Motor Fast Energizes the duplex motor at On/off. 90 seconds timeout
07-374 Lower T5 Elevate Energizes the tray 5 elevate motor On/off. Only runs while tray
Motor (MOT07-373) to move the tray transport limits are not duplex speed.
down. reached. 10 seconds time- 08-070 Registration Clutch Energizes the registration clutch On/off. 5 seconds timeout
out (CL08-070)

08-117 T5 Feed Motor Energizes the stepper motor to On/off. Paper tray must be 09-072 Scorotron Cleaner Energizes the scorotron cleaning On/off. 13 seconds timeout.
drive tray 5 nudger and feed rolls. down when motor ener- Motor: Reverse motor (MOT09-070) in the reverse Stack with scorotron cleaner
(MOT08-117) gized. 60 seconds timeout direction home sensor
09-075 Transfer / Detack When set to ON the transfer / On/off. 13 seconds timeout.
Table 16 Output codes 09 Motor: Forward detack corotron cleaner motor is Stack with transfer / detack
turned on and run in the forward corotron cleaner motor stall
direction. Moves cleaner to the sensor and motor reverse
09-010 P/R Motor Energizes the photoreceptor drive On/off. 60 seconds timeout rear.
motor (MOT09-010) 09-076 Transfer / Detack When set to ON the transfer / On/off. 13 seconds timeout.
09-022 P/R Erase Lamp Energizes the photoreceptor erase On/off. 90 seconds timeout Motor: Reverse detack corotron cleaner motor is Stack with transfer / detack
lamp. turned on and run in the reverse corotron cleaner motor stall
09-030 Ozone Fan Energizes the ozone fan. On/off. 90 seconds timeout direction. Moves cleaner to the sensor and motor reverse
09-035 P/R Cooling Fan Energizes the photoreceptor fan Full speed/half speed. 90 front.
seconds timeout
09-036 Duplex cooling Energizes the duplex path cooling On/off. 90 seconds timeout. Table 17 Output codes 10
fans enable fans When enabled the fans will Code Displayed Name Description General
switch on simultaneously
10-010 Fuser Module Web Energizes the fuser web motor On/off. 90 seconds timeout
09-040 Dispense Motor Energizes the toner dispense On/off. 5 seconds timeout
Motor (MOT10-010)
motor (MOT09-040)
10-030 Invert Mot Fwd Energizes the inverter motor On/off. 90 seconds timeout
09-045 Cartridge Motor Energizes the toner cartridge On/off. 5 seconds timeout
Slow (MOT10-030) forward at process
motor (MOT09-045) speed.
09-061 Charge Scorotron Energizes the scorotron wire at On/off. 3 seconds timeout. 10-035 Invert Mot Rev Energizes the inverter motor On/off. 90 seconds timeout
nominal drive levels with drives Linked with Charge grid 09-
Slow (MOT10-030) in reverse at pro-
off. 062. Normally stacked with
cess speed.
HVPS fault
10-040 Invert Mot Rev Dup Energizes the inverter motor On/off. 90 seconds timeout
09-062 Charge Grid Energizes the grid at nominal drive On/off. 3 seconds timeout. (MOT10-030) in reverse at duplex
level with drives off. Linked with charge
speed.
scorotron 09-061
10-045 Inverter Path Sol Energizes the invert path solenoid On/off. 5 seconds timeout
09-063 Transfer Corotron Energizes the transfer corotron On/off. 3 seconds timeout.
(SOL10-045). When de-energized
wire on at nominal drive level with Normally stacked with sheets are fed to the inverter
drives off. HVPS fault
10-050 Inverter Nip Sol Energizes the inverter nip solenoid On/off. 5 seconds timeout
09-064 Detack Corotron Energizes the detack wire on. AC On/off. 3 seconds timeout.
(SOL10-050). When de-energized
voltage and DC current offset at Normally stacked with
the nip is open
nominal drive levels with drives HVPS fault
off. 10-055 Tri Roll Split Nip Energizes the tri roll split nip sole- On/off. 5 seconds timeout
Solenoid noid (SOL10-055). When de-ener-
09-065 Chute Bias Energizes the bias voltage on at On/off. 90 seconds timeout.
gized the nip is open
nominal drive level. Normally stacked with
10-065 Vac Transport Fan Energizes the vacuum transport On/off. 90 seconds timeout
HVPS fault
fan in the short paper path assem-
09-066 Dev Bias Energizes the developer bias volt- On/off. 3 seconds timeout. bly
age on at nominal drive level with Stack with HVPS fault
drives off.
09-071 Scorotron Cleaner Energizes the scorotron cleaning On/Off. 13 seconds timeout.
Motor: Forward motor (MOT09-070) in the forward Stack with scorotron cleaner Code Displayed Name Description General
direction home sensor 11-000 Transport Motor 1 Energizes the LCSS transport Motor 1, On/off. 90 seconds
HVF transport motor 1A and Transport timeout
motor 1B (MOT11-000)

11-001 Transport Motor 2 Energizes the LCSS and HVF transport On/off. 90 seconds 11-032 Bin 1 Elev. Mot Energizes the LCSS and HVF bin 1 ele- On/off. 15 seconds
motor 2 (MOT11-001) timeout Down vate motor (MOT11-030) by increments timeout
11-002 Diverter Solenoid Energizes the LCSS, HVF diverter gate On/off. 5 seconds down
solenoid, HVF BM upper diverter solenoid timeout 11-033 Bin1 Elev. Mot Energizes the LCSS and HVF bin 1 ele- On/off. 90 seconds
(SOL11-002) Cycle vate motor (MOT11-033) to cycle bins up/ timeout.
11-003 Tamp Mot Front Energizes the LCSS and HVF front tamper On/off. 5 seconds down until time-out or stop.
Home motor (MOT11-003) to the home position. timeout 11-034 Bin 1 Offset Motor Energizes the HVF bin 1 offset motor On/off. 15 seconds
11-004 Tamp Mot Rear Energizes the LCSS and HVF rear tamper On/off. 5 seconds (MOT11-034) timeout
Home motor (MOT11-004) to home position timeout 11-042 Punch Head Move Energizes the LCSS hole punch motor On/off. 15 seconds
11-005 Tamp Mot Front Energizes the LCSS and HVF front tamper On/off. 5 seconds Home (MOT11-042) to the home position timeout
Move motor (MOT11-003) move inbound. timeout 11-043 Punch Head Run Energizes the LCSS and HVF hole punch On/off. 15 seconds
11-006 Tamp Mot Rear Energizes the LCSS and HVF rear tamper On/off. 5 seconds motor (MOT11-043) continuously timeout
Move motor (MOT11-004) move inbound. timeout 11-045 Punch Unit Motor Energizes HVF punch unit motor (MOT11- On/off.
11-007 Tampers to A4LEF Moves the LCSS tampers to A4LEF posi- On/off. 5 seconds Forward 045) moves punch unit forward
tion. timeout 11-046 Punch Unit Motor Energizes HVF punch unit motor (MOT11- On/off.
11-008 Tampers to Move the LCSS tampers to 8.5x11 LEF On/off. 5 seconds Reverse 045) moves punch unit in reverse
8.5x11LEF position. timeout 11-050 Staple Head 1 Energizes the LCSS and HVF staple head On/off. 15 seconds
11-009 Tamper Motor Cycles the LCSS tampers in and out until On/off. 90 seconds Motor 1 motor (MOT11-050) timeout
Cycle time-out or stop. timeout 11-051 SH 1 Motor Rev. Energizes the LCSS staple head 1 motor On/off. 15 seconds
11-010 CC Eject Roll Motor Energizes the HVF compiler carriage eject On/off. 90 seconds Home (MOT11-050) in reverse to the home posi- timeout
roll motor (MOT11-010) timeout tion
11-020 Ejector Motor Energizes the LCSS, ejector motor On/off. 5 seconds 11-053 SU 1 Motor For- Energizes the LCSS and HVF stapling unit On/off. 15 seconds
Home (MOT11-020) to the home position timeout ward traverse motor (MOT11-053) increment timeout
11-021 Ejector Motor Move Energizes the LCSS, ejector motor On/off. 5 seconds forward.
(MOT11-020) to the out position timeout 11-054 SU 1 Motor Energizes the LCSS and HVF stapling unit On/off. 15 seconds
Reverse traverse motor (MOT11-053) increment timeout
11-023 Ejector Motor Cycle Energizes the LCSS ejector motor (MOT On/off. 90 seconds
reverse.
11-020), and the HVF BM ejector motor timeout
(MOT11-023) cycle routines, until timeout 11-055 SU1 Index Mot Energizes the LCSS and HVF stapling unit On/off. 15 seconds
or stop. Cycle traverse motor (MOT11-053) cycle routine timeout
11-024 Paddle Roll Motor Energizes the LCSS paddle roll motor On/off. 15 seconds 11-060 BM Compiler Motor Energizes the HVF BM paper path trans- On/off. 90 seconds
Home (MOT11-024) to the home position timeout port motor (MOT11-060) timeout
11-025 Paddle Roll Motor Energizes the LCSS and HVF paddle roll On/off. 15 seconds 11-061 BM Blade Motor Energizes the HVF BM crease blade On/off. 90 seconds
Run motor (MOT11-025) until timeout or stop timeout motor (MOT11-061) cycle timeout
11-026 Paddle Roll Mot Energizes the LCSS paddle roll motor On/off. 15 seconds 11-062 BM Crease Motor Energizes the HVF BM crease roll motor On/off. 6 seconds
Rev (MOT11-024) in reverse to actuate safety timeout (MOT11-062) timeout
gate. 11-063 BM Staple Head 1 Energizes the HVF BM staple head 1 On/off. 5 seconds
11-027 Paddle Unit Motor Energizes the HVF paddle unit motor On/off. 90seconds Motor motor (MOT11-063) timeout
(MOT11-027) to lift / lower paddle unit timeout 11-065 BM Back Stop Energizes the HVF BM backstop motor On/off. 90 seconds
11-030 Bin 1 Elev. Mot Energizes the LCSS and HVF bin 1 ele- On/off. 15 seconds Motor (MOT11-065) moves to receive, then sta- timeout
Home vate motor (MOT11-030) to the home posi- timeout ple, then crease positions
tion. 11-066 BM Tamper 1 Motor Energizes the HVF BM tamper 1 motor On/off. 90 seconds
11-031 Bin 1 Elev. Mot Up Energizes the LCSS and HVF bin 1 ele- On/off. 15 seconds (MOT11-066) timeout
vate motor (MOT11-030) by increments up timeout 11-074 BM Diverter Sole- Energizes the HVF BM lower diverter gate On/off. 5 seconds
noid solenoid (SOL11-074) timeout

11-076 BM Stack Hold Sol Energizes the HVF BM stack hold sole- On/off. 5 seconds 11-404 BM Crease Gate Energizes the HVF crease roll gate motor On/off. 90 seconds
noids (SOL11-076) part of back stop timeout Open (MOT11-401) to the open position timeout
assembly 11-430 Kicker Solenoid Energizes the HVF kicker solenoid On/off. 5 seconds
11-077 Inserter Electric Energizes the HVF inserter electric clutch On/off. (SOL11-430) timeout
Clutch (CL11-077) to drive the pickup roll
11-078 Inserter Unit Motor Energizes the HVF inserter unit motor On/off.
(MOT11-078) to drive the inserter rolls Code Displayed Name Description General
11-079 Buffer Motor Energizes the HVF Buffer motor (MOT11- On/off. 90 seconds 12-005 OCT Motor Energizes the OCT motor On/off. 2 seconds
079) to drive the buffer rolls timeout timeout
11-080 Feed Motor Energizes the HVF feed motor (MOT11- On/off. 90 seconds Table 20 Output codes 14
080) to drive the feed rolls timeout
11-081 Nip Split Motor Energizes the HVF nip split motor On/off. 90 seconds Code Displayed Name Description General
(MOT11-081) to activate the buffer move- timeout 14-005 Exposure Lamp Energizes the exposure lamp On/off. 90 seconds
ment tray timeout
11-082 Clamp solenoid Energizes the HVF clamp solenoid On/off. 90 seconds Table 21 Output codes 20
(SOL11-082) to keep first sheet of paper in timeout
the buffer pocket at buffer mode Code Displayed Name Description General
11-083 Paper Pusher Energizes the HVF paper pusher motor On/off. 90 seconds 20-002 Diag. LED 30 Red Switches diagnostic LED 30 red On/off
Motor (MOT11-083) to drive the paper pusher timeout 20-003 Diag. LED 30 green Switches diagnostic LED 30 green On/off
11-084 Curl Suppressor Energizes the HVF curl suppressor sole- On/off. 90 seconds 20-010 Sngl Tone 0Hz Ln1 Emits single tone 0Hz on line 1 On/off
Solenoid noid (SOL11-084) to activate the pressing timeout
20-011 Sngl Tone 400Hz Ln1 Emits single tone 400Hz on line 1 On/off
device
11-085 Tri Folder Diverter Energizes the HVF tri folder diverter sole- On/off. 5 seconds
Solenoid noid (SOL11-085) to activate the tri folder timeout
diverter gate to divert paper to tri fold path 20-014 Sngl Tone 1650Hz Ln1 Emits single tone 1650Hz on line 1 On/off
11-086 Tri Folder Assist Energizes the HVF tri folder assist gate On/off. 5 seconds 20-015 Sngl Tone 1850Hz Ln1 Emits single tone 1850Hz on line 1 On/off
Gate Solenoid solenoid (SOL11-086) to activate the tri timeout 20-016 Sngl Tone 2100Hz Ln1 Emits single tone 2100Hz on line 1 On/off
folder assist gate to assist C fold into sec- 20-017 ANSAM Ln1 On/off
ond nip
20-018 CI Ln1 On/off
11-087 Clutch Drive Energizes the HVF clutch drive (CL11- On/off. 5 seconds
20-020 DTMF # Line1 Emits DTMF # on line 1 On/off
087) to drive tri folding rolls timeout
20-021 DTMF * Line1 Emits DTMF * on line 1 On/off
11-088 Cycle Ejector Motor Energizes the HVF ejector roll motor On/off. 90 seconds
20-022 DTMF 0 Line1 Emits DTMF 0 on line 1 On/off
(MOT11-088) cycle routine. timeout
20-023 DTMF 1 Line1 Emits DTMF 1on line 1 On/off
11-374 Offline Staple LED Energizes the LCSS offline staple LED On/off. 90 seconds
timeout 20-024 DTMF 2 Line1 Emits DTMF 2 on line 1 On/off
11-390 BM Flapper Sector Energizes the HVF Booklet maker flapper On/off. 90 seconds 20-025 DTMF 3 Line1 Emits DTMF 3 on line 1 On/off
Roll Motor sector roll motor (MOT11-390) timeout 20-026 DTMF 4 Line1 Emits DTMF 4 on line 1 On/off
11-400 BM Flapper Clutch Energizes the HVF BM flapper clutch sole- On/off. 5 seconds 20-027 DTMF 5 Line1 Emits DTMF 5 on line 1 On/off
Sol noid (SOL11-400) timeout 20-028 DTMF 6 Line1 Emits DTMF 6 on line 1 On/off
11-401 BM Crease Roll Energizes the HVF crease roll gate motor On/off. 15 seconds 20-029 DTMF 7 Line1 Emits DTMF 7 on line 1 On/off
Motor (MOT11-401) cycle routine timeout
11-402 BM Mt Conveyor Energizes the HVF BM conveyor belt drive On/off. 90 seconds
Drive motor timeout
20-032 DTMF A Line1 Emits DTMF A on line 1 On/off
11-403 BM Staple Hd 2 Energizes the HVF staple head 2 motor On/off. 5 seconds
20-033 DTMF B Line1 Emits DTMF B on line 1 On/off
Motor (MOT11-403) timeout

20-034 DTMF C Line1 Emits DTMF C on line 1 On/off 20-087 ANSAM Ln2 - On/off
20-035 DTMF D Line1 Emits DTMF D on line 1 On/off 20-088 CI Ln2 - On/off
20-040 V.21 300 bps Line1 Emits V.21 300 bps on line 1 On/off 20-090 DTMF # Line2 Emits DTMF # on line 2 On/off
20-041 V.27ter 2400 bps Line1 Emits V.27ter 2400 bps on line 1 On/off 20-091 DTMF * Line2 Emits DTMF * on line 2 On/off
20-042 V.27ter 4800 bps Line1 Emits V.27ter 4800 bps on line 1 On/off 20-092 DTMF 0 Line2 Emits DTMF 0 on line 2 On/off
20-043 V.29 7200 bps Line1 Emits V.29 7200 bps on line 1 On/off 20-093 DTMF 1 Line2 Emits DTMF 1on line 2 On/off
20-044 V.29 9600 bps Line1 Emits V.29 9600 bps on line 1 On/off 20-094 DTMF 2 Line2 Emits DTMF 2 on line 2 On/off
20-052 V.34 9600 bps Line1 Emits V.34 9600 bps on line 1 On/off 20-102 DTMF A Line2 Emits DTMF A on line 2 On/off
20-053 V.34 12000 bps Line1 Emits V.34 12000 bps on line 1 On/off 20-103 DTMF B Line2 Emits DTMF B on line 2 On/off
20-054 V.34 14400 bps Line1 Emits V.34 14400 bps on line 1 On/off 20-104 DTMF C Line2 Emits DTMF C on line 2 On/off
20-055 V.34 16800 bps Line1 Emits V.34 16800 bps on line 1 On/off 20-105 DTMF D Line2 Emits DTMF D on line 2 On/off
20-056 V.34 19200 bps Line1 Emits V.34 19200 bps on line 1 On/off 20-110 V.21 300 bps Line2 Emits V.21 300 bps on line 2 On/off
20-057 V.34 21600 bps Line1 Emits V.34 21600 bps on line 1 On/off 20-111 V.27ter 2400 bps Line2 Emits V.27ter 2400 bps on line 2 On/off
20-058 V.34 24000 bps Line1 Emits V.34 24000 bps on line 1 On/off 20-112 V.27ter 4800 bps Line2 Emits V.27ter 4800 bps on line 2 On/off
20-070 ISDN mode Loopback Applies a loop back of both B channels to the On/off 20-117 V.17 12000 bps Line2 Emits V.17 12000 bps on line 2 On/off
network 20-118 V.17 14400 bps Line2 Emits V.17 14400 bps on line 2 On/off
20-071 ISDN tst mode info 1 Provides INFO 1 signals on both B channels On/off 20-119 V.34 2400 bps Line2 Emits V.34 2400 bps on line 2 On/off
20-072 ISDN tst mode info 0 Provides INFO 0 signals on both B channels On/off 20-120 V.34 4800 bps Line2 Emits V.34 4800 bps on line 2 On/off
20-073 ISDN PH-ACT-REQ Able to initiate activation procedures (PH- On/off 20-121 V.34 7200 bps Line2 Emits V.34 7200 bps on line 2 On/off
ACTIVATE REQUEST) primitive 20-122 V.34 9600 bps Line2 Emits V.34 9600 bps on line 2 On/off
20-074 ISDN LED 10/18 Red Switches ISDN LED 10/18 red On/off 20-123 V.34 12000 bps Line2 Emits V.34 12000 bps on line 2 On/off
20-075 ISDN LED 10/18 Grn Switches ISDN LED 10/18 green On/off 20-124 V.34 14400 bps Line2 Emits V.34 14400 bps on line 2 On/off
20-076 ISDN line relay Switches SDN line relay On/off 20-125 V.34 16800 bps Line2 Emits V.34 16800 bps on line 2 On/off
20-080 Sngl Tone 0Hz Ln2 Emits single tone 0Hz on line 2 On/off 20-126 V.34 19200 bps Line2 Emits V.34 19200 bps on line 2 On/off

dC604 Registration Setup Procedure 5. Select Scanner Registration and follow the UI screen prompts.
a. The first three copies out will be the IOT test samples, one of which will be used as
Description an original to make the scanner test samples.
The registration setup routine allows the measurement and adjustment of image to paper reg-
NOTE: To obtain the correct scanner registration. Check that the registration on the
istration for the image output terminal.
IOT test samples is correct, Figure 2. If not correct then return to step 3.
NOTE: ADJ 8.1 Registration Setup contains only a reference to this diagnostic procedure. b. Place one of the IOT test sample on the platen glass.
c. Compare the zones A and D on the scanner test samples, with those in Figure 3.
Purpose
d. Adjust the registration, enter the number at the point where the scale is deleted.
To measure and adjust image to paper registration using the four routines:
For example. If the top of the zone A scale is deleted at the 10mm mark (10mm indi-
1. Image Output Terminal Registration side 1 - simplex lead and top edge registration adjust-
cates the correct scanner registration, Figure 3) then enter 10. If the top of the zone
ment.
A scale is deleted at the 5mm mark then enter 5.
2. Image Output Terminal Registration Side 2 (duplex) - duplex lead and top edge registra-
6. Select Document Handler Registration and follow the UI screen prompts.
tion adjustment.
a. The first three copies out will be IOT test samples which will be used as originals to
3. Scanner Registration - document glass lead and top edge registration adjustment. make the DADH test samples.
4. DADH Registration - constant velocity transport (CVT) lead edge and centre registration
adjustment. NOTE: To obtain the correct DADH registration. Check that the registration on IOT
test samples is correct, Figure 2. If not correct then return to step 3.
NOTE: During the scanner and the DADH registration procedures a border erase is
applied to the copied test patterns. Since the test pattern has been designed for both mar- b. Place the IOT test samples in the DADH.
kets regions, the size of the edge deletion will depend on the paper size: c. Compare the zones A and D on the DADH test samples, with those in Figure 3.
For A4 LEF paper, all edges have a 10mm deletion, but the bottom edge (Zone C on d. Adjust the registration, enter the number at the point where the scale is deleted.
Figure 1) will measure 28mm from the edge of the paper. For example. If the top of the zone A scale is deleted at the 10mm mark (10mm indi-
For 8.5 x 11 LEF paper, all edges have a 10mm deletion, but the trail edge (Zone B cates correct DADH registration, Figure 3) then enter 10mm. If the top of the zone A
on Figure 1) will measure 16mm from the edge of the paper. scale is deleted at the 5mm mark then enter 5mm.
Place the IOT test samples in the DADH to enable the Save option.
Initial Action
7. If the correct registration can not be obtained because the registration scales are out of
Ensure that 8.5 x 11 or A4 LEF paper is loaded in tray 1. range or off the page. Enter dC132 NVM Initialization, select Machine Variable NVM and
Ensure that the ROS is secured and positioned correctly. Check that the ROS securing initialize. This will reset all of the registration values to default, return to step 3, complete
screw at the front of the machine is present and secure, refer to REP 6.1. all four routines.
Procedure 8. Take samples from each tray using the individual tray select button and check the lead
edge and top edge registration is within specification, Figure 2. If the top edge registration
NOTE: Always perform the IOT Registration Side 1 adjustments before performing any other
is not correct on individual trays then go to step 9.
registration adjustment, as the IOT Registration Side 1 adjustment affects the others.
9. The individual trays can be adjusted to compensate for any mechanical variation between
1. Enter diagnostics, GP 1. the trays, which may cause an error in the top edge registration.
2. Select, Diagnostics Routines, then select Copier Routines, then select dC604 Registra- The individual tray top edge has an adjustment range of +/-10mm with increments of
tion Setup Routine. 0.5mm. When saved, the adjustment will update the NVM offset value for the specific tray.
3. Select Image Output Terminal Registration Side 1, then select All Trays, then select Print To adjust the top edge registration on individual trays perform the following:
Test Samples and follow the UI screen prompts. a. Enter diagnostics GP 1. Select, Diagnostics Routines / Copier Routines / dC 604
Registration Setup
NOTE: Do not select individual trays unless directed by the documentation.
b. Select Image Output Terminal Registration Side 1 / select the individual tray / Print
a. Compare the zones A and D on the test samples, with those in Figure 2. Test Samples.
b. Adjust the registration, enter the number on the scale at the edge of the paper.
NOTE: If the top edge of the paper aligns above the 20mm mark on zone A i.e. at
For example. If the top edge of the paper aligns with the 20mm mark on zone A (20
22mm. Then select +2mm to align the top edge of the paper with the 20mm mark on
mm indicates correct IOT registration, Figure 2) then enter 20mm. If the top edge
zone A. If the top edge of the paper aligns with the 15mm mark on zone A. Then
aligned with the 15mm mark then enter 15mm. select -5mm to align the top edge of the paper with the 20mm mark on zone A.
4. Select Image Output Terminal Registration Side 2, then select All Trays, then select Print
Test Samples and follow the UI screen prompts. Make the adjustments, then press Print Test Samples. When the top edge of the
paper aligns with the 20mm mark on zone A, the registration is correct, Figure 2.

Press Save and repeat the procedure as necessary for the other trays.
c. Select Image Output Terminal Registration Side 2 and repeat the above procedure
as necessary.
d. If Tray 5 is still out of specification, go to ADJ 7.3 and then ADJ 7.4. After checking
these adjustments, repeat the procedure in step 9.
10. Make copies of the test pattern 82E2010 or 82E2020 from the DADH and document glass
to check for skew. Refer to IQS 5 Skew. Use internal test prints 16 or 17 to check printer
skew. Refer to IQS 5 Skew.
Top edge registration on the 20mm line
Lead edge registration on the 20mm line
Figure 2 IOT registration
Figure 1 Registration test pattern

dC606 Internal Print Test Patterns
Purpose
Top edge of the paper To print internal test patterns for image quality analysis.
Lead edge of the paper
Procedure
NOTE: Refer to IQ1 for information on the test patterns.
2. Enter diagnostics Routines.
3. Enter Other Routines.
4. Enter dC606 Print Test Patterns.
5. Select Image Quality Test Patterns 1 - 19.
6. Select the Features, 1 or 2 sided and paper size.
Top edge registration on the 10mm line
NOTE: Two sided test patterns are always backed with test pattern 16, quadrille.
7. Select the Format, Label on or off and Border on or off.

8. Select Saved.
9. Touch the Start Test.
Lead edge registration on the 10mm line
10. Press Exit to return to the main diagnostic menu; select another feature or exit diagnos-
tics.
NOTE: The system administrator and key operator cannot generate print test patterns 4, 6, 7
or 8.
Figure 3 Scanner and DADH registration

dC640 Video Path Diagnostics dC905 TC Sensor Calibration
This procedure is not applicable to the WorkCenter 5790F. Do not use. Purpose
To calibrate and setup the toner concentration sensor. This routine is run at manufacture and
after installing a new developer module, (35-55 ppm) PL 9.17 Item 2 or (65-90 ppm) PL 9.15
Item 2.
Description
The TC sensor, located in the bottom of the developer housing, is used in the process control
loop to help maintain the concentration of toner in the developer tank at the optimal level.
The TC sensor needs to be calibrated by adjusting the sensor output to the required target
value for a new developer toner concentration. The sensor output voltage can be adjusted to
the correct level by varying the control voltage applied to the sensor.
The output of the sensor depends on the:

Magnetic properties of the developer material (this is a fixed value).
Applied control voltage.
Developer temperature.
Humidity.
Procedure
2. Select Diagnostics Routines, Copier Routines, dC905 TC Sensor Calibration.
3. Touch the Start button to start the routine, and follow the on screen instructions.
Message displayed Only run this routine when a new developer package has been
installed
Message displayed Make sure you have cammed on the developer before starting
this routine.
The components listed will energize:
Photoreceptor drive motor.
Photoreceptor erase lamp.
Charge scorotron and charge grid.
Developer bias voltage.
Main drive motor (to rotate the developer).
4. If the setup fails, a TC Sensor Setup Routine Failed message appears, go to 09-360, 09-
361, 09-362, 09-363 TC Sensor Failure RAP.

Tags Mod / Tag Plate Location
Purpose The processor module. Open the front door and the Mod / Tag plate is located on the left side
of the main machine frame.
To provide a list of all the tag numbers used together with a description of each of the machine
modifications.
The DADH module. Lift up the DADH and the Mod / Tag plate is located on the rear of the
DADH.
Description
Each modification to the system is assigned a unique tag number. This section of the service The 1K LCSS module. Un-dock the 1K LCSS and the Mod / Tag plate is located on the docking
documentation contains a listing and brief description of all change tags. It also references the plate.
diagnostic routine, dC111 Tag Matrix, used to access, enter, store and retrieve hardware and
software upgrade information contained in the machine's NVM. The 2K LCSS module. Un-dock the 2K LCSS and the Mod / Tag plate is located in the base
pan of the 2K LCSS.
Change tags listed in this section are listed by machine module. The module to which the tag
relates is identified by the tag prefix letter, for example; Tag F048 applies to the 2K LCSS mod- The HVF module. Un-dock the HVF and the Mod / Tag plate is located on the metal panel
ule. The module prefixes are: under the docking latch.
Processor Tags - 001 to 250 (no prefix).
The tray 5 module. Undock the tray 5 module. The Mod/Tag plate is located on the right side
DADH Tags - D001 to D050.
metal panel.
1K LCSS Tags - L001 to L050.
2K LCSS Tags - F001 to F050. On the Tray 6 inserter the Mod / Tag plate is located on the under side of the unit.
HVF Tags - V001 to V050.
Tray 6 Inserter Tags - P001 to P050. Embedded Fax. The Mod / Tag plate is located on the safety cover, PL 20.10 Item 1.
Tray 5 Tags - I001 to I050.
Fax Tags - X001 to X050.
Classification Codes
The Class or Classification code can be explained as follows:
Tag Information
Information that may be included with each tag item is as follows: Table 1 Classification codes
Tag - gives the control number for the tag. NASG XE

code code Description
Class - gives the classification codes as listed in Table 1.
Use - indicates the multinational operating markets affected by the modification. - 1 Safety: Install this tag immediately.
Manufacturing Serial Number - gives the serial number of the factory built machines with M 2 Mandatory: Install this tag at the next opportunity.
the modification installed. R 3 Repair: Install this tag as a repair, at the failure of a component.
Purpose - gives a brief description of the modification. O 4 Optional: Install as a customer option or a field engineering decision.
Name - gives the name of the part or modification. S 4 Situational: Install as the situation demands.
Kit Number - gives the part number of the kit or part required to install the modification. N 5 Manufacturing: Cannot be installed in the field.
Reference or Parts List On - indicates the parts list where the kit or modification part can 6 Refurbishing only.
be found.

Xerox WorkCentre 5790 Family 6-127 Tags
Processor Tags TAG: 005
TAG: 001 CLASS: 3
NAME: Rear gravity gate finger Kit
CLASS: 4
PURPOSE: This kit is to eliminate paper catching in the gap between the tri roll guide and
NAME: Modified Paper Tray
the rear gravity gate finger.
PURPOSE: A modification to tray 1 or tray 2 to enable Tag 002 to be installed.
KIT NUMBER:
KIT NUMBER:
PARTS LIST ON: PL 10.12 Item 25
TAG: 046
TAG: 002
CLASS: 4
CLASS: 4
NAME: Inverter decurler kit (35-55 ppm)
NAME: Tray 1 and Tray 2 lip Kit
PURPOSE: To eliminate substandard stacking on all output devices excluding the OCT,
PURPOSE: This kit is to be installed if excessive paper curl occurs in tray 1 or tray 2 W/TAG
caused by the output curl on prints from the IOT.
001. The lip is installed on the front edge of the paper tray to constrain the curl
KIT NUMBER:
on the paper. The excessive curl on the paper can cause the paper to skew and
result in paper jams. PARTS LIST ON: PL 10.20
KIT NUMBER:
TAG: 047
CLASS: 4
TAG: 004 NAME: Inverter decurler kit (65-90 ppm)
CLASS: 3 PURPOSE: To eliminate substandard stacking on all output devices excluding the OCT,
caused by the output curl on prints from the IOT.
NAME: Inverter transparency feed Kit (35-55 ppm only)
KIT NUMBER:
PURPOSE: This kit is to install an alternative post fuser exit roller. Designed to eliminate
transparencies from sticking and causing jams on exit from the fuser. PARTS LIST ON: PL 10.20
Related faults codes are 10.121 and 10.107.
KIT NUMBER:
TAG: 048
CLASS: 4
NAME: Skew bypass tray spares kit
PURPOSE: Roller spring kit to reduce Skew when copying or printing from the bypass tray.
KIT NUMBER:
PARTS LIST ON: PL 7.30

Processor Tags, DADH Tags 6-128 Xerox WorkCentre 5790 Family
TAG: 051 TAG: 111
CLASS: 4 CLASS: 4
NAME: Drive roll repair kit NAME: HCF Heater kit
PURPOSE: Replacement non-perishable shafts and roll assembly. For use in specific envi- PURPOSE: To prevent paper curl in trays 3 and 4 in high humidity environments.
ronmental condition at hospitals and petrochemical sites. KIT NUMBER: Kit part number not available for this issue of the service manual.
KIT NUMBER: PARTS LIST ON: PL 31.14
PARTS LIST ON: PL 8.15, PL 8.17, PL 8.20, PL 8.22, PL 10.14, PL 10.25
TAG: 114
TAG: 101 CLASS: 3
CLASS: 2 NAME: De-populated short paper path
NAME: Paper feed module frame repair kit PURPOSE: Introduction of a common short paper path assembly with improved motion
PURPOSE: To repair damaged bosses supporting the tray paper size leaf springs. To quality, reliability and service life. The new assembly has an improved hinge
strengthen undamaged bosses to prevent future damage. and higher deck height that reduce 10-120 faults. The assembly also has fewer
KIT NUMBER: moving parts e.g. there is no longer a vacuum transport fan or a transport roller
assembly.
KIT NUMBER:
TAG: 103
CLASS: S
NAME: Toner reorder notification set to 1 day
TAG: 120
PURPOSE: (USSG Only) To modify the toner cartridge reorder notification to stop custom- CLASS: 3
ers replacing toner cartridges prematurely. For additional information, refer to NAME: Thermistor removal
Service Bulletin T7814-10-28.

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November 2014 Introduction

Organization How to Differentiate Between Machine Variants

Section 6 General Procedures / Information

Section 7 Wiring Data

Publication Comments Sheet

November 2014 Introduction

Introduction November 2014

November 2014 Introduction

Introduction November 2014

November 2014 Introduction

Introduction November 2014

DC Voltage Levels and Tolerances

Signal description (event that

Figure 1 Signal Nomenclature

November 2014 Introduction

Table 2 Signal tolerances

Samples of RAP reference text

Go to Flag 1. Check Q08-300. Refer to:

GP 11 How to Check a Sensor.

NOTE: This links to General Procedures information.

Figure 1, IOT PWB

01D +3.3V Distribution RAP.

NOTE: This links to a RAP.

Install new components as necessary:

Symbols Used in Circuit Diagrams

Introduction November 2014

November 2014 Introduction

Introduction November 2014

Responsibilities for resolution:

November 2014 Introduction

Introduction November 2014

November 2014 Introduction

Introduction November 2014

November 2014 Introduction

Introduction November 2014

November 2014 Service Call Procedures

November 2014 Service Call Procedures

Initial Actions Initial Actions

Service Call Procedures November 2014

November 2014 Service Call Procedures

Service Call Procedures November 2014

November 2014 Service Call Procedures

Service Call Procedures November 2014

November 2014 Service Call Procedures

Service Call Procedures November 2014

November 2014 Service Call Procedures

Chain 2 - User Interface Chain 5 - DADH

November 2014 Status Indicator RAPs

Status Indicator RAPs November 2014

November 2014 Status Indicator RAPs

Chain 22 - System Errors

Status Indicator RAPs November 2014

Go to Flag 1. +12V is available at P/J17, pin 5.

Go to Flag 1. +12V is available at P/J17, pin 6.

November 2014 Status Indicator RAPs

Status Indicator RAPs November 2014

WARNING Left hand door

Figure 1 Component Location